ENGINE EXCHANGE PROGRAM 6.5 TURBO DIESEL-SERVICE INFO

SUBJECT: ENGINE EXCHANGE PROGRAM - SERVICE INFORMATION

VEHICLES AFFECTED: 1992 "C/K" TRUCKS WITH 6.5 LITRE(L65) TURBO DIESEL ENGINE

Bulletin Covers:

An engine exchange program for the new version of the 6.5L (L65) Turbo Diesel engine. This engine exchange procedure is in effect for the 1992 model year. Its purpose is to provide quick and helpful product feedback on any possible manufacturing related conditions which do not satisfy the customer.

File this information in the "Special Exchange Policy Procedures" manual.

A. EXCHANGE PROCEDURE: ----------------------- If any internal engine components require replacement, the engine must be exchanged. Only the valve rocker covers and oil pan may be removed to determine whether the engine must be replaced (a severe knocking indicating cylinder component failure or a seized engine or broken crankshaft will likely qualify). Generally, any external components (e.g., water pump, fuel nozzle, etc.) may be serviced without requesting engine exchange. Before returning the engine, any removed parts must be reinstalled.

COMPLETE ENGINES ARE REQUIRED FOR EXCHANGE!!!

B. EXCHANGE ------------ Once the above preliminary diagnosis is made and an exchange unit is deemed necessary, call your Technical Assistance Centre(TAC)

- TAC will require the VIN and serial number.

- TAC will arrange with the Moraine Engine Plant to ship a replacement engine within 48 hours. The replacement engine will be complete except for accessories (i.e., starter, generator, etc.).

- A TAC case number will be provided for each engine exchange. This number must be recorded on the identification card supplied with the replacement engine and must be affixed to the replaced engine being returned. The identification card must be filled out completely.

- To avoid a chargeback, the exchange unit must be returned to Moraine within 10 days in the original shipping crate. Failure to return the concerned unit will result in the DEALERSHIP being billed the value of an exchange unit.

- The exchange unit must be complete as removed from the vehicle. Dealerships returning incomplete units will be billed for missing materials.

All procedural steps must be followed to ensure the dealership is not billed for an engine.

The removed unit must be returned complete as removed from the vehicle in the container provided, without examination of the unit other than as described in paragraph A above. Engine dress on the removed unit must remain the same as the replacement engine shipped (i.e., manifolds, etc.). Dealerships returning units even partially disassembled will be judged as violating this procedure and as such will be subject to being billed for all materials furnished.

The exchange unit will be shipped with minimum quantity of oil; add oil per specifications.

Attached to the exchange unit will be a return shipping label (freight is prepaid).

C. PREPARATION FOR SHIPPING: ----------------------------- Visually check all fluid levels to assure they are within the normal operating range. If not, drain and measure the oil and coolant from the failed unit. Record the oil and coolant measurement results on the repair order. REPLACE THE DRAIN PLUG.

Remove engine assembly as outlined in the 1992 Service Manuals. Remove all plastic shipping plugs and covers from the exchange unit and install them on the removed unit.

If engine leaks, mark leak area on engine. Write the TAC reference number on the repair order form.

Place the removed unit into the original shipping container. Include a copy of the repair order in original envelope and attach to original engine.

D. SHIPPING INSTRUCTIONS: ------------------------- Place the shipping label over the original container shipping label. The Bill of Lading and Customs Papers (when necessary) provided with the exchange unit are the only documents required to return ship the removed engine.

NOTE: The same carrier, whose name is indicated on the Bill of Lading, should be used for the return engine shipment.

All required data on the Bill of Lading will be complete, except for the date and carrier signature. After the Bill of Lading has been dated and signed by the carrier, retain the last copy with your repair order and provide the other two copies to the carrier. Your copy of the Bill of Lading, signed by the carrier, is your proof of returning the engine.

The removed engine is to be shipped by Truck Freight Collect to:

GM Powertrain Moraine Engine Plant 4100 Springbord Pike Dayton, Ohio 45439

Attn: 6.5L (L65) Engine Exchange Program Quality Assurance Department

To increase the effectiveness of the program, the removed unit should be returned IMMEDIATELY. Failure to return the removed unit will result in the dealership being billed $5,600.00 for the unit furnished, plus an administration charge.

F. WARRANTY CLAIMS PROCESSING PROCEDURE: ----------------------------------------- Upon completion of the repair, a warranty claim is to be submitted to the Marketing Division.

Labour Operation Part Labour Number Description Allowance Hours --------- ----------- --------- ----- J1880 Replace Engine Assembly $ 490.00 5.2 hrs

Add Time:

With Air Conditioning 0.2 hr With Cruise Control 0.1 hr With Engine Block Heater 0.1 hr With Automatic Transmission 0.8 hr With Strut Rods (K Truck only) 0.2 hr

NOTE: Applicable miscellaneous items, such as engine oil and engine coolant, should be added to the above Part Allowance amount and included in the Net Amount column of the claim.

YOUR COOPERATION IS GREATLY APPRECIATED. PROMPT RETURN OF YOUR CONCERNED UNIT WILL INCREASE THE EFFECTIVENESS OF THIS PROGRAM. IF YOU HAVE ANY QUESTIONS CONCERNING THE EXCHANGE PROGRAM ADMINISTRATIVE PROCEDURES, PLEASE CONTACT THE TECHNICAL ASSISTANCE CENTRE (TRUCK CHASSIS GROUP).

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.