CAMPAIGN: EMISSION RESTRICTED CATALYTIC CONVERTER

Subject: PRODUCT EMISSION CAMPAIGN 82C31 RESTRICTED CATALYTIC CONVERTER 1981-1982 FULL SIZE CHEVROLET, CAMARO, MALIBU, MONTE CARLO, EL CAMINO AND 1981 CORVETTE MODELS

General Motors has determined that some 1981-1982 Full Size Chevrolet, Camaro, Malibu, Monte Carlo, El Camino and 1981 Corvette 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.

INVOLVED VEHICLES

Involved are certain 1981-1982 Full Size Chevrolet, Camaro, Malibu, Monte Carlo, El Camino and 1981 Corvette Models equipped with engine and emission systems within the following vehicle breakpoints:

Federal Emission Systems California Emission System (RPO NA5) (RPO NB2)

Engine RPO's VIN Code Engine RPO's VIN Code ------------ -------- ------------ -------- LC3 3.8L 229 K LG4 5.0L 305 H L39 4.4L 267 J L81 5.7L 350 6 LG4 5.0L 305 H LM1 5.7L 350 L LM1 5.7L 350 L L81 5.7L 350 6

Model Plant Year From Through ------------ ------ ---- -------- Arlington(R) 1981 SOP EOP 1982 SOP CR181936 Baltimore(B) 1981 SOP EOP 1982 SOP CB158156 Fairfax(X) 1981 SOP EOP 1982 SOP CX109177 Janesville(j) 1981 SOP EOP 1982 SOP CJ121189 Oshawa(l) 1981 SOP EOP 1982 SOP C1203793

Model Plant Year From Through ---------------------- ----- ---- -------- Norwood(N) 1981 SOP EOP All "F" W/Auto Trans 1982 SOP CN120571 All "F" Z28 Man Trans 1982 SOP EOP Van Nuys(L) 1981 SOP EOP All "F" W/Auto Trans 1982 SOP CL149636 All "F" Z28 Man Trans 1982 SOP EOP St. Louis(S) 1981 SOP EOP Bowling Green(5) 1981 SOP EOP

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. Any dealer not receiving a computer listing with the campaign bulletin was not shipped any involved vehicles.

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division as parts become available. 1981 vehicles will be campaigned first. (See copy of Owner Letter included with this bulletin.)

Owners who have previously had their catalytic converter replaced with a single bed bead converter or new dual bed bead converter identified by P/N listed in Column 2, Page 3 of this bulletin because of a malfunction should not receive notification or appear on the dealers computer listing.

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 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.

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 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.

SERVICE PROCEDURE

A. Inspection

1. Raise vehicle on hoist.

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

3. 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

Column 1 Column 2 Model Year Original Dual New Dual Bed Vehicle Bed Bead Conv. Bead Conv. -------------------- ------------- ------------ 1981 "A","ASpl" and "B" (including Police) 1982 "B","G" and "GSpl" 8999586 (including Police) 25056366 25056673 (1982 Police)

1981 "F" (non-Z28) 8999588 25056674 1981 "F" (Z28) 8999589 25056675 1982 "F" 5.OL (LG4) 8999830 25056676 1981 "Y" 8999338 25056672

B. Converter Removal, Preparation and Installation:

1. Disconnect air supply pipe from catalytic converter.

2. Disconnect intermediate pipe from rear of converter.

3. Disconnect hanger bracket from converter, except on Corvettes.

4. On Corvette, remove nuts and bolts and remove converter. All other models, remove front exhaust clamp then remove converter.

5. Stand old converter upright on inlet end and pour two(2) 8 ounce cups of water into outlet end to control catalyst dust.

6. 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 (see Figure 1 for description of upper and lower beds). Deform fill plug until it can be removed with pliers.

7. Hold converter over a clean pan (J-34155-2) and empty catalyst beads by shaking and tapping converter belt flange (Figure 1) 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. 80-93.

8. 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 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. 80-93.

9. Prop new converter up at a 450 angle with upper bed fill hole at top. (See Figure 1 for a description of upper and lower beds). Tap funnel (J-34155-3) into converter fill hole with hammer (Figure 2).

10. Install packet of new upper bed beads from kit P/N 25056590 into upper bed of the new converter.

11. Pour sifted upper bed beads (reference Step 8) or new upper beads, if required, into converter. Tap belt flange of the converter with rubber mallet to allow beads to settle. Continue filling and tapping until converter is full. See Figure 3 for definition of full upper bed.

12. If upper bed is full, proceed to Step 12. If upper bed is not full, use leftover upper bed catalyst beads from involved dual bed converters to fill upper bed beads. If there are not enough used upper bed beads, obtain upper bed catalyst kit, P/N 25056680, 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 of 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, P/N 8998202, (two provided in kit P/N 25056590) into upper bed fill hole. If outer rim of the fill plug doesn't fit flat against converter shell, re- move enough beads so it does.

15. With fill plug in fill hole, insert tool (J-34188) into fill plug (Figure 4). Tighten tool to 35 lbs.ft. (47 NM) and make sure plug outer rim is flat and tight against converter shell. Set new converter aside.

16. Remove lower bed fill plug from old converter using procedure described in Step 6.

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

18. Sift lower bed beads using procedure described in Step 8.

19. Prop new converter up at a 450 angle with lower bed fill hole at top. (See Figure 1 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 17) 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).

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, P/N 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 13 and 14.

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

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.

Number Required Description P/N Carline Per vehicle

Converter 25056673 "A","B" 1 "G"

Converter 25056674 1981 (Non-z28)

Converter 25056675 1981 "F" 1 (Z28)

Converter 25056676 1982 "F" 1

Converter 25056672 1981 "Y" 1

Upper Bed rebuild kit 25056590 All 1 (contains 300 grams of upper bed catalyst, (2) fill hole plugs P/N 8998202 and instruction sheet)

* Upper Bed Bead Kit 25056680 All As Required. (contains 700 grams of catalyst beads only)

* Lower Bed Bead Kit 25056682 All As Required. (contains 1,000 grams of catalyst beads only)

Clamp, Catalytic Converter 22505116 "A","B" 1 Air Injection Pipe "G"

Bolt (pipe to rear 11502877 "A","B" 2 converter) "F","G"

Bolt (hanger to converter) 11504596 1981 "A", 2 "B", 1982

Bolt (hanger to converter) 9424320 1981 "F" 2

Nut (pipe to converter-"Y") 9414034 1981 "F" 2 "F", 8 "Y" (hanger to converter-"F") "Y"

Washer (hanger to converter 9439512 1981 "F" 2 "F", 8 "Y" "F") (pipe to converter "Y") "Y"

Bolt (pipe to converter) 9439636 1981 "Y" 8

Clamp, Exhaust (2 1/4") 1259609 "A","B" 1 "F","G"

*Refer to special instructions outlined in the Claim Information section of this bulletin.

Special Tools:

A. Converter Bead Replacement Tool Kit Each Chevrolet Dealer will be shipped (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(l)

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, III. 48066

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

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

Parts Failed Parts Failure Labor Labor Other Net Count Part No. Allowance Code Operation Hours Hours Amount

00 V1680 .2 .1

Description: Inspect catalytic converter. If previously replaced with a single bed bead or appropriate dual bed bead converter P/N listed in Column 2 of Page 3 of this bulletin, no further action required.

Parts Failed Parts Failure Labor Labor Other Net Count Part No. Allowance Code Operation Hours Hours Amount ----- -------- --------- ------ --------- ------ ----- ------ 8 25056673 81.30 00 V1681 .9 .1

Description; Inspect, replace catalytic converter on (-Full Size Chevrolet, Malibu, Monte Carlo and El Camino Models) in accordance with the instructions outlined in this campaign bulletin.

Parts Failed Parts Failure Labor Labor Other Net Count Part No. Allowance Code Operation Hours Hours Amount ----- -------- --------- ------ --------- ----- ----- ----- 11 25056675 95.23 00 V1682 .9 .1

Description: Inspect, replace catalytic converter on (Camaro Models) in accordance with the instructions outlined in this campaign bulletin.

Parts Failed Parts Failure Labor Labor Other Net Count Part No. Allowance Code Operation Hours Hours Amount ----- --------- --------- ------ --------- ----- ----- ------ 26 25056672 103.68 00 V1683 .9 .1

Description: Inspect, replace catalytic converter on (1981 Corvette Models) in accordance with the instructions outlined in this campaign bulletin.

*Campaign Administrative Allowance.

When it is necessary to use P/N 25056680 "upper bed bead kit" and/or P/N 25056682 "lower bed bead kit", the part price plus 30% for the kit(s) MUST be entered in the "NET AMOUNT COLUMN". ZONE APPROVAL with an "E" authorization is REQUIRED.

IMPORTANT: When P/N 25056680 (upper bed bead kit) and/or P/N 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.

***The Parts Allowance should be the sum total of the current WDDGM Dealer Net plus 30% of all parts required for the repair.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign claim submission.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label". Each label provides a space to include the five digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or ballpoint pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner.

Apply "Campaign Identification Label" only on a clean dry surface.

ADMINISTRATIVE PROCEDURE

REFER TO THE CURRENT CHEVROLET SERVICE POLICIES AND PROCEDURES MANUAL AND CLAIMS PROCESSING MANUAL FOR CAMPAIGN HANDLING AND ADMINISTRATIVE PROCEDURES.

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.