Customer Satisfaction 99095 - LD9 Engine Rod Bearing Break-In Procedure

This bulletin supersedes DCS message WIA19990108. Please discard DCS message WIA19990108, dated December 21, 1999.

THIS CAMPAIGN IS IN EFFECT UNTIL MARCH 31, 2000.

General Motors has decided that certain 2000 model year Chevrolet Cavalier and Pontiac Sunfire (J car) and Oldsmobile Alero and Pontiac Grand Am (N Car), equipped with 2.4L (LD9) engine and built between 11/23/99 and 12/3/99 may have engine connecting rod bearings which may fail prematurely if the vehicle is subjected to high engine speed operation at low mileage. Involved vehicles have engine rod bearings that are slightly tighter than intended, but that will wear during break-in. Engine rod bearing failure can result in engine failure and/or damage.

To prevent the possibility of this condition occurring, dealers are to drive the vehicle at light accelerations and speeds, not to exceed 3000 engine RPM, for 40 to 50 miles (64 to 80 km). This will assure break-in of the rod bearings prior to the potential of customer operation at high engine speeds.

Important: This campaign is only to be used for dealer inventory vehicles with less than 50 miles (80 km). Vehicles with over 50 miles will not benefit from this procedure and are not included. This campaign will expire on March 31, 2000.

Involved are certain 2000 model year Chevrolet Cavalier and Pontiac Sunfire (J car) and Oldsmobile Alero and Pontiac Grand Am (N car) model vehicles equipped with 2.4L (RPO LD9) engine, built between 11/23/99 and 12/3/99 , and built within the following VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number have been prepared, and are being furnished to involved dealers with the campaign bulletin. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

This campaign involves only dealer inventory vehicles with less than 50 miles (80 km).

All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles.

Important: This procedure is to be used only on vehicles with less than 50 miles (80 km).

LD9 Engine Rod Bearing Break-In Procedure

It may be necessary to add up to three (3) gallons of fuel to the vehicle prior to performing this procedure.

1. Drive the vehicle for 40 to 50 miles (64 to 80 km) with light acceleration and speed. Do not exceed 3000 engine RPM.
2. Install the GM Campaign Identification Label.

Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label". Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in by the customer for periodic servicing. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels can be obtained from Dealer Support Materials by calling 1-888-414-6322 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Apply the "Campaign Identification Label" only on a clean, dry surface.

Submit a Product Campaign Claim with the information indicated below.

Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission.