CAMPAIGN:RESTRICTED CATALYTIC CONVERTER (REPLACE CONVERTER)
MODELS AFFECTED: ALL 1983 EQUIPPED WITH 4.1L (VIN CODE 4) V-6 ENGINES
General Motors has determined that certain 1983 Electras, LeSabres, Regals, and Rivieras equipped with 4.1L V-6 engines 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 Electras, LeSabres, Regals, and Rivieras equipped with 4.1L V-6 gasoline engines (VIN Code 4) with serial numbers within the following breakpoints.
Model Assembly Plant From Through & Including
LeSabre and Electra Sedans and Coupes Flint DH400001 DH490879
LeSabre Coupes and Sedans, LeSabre and Electra Estate Wagons Fairfax DX400001 DX463461
Regals Flint DH800001 DH945681
Regals Arlington DR400001 DR418548
Rivieras Linden DE400001 DE435612
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 Bulletin 83-238 installed, need not have this campaign performed.
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.
DEALER MATERIAL
If your dealership has vehicles involved in this campaign, you will receive the following items:
List of all vehicles involved in this campaign in the area of your dealership.
One Campaign identification label for each vehicle.
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 listings may contain owner names and addresses obtained from State Motor Vehicle records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.
OWNER NOTIFICATION
Owners will be rotified of this campaign on their vehicles by Buick Motor Division. (See copy of owner letter included with this bulletin.)
Owners who have previously had their catalytic converter replaced with Part Number 25056620 or 25056905 (included in Kit Part Number 25056983 should not receive a notification letter or appear on the dealer's computer listing.
PARTS INFORMATION
Parts are to be obtained from GMWDD 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 11502877 Converter (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 these parts will be obtained as soon as possible, they should be ordered from GM Parts (GMWDD) on a C.I.O. order with NO special instruction code, but order on an advise code (2).
SPECIAL TOOLS
A. Converter Bead Replacement Tool Kit
Each Buick dealer was shipped, during March, 1983, one (1) complete catalytic converter bead replacement tool kit J-34155, no charge. Each kit consists of:
J-34155-1 Sifting Pan (1) J-34155-2 Storage Pans (2) J-34155-3 Funnel (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
Converter plug installer J-34118, part of the 1984 Essential Service Tool Program.
TECHNICAL PROCEDURE
Part 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 Bulletin 83-238, 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.
PART 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.
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 inlet 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 completely fill the lower bed, it will be necessary to obtain a lower bed bead kit from the parts department.
Excess beads from the kit 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
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 a torque 47 N.m (35 lb. 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 lb. ft.), intermediate pipe to converter bolts to 20 N.m (15 lb. ft.) and hanger to converter bolts to 52 N.m (38 lb. ft.).
14. Lower vehicle and install campaign identification label, Part C of procedure.
PART C - CAMPAIGN IDENTIFICATION LABEL
Each vehicle modified in accordance with the instructions outlined herein 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.
DISPOSITION OF REPLACED CONVERTER
Replaced parts must be held for disposition by Buick contact personnel. Each replaced part must have a claim tag attached showing the repair order and the VIN of the vehicle from which it was removed.
WARRANTY INFORMATION
Dealers are to submit each campaigned vehicle as a separate case on the one-line Warranty Document Form S-764. Dealers submitting warranty claims by teletype terminal are to transmit campaign completions as a separate case also.
PARTS AND LABOR CREDIT
USE THE ONE APPLICABLE LABOR OPERATION SUBLET PART FAILED PARTS FAILURE LABOR LABOR OTHER DEALER OPERATION COUNT PART NO. ALLOW. CODE OP NO HOURS HOURS MTL TWG
Inspect Catalytic Converter 96 V3330 .2 hrs. *.1 hr. -
Inspect & Replace Catalytic Converter ++ 25056983 +++ 96 V3331 .9 hrs. *.1 hr. -
*Campaign administrative allowance.
++ List number of parts replaced.
+++ List current dealer price, plus 30% of all required parts.
When submitting a warranty claim, the parts amount requested must reflect an amount equal to only the portion of the lower bead package, Part Number 25056903, used for completing the repair when a complete bead package is not required. If only a portion of the bead package is used, a parts count of one (1) must be entered and included in the total parts count entry.
To assure accurate records of all transactions on this campaign, it is recommended that campaign repairs for each vehicle be listed on a separate repair order. Other repairs performed to the vehicle may be listed on the same repair order, and warranty cases other than campaigns may be listed on the same warranty document.
Warranty documents on this campaign are not to be sent to the Zone Office. Send directly to Buick, Flint, as is done with normal submissions of warranty documents.
Dear Buick Owner:
General Motors has determined that certain 1983 Electras, LeSabres, Regals, and Rivieras may develop a restricted catalytic converter 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 your vehicle. This service will be done at no charge.
If you have recently had your catalytic converter replaced with a new type catalytic converter assembly, you need not have this campaign performed.
Instructions for making this correction have been sent to your Buick dealer.
Please contact your dealer to arrange a service date to have this modification performed. The labor time required to perform this modification is approximately one hour. Please allow additional time for the dealer to process your vehicle.
The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction to your vehicle in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid owner reply card and returnina it to us.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.
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.
