CAMPAIGN: CATALYTIC CONVERTER NO START/POOR ENGINE PERFORM.

1981 FIREBIRD, LEMANS, GRAND PRIX BONNEVILLE, AND CATALINA WITH LS5 4.3 LITER 265 CU. IN. ENGINES

General Motors has determined that some 1981 Pontiac Firebird, LeMans, Grand Prix, Bonneville, and Catalina models may develop restricted catalytic converters resulting in poor engine performance or a no start condition.

To prevent the possibility of this condition occurring, it will be necessary to replace the catalytic converter on the involved vehicles.

VEHICLES INVOLVED

Involved are certain 1981 Pontiac Firebird, LeMans, Grand Prix, Bonneville, and Catalina models equipped with engine and emission systems described within the following vehicle breakpoints:

Engine Assembly Beginning Up To And Model VIN Code Plant VIN Including ----- -------- ----- --- --------- All 1981 " F " S Norwood (N) and SOP EOP w/4.3 L Van Nuys (L)

All 1981 "A" S Baltimore (B) SOP EOP w/4.3 L Oshawa (I) and SOP EOP Pontiac (P) SOP EOP

All 1981 "G" S Pontiac (P) and SOP EOP w/4.3 L St. Therese (2) SOP EOP

All 1981 "B" S Fairfax (X) SOP EOP w/4.3 L Oshawa (I) and SOP EOP Pontiac (P) SOP EOP

DEALER CAMPAIGN RESPONSIBILITY

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 before reselling or releasing the vehicle.

OWNER NOTIFICATION

Owners of vehicles involved in this campaign, as records available to Pontiac Motor Division indicate, will be notified by Pontiac Motor Division (see copy of owner letter included with this bulletin).

Owners who have previously had their catalytic converter replaced (see SERVICE PROCEDURE, PART I, Step 3) should nbt receive notification or appear on the dealer's computer listing.

Involved vehicles have been identified by Vehicle Identification Number computer listings. Computer listings contain the complete vehicle identification number, owner name and address data, and are furnished to the involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These computer listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of the law in several states. Accordingly, you are urged to limit the use of this listing for the follow-up necessary to complete this campaign.

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:

A. Catalyst dust should be controlled by wetting with water prior to bead removal as described in Step 6 of PART II- CONVERTER REMOVAL, PREPARATION AND INSTALLATION.

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

C. Applicable OSHA standards should be reviewed.

D. Allow converter to cool before handling.

SERVICE PROCEDURE

PART I - INSPECTION

1. Raise vehicle on hoist.

2. Refer to Figure 1 for location of catalytic converter part number.

3.a. The converter need not be replaced if it is a new type basketed converter, Part Number 25056619 or 25056625. Proceed to PART III if replacement of the converter is not required.

b. If the converter part number is listed in Column 1 of the table below, replace the converter with the appropriate converter part number identified in Column 2 of the table. (Only vehicle models equipped with RPO LS5 4.3 Liter 265 cu. in. engines are involved).

Column 1 Column 2 Model Year Original Dual New Dual Bed Vehicle Bed Bead Conv. Bead Conv. ------- -------------- ---------- 1981 Firebird 8999593 25056674

1981 LeMans, Grand Prix, 8999591 25056673 Bonneville, Catalina

PART II - CONVERTER REMOVAL, PREPARATION AND INSTALLATION

1. Raise vehicle on hoist.

2. Disconnect air supply pipe from front of converter (Figure 1-Item 4).

3. Disconnect intermediate pipe from rear of converter (Figure 1- Item 3).

4. Disconnect hanger bracket from converter.

5. Loosen front exhaust clamp to remove converter from vehicle. Discard clamp.

6. Stand old converter upright on inlet end and pour two (2) 8 ounce cups of water into outlet end (Figure 1-Item 3) to control catalyst dust.

7. Using hammer and chisel, remove upper bed fill hole plug from old converter by driving chisel between the converter shell and rim of fill plug (Figure 1-Items 6 and 7 for description of upper and lower beds). Deform fill plug until it can be removed with pliers.

8. Hold converter over a clean storage pan (J-34155-2) and empty catalyst beads by shaking and tapping converter belt flange (Figure 1-Item 2) with rubber mallet.

NOTICE: If upper bed is void or near void (a cup or less) of catalyst beads, the converter is considered damaged (internally) or expanded. Catalyst beads found in internally damaged or expanded converters are not to be used in new converters. These beads can be returned via exchange program described in WDDGM Bulletin IB No. 83-138.

9. Pour upper bed beads into sifting pan (J-34155-1). Sift out broken beads (smaller than half size) into a clean box. Pour sifted beads (half size and larger) into the other storage pan (J-34155-2). Set sifted beads aside for now.

Unusable beads and dust can be returned via exchange program described in WDDGM Bulletin IB No. 83-138.

10. Prop new converter up at a 45 DEG angle with upper bed fill hole at top. See Figure 1-Items 6 and 7 for a description of upper and lower beds). Tap funnel (J-34155-3) into converter fill hole with hammer (Figure 2).

11. Install packet of new upper bed beads from kit Part Number 25056799 into upper bed of the new converter.

12. Pour sifted upper bed beads (reference Step 9) or new upper beads, if required, into converter. Tap belt flanqe of the converter with rubber mallet to allow beads to settle. Continue filling and tapping until converter is full. See Figure 3 Item 1 for definition of full upper bed.

If upper bed is full, proceed to Step 13. If upper bed is not full, use leftover upper bed catalyst beads from involved dual bed converters to fill upper bed. If there are not enough used upper bed beads, obtain upper bed catalyst kit Part Number 25056802 and continue to fill upper bed until full.

NOTICE: Used upper bed beads (from non-damaged converters) are to be mixed with new upper bed beads. DO NOT MIX UPPER AND LOWER BEADS. Also, do not mix beads from converters off vehicles that are not involved. Store unused upper bed beads in a clean container marked "upper bed."

13. Lay converter down on a flat surface with upper bed on top.

14. Insert fill plug, Part Number 8998202, (two are provided in kit Part Number 25056799) into upper bed fill hole. If outer rim of the fill plug doesn't fit flat against converter shell, remove enough beads so it does.

15. With fill plug in fill hole, insert tool (J-34118) into fill plug (Figure 4-Item 2). Tighten tool to 35 lbs. ft. (47 N.m) and make sure plug outer rim is flat and tight against converter shell. Set new converter aside.

16. Remove lower bed plug from old converter using procedure described in Step 7.

17. Hold converter over a clean storage pan (J-34155-2) and empty catalyst beads by shaking and tapping converter belt flange (Figure 1-Item 2) with rubber mallet.

18. Sift lower bed beads using procedure described in Step 9.

19. Prop new converter up at 45 DEG angle with lower bed fill hole at top (see Figure 1-Items 6 and 7 for definition of upper and lower beds). Tap funnel (J-34155-3) into converter fill hole with hammer (Figure 2).

20. Pour sifted lower bed beads (ref. Step 18) or new lower bed beads if required, into new converter lower bed. Tap belt flange with rubber mallet to allow beads to settle. Continue filling and tapping until converter is full (ref. Figure 3-Item 1).

If lower bed is not full, use leftover lower bed catalyst beads saved from involved dual bed converters to fill lower bed. If there are not enough used lower bed beads, obtain lower bed bead service kit Part Number 25056682 (zone approval is required to obtain this kit), and continue filling the lower bed until full.

NOTICE: The leftover lower bed beads are to be saved for future use. Store them in a clean container marked "lower bed." DO NOT MIX UPPER AND LOWER BEADS. Also do not mix beads from converters off of vehicles that are not involved.

21. Lay converter down on flat surface with lower bed on top and install fill plug using procedure described in Steps 14 and 15.

22. Install new converter on vehicle reversing removal procedures described in this bulletin and referencing appropriate service manual.

PART III - INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified in accordance with the instructions outlined in this service procedure will require a campaign identification label. Each label provides a space to include the campaign number, the five-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. Install the label on the radiator baffle where it is readily visible. Close hood. (Additional campaign labels are available on stationery order as Form 7901-709.)

PARTS INFORMATION

The parts required to complete this campaign are to be ordered from WDDGM.

To ensure this part will be obtained as soon as possible, it should be ordered from WDDGM on a C.I.O. order with no special instruction code, but order on an advise code (2).

Parts removed from the involved vehicles are to be retained by the dealer in accordance with the current Service Policies and Procedures Manual.

Description New Part No. Model Per Vehicle

Converter 25056674 1981 F 1 Converter 25056673 1981 A,B,G 1

Rebuild Kit 25056799 All 1 (contains 300 grams of, catalyst, 2 fill hole plugs Part Number 8998202 and instruction sheet) *Upper Bed Bead Kit 25056802 All As Required (contains 700 grams of catalyst beads only) *Lower Bed Bead Kit 25056682 All As Required (contains 1,000 grams (Zone approval of catalyst beads only) necessary) Clamp, air injection 22505116 1981 All 1 pipe Bolt (pipe to rear 11502877 1981 All 2 converter

Bolt (hanger to converter) 11504596 1981 All 2 Nut (hanger to converter) 9414034 1981 F 2 Washer (hanger to 9439512 1981 F 2 converter) Clamp, Exhaust (2 1/4") 1259609 1981 All 1

*Refer to special instructions outlined in the Warranty Credit section of this bulletin.

SPECIAL TOOLS:

A. Converter Bead Replacement Tool Kit

Each Pontiac Dealer was shipped one (1) complete catalytic converter Bead Exchange Kit (J-34255), no charge. The kit con- sists of:

J-34155-1 Sifting Pan (Qty. 1) J-34155-2 Storage Pans (Qty. 2) J-34155-3 Funnel (Qty. 1 )

In the event additional kits are required by the dealer, they may be purchased from:

Kent-Moore Tool Division Kent-Moore Corporation 29784 Little Mack Roseville, MI 48066

B. Converter Plug Installer

As part of the 1983 essential service tool program, Converter Plug Installer (J-34118) has been forwarded from source to all Pontiac Dealers.

ENCLOSED WITH THE COPY OF THIS BULLETIN

A list of those vehicles involved which our records indicate are in your geographical area is attached for your follow-up. Advise the zone if vehicles appearing on the attached list are not in your area. (Ifa list of vehicles is not attached, our records indicate no affected vehicles in your area.)

If a vehicle has been transferred to sold to another location, please forward the new name and address of the vehicle to your Pontiac zone office.

RECORDING COMPLETION

Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS." Owners are being asked to present the owner reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.

DEALERS SHOULD STILL SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS: (A completed warranty claim is to be kept as a permanent record of completion.)

WARRANTY CREDIT

A separate repair order must be used for each vehicle.

OTHER* FAILURE LABOR LABOR LABOR DESCRIPTION CODE OPERATION HOURS HOURS ----------- ---- --------- ----- ----- Inspect Catalytic Converter 96 V2330 .2 0.1 Hr.

Inspect and Replace Catalytic Converter 96 V2331 .9 0.1 Hr.

When Part Number 25056802 (upper bed bead kit) and/or Part Number 25056682 (lower bed bead kit) are needed to repair a vehicle, the entire cost of the bead kit should be claimed on the vehicle for which the kit was purchased even though the entire kit is not used to complete the repair. Subsequent use of the remaining beads from the kit for future repairs must not be claimed for credit.

*In addition dealerships will receive 0.1 hours credit for dealer administrative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed for credit. This entry will not require authorization."

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

Parts(s) required are to be listed on your warranty claim in the normal manner. Parts will be credited at dealer net plus 30% dealer handling allowance.

(CREDITING)

Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claims must contain all information required and should list the labor operation as outlined.

Repairs submitted for vehicles not involved in the campaign will not be paid.

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.