For 1990-2009 cars

# CAMPAIGN:PISTON KNOCK REPLACE PARTIAL ENGINE

#### MODELS: 1986 Buick Century Models Equipped with 2.8L 2bb1 (RPO LE2) Engines Produced at Ramos

Some 1986 Buick Century models equiped with 2.8L 2bb1 (RPO LE2) engines produced at the Ramos Arizpe engine plant. These engines may have been assembled with one or more incorrectly machined piston(s). This condition could result in engine knock.

Correction of this condition will consist of inspection for suspect engine production date codes and, if required, replacement of the partial engine assembly.

#### VEHICLES AFFECTED:

1G4AH35X9GD476752 1G4AH35X9GD477402 1G4AH35X2GD477693 1G4AL35XXGD477925 1G4AH35X3GD478898 1G4AL35X7GD478952

Whenever a new vehicle subject to this campaign requires replacement of the partial engine assembly as provided in this bulletin, the following steps must be completed before selling and releasing the vehicle.

1. For now vehicles in Dealer inventory, notify prospective purchasers, prior to purchase, that a new partial engine assembly was installed by an authorized Dealer at the request of General Motors of Canada.

2. To avoid unnecessary disputes with the customers and owner dissatisfaction, place the following statement on your sale agreement with the purchaser of a new vehicle on which the services described in this bulletin are performed.

"A new partial engine assembly was installed in this new vehicle by an authorized Dealer at the request of General Motors of Canada."

Customers who have already purchased new vehicles with the suspect engine production date codes will be notified and asked to bring their vehicles to an authorized Dealer to have the engine codes checked and, if required, replacement of the partial engine assembly.

All affected vehicles have been identified by the VIN listing provided to involved Dealers with this bulletin. Any Dealer not receiving a listing was not shipped any of the affected vehicles.

#### DEALER CAMPAIGN RESPONSIBILITY:

Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your Dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the Dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.

#### CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

#### OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors. The listings provided are for campaign activity only and should not be used for any other purpose.

#### PARTS INFORMATION:

Parts required for this modification should be ordered through regular channels as follows:

PART NUMBER QUANTITY DESCRIPTION ----------- -------- ------------ 14089008 1 Partial Engine

P/N 14089008 CONSISTS OF BLOCK, PISTONS AND ROD ASSEMBLIES, CRANKSHAFT, CAMSHAFT BEARINGS, CONNECTING ROD BEARINGS AND CRANKSHAFT REAR OIL SEAL.

14101336 1 Gasket Kit 10048958 1 Gasket Kit-Cylinder Head 1977935 1 Distributor Gasket 14077676 1 Oil Pan Rear Seal 25010908 1 Oil Filter (From Bulk) 4 Qts. SAE 5W30 Oil (From Bulk) 1/2 Qt. Engine Coolant 992654 1 1/2 Cans Engine Paint 992708 lTube RTV 992869 1/4 Qt. Lube - EOS 992545 1/2 Tube Pipe Sealant

#### PARTS AND LABOUR CLAIM INFORMATION:

For 2A, 3A, 4A, 5A, completed claims should be sent to Oshawa so that credit may be processed. Campaign system is not set up to cover such large amounts.

Repair Code Operation Time Allowance ----------- --------- -------------- 1A Inspect for involvement, check .3 A0605 engine prefix. No involvement, no further action required.

2A Replace partial engine assembly 13.1 Vehicles without A/C or cruise

3A Replace partial engine assembly 13.6 Vehicles without A/C

4A Replace partial engine assembly 13.2 Vehicles with cruise

5A Replace partial engine assembly 13.7 Vehicles with cruise & A/C

PARTIAL ENGINE ASSEMBLTES REMOVED FROM VEHICLES ARE TO BE HELD BY THE DEALER FOR SCRAPPING BY AN AUTHORIZED ZONE REPRESENTATIVE.

Time allowance includes 0.1 hour for Dealer administrative detail associated with this campaign. Parts credit will be based on Dealer net plus 30% to cover parts handling.

#### SERVICE PROCEDURE:

Some partial engine assemblies may not be painted as received from Parts Department. Paint as required.

Engine coolant is to be re-used. When draining system be sure to use a clean container to prevent contamination of the coolant.

Consult the 1986 Shop Manual for proper fastener torque values.

#### INSPECTION:

---------- 1. Inspect engine production code stamped on the horizontally machined surface of the engine block just forward of the intake manifold (see Figure 1). It may be necessary to clean the surface in order to read the code.

2. If the first five (5) characters of the 10 character engine production code (see Figure 2)are A0605*****, replacement of the partial engine assembly is required.

If the first five (5) characters of the engine production code are anything other than A0605*****, the vehicle is not involved. Install campaign completion label.

#### PROCEDURE TO REMOVE ENGINE:

1. Disconnect battery.

2. Remove air cleaner.

3. Disconnect accelerator cable.

4. Disconnect T.V. cable.

5. Disconnect cruise cable and remove bracket.

6. Drain cooling system. Using a clean container, save coolant for re-use.

7. Disconnect upper radiator hose.

8. Disconnect heater hose at thermostat housing.

9. Disconnect grounds at thermostat housing.

10. Disconnect brake booster vacuum hose.

11. Disconnect necessary vacuum hoses.

12. Disconnect necessary wires at engine (top).

13. Remove thermostat housing stud (to remove crossover).

14. Remove exhaust crossover.

15. Remove alternator belt.

16. Remove AIR pump pulley & belt.

17. Remove A/C Belt.

18. Disconnect heater hose at water pump.

19. Remove P/S belt.

20. Disconnect P/S pump at engine.

21. Disconnect wires at A/C comp. & press. cut-off switch.

22. Disconnect A/C comp. from brackets.

23. Disconnect AIR hose at catalytic converter AIR pipe.

24. Disconnect wire harness at rear of RH head.

25. Disconnect transmission dipstick tube at manifold.

26. Disconnect fuel lines at transmission.

27. Raise vehicle.

28. Remove inner fender splash shield.

29. Remove flywheel cover.

30. Disconnect wires at starter.

31. Remove starter.

32. Remove lower A/C adjusting bracket.

33. Disconnect fuel lines at fuel pump.

34. Disconnect lower radiator hose.

35. Disconnect exhaust pipe at manifold.

36. Remove flexplate to torque converter bolts.

37. Remove crank pulley.

38. Disconnect transmission bracket at engine.

39. Remove mount nuts.

40. Disconnect wires at engine (bottom).

41. Lower vehicle.

42. Disconnect strut bracket at radiator support and swing on top of engine.

43. Disconnect grounds & harness bracket at bellhousing studs.

44. Remove bellhousing bolts.

45. Remove hood.

46. Install jack under trans.

47. Install lift device.

48. Remove engine.

49. Remove flexplate.

50. Mount engine on stand.

#### PROCEDURE TO DISASSEMBLE OLD ENGINE:

1. Remove carburetor & vacuum hoses.

2. Remove distributor cap & plug wires.

3. Remove AIR pump.

4. Remove alternator & mount bracket.

5. Remove alternator/AIR pump adj. bracket.

6. Remove AIR management valve, deceleration valve, & hoses.

7. Remove fuel pump & push rod.

8. Remove torque strut & bracket.

9. Remove water pump pulley.

10. Remove oil sending unit.

11. Remove solenoids & brackets (EGR, idle speed & carburetor bowl vent).

12. Remove distributor.

13. Remove rocker covers and clean.

14. Remove intake manifold and clean.

15. Remove push rods.

16. Remove lifters.

17. Remove cylinder heads and clean heads & bolts.

18. Remove water pump.

19. Remove harmonic balancer, front cover, timing chain & gears, & chain guide.

20. Remove camahaft.

21. Drain engine oil.

22. Rotate engine on stand.

23. Remove motor mount & bracket.

24. Remove oil pan & pump and clean pan.

#### PROCEDURE TO ASSEMBLE NEW ENGINE:

1. Mount new short block on stand.

2. Install camshaft.

(1) Coat cam bearings with P/N 1052367 lube.

(2) Coat cam lobes with P/N 1052367 lube.

(3) Coat cam journals with engine oil.

3. Install timing chain & gears, timing chain guide, front cover, & harmonic balancer.

(1) Coat sprocket thrust surface with Molykote.

(2) Coat timing chain with engine oil.

(3) Coat front cover seal contact area on harmonic balancer with engine oil.

(4) Apply sealant to key & keyway.

4. Install water pump.

Coat bolt threads with pipe sealant P/N 1052080.

5. Rotate engine on stand.

6. Install oil pump & drive shaft.

7. Install oil pan.

(1) Apply a continuous 3rmn (1/8") bead of P/N 1052917 RTV sealer to oil pan sealing surface on front cover of the oil pan sealing flange.

(2) Replace rear oil pan seal.

8. Install motor mounts & brackets.

9. Install fuel pump & fuel pump push rod.

10. Rotate engine on stand.

11. Install lifters.

Coat lifters with engine oil.

12. Install cylinder heads.

Cost cylinder head bolts with P/N 1052080 sealer.

13. Install push rods and adjust lash.

14. Install intake manifold.

(1) Apply a 5mm (3/16") diameter bead of P/N 1052917 RTV sealer to front & rear block sealing surfaces.

(2) Place a 3mm (1/8") diameter dot of P/N 1052917 RTV sealer at the intake manifold & cylinder head split lines.

15. Install rocker covers.

16. Install distributor.

17. Install solenoids & brackets (EGR, idle speed, & carburetor bowl vent).

18. Install oil sending unit.

19. Install water pump pulley.

20. Install torque strut & bracket.

21. Install AIR management valve, decelerator valve, & hoses.

22. Install alternator/AIR pump adjusting bracket.

23. Install alternator & mount bracket.

24. Install AIR pump.

25. Install distributor cap & plug wires.

26. Install carburetor & vacuum hoses.

27. Fill engine with oil.

#### PROCEDURE TO INSTALL NEW ENGINE:

1. Install lift device.

2. Dismount engine from stand.

3. Install flexplate.

4. Install engine in car.

5. Install bellhousing bolts.

6. Connect grounds & harness bracket at bellhousing studs.

7. Connect strut bracket at radiator support.

8. Raise vehicle.

9. Connect wires at engine (bottom).

10. Install mount nuts.

11. Connect transmission bracket at engine.

12. Install crank pulley.

13. Install flexplate to torque converter bolts.

14. Connect exhaust pipe at manifold.

15. Connect lower radiator hose.

16. Connect fuel lines at fuel pump.

17. Install lower A/C adjusting bracket.

18. Install starter.

19. Connect wires at starter.

20. Install flywheel cover.

21. Install inner fender splash shield.

22. Lower vehicle.

23. Connect fuel lines at trans.

24. Connect transmission dipstick tube at manifold.

25. Connect wire harness at rear of RH head.

26. Connect AIR hose at catalytic converter AIR pipe.

27. Connect A/C comressor from brackets.

28. Connect wires at A/C compressor & pressure cut-off switch.

29. Connect P/S pump at engine.

30. Install P/S belt and adjust.

31. Connect heater hose at water pump.

32. Install A/C belt and adjust.

33. Install AIR pump pulley & belt.

34. Install alternator belt and adjust.

35. Install exhaust crossover.

36. Install thermostat housing stud (to attach crossover).

37. Connect necessary wires at engine (top).

38. Connect necessary vacuum hoses.

39. Connect brake booster vacuum hose.

40. Connect grounds at thermostat housing.

41. Connect heater hose at thermostat housing.

42. Connect upper radiator hose.

43. Refill cooling system using original coolant. Top off coolant level as required.

44. Connect cruise cable and install bracket.

45. Connect T.V. cable.

46. Connect accelerator cable.

47. Install air cleaner, battery and hood.

48. Start engine and adjust timing & idle speed.

49. Road test vehicle.

50. Install Campaign completion Label.

#### INSTALL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

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.