Campaign Procedures
Campaign ProceduresPARTS INFORMATION:
A pre-shipment of gaskets will be sent to involved dealers on December 16, 1993. Pre-shipment will equal parts for 35% of the number of vehicles to be repaired. A minimum of one will be sent to dealers with involved vehicles. Pre-shipment parts will be charged to the dealers' open parts account.
Additional parts required to complete the campaign are to be obtained from General Motors Service Parts Operation (GMSPO). To ensure that these parts are obtained as soon as possible, they should be ordered from GMSPO on a C.I.O. order with no special instruction code, but on an advise code (2)
DESCRIPTION PART NUMBER QUANTITY/VEHICLE
Lower Intake Manifold Gasket 24574409 1
1. Relieve fuel pressure according to service manual page 6E3-C2-7.
2. With negative battery cable disconnected, remove air cleaner duct assembly and top half of air cleaner.
3. Remove torque strut from engine and rotate engine forward.
4. Remove vacuum hose harness from top of air inlet.
5. Disconnect crankcase ventilation valve and power brake vacuum hoses. Position vacuum hoses out of the way.
6. Remove transaxle fill tube attaching nut and position transaxle fill tube and indicator assembly aside.
7. Remove throttle modulator cover. (See service manual figure C2-12 on page 6E3-C2-12).
8. Remove bolts/nuts attaching throttle cable bracket. Position bracket and cables out of the way.
9. Disconnect spark plug wiring from the spark plugs and unroute harness.
10. Route power steering lines under the air inlet blower case.
11. Loosen the power steering pencil brace bolt at the power steering pump and remove the power steering pencil brace bolt at the lower intake manifold. Position brace aside (do not remove from vehicle).
12. Loosen the fuel line retainer under the intake manifold (refer to service manual section 6C).
13. Remove the fuel feed hose retainer from the intake manifold.
14. Disconnect both fuel lines from the lower intake manifold.
15. Remove lower intake manifold attaching nuts.
16. Remove the intake manifold with plenum attached from the cylinder head. Discard old gasket.
NOTICE:
USE CARE IN CLEANING OLD GASKET MATERIAL FROM MACHINED ALUMINUM SURFACES AS SHARP TOOLS MAY DAMAGE SEALING SURFACES.
17. Clean and inspect the lower intake manifold and cylinder head mating surfaces.
NOTICE:
MATING SURFACES MUST BE CLEAN AND FREE OF ANY FOREIGN MATERIAL, GREASE OR DIRT. DO NOT SAND OR ROUGH UP EITHER OF THE MATING SURFACES PRIOR TO INSTALLATION OF THE NEW GASKET.
18. Install new lower intake gasket and intake manifold assembly.
NOTICE:
INSTALL THE LOWER INTAKE GASKET AGAINST THE CYLINDER HEAD BEFORE INSTALLING THE INTAKE MANIFOLD OR DAMAGE KAY RESULT. DO NOT USE ANY ADDITIONAL MATERIALS OR SEALANTS TO IMPROVE THE GASKETS SEALING ABILITY.
19. Tighten the lower intake manifold fasteners to 30 N.m (22 lbs. ft.) in sequence shown in figure C2-13, page 6E2-C2-14 of service manual.
20. Reverse removal procedure, being careful to re-route all lines, wiring, and cables back to original positions. Torques:
- Torque strut to engine bolt 55 N.m (41 lbs.ft.)
- Power steering pencil brace to pump and manifold 31 N.m (23 lbs.ft.)
- Transaxle fill tube attaching nut 25 N.m (18 lbs.ft.)
- Fuel line retainers 10 N.m (89 lbs.in.)
- Accelerator cable bracket nut 30 N.m (22 lbs.ft.)
- Accelerator cable bracket bolts 25 N.m (18 lbs.ft.)
- Fuel inlet retaining nut 30 N.m (22 lbs.ft.)
21. Tighten fuel filler cap and connect negative battery cable.
22. Cycle ignition "ON" and "OFF" twice, waiting ten seconds between cycles, then check for fuel leaks. If any leaks are detected, repair as necessary.
23. Start vehicle and check operation.
24. Advise owner that battery has been disconnected and that any memory functions, such as radio stations and clock may have been lost.
25. 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 (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point 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.
WARRANTY CLAIM INFORMATION: