CAMPAIGN: RESTRICTED EXHAUST PLUGGED CATALYTIC CONVERTER
MODELS AFFECTED: ALL 1981 AND 1982 EQUIPPED WITH 5.0L (VIN CODE Y) V-8 ENGINES
General Motors has determined that some 1981 and 1982 Electras, LeSabres, and Rivieras with 5.0L V-8 gasoline engines may develop a restricted exhaust due to the catalytic converter becoming plugged.
VEHICLES INVOLVED
All 1981 and 1982 Electras, LeSabres, and Rivieras equipped with 5.0L V-8 gasoline engines (VIN Code Y).
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 82-T-124 installed need not have this campaign performed.
DEALER ACTION
To correct this condition on vehicles involved, the catalytic converter will require replacement.
Dealers are to service all vehicles subject to this campaign at no charge to the owner, regardless of mileage, age of vehicle, or ownership from this time forward.
Whenever a vehicle subject to this campaign is taken into your new or 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. Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer and arrangements made to make the required modification according to instructions contained in this bulletin.
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 Registration 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 notified 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 numbers 25056622 or 25056894 should not receive a notification letter or appear on the dealer's computer listing.
TRANSFER OF VEHICLE
If a vehicle has been transferred or sold to another location, please forward vehicle information for this vehicle to your Buick Zone Office for handling with the proper dealer.
CHANGE OF OWNER INFORMATION
Buick dealers are to use the Dealer Communication System (D.C.S.) to provide Buick Motor Division with subsequent Buick owner information. By reporting a change of owner name or address of a vehicle in campaign status over the D.C.S., the need to send in an S-866 Form for that vehicle is eliminated. Terminal input instructions are covered in the D.C.S. Manual under Section 9, page 9-J01A and B.
PARTS INFORMATION
Parts are to be obtained from GMWDD using the following part numbers:
DESCRIPTION PART NUMBER
(Catalytic Converter with Upper Beads 25057007 (Includes Fill Hole Plug)
*Package, Lower Bed Bead 25056895 (If needed to Fill Converter)
Clamp, Converter Front Exhaust 1259609 (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, Michigan 48066
B. Converter Plug Installer
Converter plug installed J-34118, part of the 1984 Essential Service Tool Program.
TECHNICAL PROCEDURE
1. Install seat and fender covers and raise the vehicle on a hoist.
Inspection: The converter need not be replaced -
If it is one of the new type basketed converter assemblies, part number 25056622.
If it is one of the converters used in Dealer Technical Bulletin 82-T-27, part number 25056894.
The part numbers are stamped on the bottom of the inboard flange near the converter inlet. Refer to Figure 1.
Proceed to Step 15 if replacement of the converter is not required.
2. If the converter is of the original type, remove both converter clamps and brackets.
3. Remove the A.I.R. clamp and pipe.
4. Remove the converter (using a torch to heat the joints.)
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 pre- cautions include:
A. Catalyst dust should be controlled by wetting with water prior to bead removal, as described in Step 5.
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.
5. Stand the old converter upright on the inlet end and pour 16 ounces of water into the outlet to control catalyst dust.
6. 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 Figure 1 and 2.
7. 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.
8. Pour the beads into, a sifting pan (J-34155-1) and sift to remove under-sized beads.
9. Prop the new converter up at a 45-degree angle with the lower bed fill hole at the top.
10. Using funnel J-34155-3, pour the sifted beads into the lower bed of the new converter. 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.
11. Lay the converter down on a flat surface with the lower bed fill hole on top. Figure 2.
12. Insert the fill plug into the lower bed fill hole. The fill plug outer rim must rest against the converter body.
13. Insert the plug installer tool (J-34118) into the fill plug and tighten to a torque of 47 N.m (35 lbs. ft.). Figure 3.
14. Install the converter on the vehicle by reversing the removal procedure.
15. Install a 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 (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 radiator upper mounting support and apply the campaign label where it is readily visible.
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
SUBLET PART FAILED PARTS FAILURE LABOR LABOR OTHER DEALER OPER. COUNT PART NO. ALLOW. CODE OP. NO. HOURS HOURS* MTL TWG
Inspect Catalytic Converter 96 V2370 .2 hrs. .1 hr.
Inspect & Replace Catalytic Converter ++ 25057007 +++ 96 V2371 .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 25056895 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 1981 and 1982 Electras, LeSabres, and Riverias equipped with a 5.0L V-8 gasoline engine 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 your vehicle.
If you have recently had your catalytic converter replaced with a new type catalytic converter assembly or catalytic converter kit, 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 returning 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.
