CAMPAIGN:RESTRICTED CATALYTIC CONVERTER 1982 & 83 CARS

GENERAL MOTORS HAS DETERMINED THAT SOME 1982 AND 1983 CADILLACS EQUIPPED WITH 4.1 LITER V8 GASOLINE ENGINES MAY DEVELOP A RESTRICTED CATALYTIC CONVERTER. THIS MAY RESULT IN POOR ENGINE PERFORMANCE OR A NO START CONDITION. TO PREVENT THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO INSPECT AND IF NECESSARY, REPLACE THE CATALYTIC CONVERTER ON ALL AFFECTED 1982 VEHICLES. ADDITIONALLY, DEALERS ARE TO REPLACE THE CATALYTIC CONVERTER ON ALL 1983 VEHICLES SUBJECT TO THIS CAMPAIGN. VEHICLES INVOLVED THE VEHICLES LISTED BELOW EQUIPPED WITH 4.1 LITER V8 GASOLINE ENGINES REQUIRE THE SERVICE PROCEDURE DESCRIBED IN THIS BULLETIN. 1. ALL 1982 CADILLACS (CADILLAC RECORDS INDICATE THAT A TOTAL OF 170,604 VEHICLES ARE INVOLVED). 2. ALL 1983 CADILLACS WITHIN THE FOLLOWING VIN RANGE (CADILLAC RECORDS INDICATE THAT A TOTAL OF 192,648 VEHICLES ARE INVOLVED): "C" 100001 - 229506 "E" 600001 - 647667 "K" 800001 - 821885 PARTS INFORMATION THE PARTS REQUIRED TO COMPLETE THIS CAMPAIGN SHOULD BE OBTAINED FROM THE PARTS DISTRIBUTION CENTERS OF THE GENERAL MOTORS WAREHOUSING AND DISTRIBUTION DIVISION (WDDGM). THE TABLE BELOW SUMMARIZES THE PARTS INVOLVED IN THIS CAMPAIGN. APPLICATION PART NUMBER DESCRIPTION QUANTITY 1982-1983 MODEL YEAR 25057007 CONVERTER (UPPER BED FILLED) KIT 1 1983 MODEL YEAR 25057558 CONVERTER BEAD (LOWER BED SERVICE KIT (125 CU.IN) 1 1982 MODEL YEAR 25100011 CONVERTER BEAD (LOWER BED) TOP-OFF KIT (10 CU.IN) 1 IF THERE IS DIFFICULTY IN OBTAINING THESE PARTS USING NORMAL ORDERING PROCEDURES, DEALERS MAY PLACE A CIO ORDER USING ADVISE CODE "2" WITH NO SPECIAL INSTRUCTION CODE. THESE PARTS MAY ALSO BE ORDERED ON A VIP ORDER; HOWEVER, UNLESS PRIOR ZONE APPROVAL IS OBTAINED, DEALERS WILL BE REQUIRED TO ABSORB ANY SURCHARGE INVOLVED UNDER THE VIP SYSTEM. IF ANY PROBLEMS ARE ENCOUNTERED IN OBTAINING THESE PARTS, PLEASE FOLLOW THE THREE-STEP PROCEDURE AS STATED IN THE GM PARTS EMERGENCY ORDER FOLLOW-UP PROCEDURE. (REFER TO GM PARTS POLICY AND PROCEDURE MANUAL, EXHIBIT 20, SECTION IV, PAGE 38.) SERVICE PROCEDURE RAISE THE VEHICLE TO ALLOW FOR VISUAL INSPECTION OF THE CATALYTIC CONVERTER. INSPECT THE PART NUMBER STAMPED ON THE INBOARD FLANGE NEAR THE CONVERTER INLET (SEE FIGURE 1). THE CONVERTER SHOULD NOT BE REPLACED IF IT IS A BASKETED CONVERTER ASSEMBLY, P/N 25056623, OR A NEW TYPE DESIGN ASSEMBLY, P/N 25056894 (WHICH IS CONTAINED IN CONVERTER KIT PART NUMBER 25057007. PROCEED TO STEP 12 IF REPLACEMENT OF THE CONVERTER IS NOT REQUIRED. 1983 VEHICLES AND 1982 VEHICLES REQUIRING 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 THE FOLLOWING SERVICE PROCEDURE. -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. REMOVE CATALYTIC CONVERTER FROM VEHICLE USING THE PROCEDURE DESCRIBED IN THE APPROPRIATE 1982 OR 1983 CADILLAC SERVICE INFORMATION MANUAL. IF SERVICING A 1983 VEHICLE, PROCEED TO STEP 7. 2. STAND OLD CONVERTER UPRIGHT ON INLET END AND POUR TWO EIGHT OUNCE CUPS OF WATER INTO OUTLET END TO CONTROL CATALYST DUST. 3. USING HAMMER AND CHISEL, REMOVE LOWER BED FILL HOLE PLUG FROM OLD CONVERTER BY DRIVING CHISEL BETWEEN THE CONVERTER SHELL AND RIM OF FILL PLUG (SEE FIGURE 1 FOR DESCRIPTION OF UPPER AND LOWER BEDS). DEFORM FILL PLUG UNTIL IT CAN BE REMOVED WITH PLIERS. 4. HOLD CONVERTER OVER A CLEAN PAN (J-34155-2) AND EMPTY CATALYST BEADS BY SHAKING AND TAPPING CONVERTER BELT FLANGE (SEE FIGURE 1) WITH RUBBER MALLET. NOTICE: IF LOWER BED IS EMPTY OR NEAR EMPTY (A CUP OR LESS) OF CATALYST BEADS, OR IF THE CONVERTER IS EXPANDED, THE CONVERTER IS CONSIDERED DAMAGED (INTERNALLY). CATALYST BEADS FOUND IN INTERNALLY DAMAGED OR EXPANDED CONVERTERS ARE NOT TO BE USED IN NEW CONVERTERS. THESE BEADS CAN BE RETURNED VIA THE EXCHANGE PROGRAM DESCRIBED IN WDDGM BULLETIN IB NO. 80-93. 5. POUR LOWER 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 PAN (J-34155-2). SET SIFTED BEADS (HALF SIZE AND LARGER) ASIDE FOR NOW. 6. PROP NEW CONVERTER UP AT A 45 DEGREE ANGLE WITH LOWER BED FILL HOLE AT THE TOP (SEE FIGURE 1 FOR A DESCRIPTION OF LOWER BED). TAP FUNNEL (J-34155-3) INTO CONVERTER FILL HOLE WITH HAMMER (SEE FIGURE 1 FOR A DESCRIPTION OF LOWER BED). TAP FUNNEL (J-34155-3) (J-34155-3) INTO CONVERTER FILL HOLE WITH HAMMER (SEE FIGURE 1). 7. 1983 VEHICLES ONLY -- INSTALL NEW PACKET OF BEADS INCLUDED IN CONVERTER BEAD SERVICE KIT, P/N 25057558. TAP BELT FLANGE OF CONVERTER WITH RUBBER MALLET TO ALLOW BEADS TO SETTLE. STOP FILLING THE CONVERTER WHEN THE BEAD LEVEL REACHES THE BOTTOM EDGE OF THE FILL HOLE WHEN THE CONVERTER IS STOOD IN AN UPRIGHT POSITION. PROCEED TO STEP 8. 1982 VEHICLES ONLY -- POUR SIFTED LOWER BED BEADS (HALF SIZE AND LARGER - REFERENCE STEP 5) INTO LOWER BED OF NEW CONVERTER. TAP BELT FLANGE OF CONVERTER WITH RUBBER MALLET TO ALLOW BEADS TO SETTLE. CONTINUE FILLING AND TAPPING UNTIL THE BEAD LEVEL REACHES THE BOTTOM EDGE OF THE FILL HOLE WHEN THE CONVERTER IS STOOD IN AN UPRIGHT POSITION. IF LOWER BED IS FULL, PROCEED TO STEP 11. IF LOWER BED IS NOT FULL, USE CONVERTER BEAD TOP-OFF, P/N 25100011. 8. LAY CONVERTER DOWN ON FLAT SURFACE WITH LOWER BED FACING UP. 9. INSERT FILL PLUG, P/N 8998202, WHICH IS INCLUDED IN THE CONVERTER KIT, P/N 25056984 INTO LOWER BED FILL HOLE. IF THE OUTER RIM OF THE FILL PLUG DOES NOT FIT FLAT AGAINST CONVERTER SHELL, REMOVE ENOUGH BEADS TO ENSURE A FLAT FIT. 10. WITH FILL PLUG IN FILL HOLE, INSERT TOOL J-34118 INTO FILL PLUG (SEE FIGURE 2). USING A TORQUE WRENCH AND TOOL J-34118, TIGHTEN PLUG TO 35 FT. LBS. (47 N.M) AND MAKE SURE PLUG OUTER RIM IS FLAT AND TIGHT AGAINST CONVERTER SHELL. 11. INSTALL THE CONVERTER ON VEHICLE USING PROCEDURE DESCRIBED IN APPROPRIATE 1982 OR 1983 SERVICE INFORMATION MANUAL. 12. LOWER THE VEHICLE AND INSTALL CAMPAIGN COMPLETION LABEL DESCRIBED IN THIS BULLETIN.

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.