For 1990-2009 cars

# REVISED SPECIAL POLICY ADJ. 2.3L ENGINE CYLINDER HEAD

#### SUBJECT: REVISED SPECIAL POLICY ADJUSTMENT 2.3L ENGINE CYLINDER HEAD

YEAR/MODEL: 1987 - 1991 CUTLASS CALAIS & 1990 - 1991 CUTLASS SUPREME MODELS WITH QUAD 4 ENGINES

This bulletin cancels and supersedes all related previous service bulletins including Dealer Technical Bulletin 91-T-244, which should be discarded.

#### CONDITION

General Motors has determined that some 1987-91 Oldsmobile Cutlass Calais and 1990-91 Cutlass Supreme model vehicles built with 2.3L engines (VIN Code "A" or "D"; RPO LGO or LD2), 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.

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 1987-91 Oldsmobile Cutlass Calais and 1990-91 Cutlass Supreme model vehicles built with 2.3L engines (VIN Code "A" or "D"; RPO LGO or LD2), within the following breakpoints:

Engine Beginning Through & Year Model Model Name VIN Code VIN Including ---- ----- ---------- -------- --------- --------- 1987 N Cutlass Calais D HM222794 HM315582

1988-1989 N Cutlass Calais D S.O.P. E.O.P.

1989 N Cutlass Calais A KM282850 KM303103

1990-1991 N Cutlass Calais A or D S.O.P. E.O.P.

1990-1991 W Cutlass Supreme A or D S.O.P. E.O.P.

#### NOTE: This policy applies only to those vehicles produced with RPO LG0 or LD2 engines (VIN Code "A" or "D").

S.O.P. means "Start of Production" and E.O.P. means "End of Production".

#### SPECIAL POLICY ADJUSTMENT

This special policy covers the condition described above for a period of six years or 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.

#### OWNER 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 for all states except Virginia, Connecticut, and Wisconsin. Virginia, Connecticut, and Wisconsin owners have up to two (2) years from the date on the repair order to submit for reimbursement. 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 that reasonably confirms the amount of unreimbursed repair expense, a description of the repair, the date of the repair, and the person or entity who performed the repair.

Claims for customer reimbursement on previously paid repairs are to be submitted according to the Warranty Claim Information instructions. Use the "Owner Reimbursement" labor operation and list all owner expenses concerning previous repairs in the net items column of the warranty claim.

#### 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.

#### SERVICE PROCEDURE

1. Completely drain the cooling system.

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

2. Remove the cylinder head. Refer to the appropriate service manual section.

3. Inspect the timing chain tensioner shoe, refer to Figure 1.

#### IMPORTANT: On 1988 and earlier vehicles, also check the thickness of the backing plate. If the thickness is 2 mm (0.079 in.), replace the tensioner shoe and stud with GM Kit Part No. 12340864. The new tensioner shoe backing plate will be 3.7 mm (0.146 in.) thick, refer to Figure 1. GM P/N 24570357 will be an updated chain with smooth edges that will reduce tensioner shoe wear.

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 (ex. the parts cleaner) 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 the cylinder head bolts for damaged threads or for damaged heads caused by improper use of tools. Replace head bolts if necessary.

7. Thoroughly clean the cylinder head and block surfaces and check for flatness.

#### 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 M 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 3). If corrosion is evident outside of the outside diameter (OD) of the combustion seal area, (shaded area - Figure 3), the cylinder head may be reused.

9. Clean each head bolt seat boss on the cylinder head. Clean the bolt holes in the cylinder block, refer to Figure 4. MAKE SURE THAT ALL PUDDLES OF OIL AND COOLANT HAVE BEEN REMOVED FROM BOLT HOLES OTHERWISE THE TIGHTENING SEQUENCE WILL NOT OBTAIN THE PROPER CLAMP LOAD BECAUSE OF HYDRA-STATIC LOCK. IF THE BOLT HOLES ARE NOT CLEANED THE HEAD GASKET MAY LEAK.

10. Replace the oil flow check valve (see Figure 5) in 1987 through 1989 model year vehicles. Refer to the applicable 1991 model year service manual. The check valve does not need to be replaced in 1990 or newer vehicles or those vehicles where the check valve has been previously replaced.

#### IMPORTANT: To determine if the check valve has been previously replaced on 1987 through 1989 vehicles, shine a flashlight into the oil check valve. If there are three dimples immediately above the check ball, it is the new style oil flow valve and should not be replaced (Figure 5).

11. Apply clean engine oil SPARINGLY to the threads and the bottom side of the flange of the bolt (Figure 6).

#### NOTICE: The following tightening procedure must be used to assure gasket life. Failure to follow this procedure exactly may result in cylinder head gasket leakage.

12. Install and tighten cylinder head bolts to the N-m (lbs. ft.) specification in SEQUENCE. Refer to step A in Figure 7 for the specification.

13. After completing step 10 on all ten bolts, tighten all the cylinder head bolts an additional 90 degrees indicated in Step B of Figure 7 in SEQUENCE using J 36660.

14. Replace thermostat.

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

16. Change the engine oil and filter, be sure to use a PF 1225 oil filter.

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

18. Fill the cooling system. Use a mixture of water and coolant meeting GM specification 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 than 70% antifreeze in it.

* 1987 - 88 Model/Years:

a. Disconnect heater inlet hose from engine coolant outlet.

b. Remove pressure cap from radiator and fill with coolant until coolant drains from the engine coolant outlet.

#### IMPORTANT: This process may take up to 15 minutes.

c. Reconnect heater hose to engine coolant outlet.

d. Start engine.

e. Continue to fill radiator as coolant level drops until the radiator hose at the radiator inlet is hot and coolant level in radiator becomes stable.

f. Fill radiator completely.

g. Install pressure cap.

h. Stop engine.

* 1989 - 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.

#### PARTS INFORMATION

To ensure parts are obtained as soon as possible, order them from General Motors Service Parts Operations (GMSPO) on a C.I.O. order, with NO special instruction code, but order on an advise code (2).

PART NUMBER DESCRIPTION QUANTITY PER VEHICLE ----------- ----------- -------------------- 12354854 Gasket Kit, Cylinder Head 1

03634621 Engine Cooling System Sealer 2 pellets (Package of 6) 1052754 Coolant, Engine (Bulk) 5 quarts 12340864 Tensioner Shoe and Stud, Timing Chain 1, if required

PART NUMBER DESCRIPTION QUANTITY PER VEHICLE ----------- ------------ -------------------- 12345612 Oil, Engine 5W-30 (Bulk) 4.25 quarts (w/filter change)

25014233 Filter, Engine Oil (PF 1225) 1

#### VIDEO TRAINING TAPE

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

#### WARRANTY CLAIM INFORMATION

#### NOTICE: The labor hours have been revised to reflect the revised procedure which eliminates the pre-conditioning of the head gasket.

Use one of the applicable warranty labor operation numbers below:

REPAIR PERFORMED FC LAB-OP LHRS ST ---------------- -- ------ ---- -- Replace Head Gasket, Cutlass Calais 95 T4681 7.2 ---

Replace Head Gasket, Cutlass Supreme 95 T4681 6.3 ---

Add-Time W/Locking Wheel Covers/Nuts 0.1 (One Or All) Add-Time To Clean Parts On Vehicles 0.4 Over 30,000 Miles if necessary. Add-Time To Replace Cylinder Head 1.4 (If Necessary) Customer Reimbursement 95 T4682 --- 0.2*

Parts Allowance: Current dealer price, plus 30% handling allowance.

* 0.2 hour for clerical administration may be applied for in the Straight Time (ST) column.

#### NOTE: Labor Op T4681 includes time for changing the engine oil and filter.

#### NOTE: Dealer payment for coolant and engine oil may be applied for in the usual manner.

#### OWNER LETTER

This is a representative letter for the 47 states. The Connecticut/Virginia/Wisconsin version notes that the owner has two years from the date of repair in which to seek a reimbursement. Also, there is a separate owner letter for each model year, 1987 - 1991.

Dear Oldsmobile Owner:

As the owner of a [1987-91] Oldsmobile 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 certan 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 [1987-91] Oldsmobile Cutlass Calais [and 1990-91 Cutlass Supreme 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 mentioned 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 the waiving of any deductible that might normally apply.

If you previously paid for this repair. you should contact your Oldsmobile dealer by June 30, 1993 to request reimbursement.

We suggest you keep this letter and place it in the instrument panel compartment of your vehicle with the Owner's Manual, Maintenance Schedule, and Warranty Booklet.

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

Oldsmobile Division GENERAL MOTORS CORPORATION

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.