SPECIAL POLICY: 2.3L ENGINE CYLINDER HEAD GASKET. Chevrolet Beretta 1991

For 1990-2009 cars

# SPECIAL POLICY: 2.3L ENGINE CYLINDER HEAD GASKET

#### Subject: SPECIAL POLICY ADJUSTMENT 2.3L ENGINE CYLINDER HEAD GASKET

#### Model and Year: 1990-91 BERETTA GTZ W/ 2.3L ENGINES

This bulletin cancels and supersedes Dealer Service Bulletin 91-525-6A which should be discarded.

#### CONDITION:

--------- General Motors has determined that some 1990-91 Chevrolet Beretta GTZ model vehicles with 2.3L engines (VIN Code "A"; RPO LGO) may develop a condition with the cylinder head gasket which allows coolant to leak past the head gasket into one or more cylinders. Early evidence of this condition would be a loss of coolant in the reservoir and/or "white smoke" from the tail pipe.

To correct this condition a new cylinder head gasket must be installed using the information and procedure outlined in this revised bulletin.

#### VEHICLES INVOLVED:

Involved are some 1990-91 Chevrolet Beretta GTZ model vehicles with 2.3L engines (VIN Code "A"; RPO LGO) built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---------------------------------------------------- 1990 Beretta Wilmington "Y" LY100005 LY266135 1991 Beretta Wilmington "Y" MY100001 MY246253

#### SPECIAL POLICY ADJUSTMENT:

This special policy covers the condition described above for a period of six years of 60,000 miles, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the owner. This Special Policy Adjustment applies ONLY to repairs requiring head gasket replacement as a RESULT of the head gasket leaking coolant into engine cylinders; It does NOT cover other conditions which may necessitate replacement of the head gasket.

This Special Policy Adjustment Bulletin should be filed in your "Special Policy Adjustment Bulletins" binder furnished to dealers previously.

#### REIMBURSEMENT:

------------- Customer claims for reimbursement on previously paid repairs to replace the cylinder head gasket as a result of the gasket leaking coolant into cylinders were to be submitted by June 30, 1993 according to the forms (additional copies to be reproduced locally) and instructions included in this original bulletin (the time limitation for presenting the original paid receipt may be longer depending upon the law in your state). Repairs must have occurred within six years of the date the vehicle was originally placed in service, or 60,000 miles, whichever occurs first. Owners must submit original documentation which reasonably confirms the amount of unreimbursed repair expense(s), a description of the repair, and the person or entity performing the repair. Note that residents of Connecticut, Virginia and Wisconsin must submit requests for reimbursement in writing to Chevrolet Motor Division per instructions in the owner letter.

#### OWNER NOTIFICATION:

Owners were notified of this Special Policy by Chevrolet Motor Division (see copy of owner letter included with this bulletin).

#### DIAGNOSIS:

#### NOTICE: THIS SERVICE PROCEDURE SUPERSEDES ALL PREVIOUS SERVICE BULLETINS AND INSTRUCTION SHEETS FOUND IN THE PART KITS.

The following inspections may be performed to verify that there is a concern with the head gasket.

#### NOTICE: ONE OR MORE OF THE FOLLOWING FOUR (4) CONDITIONS LISTED BELOW MAY INDICATE A FAILED HEAD GASKET.

1. Confirm that there is coolant (loss) with no external leaks.

2. Check for bubbling in the coolant recovery or surge tank.

3. White smoke from exhaust system when vehicle is at normal operating temperature.

4. Remove spark plugs from a cool engine, refer to SECTION 6D4.

- Inspect cylinder by looking through the spark plug hole. Water or coolant in the cylinder or a washed (clean) piston may mean there is a concern with the head gasket.

- Remove ECM fuse and crank engine with spark plugs removed. Water or coolant vapor coming out of the spark plug hole may mean there is a concern with the head gasket.

- Inspect spark plugs. Green contamination may indicate an internal coolant leak.

5. If steps 1 through 4 give no indication of a head gasket concern, fill the coolant recovery or surge tank. Mark and date the tank at the coolant level. Return vehicle to the owner. Ask the customer not to add any coolant to the system and monitor the coolant level. Have the customer return the vehicle to the dealership if the coolant level is low.

#### IMPORTANT: Condensation in the oil does not necessarily indicate a head gasket concern if there is no coolant loss. Some condensation in the oil may be considered normal.

#### PARTS INFORMATION:

Parts are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).

PART NO. DESCRIPTION QTY/VEHICLE -------- ----------- ----------- 12354854 Gasket Kit, Cylinder Head 1 3634621 Engine Coolant System Sealer 2 pellets (Package of 6) 12340864 Tensioner Shoe and Stud 1 (if required) 1052754 Engine Coolant 5 Quarts 25014233 Oil Filter, Engine (PF1225) 1 12345612 Oil, Engine (SAE 5W-30) 4.25 Quarts

#### NOTICE: The cylinder head gasket kit (P/N 12354854) contains a check valve which will not be used for this policy action.

#### VIDEO TRAINING TAPE:

Each dealership will be sent one video tape on the subject of Quad 4 head gasket repair at no charge. The video will be mailed by early September, 1993.

#### SERVICE PROCEDURE:

#### NOTICE: The following procedure supplements the existing service manual procedure. The tightening sequence replaces all existing 1990-91 service manual head tightening procedures for Quad 4 engines.

Tool Required: J-36660 Torque Angle Meter

1. Completely drain cooling system and dispose of coolant. DO NOT recycle coolant from this engine.

#### NOTICE: Cylinder block, head, radiator and heater core must be completely drained of coolant since old coolant will be contaminated with combustion residue. Refer to appropriate service manual section for coolant draining procedure.

2. Remove cylinder head. Refer to appropriate service manual for details of Removal Procedure.

3. For 1990 model vehicles, inspect timing chain tensioner shoe. If timing chain has worn grooves into tensioner shoe in excess of 1.14 mm (0.045 in.) deep replace tensioner shoe and stud (see Figure 1).

4. If the tensioner shoe is broken and the chain is worn from contacting the metal surface, use GM kit P/N 12340864 to replace the tensioner shoe and stud. P/N 24570357 to replace the chain and P/N 24570356 to replace the tensioner.

5. Disassemble, clean and inspect the tensioner assembly. Be sure to pay special attention to the oil feed and drain holes, refer to Figure 2. Make sure the oil holes are free of dirt so they will allow proper oil flow. If there is varnish in the tensioner bore or on the plunger that may cause the plunger to stick in the bore. LIGHTLY polish the plunger or bore with SCOTCH BRITE or equivalent. Do not use any other method or technique to clean the plunger or bore. Smooth surfaces will ensure the plunger will not stick in the bore. If the plunger still does not operate smoothly use GM P/N 24570356 to replace the parts. Store the tensioner assembly until it is needed for assembly in a location where dirt will not get into the oil holes. DO NOT USE ANY CLEANING MATERIAL OR METHOD THAT WILL REMOVE METAL FROM THE PLUNGER OR BORE.

6. Inspect cylinder head bolts for damaged threads for damaged bolt heads caused by improper use of tools. Replace head bolts as appropriate.

7. Thoroughly clean the cylinder head and block surfaces and check for flatness. (Figure 3.)

#### NOTICE: DO NOT USE POWERED ABRASIVE PADS TO CLEAN THE CYLINDER HEAD OR BLOCK SURFACES. A POWERED ABRASIVE PAD MAY DAMAGE THE CYLINDER HEAD AND BLOCK.

A. Carefully remove all gasket material. Use only a plastic or wood scraper. Use Loctite brand "Chisel Gasket Remover" (P/N 79040) or Permatex brand "Gasket Remover" (P/N 4MA), or equivalent. Do not use any other method or technique to remove gasket material.

#### IMPORTANT: DO NOT USE A TAP TO CLEAN THE HEAD BOLT HOLES.

B. Check cylinder head for flatness. Refer to service manual SECTION 6A7 for cylinder head checking procedure and specifications.

8. Inspect the cylinder head surface for corrosion or cracks. The combustion seal area will leave a "shadow" mark on the cylinder head (shaded area - Figure 4). If corrosion is evident outside of the diameter (OD) of the combustion seal area, (shaded area - Figure 4), the cylinder head may be reused.

9. Clean each head bolt seat boss on cylinder head. Clean bolt holes in cylinder block. DO NOT USE A TAP TO CLEAN HOLES.

10. Apply clean engine oil to threads and bottom side of the flange of the head bolts (see Figure 5).

11. Install and tighten cylinder head bolts to the N.m (lbs. ft.) specification in SEQUENCE. Refer to Figure 6 for the specification.

12. After completing Step 11 on all ten bolts, tighten all the cylinder head bolts an additional 90 degrees in SEQUENCE using J 36660. (Refer to Figure 6.)

13. Replace thermostat.

14. Assemble the rest of the engine, refer to appropriate service manual.

15. Change engine oil and filter, being sure to use a PF 1225 oil filter, or equivalent.

16. Add (2) engine cooling system sealer pellets from package, P/N 03634621, to the cooling system.

17. Fill the cooling system. Use a mixture of water and coolant meeting GM specifications 1825-M to get a protection level of -37 degrees Celsius (-34 degrees Fahrenheit) to maintain sufficient engine cooling, freezing and corrosion protection. Do not use a mixture that has more 70% anti-freeze in it.

- 1990-91 Model/Years.

a. Remove the top radiator hose from the radiator prior to refilling the coolant.

b. Fill the coolant system until coolant appears at the radiator inlet.

c. Re-install the top radiator hose to the radiator inlet and continue filling surge tank to the base of the filler neck.

#### CLAIM INFORMATION:

Submit a claim with the information indicated below:

FAILED PARTS LAB LAB OTH NET REPAIR PERFORMED PC PART NO. ALLOW CC-FC OP HRS HRS AMT ------------------------------------------------------------------------- ** *** Replace Head Gasket 14 12354854 * SP-95 T4681 7.6 -- $#.##

Reimbursement For Prior Head Gasket - - - -- SP-95 T4682 - - 0.2 $#.## Replacement

* The "Parts Allowance" should be the sum of the GMSPO Dealer Net price plus 30% of parts required for the cylinder head gasket repair. THE CORRECT DOLLAR AMOUNT FOR ENGINE OIL, ENGINE OIL FILTER AND ENGINE COOLANT IS INCLUDED IN THIS ALLOWANCE.

** The 7.6 "Labor Hours" shown includes time (0.1 hrs.) for removing wheel lock nuts, changing engine oil and filter, and also replacement of timing chain tensioner shoe and stud, if necessary. Additionally, the following "Add-Times" may be selected when applicable:

ITEM ADD HOURS ---- --------- Clean Parts For Vehicles Over 30,000 Miles 0.4 Replace Cylinder Head 1.4

*** The $#.## identified in the "Net Amount" column should be used to represent the dealer cost plus 30% for cylinder head replacement (IF REQUIRED) AND/OR THE AMOUNT TO BE REIMBURSED TO THE OWNER.

Refer to the Chevrolet Claims Processing Manual for details on claim submission.

Dear Chevrolet Beretta GTZ Owner:

As the owner of a 1990-91 Chevrolet Beretta GTZ equipped with a 2.3L engine, your continued satisfaction with our product is of utmost concern to us. Your vehicle was provided with a new vehicle warranty which covers certain parts of your vehicle for a specified period. These warranties are of considerable value to you if you experience problems with your vehicle.

This letter is intended to make you aware that some 1990-91 Chevrolet Beretta GTZ model vehicles built with 2.3L engines may develop a condition of the cylinder head gasket which allows coolant to leak past the head gasket into one or more cylinders. Early evidence of this condition would be a loss of coolant in the coolant reservoir and/or "white smoke" from the tail pipe.

If the above condition occurs within six years of the date your vehicle was originally placed in service, or 60,000 miles, whichever occurs first, your vehicle will be repaired for you free of charge, including waiving of any deductible that might normally apply.

If you have already experienced this condition, and you have paid to have it repaired, you should contact your Chevrolet dealer to seek reimbursement. Connecticut, Wisconsin and Virginia residents must write to Chevrolet Motor Division, Customer Assistance Center, P.O. Box 7047, Troy, MI 48007-7047, for reimbursement. In either situation, please provide your original paid receipts or invoices verifying the repair, the amount charged, proof of your payment and date of payment of those charges. This information must be provided by June 30, 1993 (this time limitation for presenting the original paid receipt may be longer depending upon the law in your state).

If your vehicle has not experienced this condition, do nothing at this time. Just place this letter in the glove box with your owner's manual and other warranty information in case you should need to take advantage of this policy in the future. If you sell or trade your car anytime during this additional warranty period, please leave the information with the owner's manual so the new owner will be aware of eligibility during the unexpired portion of the coverage.

Should you have any questions regarding this action, please feel free to call us. Our toll free number is 1-800-222-1020, and one of our Customer Assistance Specialists will be happy to answer any questions you may have.

We regret any inconvenience that you may experience; however, we have taken this action in the interest of your continued satisfaction with our products.

Chevrolet Motor Division GENERAL MOTORS CORPORATION

#### INSTRUCTIONS

1. R.O. # & DATE The dealership should enter the repair order number and date of the reimbursement request.

2. WORK PERFORMED DATE Date owner or dealer had work performed. (MONTH, DAY)

3. VEHICLE IDENTIFICATION NUMBER VIN involved.

4. MILEAGE Enter mileage at time of repair. (If not available, enter "0".) Should not be greater than 60,000 miles.

5. CC/FC Code is preprinted on form.

6. LABOR OPERATION Labor Operation as referenced in bulletin.

7 & 8 SUBLET DMN & Enter exact amount of reimbursement. No de- LINE TOTAL ductible will be taken. (Do not enter parts or labor hours on claim.)

9. AUTH CODE If the amount of reimbursement approved is $1000 or less, no authorization is needed. If the amount exceeds $1000, contact Chevrolet Dealer Assistance Center 1-800-CHEV-454.

10. REQUESTED Dealer Service Manager enters the amount de- REIMBURSEMENT termined from owner supplied invoices or paid receipts, which are covered.

11. APPROVED AMOUNT Dealer Service Manager to determine based on reimbursement policy of this bulletin. If the total amount exceeds $1000, contact Chevrolet Dealer Assistance Center -800-CHEV-454.

12. 740 STAMP See Item #11 to determine need for author- ization.

13. DEALER REFERENCE A Enter Document Number & Line Number on which INFORMATION claim was submitted.

B Enter Claim Memo Number and Date when claim is credited.

C Enter number of dealer check to owner, if applicable. date check was written, if applicable. Date copy of check was attached to OWNER REQUEST FOR REIMBURSEMENT file.

14. OWNER INFORMATION Must include telephone number.

15. DEALER INFORMATION Includes Dealer Code, Dealer Name, Service Manager's Signature and social security number. To be completed by Service Manager.

16. EXPLAIN Should the dealer Service Manager determine, after review of owner's invoices/receipts, that the reimbursement case is not eligible; Service Manager should write reason on work- sheet, explain to owner, and place a copy of the worksheet in the vehicle history file.

17. The dealer is then to issue the owner a check for the reimbursement in the approved amount. A copy of the check issued to the owner is to be attached to the dealer's file copy of the request and retained for 24 months from date of credit.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.