For 1990-2009 cars

# Service Information on L-Series L61 Engine Exchange Program

Subject: | Service Information on L- Series DOHC 2.2L (L61) Engine Exchange Program. Due to the engine exchange program being extended until June 30, 2000 and changes under SHIPPING INFORMATION, this bulletin has been revised and supercedes bulletin 99-t-28, which should be discarded.

Models: | 2000 Saturn L- Series vehicles equipped with DOHC 2.2L (L61) engines

### Purpose

The purpose of this bulletin is to outline the Engine Exchange Program for the 2000 model year Saturn L-Series vehicles equipped with L61 2.2L engines. The Engine Exchange Program will be used to provide quick and reliable product feedback that product engineering will use to identify and resolve product concerns. The program has been extended and will be in effect until June 30, 2000.

The Engine Exchange program will be administered through the Saturn Technical Assistance Center (TAC) in the United States at1-800-828-2112, prompt 1; Monday, 9:30 a.m. - 6:30 p.m. CST; Tuesday through Friday, 7:30 a.m. - 6:300 p.m. CST. (For Canada vehicles, this program will be administered by the GM of Canada Technical Assistance Center at 1-800-263-7740 for English or 1-800-263-7960 for French: Monday through Friday from 6:30 a.m. - 8:00 p.m. E.S.T.) All engine exchange requests must be reviewed with the appropriate Technical Assistance Center. Refer to the Engine Exchange program information in this bulletin.

### AUTHORIZED ENGINE REPAIRS

There are certain repairs that can be performed on DOHC 2.2L (L61) engines that do not require an engine to be exchanged. During the six-month Engine Exchange program period, Retailers may replace any of the components listed below without participating in the Engine Exchange program:

Accessory Drive (Belt, Tensioner) | A/C Compressor
All Engine Sensors | Engine Block Heater (if equipped)
Brackets | Engine/Transaxle Mounts
Cam Cover and Seal | Coolant Pump Only (Drive sprocket not included)
EGR Blank Plate and Gasket | Engine Wiring Harness
Exhaust Manifold and Gasket | Flywheel and Flex Plate Assemblies
Fuel Rail | Fuel Injectors
Fuel System | Generator Assembly
Harmonic Balancer | Heater Pipes/O-Rings
Intake Manifold | Fuel Injector Wire Harness
Oil Filter | Oil Level Indicator and Tube
PCV System | Power Steering Pump
PCM | Starter Motor
Thermostat Housing/Gasket | Throttle Body/Related Components
Vacuum Tubes | Vapor Vent Lines/Seals
Ignition System (Coil Module, Spark Plugs, High Voltage Switch) |

### OIL LEAKS

Oil leaks coming from any of the components in the above list should be repaired at the Retailer without exchanging the engine. Oil leaks coming from the oil pan or front cover assembly will be reviewed on a case-by-case basis. Verify that the leak is originating from the front cover or oil pan by performing a oil dye check using J-28428-E Dye and Light Kit. Once the leak has been verified, contact the appropriate Technical Assistance Center to determine if an engine exchange is necessary. If the engine has an oil leak that is NOT coming from the oil pan, front cover, or a component on the above list, the engine must be exchanged.

The purpose of the illustration on the last page of this bulletin is to assist Saturn in determining the exact origin of a pan or front cover leak. The Technician Assistance Engineer will adviser Retailers on use of the illustration when necessary.

### INTERNAL ENGINE COMPONENT REPAIR

If any internal components of the engine require replacement, the engine must be exchanged. The new replacement engine will arrive as a assembly including intake and exhaust manifolds, fuel rail power steering pump, ignition system, engine sensors, flexplate (automatic transaxle), and the flywheel and clutch assembly (manual ) transaxle). All of these components must be assembled on the failed engine prior to shipment if they have been removed. For effective engineering analysis, please do not remove any components from the engine assembly. Any components that are reinstalled on the failed engine must be torqued to specification to avoid operator injury during pre-teardown testing. Refer to the 2000 L- Series service manuals for proper torque specifications. Retail facilities that return partially disassembled engines will be billed for all materials furnished.

### ENGINE EXCHANGE PROGRAM PROCESS OVERVIEW

When a Saturn Retailer contacts the Technical Assistance Center to request an exchange engine, the Technical Assistance Engineer will arrange to ship a new engine to the retailer overnight at no charge. Saturday delivery service is not available. Engines will typically take between 72 and 96 hours to arrive at Canadian Retailers. Exchange engines will be shipped with a quantity of oil. Check engine oil level before starting the engine. Exchange engines will be shipped with return engine shipping instructions, including a return shipping label (freight collect at destination) and a partially completed Bill of Lading document.

### SHIPPING PREPARATION

1. Drain all fluids from the removed engine and install any plugs removed from the engine.
2. Crate removed engine in the original shipping container.
3. Place a copy of the service order and completed identification card contained with the exchange engine in an envelope and attach the envelope to the engine being returned.
4. If engine is being returned for an oil leak, mark position of leak on engine with a grease pencil.
5. Place retailer address (return address) and Technical Assistance case number on outside of shipping crate.

### SHIPPING INSTRUCTIONS

Remove the original shipping tag and attach the return shipping label to the container. The Bill of Lading and Customs Papers (Canada Only) provided with the exchange engine are the only documents required to return the removed engine.

Important: To make arrangements to have an engine core picked up contact CF Logistics at 1-800-260-7834. CF Logistics will coordinate all exchange engine returns. Their hours of operation are Monday through Friday, 7 a.m. to 6 p.m. Central Standard Time (CST). ALL ENGINES ARE REQUIRED TO BE RETURNED USING GUARANTEED DELIVERY SERVICE.

### SHIPPING INFORMATION

After the Bill of Lading has been dated and signed by the carrier, retain the last copy with your service order. Provide the other copies to the carrier.

Important: Your copy of the Bill of Lading, signed by the carrier, is your proof that the engine was returned.

The removed engine will be shipped by CF Motor freight -- collect -- to the engine assembly plant. Once again, contact CF Logistics if you have any questions regarding proper engine core return procedures. Please ensure the Retailer address (return address) and Technical Assistance case number can be identified on the outside of this crate.

If the envelope containing the shipping information is lost, refer to the following:

• | Saturn Retailers located in the United States, contact the Saturn Service Parts Assistance Center at 1-800-828-2112, Prompt 2.

• | Saturn Retailers located in Canada, contact the Canadian Technical Assistance Center for assistance.

### Claim Information

To receive credit for replacing an L61 engine assembly during the Engine Exchange program, submit a claim with the following information below:

Case Type | Description | Labor Operation Code | Labor Hrs. | Admin.* Hrs. | Net Item** Amount | Net Item Code
--- | --- | --- | --- | --- | --- | ---
VW | Replace Engine Assembly | J1880 | 6.5 Manual Transaxle | 0.2 | $434.00 | M
|  |  | 6.2 Automatic Transaxle |  |  |

Important: Applicable miscellaneous parts, such as engine oil and coolant, are to be sold to the Customer Service Order (CSO) following standard CSO preparation procedures.

* Engine Exchange Program administrative allowance

* * This is the engine assembly part allowance