Campaign - Coolant Loss/Cracked Cylinder Head: Overview
File In Section: Special PolicyBulletin No.: 57-61-26A
Date: February, 1996
SPECIAL POLICY
Subject:
Special Policy Adjustment - Coolant Loss, Low Coolant Lamp On, Visible Coolant Leakage, or Coolant Odor, Caused by a Cracked Cylinder Head
Models:
1992-93 Buick Skylark
1992-93 Oldsmobile Achieva
1992-93 Pontiac Grand Am
with 2.3L Quad OHC Engine (VIN Engine Code 3 - RPO L40)
(Single Overhead Cam Only)
This bulletin is being revised to include valve guide seals needed for cylinder head replacement and to clarify service information regarding gaskets and the cam carrier assembly. Please discard Corporate Bulletin Number 57-61-26 (Section - Special Policy).
This Special Policy Adjustment applies only to those vehicles built through April 1993 and only to those produced with RPO L4O engines.
Condition
Some customers may comment about engine coolant loss, a low coolant lamp, or an odor of engine coolant in the vehicle.
Cause
Some 1992-93 L4O 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)
Special Policy Adjustment
This special policy covers the condition described above for a period of seven years or 100,000 miles (150,000 km), 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 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.
Parts Information
Whenever ordering parts for a cylinder head replacement, refer to the part numbers in figure:
Service Information
Many of the gaskets and seals on the Quad OHC engine are reusable. The reusable gaskets that you will encounter during cylinder head replacement are the inner and outer timing chain cover gaskets. The timing chain cover gaskets should be reused if they are not torn or damaged. In addition, the Cam carrier should not be separated during this procedure, therefore there should be no need for Cam carrier seals.
Owner Notification
Owners will be notified of this special policy by (Buick / Oldsmobile / Pontiac) Division (see copy of the owner letter included with this bulletin).
Owner Reimbursement
Customer claims for reimbursement on previously paid repairs to replace the cylinder head as a result of cylinder head cracking that resulted in an engine coolant leak, are to be submitted by November 1, 1996 (this time limitation may be longer depending on the law in some states, such as California, Connecticut, Virginia, and Wisconsin). Repairs must have occurred within seven years of the date the vehicle was originally placed in service, or 100,000 miles (160,000 km), whichever occurs first. 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. CUSTOMERS FROM THE STATES OF CALIFORNIA, CONNECTICUT, VIRGINIA, and WISCONSIN MUST SUBMIT REQUESTS FOR REIMBURSEMENT DIRECTLY TO (BUICK / OLDSMOBILE / PONTIAC) PER INSTRUCTIONS IN THE OWNER LETTER.
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 (1/4 turn) in sequence using J 36660 tool.
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 VIN. The marking should be made with a yellow paint or permanent felt tip marker on any flat area of the cylinder head.
Warranty Information
For vehicles repaired under warranty, use:
Important:
T2141 is not to be used for residents of the states of California, Connecticut, Virginia, or Wisconsin. Requests from these residents must be submitted in writing to (Buick / Oldsmobile / Pontiac) Division. See owner letter for instruction.