CAMPAIGN: REAR ENG LIFT/COIL MOUNTING BRKT AND COIL WIRE. Pontiac Sunbird 1987

For 1990-2009 cars

# CAMPAIGN: REAR ENG LIFT/COIL MOUNTING BRKT AND COIL WIRE

PRODUCT CAMPAIGN 87-C-07 REAR ENGINE LIFT/COIL MOUNTING BRACKET AND COIL WIRE SHIELD

VECHILES AFFECTED: 1987 Pontiac Sunbirds Equipped With 2.OL ----------------- (RPO LT2/LT3) L4 OHC Engine (VIN Codes K and M)

#### TO: ALL PONTIAC DEALERS

General Motors has determined that some 1987 Pontiac Sunbird models may experience fatigue fracture of the rear engine lift bracket. The ignition coil and coil bracket is mounted to the rear engine lift bracket. If the lift bracket fractures, the coil may become unsupported. This condition may ultimately result in engine misfire and possible loss of engine operation.

Additionally, high frequency magnetic coupling between the ignition coil and distributor coil magnetic pickup can result in extra pulses in the RPM reference signal. This condition may cause extended cold cranking/no start, pop back during cranking and/or occasional "Service Engine Soon" light with stored code 42.

To protect against fatigue fracture of the rear engine lift bracket, the lift bracket will be inspected and, if necessary, replaced. Additionally, a pencil brace (service kit) will be installed as required on involved vehicles.

To prevent the possibility of magnetic coupling between the ignition coil and distributor coil magnetic pickup, a coil wire shield will be installed on all involved vehicles.

#### VEHICLES INVOLVED

Involved are certain 1987 Pontiac Sunbird models equipped with 2.OL (RPO LT2/LT3) L4 OHC engines (VIN codes K and M) and built within the following vehicle breakpoints:

#### Model Year Plant From Through Service Required ---------- ----- ---- ------- ---------------- 1987 Lordstown SOP H7535565 Lift Bracket Pencil Brace and Coil Wire Shield

1987 Lordstown H7535566 H7584931 Coil Wire Shield Only

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 the involved dealers with the campaign bulletin. Owner name and address data 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 such listings 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.

#### OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Pontiac Division (see copy of owner letter included with this bulletin.)

#### DEALER CAMPAIGN RESPONSIBILITY

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.

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, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle. Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.

#### PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operation (GMSPO). To insure that these parts are obtained as soon as possible they should be ordered on a C.I.O. order with no special instruction code, but on advise code (2).

PART NUMBER DESCRIPTION QUANTITY/VEHICLE ----------- ----------- ---------------- 10068556 Rear Engine Lift 1 (As Required) Bracket Service Kit*

* Service Kit Consists of: (1) P/N 11508279 Nut (1) P/N 11508477 Bolt (2) P/N 11508006 Nut (1) P/N 10068555 Pencil Brace (1) P/N 10068560 Instruction Sheet

PART NUMBER DESCRIPTION QUANTITY/VEHICLE ----------- ----------- ----------------

14076453 Rear Engine Lift 1 (As Required) Bracket **

** It is estimated that only 11% of the vehicles requiring a pencil brace will also require lift bracket replacement, order parts accordingly.

10103509 Coil Wire Shield 1 Service Kit ***

*** Service Kit consists of: (1) P/N 10083160 Shield (1) P/N 10103508 Instruction Sheet

#### SERVICE PROCEDURE

1. Disconnect negative battery cable.

2. Remove air cleaner and inspect for pencil brace (See Figure 1). If pencil brace is NOT present, follow instructions for "PENCIL BRACE AND COIL WIRE SHIELD-REQUIRED" otherwise follow instructions for "COIL SHIELD ONLY REQUIRED" as described below.

#### PENCIL BRACE AND COIL WIRE SHIELD REQUIRED

3. Disconnect electrical wiring from coil.

4. Remove upper existing coil bracket bolt (20mm long) and loosen lower existing coil bolts.

5. Remove two (2) lift bracket nuts and discard.

6. Remove lift bracket from engine and inspect for signs of a fatigue type crack appearing between the two (2) mounting stud holes. If a crack is present, replacement of lift bracket (P/N 14076453) is required. Transfer lower coil bolts, coil and add coil wire shield to new bracket. (See Figure 2).

7. Install new coil bracket bolt (top) (30 mm long) and attach lift bracket (pencil) brace and nut from service kit (See Figure 1).

8. Position lift bracket, coil and coil wire shield on engine and attach end of pencil brace to front lift bracket stud.

9. Install new lift bracket nuts (washer faced) to studs.

10. Torque coil bracket nut first to position pencil brace 20-30 Nm (15-22 lb. ft.).

11. With shield in position, insure at least 2 mm clearance to the distributor cap (See Figure 2, View A). Bend engine lift bracket if required for minimum clearance. SHIELD MUST NOT CONTACT DISTRIBUTOR CAP.

12. Torque lift bracket nuts 40-60 Nm (30-45 lb. ft.).

13. Torque lower coil bolts 20-30 Nm (15-22 lb. ft.).

14. Connect electrical wiring at coil. COIL WIRE NIPPLE MUST NOT CONTACT SHIELD.

15. Install air cleaner.

16. Connect negative battery cable.

17. Install campaign identification label.

#### COIL WIRE SHIELD ONLY REQUIRED

3. Remove upper existing coil bolt.

4. Loosen lower existing coil bolts.

5. Install shield (See Figure 2.)

6. Reinstall existing upper coil bolt and hand tighten.

7. Hand tighten lower coil bolts.

8. With shield in position, insure at least 2 m clearance to the distributor cap (See Figure 2, View A). Bend engine lift bracket if required for minimum clearance. SHIELD MUST NOT CONTACT DISTRIBUTOR CAP.

9. Torque upper and lower coil bolts 20-30 Nm (15-22 lb. ft.).

SHIELD.

11. Install air cleaner.

12. Connect negative battery cable.

13. 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 ball point 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 7901-709).

#### 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 --------- ------- --------- ----- ----- Install Pencil Brace 96 V4110 0.5 0.1 and Coil Wire Shield

Replace Engine Lift 96 V4111 0.5 0.1 Bracket, Install Penci Brace and Coil Wire Shield

Install Coil Wire 96 V4112 0.3 0.1 Shield Only

* 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 campaign repair listed for credit. This entry will not require authorization.

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

Parts required are to be listed in 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. Claims 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.

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.