Parts Exchange Program

A special limited parts exchange program will be conducted until further notice which involves the replacement of the Quad 4 engine assembly with a special exchange engine or the replacement of the Integrated Direct Ignition (IDI) assembly. An exchange unit is to be used when diagnosis indicates a failure with either of these assemblies.

Engine Exchange: The special exchange engine includes the block, hood, cam housings and covers, internal parts, the oil pan, front cover and the water pump body assembly.

Conditions Qualifying For An Exchange Engine

1. Conditions which would normally require a block or block components as indicated by the following symptoms or conditions:

^ Cracks or porosity in cylinder block
^ Knock noises deep in engine, i.e., crankshaft or rod bearing, piston or piston pin
^ Engine seized, i.e., locked and won't turn over with spark plugs removed
^ Low or no compression
^ Engine damage due to low or no oil pressure
^ Excessive exhaust smoke or excessive oil consumption caused by other than external oil leak.

2. Conditions of coolant leakage as evidenced by:

^ Head gasket leakage
^ Coolant in combustion chamber or in crankcase oil
^ Bubbles entering coolant overflow tank

Dealer Service Items

Conditions, other than 1 and 2 above describing engine exchange serviced in the normal manner. All engine parts replaced during normal dealer warranty service other than engines, IDIs, water pumps and tensioner brackets are to be retained for disposition by zone personnel.
Refer to the appropriate diagnosis section of the 1988 Firenza, Cutlass Calais, Cutlass Supreme Classic and Custom Cruiser New Product Service Manual when diagnosing the above conditions. The returned engine will be evaluated for the product problem suspected; therefore, it is important not to disassemble the engine any further than is necessary during diagnosis.

IDI Assembly Exchange

The IDI assembly should be exchanged any time an ignition system failure is diagnosed when using the "Integrated Direct Ignition" diagnosis sheets included in this bulletin, and they direct the technician to exchange the "IDI". It is important that the IDI assembly not be disassembled beyond that specified in the diagnosis sheets before returning it to Lansing. Refer to IDI Diagnosis and Exchange Program on page 1.

The IDI assembly includes the ignition cover, module, two coils, coil housing and spark plug connector assemblies. IDI assembly installation bolt torque is 18 N-m (13 ft.lbs.).

Obtaining an Exchange Part

If an exchange engine or IDI assembly is required, dealer personnel are to call Product Service Engineering (517-885-OLDS) to have the part shipped. When calling, have the following information available:

1. Vehicle identification number
2. Vehicle mileage
3. Repair order number
4. Description of customer complaint
5. Diagnostic work performed
6. Dealer parts code
7. Dealer shipping address (not P.O. Box)
8. Dealer telephone number

The service engineer will qualify the need for an exchange part and will make the shipping arrangements. The part will be shipped on a no-charge basis, quickest way prepaid, usually the same day. In the case of the engine, it will be shipped with all the necessary gaskets to complete the engine installation. It may be necessary to fill the engine with four quarts of 5W30 SF/CC oil as specified in the 1988 New Product Service Manual.

Returning the Exchange Part

The parts will be shipped to you in a returnable shipping container. Care should be exercised not to damage the container when unpackaging the part. With the part, you will receive:

Engine

1. A Bill of Lading for return of the engine
2. Self-addressed shipping label
3. Plastic bag
4. Information Return Tag

IDI Assembly

1. Self-addressed shipping label
2. Diagnostic feedback chart
3. Information Return Tag
Packaging and Shipment

Engine

Fill out the Information Return Tag and attach it to the engine.

If the engine is leaking oil, it will be necessary to place the plastic under the engine to keep the oil from dripping in the truck. If oil is not a problem, you can either place the engine in the bag or put the engine in the crate and place the bag over the top. In either case, make sure the bag will protect the engine from rain or snow during transit.

Recrate the engine and staple the return shipping label to the outside of the crate.

The Bill of Lading is the only shipping document you need to ship the engine. It is important that the carrier name indicated on the Bill of Lading be used to return the engine. All required data has been filled out except for the date. Please do this and keep 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.

Ship the engine by truck, freight collect, to:

BOC Powertrain Delta Engine Plant Stores 9 2901 South Canal Road Lansing, MI 48917
ATTN: Parts Return