Service Information

All requirements qualifying for engine exchange, warranty claims, processing procedures and shipping instructions are explained below. Your cooperation in following these procedures will greatly improve the effectiveness of the program.

A. Engine Exchange Guidelines

Conditions normally requiring partial engine replacement, a block or block components are indicated by the following symptoms:

1. Knock noises deep in the engine (i.e., crankshaft or rod bearing, piston or piston pin).
2. Seized engine (i.e., engine is locked and will not turn over with spark plugs removed).
3. Low or no cylinder compression.
4. Excessive oil consumption.
5. Hydraulic lock.
6. Crack or porosity in cylinder block.
7. Coolant in oil, and/or bubbles in surge tank.
8. Conditions of excessive chain rattle noticed inside the car with the engine running at idle speed.
9. Valve train noise conditions requiring cylinder head removal.

B. Exchange Procedure

Once the above preliminary diagnosis is made and an exchange unit is deemed necessary, call your technical assistance.

^ Technical assistance will require the VIN and engine serial number. (The engine serial number can be read from a boss on the block at the head face, exhaust side near the transmission bell housing. The number begins with the letter "T" and is followed by four numbers and three additional letters.)
^ Technical assistance will also require a street shipping address and not a post office box. Addresses with post office boxes will not be used.
^ Technical assistance will arrange to ship a replacement engine as soon as possible.
^ The replacement engine will include the following:

- Complete engine block assembly with pistons, rods, camshaft, lifters, pushrods, crankshaft and oil pump.
- Oil pan.
- Complete cylinder head assembly with valves and springs.
- Timing chain and sprockets with timing chain front cover.

Engine components which may be serviced:

^ All electrical sensors
^ Any brackets
^ Block heater (if applicable)
^ Complete accessory drive and supporting brackets, including starter, generator, A/C compressor, power steering pump and all attaching parts
^ Coolant pump and related gaskets, filter inlets, outlets, pipes, hoses and thermostats
^ Exhaust manifold, EGR valve and related gaskets
^ Flywheel or flexplate
^ Front and rear crankshaft oil seals
^ Fuel injectors and fuel pressure regulator
^ Ignition: Spark plugs, ignition coils and spark plug wires
^ Oil pan, oil dipstick/tube and oil filter
^ Upper and lower intake manifold
^ Crankshaft pulley
^ Vacuum tubes

A technical assistance 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 engine being returned. The identification card must be fully completed.

To avoid a charge back, the exchange unit must be returned to Tonawanda 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 removed unit must be returned complete as removed from the vehicle in the container provided, without examination of the unit other than as described above. Dealerships returning units even partially disassembled (unless requested to otherwise) 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.

Included with the exchange unit will be a return shipping label (freight is prepaid).