Engine - Exchange Program 6.5L Diesel
Group Ref.: Engine MechanicalBulletin No.: 376115
Date: November, 1993
EXCHANGE PROGRAM
SUBJECT:
ENGINE EXCHANGE PROGRAM FOR 6.5L DIESEL ENGINE WITH ELECTRONIC FUEL INJECTION
MODELS:
1994 CHEVROLET AND GMC C/K, P TRUCKS AND G VANS
TO GAIN NEEDED PRODUCT FEEDBACK ON THE NEW ELECTRONIC FUEL INJECTION VERSION OF THE 6.5L DIESEL ENGINE (L65 VIN CODE F, L56 VIN CODE S, AND L49 VIN CODE P), AN EXCHANGE PROGRAM IS NOW IN EFFECT AND WILL CONTINUE FOR THE 1994 MODEL YEAR
NOTE:
L57 VIN Y IS NOT INCLUDED IN THIS PROGRAM.
The exchange program will be administered by divisional technical assistance groups (TAN/TAC/TAS).
CHEVROLET DEALERS:
This information should be filed in the "Special Exchange Policy Procedures" manual previously provided.
If your dealership receives a customer concern on this engine, follow the procedure below.
A. DIAGNOSIS
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. Generally, any external components (i.e., water pump, fuel system including injection pump, glow plugs, turbocharger, etc.) may be serviced without requesting an engine exchange. If a replacement engine is needed, any of the above mentioned parts that were removed must be reinstalled (i.e., complete engines are required for exchange).
NOTE:
Excessive oil consumption cases need to be documented and reviewed with Technical Assistance prior to the exchange.
NOTE:
Removal of the cylinder head is permitted ONLY when it is necessary to retrieve failed glow plugs. Cylinder heads should NOT be removed for any other reason.
B. EXCHANGE PROCEDURE
Once the above diagnosis is made and an exchange engine is deemed necessary, call the divisional technical assistance group.
- TAN/TAC/TAS will require the VIN and engine serial number along with a description of your diagnosis.
- TAN/TAC/TAS will arrange to ship a replacement engine within 48 hours and provide a case reference number.
- The replacement engine will be complete except for accessories (i.e., starter, generator, power steering pump, etc.).
- The replacement engine will be shipped with minimum oil quantity; add oil per specifications.
- The replacement engine will also include an envelope with the following:
- Return shipping label
- Identification card
- Bill of Lading
C. PREPARATION FOR SHIPPING
The removed engine must be returned in the container provided, without examination other than as described in section A above. The engine must be returned in the same level of assembly as the replacement engine is received (i.e., manifolds, injection pump, etc., installed). Dealerships returning units even partially disassembled will be judged as violating this procedure and as such will be subject to being billed $4,875 (L49/L56) or $5,175 (L65) for all materials furnished plus an administration charge.
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 concerned unit. Record the oil and coolant measurement results on the repair order. REPLACE THE DRAIN PLUG.
Remove the engine assembly as outlined in the 1994 service manual.
Remove all plastic shipping plugs and covers from the replacement engine and install them on the removed engine.
If the removed engine leaks, mark leak area on engine.
- Write the TAN reference number on the repair order and on the identification card provided.
- Fully complete the identification card.
- Place a copy of the repair order and the completed identification card in the original envelope and attach it to the removed engine.
D. SHIPPING INSTRUCTIONS
- Place the return shipping label provided over the original shipping container label.
- The Bill of Lading provided is the only document 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 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 the engine return. The removed engine is to be shipped by Truck Freight Collect to:
GM Powertrain
Moraine Engine Plant
4100 Springboro Pike
Dayton, Ohio 45439
ATTN: 6.5L (L65/L56/L49)
Engine Exchange Program
Quality Assurance Department To increase the effectiveness of the program, the removed unit should be returned immediately after removal. Failure to return the removed unit within 10 days after the completed repair will result in the dealership being billed $4,875.00 (L49/L56) or $5,175.00 (L65) for the unit furnished, plus an administration charge.
E. WARRANTY CLAIMS PROCESSING PROCEDURE
Upon completion of the repair, submit a warranty claim. See illustration.
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 (DMN) column of the claim.
YOUR COOPERATION IS GREATLY APPRECIATED. PROMPT RETURN OF THE REMOVED ENGINE WILL INCREASE PROGRAM EFFECTIVENESS. IF YOU HAVE ANY QUESTIONS CONCERNING THE EXCHANGE PROGRAM ADMINISTRATIVE PROCEDURES, PLEASE CONTACT YOUR DIVISIONAL TECHNICAL ASSISTANCE GROUP.