File in Section:

Service Bulletin

Bulletin No.:
Date:

PI0768C
October, 2012

PRELIMINARY INFORMATION
Subject:

Engine Exchange Program for 2013 Model Year (GMNA Only)

Models:

2013 Cadillac ATS
2013 Chevrolet Malibu
Equipped with 2.5L or 2.0L Engine (RPOs LCV, LTG)

This PI is being revised to include questions 1-8 in the OEM Engine Exchange Worksheet.
Please discard PI0768B.

This PI will cover the engine exchange program only for the 2013 models listed above. This exchange program will
be in effect for the first full year of vehicle production. Additional PIs will be published for each engine or component
as they are introduced.
During the launch of the 2013 model year, the following engines will be under an exchange program:
– 2.5L Engine Assembly (VIN A - RPO LCV)
– 2.0L Engine Assembly (VIN X - RPO LTG)
Product teams continually seek valuable information for engineering improvements. To assist in this effort, an engine
exchange program will be used for the listed engine and vehicles. The 2013 model year engine exchange program
will be administered by the GM Product Quality Center (PQC). Dealerships are required to call the PQC, not GM
Technical Assistance (TAC), to request an exchange. Prior to calling the PQC, please make sure to complete the
"OEM Engine Exchange" template in this PI. Use of the templates will minimize the time spent on the telephone and
avoid the need of a second call to the PQC. Guidelines for honoring exchange requests under this program are
being strictly enforced.
The PQC may refer the dealer technician to TAC if additional diagnosis is required. TAC will be available for product
inquiries that do not require assembly replacement.
Division

PQC Telephone Number

US Cars and Trucks
Canada – English and
French

1-866-654-7654

Components that may be removed and serviced without exchange are identified by an "X" in the appropriate column
of the table below. Any repairs involving engine components not identified in the table below, engine noise concerns,
oil consumption, or related symptoms may require an engine exchange.
Important: Engine block and internal components along with any component in which a cylinder head has to be
removed to perform the repair will require an engine exchange.
Please note that this list is subject to change as the program progresses. You will be notified by the PQC consultant
if additional items are considered serviceable on a particular engine.
Serviceable Components

2013 2.5L
(RPO LCV)

2013 2.0
(RPO LTG)

Accessory Drive

X

X

A/C Compressor

X

X

All Cooling System Hoses

X

X

All Engine Sensors

X

X

Brackets

X

X

Serviceable Components

2013 2.5L
(RPO LCV)

2013 2.0
(RPO LTG)

Camshaft Cover

X

X

Coolant Pump

X

X

Cooling System
Bypass Pipe

X

X

Cooling System Radiator
Inlet/Outlet Pipes

X

X

Coolant Outlet Assembly

X

X

Crankshaft Damper

X

X

Engine Control
Module (ECM)

X

X

Engine Mounts / Transaxle
Mounts

X

X

Engine Wiring Harness

X

X

Exhaust Manifold / Gasket

X

X

Flywheel / Flex Plate

X

X

Fuel Injectors

X

X

Fuel Injector Wiring
Harness

X

X

Fuel Rail

X

X

Generator

X

X

Heater Outlet / Inlet Fittings

X

X

Ignition System (Coil,
Spark Plug)

X

X

Intake Air Ducts and related
components

X

X

Intake Air Temperature
Sensor

X

X

Intake Manifold

X

X

Knock Sensors

X

X

MAP or Baro Sensor

X

X

Mass Air Flow Sensor

X

X

Oil Fill Cap

X

X

Oil Filter

X

X

Oil Level Indicator

X

X

Oil Pressure Switch

X

X

Oxygen Sensors

X

X

PCV Hose’s

X

X

PCV System

X

X

Purge Solenoid

X

X

Starter Motor and Solenoid

X

X

Thermostat Housing /
Gasket

X

X

Throttle Body / Related
Components

X

X

Vacuum Pump and Lines

X

X

Vapor Vent Lines / Seals

X

X

Turbo Assembly / POA
parts/ Bracket/ Gasket

X

Turbo Oil and Coolant Pipes

X

Oil Cooler / Pipes

X

Serviceable Components
Fuel Pipes & HP Fuel Pump
Assembly

2013 2.5L
(RPO LCV)

2013 2.0
(RPO LTG)

X

X

SAI

X

Hi / Lo Pressure Fuel Lines

X

X

Engine Cover / beauty
Cover

X

X

Oil Pressure Control
Solenoid Valve

X

Important: Engine repairs or failures that are caused by components external to the engine do NOT fall under the
exchange program. For example, if an engine failure is caused by incorrectly installed engine coolant lines, the
engine assembly (or parts required to complete a repair) must be obtained from General Motors Customer Care and
Aftersales (GMCC&A) through the normal parts ordering process. The exchange program is created as a way to
correct internal concerns and to take what is learned and find a way to eliminate these concerns. External
components causing a failure do not provide any useful information in improving an engine. The engine received
from GMCC&A through the normal parts ordering process will be a new service engine.

Engine Broadcast Code Location
2.5L (LCV) Engine

2864224

2.0L (LTG) Engine

2904642

As shown in the above photos, the engine broadcast code can be found on the front of the engine.

Procedures
A thorough diagnosis must be performed on the condition in order to prevent unnecessary component replacements.
Contact the Product Quality Center (PQC) to verify the proper diagnosis has been performed. Upon review of the
diagnosis, the PQC will establish a case reference number and make arrangements for shipping an exchange unit to
your dealership. The replaced engine must be returned to the Warranty Parts Center (WPC). DO NOT SHIP AN
ENGINE TO THE (WPC) WITHOUT AN OFFICIAL WPC REQUEST.
Important: Failure to return the replaced engine by the due date will result in the dealership being debited the entire
warranty claim (parts and labor). The removed unit must be returned complete in the original exchange shipping
container. For effective engineering analysis, please do not remove any components. Dress items on the removed
unit must remain the same as the replacement engine (e.g., exhaust manifolds, throttle body, etc.). Dealerships
returning engines/components that have been even partially disassembled will be judged as violating this procedure
and, as such, will be billed for all materials furnished.
Notice: The exchange unit will be shipped with a quantity of oil; check oil level before starting the engine. Low oil
level could result in internal engine damage.

WPC Request
The Warranty Parts Center (WPC) will fax a Special Part Request to your dealership requesting the return of the
removed engine. DO NOT wait for the warranty claim to be paid before returning the removed engine.
The Special Part Request will provide a request number. This request number must be written on the outside of the
return container using a permanent marker. Failure to write the request number on the return container may delay
the processing of your return.
If you do not receive the WPC Special Part Request, contact Julie Cumo at 248-371-9939 (for French call PQC
1-866-654-7654) to obtain the proper paperwork in order to return the removed engine. Failure to return the engine
may result in a debit.
Shipping Preparation
1. Remove the engine assembly/component as outlined in the applicable Service Manual.
2. Drain all fluids from the removed engine.
3. Retorque any fasteners that were loosened or removed to the original torque specification.
4. Remove any plastic shipping plugs and covers from the exchange unit and install them on the removed unit.
5. If the concerned engine leaks, mark the area directly on the engine with a permanent marker.
6. Write the PQC case reference number on the repair order form.
7. Write the PQC case reference number directly on the component in a visible location.
8. Insert a copy of the WPC Special Part Request, repair order with technician comments, and the completed OEM
Engine Exchange Worksheet (template in this bulletin) into a plastic bag and securely fasten to the engine.
9. Place the removed engine into the original shipping container.

Shipping Instructions
1. Write the WPC request number and the PQC case reference number on the outside of the container with a
permanent marker.
2. U.S. Dealers – Please go to www.gmwpc.com, click on the UPS emblem, enter your BAC and select “dealer
inquires.” Select “available forms” located on the left side of the screen in blue, then select “Central Transport
BOL.” A partially complete BOL will appear. Please print this Central Transport BOL and fill out “from” section
with your dealer information and complete the description fields.
Canadian Dealers – Refer to the latest version of Corporate Bulletin Number 99-00-89-019 for detailed shipping
information.
3. Contact the specified carrier to arrange for pick-up of the removed engine. If lift gate service is necessary,
please request it at the time of arranging pick-up service.
4. Have the driver sign the bill of lading. Retain a copy of the signed bill of lading. Attach your copy to the original
repair order. This will be your proof of returning the removed engine.
5. Ship all return exchanges/components Third Party Freight Collect with appropriate paperwork to:
GM Warranty Parts Center
45 Northpointe Drive
Orion, MI 48359

Warranty Information
For vehicles repaired under warranty, use:
Labor
Operation

Description

J1840*

Engine

Labor Time

Parts
Allowance

Replacement
Use Published Labor Operation Time
$400.00
Add
Administrative Allowance
0.2 hr
*Use published labor operation time plus the administrative allowance indicated above.

Important: Applicable miscellaneous items such as engine oil and coolant should be added to the part allowance
amount and claimed in the Parts Cost column and not included in the Net Amount (DMN) column of the warranty
claim.
Your cooperation is greatly appreciated. Prompt return of the original engine will increase the effectiveness of this
program. If you have any questions regarding the exchange program administrative procedures, please contact the
Product Quality Center.

OEM Engine Exchange Worksheet
Caller’s Name/Position:
Parts Manager name:
Technician Direct Phone:
Dealership’s Fax Number:
Parts Dept fax number:
Customer Concern:
Has dealer completed the "OEM Engine Exchange" template in bulletin and reviewed Serviceable Components?
(If no, dealer MUST complete Bulletin and call back)
Has the vehicle been modified with non-production accessories?
What type of service is the vehicle being used in (police, taxi, towing, personal, etc.)?

Describe the failure of the engine:

Broadcast Code:
Engine Serial Number:
Replacement Cost = $
Requested Labor Time:
Leaks
What type of leak?

Where is the leak located?

Noise
What kind:

Where is it:

Frequency of noise:

When does is occur:

How long does it last:

At what temperature does it occur:

Lubrication
Oil pressure readings:

Results of oil consumption test:

Oil contamination?

Performance Concern
Low power?

Misfire?

Detonation?

Blue smoke?

White smoke?

Will not crank?

Vibration?

Did the engine show evidence of:
Overheating?

DTCs in the ECM/TCM/BCM? ***Note: GDS must be launched from TIS to make sure all the data is captured and can be
retrieved.

Coolant consumption?

Coolant contamination?

Low compression?

Please provide the readings: