CAMPAIGN:PISTON KNOCK REPLACE PARTIAL ENGINE

PISTON KNOCK 1986 OLDSMOBILE CUTLASS CIERA MODELS

MODELS/YEARS: EQUIPPED WITH 2.8L 2BBL LE2 (VIN CODE X) ENGINES PRODUCED AT RAMOS ARIZPE ENGINE PLANT

CONDITION

Some 1986 Oldsmobile Cutlass Ciera models equipped with a 2.8L 2BBL LE2 (VIN Code X) engine 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.

VEHICLES INVOLVED

Involved are certain 1986 Oldsmobile Cutlass Ciera models equipped with a 2.8L 2BBL LE2 (VIN Code X) 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 (G) G395469 G402834 Doraville (D) D433534 D440853

DEALER ACTION

Whenever a new vehicle subject to this campaign requires replacement of the partial engine anembly as provided in this bulletin, the following steps must be completed before selling and releasing the 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 Oldsmobile 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 anembly was installed in this new vehicle by an authorized dealer at the request of Oldsmobile 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.

SERVICE PROCEDURE

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 and 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 compressor and pressure cut-off switch.

22. Disconnect A/C compressor from brackets.

23. Disconnect AIR hose at catalytic converter AIR pipe.

24. Disconnect wire harness at rear of RH head.

25. Disconnect transaxle fluid fill tube at manifold.

26. Disconnect fuel lines at transaxle.

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 flywheel to torque converter bolts.

37. Remove crank pulley.

38. Disconnect transaxle 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 ground sand harness bracket at bellhousing studs.

44. Remove bellhousing bolts.

45. Remove hood.

46. Install jack under transaxle.

47. Install lift device.

48. Remove engine.

49. Remove flywheel.

50. Mount engine on stand.

Procedure to Disassemble Old Engine.

1. Remove carburetor and vacuum hoses.

2. Remove distributor cap and plug wires.

3. Remove AIR pump.

4. Remove alternator and mount bracket.

5. Remove alternator/AIR pump adjusting bracket.

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

7. Remove fuel pump and push rod.

8. Remove torque strut and bracket.

9. Remove water pump pulley.

10. Remove oil sending unit.

11. Remove solenoids and brackets (EGR, idle speed and 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. Keep push rods and lifters in the same order as they were originally installed. Used lifters must be reinstalled on the same cam lobe they were running on.

17. Remove cylinder heads and clean heads and bolts.

18. Remove water pump.

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

20. Remove camshaft.

21. Drain engine oil.

22. Rotate engine on stand.

23. Remove motor mount and bracket.

24. Remove oil pan and pump and clean pan.

Procedure to Assemble New Engine:

1. Mount new short block on stand.

2. Install camshaft.

a. Coat cam bearings with part number 1052367 lube. b. Coat cam lobes with part number 1052367 lube. c. Coat cam journals with engine oil.

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

a. Coat sprocket thrust surface with Molykote. b. Coat timing chain with engine oil. c. Coat front cover seal contact area on harmonic balancer with engine oil. d. Apply sealant to key and keyway.

4. Install water pump. o Coat bolt threads with pipe sealant part number 1052080.

5. Rotate engine on stand.

6. Install oil pump and drive shaft.

7. Install oil pan.

a. Apply a continuous 3 mm (1/8") bead of part number 1052917 RTV sealer to oil pan sealing surface of front cover and the oil pan sealing flange. b. Replace rear oil pan seal.

8. Install motor mounts and brackets.

9. Install fuel pump and fuel pump push rod.

10. Rotate engine on stand.

11. Install lifters. Be sure to install lifters on the cam lobe they originally ran on.

o Coat lifters with engine oil.

12. Install cylinder heads.

o Coat cylinder head bolts with part number 1052080 sealer.

13. Install push rods in the correct lifter, in the correct order and adjust lash.

14. Install intake manifold.

a. Apply a 5 mm (3/16") diameter bead of part number 1052917 RTV sealer to front and rear block sealing surfaces. b. Place a 3 mm (1/8") diameter dot of part number 1052917 RTV sealer at the intake manifold and cylinder head split lines.

15. Install rocker covers.

16. Install distributor.

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

18. Install oil sending unit.

19. Install water pump pulley.

20. Install torque strut and bracket.

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

22. Install alternator/AIR pump adjusting bracket.

23. Install alternator and mount bracket.

24. Install AIR pump.

25. Install distributor cap and plug wires.

26. Install carburetor and vacuum hoses.

27. Fill engine with oil.

Procedure to Install New Engine:

1. Install lift device.

2. Dismount engine from stand.

3. Install flywheel.

4. Install engine in car.

5. Install bellhousing bolts.

6. Connect grounds and 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 transaxle bracket at engine.

12. Install crank pulley.

13. Install flywheel 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 transaxle.

24. Connect transaxle fluid fill 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 to brackets.

28. Connect wires at A/C compressor and 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 and belt.

34. Install alternator belt and adjust.

35. Install exhaust crossover.

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

37. Construct 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 and idle speed.

49. Road test vehicle.

50. Install Campaign Completion 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.

PARTS INFORMATION

Parts required to complete this correction are to be obtained from WDDGM. To ensure these parts will be obtained as soon as possible, they should be ordered from WDDGM 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

PART NUMBER 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) 4Qts. SAE 5W30 Oil (From Bulk) 1/2Qt. Engine Coolant 1052439 1 1/2 Cans Engine Paint 1052917 1 Tube RTV 1052367 1/40t. Lube - EOS 1052080 1/2 Tube Pipe Sealant

o Some partial engine assemblies may not be painted as received from WDDGM. 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 Cutlass Ciera Service Manual for proper fastener torque values.

CLAIM INFORMATION

Failed Failure Labor Labor Repair Performed Part Number Code Operation Hours ---------------- ----------- ------- --------- ----- Inspection of Engine Code 96 V3580 .2

Replace Partial Engine Assembly 14089008 96 V3581 13.0 Vehicles Without A/C or Cruise

Replace Partial Engine Assembly 14089008 96 V3582 13.5 Vehicles With A/C

Replace Partial Engine Assembly 14089008 96 V3583 13.1 Vehicles With Cruise

Replace Partial Engine Assembly 14089008 96 V3584 13.6 Vehicles With A/C and Cruise

.1 hour for clerical administration may be added to the above operations.

Parts will be credited at dealer cost plus 30%.

Partial engine assemblies removed from vehicles are to be held by the dealer for scrapping by an authorized zone representative.

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.