CAMPAIGN: COOLANT PUMP. Pontiac Sunbird 1992

For 1990-2009 cars

# CAMPAIGN: COOLANT PUMP

#### Subject: CUSTOMER SATISFACTION CAMPAIGN 93-C-54A COOLANT PUMP

#### Models Affected: 1992-93 PONTIAC SUNBIRDS WITH 2.OL ENGINE (RPO LE4; VIN CODE H)

"This bulletin supersedes bulletin 93-C-54, which should be discarded This bulletin is being issued to list the current part number, correct service procedure step #16 and add labor operations."

#### TO: ALL PONTIAC DEALERS

#### DEFECT INVOLVED

General Motors has determined that some 1992-93 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 your vehicle's coolant pump and, if necessary, replace the coolant pump.

#### VEHICLES INVOLVED

Involved are certain 1992-93 Pontiac Sunbird model vehicles equipped with the 2.OL engine that fall within the following VIN breakpoints:

UP TO AND YEAR MODEL PLANT BEGINNING INCLUDING ------------------------------------------------------- 1992 Sunbird Lordstown N7539565 N7600508 1993 Sunbird Lordstown P7500020 P7523040

Vehicles which Pontiac records indicate were previously repaired under warranty with coolant pump P/N 93215645 or P/N 93221331 are not included in this campaign.

All vehicles listed on the dealer printout will require inspection, and as necessary, correction. Other suspect vehicles should be checked for campaign involvement by utilizing the Vehicle Information Service System (VISS) for verification.

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

#### PARTS INFORMATION

General Motors Service Parts Operations (GMSPO) will preship 40% of required parts to complete this campaign to affected dealers the during the week of October 10, 1994. Preshipped parts will be charged to the dealers' open parts account. Additional parts required to complete this campaign are to be obtained from GMSPO. To ensure parts will be obtained as soon as possible, order them from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).

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

Replace the parts listed below only if necessary.

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

#### OWNER NOTIFICATION

Owners will be notified of this campaign by Pontiac. Division (see copy of Owner Letter included with this bulletin).

#### DEALER CAMPAIGN RESPONSIBILITY

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 owners take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, 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 the instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owners 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 it 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.

#### SERVICE PROCEDURE

If a vehicle subject to this campaign has been repaired for this condition and the repair order indicates that P/N 93215645 or P/N 93221331 has 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 19 mm wrench on tensioner assembly.

3. Remove fuel vapor 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 both upper and lower coolant pump weep holes using shop flash light 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 coolant pump has two weep holes. Refer to Figure 3.

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 tension 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 the 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 vapor line from timing belt cover.

60. Install serpentine drive belt with a 19 mm 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.

#### CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified 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, the five digit dealer code of the dealer performing the campaign service, and the date the vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. Install the label only on a clean, dry surface of the radiator baffle where it is readily visible. (Additional campaign labels are available on stationery order as Form 7201-709.)

#### CLAIM INFORMATION

A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.

DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:

*Other Failure Labor Labor Labor Operation Code Operation Hours Hours --------- ----------------------------------- Coolant Pump Inspection 96 V9200 1.2 0.1 Add for A/C 0.1

Inspect and Replace Coolant Pump 96 V9201 2.4 0.1 Add for A/C 0.1

Correct P/N Verified By R.O. From 96 V9202 0.2 --- Previous Repair

Owner Reimbursement for Previous Repair 96 T2599 --- **0.2

CLAIMS FOR OWNER REIMBURSEMENT - T2599 - MUST BE SUBMITTED WITH THE CORRECT V- LABOR OPERATION (V9200, V9201, V9202) TO REMOVE VEHICLE FROM CAMPAIGN LIST.

* In addition, dealerships will receive 0.1 hours credit for dealer administrative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each "V" labor operation campaign repair listed for credit. This entry will not require authorization.

** 0.2 hour for clerical administration may be applied for in the Other Labor Hours on customer reimbursement. Customer reimbursement over $300.00 must be submitted to the zone office.

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

Parts required are to be listed on your warranty claim in the normal manner. Parts will be credited at dealer net plus 30% dealer handling allowance.

Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the labor operation as outlined.

#### RECORDING COMPLETION

Repairs submitted for vehicles not involved in the campaign will not be paid.

Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS." Owners are being asked to present the owner reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.

Dear Pontiac Owner:

#### REASON FOR THIS RECALL

General Motors has determined that some 1992-93 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.

#### WHAT WE WILL DO

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

This service will be provided for you at no charge.

#### WHAT YOU SHOULD DO

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

Instructions for making this inspection/correction have been sent to your Pontiac Dealer. The labor time to perform this service is approximately two and one half (2 1/2) hours. Please allow additional time for your dealer to process your vehicle.

The enclosed Campaign Owner Reply Card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary inspection/correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage-paid Owner Reply Card and returning it to us.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products.

PONTIAC DIVISION General Motors Corporation

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.