CAMPAIGN: COOLANT PUMP. Pontiac Sunbird 1992

For 1990-2009 cars

# CAMPAIGN: COOLANT PUMP

#### SUBJECT: COOLANT PUMP

#### Models: 1992-1993 Pontiac Sunbirds with 2.OL Engine (RPO LE4; VIN Code H)

#### TO: ALL GENERAL MOTORS DEALERS

General Motors of Canada Limited has determined that some 1992-1993 Pontiac Sunbird model vehicles equipped with a 2.OL engine may have been assembled with the incorrect coolant pump. Coolant may leak past the internal coolant pump seal and into the pump bearings. This may cause premature bearing failure resulting in a coolant pump knocking noise. If not repaired, this condition may result in a loose timing belt tensioner which could cause the engine to fail to start.

To prevent this condition from occurring, dealers will inspect affected vehicle's coolant pump and, if necessary, replace the coolant pump.

#### VEHICLES INVOLVED:

Involved are certain 1992-1993 Pontiac Sunbird model vehicles equipped with 2.OL engine that fall within the following VIN breakpoints:

#### Year Model Plant Plant Code From Through

1992 Sunbird Lordstown 7 N7539565 EOP 1993 Sunbird Lordstown 7 SOP P7523040

Vehicles which our records indicate were previously repaired under warranty with coolant pump, P/N93215645 and 93221331, are not included in this campaign.

#### NOTE: PLEASE CHECK DCS SCREEN 45 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN, TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

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:

All unsold new vehicles in dealer's possession and subject to this campaign MUST be held and inspected/repaired per the Service Procedure of this Campaign Bulletin before owners take possession of these vehicles.

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner letter accompanying this bulletin. Campaign, follow- up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

#### 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 (see copy of owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.

#### PARTS INFORMATION

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ---------------------------------------------------------------------------- 93221331 Kit, Coolant Pump 1

Replace the parts listed below only if necessary.

Belt, Timing .......................... Refer to applicable parts catalogue Cover, Timing Belt ..................... Refer to applicable parts catalogue Tensioner, Timing Belt ................. Refer to applicable parts catalogue

#### PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

#### Repair Code Description Time Allowance

2A Coolant pump Inspection 1.3 3A Coolant Pump Inspection with A/C 1.4 6A Inspect and Replace Coolant Pump 2.5 Add 0.1 for A/C T2599 Owner Reimbursement for Previous Repair .2

*0.2 hour dealer administration allowance which is entered as other 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 as a net dollar amount.

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:

If a vehicle subject to this campaign has been repaired for this condition and the repair order indicates that the new part number 93215645 or part number 93221331 have been installed, this procedure is not required. Proceed to Step 60.

1. Disconnect negative battery cable.

#### NOTICE: Prior to disconnecting battery cable, preset radio stations should be reviewed and recorded, then reset for customer prior to vehicle delivery.

2. Remove serpentine drive belt with a 19mm wrench on tensioner assembly.

3. Remove fuel vapour line from timing belt cover.

4. Remove timing belt cover upper fasteners.

5. Remove serpentine belt tensioner assembly.

6. Loosen the A/C belt at the tensioner.

7. Raise vehicle.

8. Remove front air deflector.

9. Remove lower right side splash shield.

10. Remove A/C belt

11. Remove crankshaft pulley.

12. Remove timing belt cover lower fasteners.

13. Lower vehicle.

14. Remove timing belt cover.

15. Raise vehicle.

16. Inspect for upper and lower coolant pump weep holes using shop flashlight and mirror. Refer to Figures 1 and 2.

17. If there are two weep holes refer to Steps 48 through 64. If the coolant pump has one weep hole, proceed to Step 18.

Use this procedure only if the coolant pump has one weep hole. Be sure replacement pump has two weep holes.

18. Drain cooling system

19. Lower vehicle.

20. Remove coolant reservoir tank.

21. Align timing marks on crankshaft sprocket to rear timing belt cover by rotating crankshaft

22. Loosen coolant pump bolts and release timing belt tensioner using J33039-A.

23. Remove timing belt

24. Remove timing belt tensioner.

#### IMPORTANT: Inspect the timing belt tensioner for cracks. Refer to Figure 4. Replace the tensioner if cracks are found.

25. Remove camshaft carrier cover.

26. Remove camshaft sprocket

27. Raise vehicle.

28. Remove flywheel inspection cover.

29. Remove crankshaft sprocket while using J37096 to hold flywheel while loosening sprocket bolt.

30. Lower vehicle.

31. Remove rear timing belt cover.

32. Remove coolant pump.

33. Install coolant pump. Finger tighten the coolant pump bolts at this time

34. Install rear timing belt cover.

35. Raise vehicle.

36. Install crankshaft sprocket - use J37096 to hold flywheel while tightening the sprocket bolt.

37. Install flywheel inspection cover.

38. Lower vehicle.

39. Install camshaft sprocket

40. Install camshaft carrier cover.

41. Install timing belt tensioner.

42. Install timing belt and rotate the coolant pump eccentric clockwise until the tensioner arm contacts the high torque stop.

43. Tighten die coolant pump bolts slightly.

44. Rotate the engine 720 degrees (2 revolutions) by the crankshaft gear.

45. Turn the coolant pump eccentric clockwise until the hole in the tensioner arm is aligned with the hole in the base.

46. Tighten the coolant pump bolts to specifications.

47. Install the coolant reservoir tank.

48. Install timing belt cover.

49. Raise vehicle.

50. Install timing belt cover lower fasteners.

51. Install crankshaft pulley.

52. Install A/C belt.

53. Install lower right side splash shield.

54. Install front air deflector.

55. Lower vehicle.

56. Adjust A/C timing belt tension at the tensioner.

57. Install timing belt cover upper fasteners.

58. Install serpentine belt tensioner assembly.

59. Connect fuel vapour line from timing belt cover.

60. Install serpentine drive belt with a 19mm wrench on tensioner assembly.

61. Fill the cooling system.

62. Connect the negative battery cable.

63. Ensure radio stations are returned to preset positions and reset clock.

64. Install Campaign Identification Label.

#### INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

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.

Dear General Motors Customer.

General Motors of Canada Limited has determined that some 1992-1993 Pontiac Sunbird model vehicles equipped with a 2.OL engine may have been assembled with the incorrect coolant pump. Coolant may leak past die internal coolant pump seal and into the pump bearings. This may cause premature bearing failure resulting in a coolant pump knocking noise. If not repaired, this condition may result in a loose timing belt tensioner which could cause the engine to fail to start.

To prevent this condition form occurring, your dealer will inspect your vehicle's coolant pump and, if necessary, replace the coolant pump.

This service will be provided for you at no charge.

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.

If you have already encountered this condition and paid for all or part of the repair, you should contact your GM dealer. When requesting reimbursement, you should present the dealer with your original paid receipt, verifying expenses incurred for such repair.

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.