For 1990-2009 cars

# SPECIAL POLICY COOLANT LOSS, LOW COOLANT LAMP ON, VISIBLE

COOLANT LOSS, LOW COOLANT LAMP ON, VISIBLE COOLANT LEAKAGE, OR COOLANT ODOUR, CAUSED BY A CRACKED CYLINDER HEAD

#### MODELS: 1992-1993 Oldsmobile Achieva 1992-1993 Pontiac Grand Am 1992-1993 Buick Skylark with 2.3L Quad OHC Engine (VIN 3 - RPO L40) (Single Overhead Cam Only)

#### TO: ALL GENERAL MOTORS DEALERS

THIS SPECIAL POLICY ADJUSTMENT APPLIES ONLY TO THOSE VEHICLES BUILT THROUGH APRIL 1993 AND ONLY TO THOSE PRODUCED WITH RPO L40 ENGINE.

#### CONDITION:

--------- Some customers may comment about engine coolant loss, a low coolant lamp, or an odour of engine coolant in the vehicle.

Some 1992-1993 single overhead cam 2.3 litre (L40) engines may develop a cracking condition of the cylinder head. The cracking occurs on the outside of the cylinder head causing an external coolant leak that may cause the owner to comment about the conditions noted above. The cracking occurs in specific areas of the cylinder head and may leave a coolant deposit on the rear (exhaust side) of the cylinder head that may indicate leakage from these cracks. (See Figure 1)

#### VEHICLES INVOLVED:

Involved are some 1992 and 1993 (Buick Skylark/Oldsmobile Achieva/Pontiac Grand Am) model vehicles built through April 1993 with 2.3L engine (VIN code "3"; RPO L40) within the following breakpoints:

#### Year Model Plant Code From Through

1992 Buick Skylark C NC600001 NC660609 1993 Buick Skylark C PC250001 PC294508 1992 Oldsmobile Achieva M NM400001 NM477457 1993 Oldsmobile Achieva M PM000001 PM034139 1992 Pontiac Grand Am C NC200001 NC303621 1992 Pontiac Grand Am M NM000001 NM104947 1993 Pontiac Grand Am C PC700001 PC785617 1993 Pontiac Grand Am M PM500001 PM598811

#### SPECIAL POLICY ADJUSTMENT:

This Special Policy covers the condition described above for a period of seven years or 160,000 km, whichever comes 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 applies ONLY to repairs requiring cylinder head replacement as a result of cylinder head cracking that results in an engine coolant leak. It does not cover other conditions that may necessitate replacement of the cylinder head or engine damage resulting from the owner continuing to operate the vehicle in an overheated condition.

#### PARTS INFORMATION:

Parts required to complete the service procedure are to be ordered through regular channels.

#### Part Number Part Description Quantity Per Vehicle

24574472 HEAD, Cylinder 1 12356554 GASKET KIT, Cylinder Head 1 1051687 SEALER, Cooling system 2 Pellets Per Vehicle PACKAGE OF 6 PELLETS

993193 ENGINE OIL 5W30 4.25 Litres

25014233 FILTER, ENGINE OIL PF1225 1

993089 ENGINE COOLANT 5 Litres

#### OWNER NOTIFICATION:

Owners will be notified of this Special Policy by General Motors of Canada Limited. (See copy of the owner letter included with this bulletin.)

#### OWNER REIMBURSEMENT:

If an owner has already paid for some or all the cost to have the cylinder head replaced and the repairs occurred within seven years of the date the vehicle was originally placed in service, or 160,000 km, whichever occurs first, the owner may be eligible for partial or complete reimbursement of costs if genuine GM parts were used in the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount the repair would have cost GM to have it completed by a GM dealership. Owners (and/or prior owners) must submit original documentation which reasonably confirms the amount of unreimbursed repair expense(s), a description of the repair, date of the repair, and the person or entity performing the repair.

Claims for reimbursement are to be submitted by November 1, 1996.

#### DIAGNOSIS:

--------- 1. If any of the above conditions are noted, first inspect vehicle per section 6B in the Service Manual. If no other cause is found for this condition, proceed with step 2.

2. Remove the ignition coil housing cover and inspect rear (exhaust side) of the cylinder head for visible cracks and a buildup of coolant deposits. (See Figure 1.)

3. If any cracks are found in the cylinder head, replace the cylinder head as described below.

#### SERVICE PROCEDURE:

Install a revised cylinder head using the procedure outlined in Service Bulletin 276113 regarding cylinder head tightening and cleaning procedure. The revised cylinder head GM P/N 24574472 with casting number 24574468 may be identified by the appearance differences illustrated in Figure 2.

#### ---------IMPORTANT:

CYLINDER HEAD TIGHTENING PROCEDURE (This is the same tightening procedure as noted in Service Bulletin 276113.)

A. Tighten the bolts to the following N.m (lb. ft.) specification in sequence:

1. Bolts 1 through 8 (long bolts): 40 N.m (30 lb. ft.)

2. Bolts 9 and 10 (short bolts): 35 N.m (26 lb. ft.)

B. Then turn all 10 bolts 90 degrees (1/4 turn) in sequence using J36660.

#### NOTICE:

Never use abrasive pads to clean the cylinder head or block surfaces. An abrasive pad may damage the cylinder head and the block. Abrasive pads will produce a fine grit that the oil filter will not be able to remove from the oil THIS GRIT IS ABRASIVE AND HAS BEEN KNOWN TO CAUSE INTERNAL ENGINE DAMAGE. Also, abrasive pads may round the cylinder head edges or remove enough metal during cleaning to affect cylinder head flatness, both of which are known to affect the cylinder head gasket seal.

#### DISPOSITION OF REPLACED CYLINDER HEADS:

#### NOTICE:

There is a core charge on the cylinder heads from GMSPO, when the cylinder head is removed from the vehicle it will need to be returned to receive the core charge in accordance with GMSPO procedures. The cracked cylinder head being returned must be marked with the last eight digits of the Vehicle Identification Number. The marking should be made with a yellow paint or permanent felt tip marker on any flat area of the cylinder head.

#### WARRANTY CLAIM INFORMATION

When performing the repair as outlined in this Special Policy, the dealer is requested to submit a Warranty Claim for credit as follows:

Parts Labour Labour Add Description Allow OP Hours Time ----------- -------------------------------- Head Cylinder - Replace * T-2140 9.0 To Clean Parts on Vehicle Over 48,000 km **0.2 For Vehicles with Locking Wheel Covers or Wheel Nuts **0.1 Reimbursement For Previous Cylinder Head Replacements T-2141 ***0.2

*The "PARTS ALLOWANCE" should be the sum total of the current GMSPO dealer net price plus 30% handling allowance of all parts required for the repair.

**Add Times

***0.2 hour dealer administrative allowance which is entered as regular hours in the Warranty Claim Submission. The appropriate customer reimbursement is to be entered in the claim submission with the current order date and the current odometer reading and as a net dollar amount.

Dear General Motors Customer:

As the owner of a 1992 or 1993 Buick Skylark, Oldsmobile Achieva, or Pontiac Grand Am, equipped with a 2.3L Quad Overhead Cam engine, your satisfaction with our product is of the 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 should experience problems with your vehicles.

This letter is intended to make you aware that some 1992 and 1993 Buick Skylark, Oldsmobile Achieva, or Pontiac Grand Am model vehicles with 2.3L Quad Overhead Cam engines may develop a cracking condition of the cylinder head that allows coolant to leak from the cylinder head. Early evidence of this would be a loss of coolant in the coolant reservoir and coolant deposits on the exterior of the cylinder head. These may be combined with the odour of coolant from the engine compartment.

General Motors of Canada Limited is therefore taking the following action:

We are providing owners with special coverage. If the above mentioned condition occurs within seven (7) years of the date your vehicle was originally placed in service or 160,000 km, whichever comes first, the condition will be repaired for you at no charge. This Special Policy applies ONLY to repairs requiring cylinder head replacement as a result of cylinder head cracking that results in an engine coolant leak. It does not cover other conditions that may necessitate replacement of the cylinder head or engine damage resulting from operating the vehicle in an overheated condition.

This is not a recall campaign. Do not take your vehicle to your dealer as a result of this letter unless you believe that your vehicle has the condition as described above.

If you have already paid for some or all of the costs to have the cylinder head replaced and your mileage and in service time was less than seven (7) years and 160,000 km, you should contact your dealer. You may be eligible for partial or complete reimbursement of costs if genuine GM parts were used in the repair. If the work was done by someone other than a GM dealership the amount of reimbursement will be limited to the amount the repair would have cost GM to have it completed by a GM dealership. Please provide your dealer with your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, and the date of payment of those charges by November 1, 1996.

Repairs and adjustments qualifying under this Special Policy coverage must be performed by your GM dealer. Please contact your GM dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department General Motors of Canada Limited

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.