Customer Satisfaction Program - 02041A - Cam Drive Idler and Tensioner Pulleys and Water Pump-Inspect/Replace

THIS BULLETIN REVISION ADDS 1999-01 MODEL YEAR CATERAS TO THE PROGRAM AND SUPERSEDES PROGRAM BULLETIN 02041, ISSUED SEPTEMBER, 2002. PLEASE DISCARD ALL COPIES OF 02041.

General Motors has decided that certain 1997, 1998, 1999, 2000 and 2001 Cadillac Catera model vehicles equipped with 3.0L (RPO L81 - VIN Code R) V6 engines may exhibit a condition in which the cam drive timing belt idler pulleys and tensioner pulley and water pump may fail. This may result in engine failure and a "walk home" condition.

Dealers are to inspect the cam drive idler pulleys, tensioner pulley, timing belt and water pump and replace as required.

Involved are all 1997,1998, 1999, 2000 and 2001 Cadillac Catera model vehicles equipped with 3.0L (RPO L81 - VIN Code R) V6 engine and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) prior to beginning program repairs.

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the program bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. Any dealer not receiving a computer listing with the program bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this program.

Parts required to complete this program are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

Important: It is estimated that most 1997 Cateras will require at least one idler pulley and 30% will require a second idler pulley replacement. Only 10% of 1998 Cateras will require one idler pulley replacement. Please order parts accordingly. The Drive Belt Tensioner Kit includes a tensioner pulley with extra nut and washer, a timing belt and a water pump with O-ring seal.

Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information.

Tools Required

1. Disconnect the negative battery cable.
2. Loosen the clamps on the intake air resonator to the throttle body.
3. Remove the vacuum lines and electrical connector to the intake air resonator.
4. Remove the intake air resonator.

Important: If the vehicle is a 1999-01 Catera with electronic throttle body control (ETC), continue to Step 5 and remove the plenum and throttle body. If the vehicle is a 1997 or 1998, go to Step 7.

5. Remove all vacuum lines and electrical connectors.
6. Remove the throttle body and plenum.
7. Remove the AIR crossover pipe clamps, hoses and assembly.
8. Remove the accessory drive belt, belt tensioner and power steering retaining bolt.
9. Remove the wire harness cover, harness and harness channel from the timing cover.
10. Remove the water pump pulley.
11. Remove the crankshaft pulley.
12. Remove the timing belt cover.
13. Inspect the water pump to see if it is the new "Type C" water pump by looking to the right and just below the top water pump flange bolt for GM P/N 24465319. If another number appears at this location, continue to Step 14 and replace the water pump with a "Type C" water pump and seal kit, P/N 55352002 (also part of 1997-98 kit, P/N 55352000; and 1999-01 kit, P/N 55352001). If the water pump is already a "Type C", go to Step 16.
14. Drain the coolant from the system and remove the water pump.
15. Clean the engine block surface and use a thread tap to clean the threads in the block. Coat the water pump seal with silicone grease. Use thread locker on the water pump bolts and install the pump.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

16. Inspect the two idler and one tensioner pulleys for the good "brown" color "Viton" bearing seal. Replace any of the three pulleys that contain a "black" bearing seal with a brown "Viton" seal pulley. If no components are replaced, go to Step 22.
17. Replace the timing belt if any component in the cam drive system is replaced.
18. Install the J tool from kit J 42069 in between cam gears 1+2, 3+4.
19. Loosen the idler and tensioner pulleys and remove the timing belt.
20. Replace the idler and tensioner pulleys as needed.

Important: Re-use all timing belt pulley spacers, which are located behind each timing belt pulley, as originally installed. This will ensure proper timing belt alignment.

21. Refer to timing belt procedure and install the new timing belt.

Important: Catera timing belts have timing marks, which are intended as initial assembly aids only. The J tools from kit J 42049 must be used to assure accurate camshaft timing. A few 1997-98 Cateras have previously been repaired by installation of a "hybrid" long block engine assembly (P/N 9194558), which has the same cam drive pulley layout as the 1999-01 engines. The timing belt in 1997-98 kit, P/N 55352000, may be used for the "hybrid" long block, but does not have assembly aid timing marks in the correct locations. The timing belt in either 1999-01 kit, P/N 55352001 or kit, P/N 55352044, may also be used and has assembly aid timing marks in the correct locations for the "hybrid" block. Original 1997-98 engines can be identified by a spin-on style oil filter (PF47) and the "hybrid" and later model engines have a cartridge style oil filter.

22. Inspect the timing belt cover seal and replace if necessary.
23. Install the timing belt cover.

Tighten
Tighten the bolts to 8 N·m (71 lb in).

24. Install the crankshaft balancer.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).

25. Clean the water pump pulley bolts on a wire wheel to remove the old thread locker. Install the water pump pulley and bolts, using thread locker on the bolts.

Tighten
Tighten the bolts to 8 N·m (71 lb in).

26. Install the wire harness channel onto the timing belt cover. Route the wire harness in the channel and install the harness cover.
27. Install the accessory belt tensioner, power steering retaining bolt and drive belt.
28. Install the AIR crossover pipe, clamps and hose assembly.

Important: If the vehicle is a 1999-01 Catera with electronic throttle control, continue to Step 29 and install the plenum and throttle body. If the vehicle is a 1997 or 1998, go to Step 31.

29. Install the plenum and throttle body, making sure to lightly coat the plenum O-ring(s) with engine oil. Inspect the O-rings and replace if necessary.

Tighten

•	Tighten the plenum bolts to 8 N·m (71 lb in).

•	Tighten the throttle body bolts to 12 N·m (106 lb in).

30. Install the vacuum lines and electrical connectors to the plenum and throttle body.
31. Install the intake air resonator.
32. Install the vacuum lines and electrical connector to the intake air resonator and tighten the two clamps on the throttle body.
33. Install the GM Recall Identification Label.

For US and IPC

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

Put the Program Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Program Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Program Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Request Item Number S-1015 when ordering.

Additional Program Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

For Canada

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

Put the Program Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Program Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP91 when ordering.

Customer requests for reimbursement of previously paid repairs to the cam drive timing belt idler pulleys and tensioner pulley, and water pump are to be submitted by June 30, 2004 (this time limit may be longer depending upon the law in your state/province/country). Repairs must have occurred within 7 years of the date the vehicle was originally placed in service, or 100,000 miles (161,00 km), whichever occurs first.

Consideration for reimbursement will be allowed only if genuine General Motors parts were used. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

When a customer requests reimbursement, they must provide the following:

Customers from the States of California, Connecticut, Virginia, and Wisconsin must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter.

Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS.

Important: Refer to the GM service policies and procedures manual, section 1.6.2, for specific procedures regarding customer reimbursement verification.

The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

Submit a Product Program Claim with the information indicated below.

Refer to the General Motors WINS Claim Processing Manual for details on Product Recall Claim Submission.

For US and Canada

Customers will be notified of this program on their vehicles by General Motors (see copy of customer letter included with this bulletin).

For IPC

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached suggested dealer letter.

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

Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle.

Dear Cadillac Customer:

We want your experience owning your 1997, 1998, 1999, 2000 or 2001 Cadillac Catera model vehicle to be better than any other you've had ... which is why we're writing.

We have learned that your 1997, 1998, 1999, 2000 or 2001 Cadillac Catera model vehicle, equipped with a 3.0L V6 engine, may exhibit a condition in which the cam drive timing belt idler pulleys and tensioner pulley, and water pump may fail. This may result in engine failure and a "walk home" condition.

We've sent the correct parts information to your dealer so that your 1997, 1998, 1999, 2000 or 2001 Cadillac Catera model vehicle can be serviced as quickly as possible. This service will be performed for you at no charge .

We recommend that you contact your dealer to arrange a service date.

Presenting the attached card to your dealer will assist in making the necessary correction in the shortest possible time.

If you no longer own this vehicle, please check the appropriate box and provide new owner information, if available.

(Statement for all states except as shown below)

If you have already paid for some of all of the cost to have these parts replaced, or had your engine repaired or replaced as a result of timing belt failure, and you have not received reimbursement under a Vehicle Service Contract, and the in-service time and mileage was less than 7 years and 100,000 miles (161,000 km), you should contact your dealer to seek reimbursement. Please provide your dealer with your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair. Your request for reimbursement, including the information and documents mentioned above, must be received by your dealer by June 30, 2004.

(Statement for California, Connecticut, Virginia, and Wisconsin)

If you have already paid for some or all of the cost to have these parts replaced, or had your engine repaired or replaced as a result of timing belt failure, and you have not received reimbursement under a Vehicle Service Contract, and the in-service time and mileage was less than 7 years and 100,000 miles (161,000 km), you should write to the Cadillac Motor Division, P.O. Box 33169, Detroit, MI 48232-5169 to seek reimbursement. Please provide your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges and proof of ownership of the vehicle at the time of the repair. This information must be provided within two (2) years after the date on which you paid for the repair, or by June 30, 2004, whichever is greater.

If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below:

Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation.

We sincerely regret any inconvenience this causes you. Also, we want you to know that we will continue to do everything we can to ensure that you are completely satisfied with our products.

General Motors Corporation

Enclosure