ENGINE EXCHANGE PROGRAM 4.3L (SERVICE INFORMATION). GMC Truck S15 Pickup - 4WD 1992

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# ENGINE EXCHANGE PROGRAM 4.3L (SERVICE INFORMATION)

#### SUBJECT: ENGINE EXCHANGE PROGRAM - SERVICE INFORMATION

#### VEHICLES AFFECTED: 1992 M/L, S/T MODELS W/4.3L(L35) CENTRAL PORT FUEL INJECTED V6 ENGINE ----------------------------------------------------------------------------

#### Bulletin Covers:

An engine exchange program for the new version of the 4.3L V6 engine. This engine exchange procedure is in effect for the 1992 model year. Its purpose is to provide quick and helpful product feedback on possible manufacturing related conditions which result in customer dissatisfaction.

New 4.3L V6 engine features are as follows:

New Option Code - L35 CPI (Central Port Fuel Injection) Counter Rotating Balance Shaft, which is gear driven off camshaft Modified cylinder head with a new Intake Runner and Net Valve Lash design Modified Piston design.

#### Service Information:

If any internal components require replacement, the engine must be exchanged.

A. ENGINE COMPONENTS WHICH MAY SERVICED (without exchange): ------------------------------------------------------------- Only the valve rocker covers, oil pan, water pump, exhaust manifold, upper half of the intake manifold, and CPI fuel injection unit may be removed to determine whether the engine should be replaced. Before returning the engine, the above mentioned parts must be reinstalled.

#### NOTE: Any engine component identified above that is in need of repair should be repaired following service procedures in 1992 Service Manuals.

B. ENGINE EXCHANGE ------------------ Any deficient engine component not included in paragraph "A" above may necessitate an engine exchange.

COMPLETE ENGINES ARE REQUIRED FOR EXCHANGE

C. EXCHANGE PROCEDURE: ----------------------- Once the above preliminary diagnosis is made and an exchange unit is deemed necessary, call your Technical Assistance (TAC) TRUCK CHASSIS GROUP.

- TAC will require the VIN and serial number (the engine serial number can be found as shown on the attached illustration).

- TAC will arrange with Tonawanda Engine Plant to directly ship a replacement engine within 48 hours. The replacement engine will be complete except for accessories (i.e., starter, accessory drive, etc.).

- A TAC case number will be provided for each engine exchange. This number must be recorded on the identification card supplied with the replacement engine and must be affixed to the replaced engine being returned. The identification card must be filled out completely.

- The exchange unit must be returned to Tonawanda within 15 days in the original shipping crate. Failure to return the concerned unit will result in the DEALERSHIP being billed the value of an exchange unit.

- The exchange unit must be complete as removed from the vehicle. Dealerships returning incomplete units will be billed for missing materials.

All procedural steps must be followed to ensure the dealership is not billed for a replacement engine under this procedure.

The removed unit must be returned complete as removed from the vehicle in the container provided, without examination of the unit other than as described in paragraph A above. Engine dress on the removed unit must remain the same as the replacement engine shipped (i.e., manifolds, throttle body, etc.). Dealerships returning units even partially disassembled have not complied with this procedure and will be billed for all materials furnished.

The exchange unit will be shipped with minimum quantity of oil; add oil per specifications.

Attached to the exchange unit will be a return shipping label (freight is prepaid).

D. PREPARATION FOR SHIPPING: ----------------------------- Visually check all fluid levels to assure they are within the normal operating range. If not, drain and measure the oil and coolant from the concerned unit. Record the oil and coolant measurement results on the repair order. REPLACE THE DRAIN PLUG.

Remove engine assembly as outlined in the 1992 Service Manuals. Remove all plastic shipping plugs and covers from the exchange unit and install them on the removed unit.

If engine leaks, mark leak area on engine. Write the TAC reference number on the repair order form.

Place the removed unit into the original shipping container. Include a copy of the repair order in original envelope and attach to original engine.

E. SHIPPING INSTRUCTIONS: -------------------------- Place the shipping label over the original container shipping label.

The Bill of Lading and Customs Papers (when necessary) provided with the exchange engine are the only documents required to return ship the removed engine.

#### NOTE: The same carrier, whose name is indicated on the Bill of Lading, should be used for the return shipment.

All required data on the Bill of Lading will be complete, except for the date and carrier signature. After the Bill of Lading has been dated and signed by the carrier, retain the last copy with your repair order and provide the other two copies to the carrier. Your copy of the Bill of Lading, signed by the carrier, is your proof of returning the engine.

The removed engine is to be shipped by Truck Freight Collect to:

GM Powertrain Tonawanda Engine Plant River Road Tonawanda, NY 14150

Attn: 4.3L (L35) Engine Exchange Program Quality Assurance Department

To increase the effectiveness of the program, the removed unit should be returned IMMEDIATELY. Failure to return the removed unit will result in the dealership being billed $2,600.00 for the unit furnished, plus an administration charge.

F. WARRANTY CLAIMS PROCESSING PROCEDURE: ----------------------------------------- Upon completion of the repair, a warranty claim is to be submitted to G.M. of CANADA.

Labour Operation **Part Labour *Other Number Description Allowance Hours Hours --------- ----------- --------- ----- ------ J1880 Replace Engine Assembly $ 345.00 0.2 hr (Vehicle Application) M 6.7 hrs L 7.0 hrs S 6.4 hrs T 6.8 hrs

Add Time: (With Air Conditioning) M 0.9 hrs L 0.1 hrs S/T 0.2 hrs

(With Power Steering) M/L 0.1 hr S 0.2 hr

(With Cruise) M/L 0.1 hr

(With Automatic Trans) M/L 0.3 hr S/T 0.1 hr

* Administrative Allowance.

#### NOTE: Applicable miscellaneous items, such as engine oil and engine coolant, should be added to the Part Allowance amount and included in the Net Amount column of the claim.

YOUR COOPERATION IS GREATLY APPRECIATED. PROMPT RETURN OF YOUR CONCERNED UNIT WILL INCREASE THE EFFECTIVENESS OF THIS PROGRAM. IF YOU HAVE ANY QUESTIONS CONCERNING THE EXCHANGE PROGRAM ADMINISTRATIVE PROCEDURES, PLEASE CONTACT THE TECHNICAL ASSISTANCE (TAC) TRUCK CHASSIS GROUP.

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.