CAMPAIGN:PISTON KNOCK REPLACE PARTIAL ENGINE

Model and Year: 1986 CHEVROLET CELEBRITY MODELS EQUIPPED WITH 2.8L 2BBL (RPO LE2) ENGINES PRODUCED AT RAMOS ARIZPE ENGINE PLANT

TO: ALL CHEVROLET DEALERS

Some 1986 Chevrolet Celebrity models equipped with 2.8L 2BBL (RPO LE2) engines produced at the Ramos Arizpe engine plant may have been assembled with one or more incorrectly machined piston(s). This condition could result in engine knock.

Correction of this condition will consist of inspection for suspect engine production date codes and, if required, replacement of the partial engine assembly.

DEALER CAMPAIGN RESPONSIBILITY

WHENEVER A NEW VEHICLE SUBJECT TO THIS CAMPAIGN REQUIRES REPLACEMENT OF THE PARTIAL ENGINE ASSEMBLY AS PROVIDED IN THIS BULLETIN, THE FOLLOWING STEPS MUST BE COMPLETED BEFORE SELLING OR RELEASING VEHICLE.

1. For new vehicles in dealer inventory, notify prospective purchasers, prior to purchase, that a new partial engine assembly was installed by an authorized dealer at the request of Chevrolet Motor Division.

2. To avoid unnecessary disputes with the customers and owner dissatisfaction, place the following statement on your sale agreement with the purchaser of a new vehicle on which the services described in this bulletin are performed.

"A new partial engine assembly was installed in this new vehicle by an authorized dealer at the request of Chevrolet Motor Division."

Dealers are to perform the services described in this bulletin on 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 as instructed before reselling or releasing the vehicle.

VEHICLES INVOLVED

Involved are certain 1986 Chevrolet Celebrity models equipped with 2.8L 2BBL (RPO LE2) engine produced at the Ramos Arizpe engine plant with the suspect engine production date codes and built within the following vehicle identification number breakpoints:

PLANT FROM THROUGH ----- ----- ------- Framingham GG140861 GG143465 Oklahoma City G6250061 C6271234

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 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.

OWNER NOTIFICATION

Customers who have already purchased new vehicles with the suspect engine production date codes will be notified by Chevrolet Motor Division and asked to bring their vehicles to an authorized dealer to have the engine codes checked and, if required, replacement of the partial engine assembly.

PARTS INFORMATION

Parts required to complete this correction are to be obtained from General Motors Warehousing and Distribution Division (GMWDD). To ensure these parts will be obtained as soon as possible, they should be ordered from GMWDD on a C.I.O. order with NO special instruction code, but on an advise code (2).

PART NUMBER QUANTITY DESCRIPTION ----------- -------- ----------- 14089008 1 Partial Engine

P/N 14089008 CONSISTS OF BLOCK, PISTONS AND ROD ASSEMBLIES, CRANKSHAFT, CAMSHAFT BEARINGS, CONNECTING ROD BEARINGS AND CRANKSHAFT REAR OIL SEAL.

14101336 1 Gasket Kit 10048958 1 Gasket Kit-Cylinder Head 1977935 1 Distributor Gasket 14077876 1 Oil Pan Rear Seal 25010908 1 Oil Filter (From Bulk) 4 Qts. SAE 5W30 Oil (From Bulk) 1/2 Qt. Engine Coolant 1052439 1 1/2 Cans Engine Paint 1052917 1 Tube RTV 1052367 1/4 Quart Lube - EOS 1052080 1/2 Tube Pipe Sealant

SERVICE PROCEDURE

o Some partial engine assemblies may not be painted as received from GMWDD. Paint as required.

o Engine coolant is to be re-used. When draining system be sure to use a clean container to prevent contamination of the coolant.

o Consult the 1986 Celebrity Shop Manual (ST-365-86) for proper fastener torque values.

INSPECTION

1. Inspect engine production code stamped on the horizontally machined surface of the engine block just forward of the intake manifold (see Figure 1). It may be necessary to clean the surface in order to read the code.

2. If the first five (5) characters of the 10 character engine production code (see Figure 2) are A0605*****, replacement of the partial engine assembly is required.

If the first five (5) characters of the engine production code are anything other than A0605*****, the vehicle is not involved. Install Campaign completion label.

PROCEDURE TO REMOVE ENGINE:

1. Disconnect battery.

2. Remove air cleaner.

3. Disconnect accelerator cable.

4. Disconnect T.V. cable.

5. Disconnect cruise cable and remove bracket.

6. Drain cooling system. Using a clean container, save coolant for re-use.

7. Disconnect upper radiator hose.

8. Disconnect heater hose at thermostat housing.

9. Disconnect grounds at thermostat housing.

10. Disconnect brake booster vacuum hose.

11. Disconnect necessary vacuum hoses.

12. Disconnect necessary wires at engine (top).

13. Remove thermostat housing stud (to remove crossover).

14. Remove exhaust crossover.

15. Remove alternator belt.

16. Remove AIR pump pulley & belt.

17. Remove A/C belt.

18. Disconnect heater hose at water pump.

19. Remove P/S belt.

20. Disconnect P/S pump at engine.

21. Disconnect wires at A/C comp. & press, cut-off switch.

22. Disconnect A/C comp. from brackets.

23. Disconnect AIR hose at catalytic converter AIR pipe.

24. Disconnect wire harness at rear of RH head.

25. Disconnect transmission dipstick tube at manifold.

26 Disconnect fuel lines at transmission,.

27. Raise vehicle.

28. Remove inner fender splash shield.

29. Remove flywheel cover.

30. Disconnect wires at starter.

31. Remove starter.

32. Remove lower A/C adjusting bracket.

33. Disconnect fuel lines at fuel pump.

34. Disconnect lower radiator hose.

35. Disconnect exhaust pipe at manifold.

36. Remove flexplate to torque converter bolts.

37. Remove crank pulley.

38. Disconnect transmission bracket at engine.

39. Remove mount nuts.

40. Disconnect wires at engine (bottom).

41. Lower vehicle.

42. Disconnect strut bracket at radiator support and swing on top of engine.

43. Disconnect grounds & harness bracket at bellhousing studs.

44. Remove bellhousing bolts.

45. Remove hood.

46 Install jack under trans.

47. Install lift device.

48. Remove engine.

49. Remove flexplate.

50. Mount engine on stand.

PROCEDURE TO DISASSEMBLE OLD ENGINE:

1. Remove carburetor & vacuum hoses.

2. Remove distributor cap & plug wires.

3. Remove AIR pump.

4. Remove alternator & mount bracket.

5. Remove alternator/AIR pump adj. bracket.

6. Remove AIR management valve, deceleration valve, & hoses.

7. Remove fuel pump & push rod.

8. Remove torque strut & bracket.

9. Remove water pump pulley.

10. Remove oil sending unit.

11. Remove solenoids & brackets (EGR, idle speed & carburetor bowl vent).

12. Remove distributor.

13. Remove rocker covers and clean.

14. Remove intake manifold and clean.

15. Remove push rods.

16. Remove lifters.

17. Remove cylinder heads and clean heads & bolts.

18. Remove water pump.

19. Remove harmonic balancer, front cover, timing chain & gears, & chain guide.

20. Remove camshaft.

21. Drain engine oil.

22. Rotate engine on stand.

23. Remove motor mount & bracket.

24. Remove oil pan & pump and clean pan.

PROCEDURE TO ASSEMBLE NEW ENGINE:

1. Mount new short block on stand.

2. Install camshaft.

(1) Coat cam bearings with P/N 1052367 lube.

(2) Coat cam lobes with P/N 1052367 lube.

(3) Coat cam journals with engine oil.

3. Install timing chain & gears, timing chain guide, front cover, & harmonic balancer.

(1) Coat sprocket thrust surface with Molykote.

(2) Coat timing chain with engine oil.

(3) Coat front cover seal contact area on harmonic balancer with engine oil.

(4) Apply sealant to key & keyway.

4. Install water pump.

o Coat bolt threads with pipe sealant P/N 1052080.

5. Rotate engine on stand.

6. Install oil pump & drive shaft.

7. Install oil pan.

(1) Apply a continuous 3mm (1/8") bead of P/N 1052917 RTV sealer to oil pan sealing surface of front cover and the oil pan sealing flange.

(2) Replace rear oil pan seal.

8. Install motor mounts & brackets.

9. Install fuel pump & fuel pump push rod.

10. Rotate engine on stand.

11. Install lifters.

o Coat lifters with engine oil.

12. Install cylinder heads.

o Coat cylinder head bolts with P/N 1052080 sealer.

13. Install push rods and adjust lash.

14. Install intake manifold.

(1) Apply a 5mm (3/16") diameter bead of P/N 1052917 RTV sealer to front & rear block sealing surfaces.

(2) Place a 3mm (1/8") diameter dot of P/N 1052917 RTV sealer at the intake manifold & cylinder head split lines.

15. Install rocker covers.

16. Install distributor.

17. Install solenoids & brackets (EGR, idle speed, & carburetor bowl vent).

18. Install oil sending unit.

19. Install water pump pulley.

20. Install torque strut & bracket.

21. Install AIR management valve, decelerator valve, & hoses.

22. Install alternator/AIR pump adjusting bracket.

23. Install alternator & mount bracket.

24. Install AIR pump.

25. Install distributor cap & plug wires.

26. Install carburetor & vacuum hoses.

27. Fill engine with oil.

PROCEDURE TO INSTALL NEW ENGINE:

1. Install lift device.

2. Dismount engine from stand.

3. Install flexplate.

4. Install engine in car.

5. Install bellhousing bolts.

6. Connect grounds & harness bracket at bellhousing studs.

7. Connect strut bracket at radiator support.

8. Raise vehicle.

9. Connect wires at engine (bottom).

10. Install mount nuts.

11. Connect transmission bracket at engine.

12. Install crank pulley.

13. Install flexplate to torque converter bolts.

14. Connect exhaust pipe at manifold.

15. Connect lower radiator hose.

16. Connect fuel lines at fuel pump.

17. Install lower A/C adjusting bracket.

18. Install starter.

19. Connect wires at starter.

20. Install flywheel cover.

21. Install inner fender splash shield.

22. Lower vehicle.

23. Connect fuel lines at trans.

24. Connect transmission dipstick tube at manifold.

25. Connect wire harness at rear of RH head.

26. Connect AIR hose at catalytic converter AIR pipe.

27. Connect A/C compressor from brackets.

28. Connect wires at A/C compressor & pressure cut-off switch.

29. Connect P/S pump at engine.

30. Install P/S belt and adjust.

31. Connect heater hose at water pump.

32. Install A/C belt and adjust.

33. Install AIR pump pulley & belt.

34. Install alternator belt and adjust.

35. Install exhaust crossover.

36. Install thermostat housing stud (to attach crossover).

37. Connect necessary wires at engine (top).

38. Connect necessary vacuum hoses.

39. Connect brake booster vacuum hose.

40. Connect grounds at thermostat housing.

41. Connect heater hose at thermostat housing.

42. Connect upper radiator hose.

43. Refill cooling system using original coolant. Top off coolant level as required.

44. Connect cruise cable and install bracket.

45. Connect T.V. cable.

46. Connect accelerator cable.

47. Install air cleaner, battery and hood.

48. Start engine and adjust timing & idle speed.

49. Road test vehicle.

50. Install Campaign Identification Label.

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 five digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or ballpoint 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 for periodic servicing by the owner.

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

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

* FAILED PARTS LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW FC OP HRS HRS ---------------- ---- -------- ----- ---- -- --- --- Inspect for involvement not A0605 engine prefix no futher action required 00 V3580 .2 .1

Replace partial engine assy without A/C or cruise 12 14089008 ** 00 V3581 13.0 .1

Replace partial engine assy with A/C & without cruise 12 14089008 ** 00 V3582 13.5 .1

Replace partial engine assy with cruise & without A/C 12 14089008 ** 00 V3583 13.1 .1

Replace partial engine assy with cruise & A/C 12 14089008 ** 00 V3584 13.6 .1

* Campaign Administrative Allowance.

** The Parts Allowance should be the sum total of the current GMWDD Dealer Net plus 30% of all parts required for the repair.

PARTIAL ENGINE ASSEMBLIES REMOVED FROM VEHICLES ARE TO BE HELD BY THE DEALER FOR SCRAPPING BY AN AUTHORIZED ZONE REPRESENTATIVE.

Dealers will automatically receive the correct parts and labor allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim submission.

(Notification Used By Chevrolet Motor Division)

Dear Chevrolet Owner:

Some 1986 Chevrolet Celebrity models equipped with 2.8L 2BBL engines may have been produced with one (1) or more incorrectly machined pistons. This condition could result in engine knock.

To prevent the possibility of this condition occurring on your vehicle, a new partial engine assembly will be installed. This service will be performed for you at no charge.

Instructions for this service have been sent to your Chevrolet Dealer. Please contact your Chevrolet Dealer to arrange a service date. Although the labor time allowance to perform this correction is about thirteen (13) hours, the actual amount of time to correct and process your vehicle may take two days or more. The actual time required depends upon the workload and procedures in your dealer's service department. Please ask your dealer how much time will be necessary.

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

Chevrolet Motor 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.