CAMPAIGN:RESTRICTED CATALYTIC CONVERTER (REPLACE CONVERTER)

MODELS/YEARS: CERTAIN 1983 NINETY-EIGHTS AND TORONADOS E QUIPPED WITH A 4.1 L (VIN CODE 4) V-6 ENGINE

CONDITION

General Motors has determined that certain 1983 Ninety-Eights and Toronados equipped with a 4.1 L V-6 engine may develop a restricted catalytic converter resulting in poor engine performance or a no-start condition.

To prevent the possibility of this condition occurring on vehicles involved, the catalytic converter will require replacement.

VEHICLES INVOLVED

1983 Ninety-Eights and Toronados equipped with a 4.1 L V-6 gasoline engine (VIN Code 4) with serial numbers within the following breakpoints:

Model Assembly Plant From Through and Including ----- -------------- ---- --------------------- Ninety-Eight Lansing (M) Start of Production DM882628 Toronado Linden (E) Start of Production DE328776

Vehicles that have had the catalytic converter replaced since approximately June 1, 1983 with the new type basketed converter assembly or that have had the converter kit part number listed in this bulletin and in Dealer Technical Bulletin 83-T-25A installed need not have this campaign performed.

DEALER ACTION

Dealers are to service all vehicles subject to this campaign at no charge to owners regardless of mileage, age of vehicle, or ownership from this time forward. Whenever a vehicle subject to this campaign is taken into your used vehicle inventory or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made.

SERVICE PROCEDURE

A. Inspection

1. Install seat and fender covers and raise vehicle on hoist.

Inspection: The converter need not be replaced -

If it is one of the new type basketed converter assemblies, part number 25056620.

If it is one of the converters used in Dealer Technical Bulletin 83-T-25A part number 25056905 (included in kit part number 25056983).

The part numbers are stamped on the bottom of the inboard flange near the converter inlet. Refer to Figure 1.

Proceed to Part C if replacement of the converter is not required.

B. Converter Replacement

CAUTION:

The catalytic converter beads contain platinum, palladium, and/or rhodium. Additionally, the beads may be finely coated with lead compounds. Therefore, precautions should be taken to minimize dust generation during the replacement procedure. These precautions include:

Catalyst dust should be controlled by wetting with water prior to bead removal, as described in Step 4 below.

The use of a suitable dust mask, rubber gloves, and safety glasses is recommended when handling catalyst beads.

Applicable OSHA standards should be reviewed.

Allow converter to cool before handling.

1. Loosen clamp and disconnect AIR pipe from converter.

2. Disconnect intermediate exhaust pipe and hanger from rear of converter.

3. Remove clamp and disconnect converter from front exhaust pipe.

4. Stand the old converter upright on the iniet end and pour 16 ounces of water into the outlet end to control catalyst dust.

5. Using a hammer and chisel, remove the fill hole plug from the lower bed. (The smooth side of the converter is the lower bed side.) See Figures 1 and 2.

6. Hold the converter over a clean pan (J 34155-2) and empty the catalyst beads by shaking. It may be necessary to tap the converter belt flange with a hammer to loosen the beads.

7. Pour the beads into a sifting pan (J 34155-1) and sift to remove undersized beads.

8. Prop the new converter up at a 45 degree angle with the lower bed fill hole at the top.

9. Using funnel J 34155-3, pour the sifted beads into the lower bed of the new converter. See Figure 2. Tap belt flange with rubber mallet to allow beads to settle. Continue filling and tapping until converter is full. If additional beads are required to fill the lower bed completely, it will be necessary to obtain a lower bed bead package from the parts department.

Excess beads from the package should be saved in a clean container for future use.

10.Lay the converter down on a flat surface with the lower bed fill hole on top.

11.Insert the fill plug into the lower bed fill hole. The fill plug outer rim must rest against the converter body.

12.Insert tool J 34118 into fill plug and tighten to 47 N-m (35 lbs. ft.). (See Figure 3.)

13.Install new converter in vehicle reversing removal procedure (Steps 1, 2, and 3) and using new bolts and clamp as required. Torque front clamp nuts to 35 N-m (26 lbs. ft.), intermediate pipe to converter bolts to 20 N - m (15 lbs. ft.) and hanger to converter bolts to 52 N - m (38 lbs. ft.).

14.Lower vehicle and install Campaign Identification Label, Part C of procedure.

C. CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified in accordance with the instructions outlined in this procedure will require a Campaign Identification Label. Each label provides a space to include the campaign number, the five (5) digit dealer code of the dealer performing the campaign service, and the date vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. When installing label, clean the surface of the fan shroud and apply the campaign label.

PARTS INFORMATION

Parts are to be obtained from WDDGM using the following part numbers:

Description Part Number

Kit, Catalytic Converter with Upper Beads 25056983 (includes converter number 25056905, fill hole plug 8998202, and instruction sheet)

*Package, Lower Bed Bead 25056903 (as needed to fill converter)

Clamp, Converter Front Exhaust 15595206 (if needed)

Bolt, Intermediate Exhaust Pipe to Converter 11502877 (two per vehicle, if needed)

Bolt, Exhaust Hanger to Converter 11504596 (two per vehicle, if needed)

*A lower bed bead package, when used along with the beads removed from the old converter, will complete approximately ten (10) vehicles.

Additional fill hole plugs, if required, may be ordered using part number 8998202.

To ensure parts will be obtained as soon as possible, they should be ordered from GM Parts (WDDGM) on a C.I.O. order with NO special instruction code, but order on an advise code (2).

Parts are to be retained for disposition by zone personnel.

CLAIM INFORMATION

Converter Kit Failure Labor Labor Operation Part No. Code Operation Hours --------- --------- ---- ---------- -----

Inspection Only - 96 v3330 .2

Inspect & Replace 25056983 96 v3331 .9 Catalytic Converter

Parts will be credited at dealer cost plus 30%.

.1 hour for clerical administration may be added to the above operations.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.