CAMPAIGN: CATALYTIC CONVERTER WELDED INTO EXHAUST PIPE
SUBJECT: CATALYTIC CONVERTER WELDED INTO EXHAUST PIPE BACKWARDS ------------------------------------------------------
Model: 1996 GMC and Chevrolet C/K Trucks With Heavy Duty Exhaust Emissions -------------------------------------------------------------------
TO: ALL GENERAL MOTORS DEALERS
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General Motors of Canada Limited has decided that CERTAIN 1996 GMC and Chevrolet C/K pickups and chassis-cabs with 5.7L (L31) or 7.4L (L29) gasoline engines and heavy duty exhaust emissions may have been built with catalytic converters that were welded into the exhaust pipe backwards.
To correct this condition, dealers will inspect to see if the catalytic converter is installed in the proper orientation. If not, the exhaust crossover pipe assembly will be replaced.
VEHICLES INVOLVED:
Involved are CERTAIN 1996 GMC and Chevrolet C/K pickups and chassis-cabs with 5.7L (L31) or 7.4L (L29) gasoline engines and heavy duty exhaust emissions built within the following VIN breakpoints:
Year Model Plant Plant Code From Through ---- ------ ----- ---------- ---- -------
1996 GMC C/K Truck Flint F TFOOOOOI TF003266 1996 GMC C/K Truck Pontiac East E TE502575 TE506508 1996 GMC C/K Truck Fort Wayne Z TZ500446 TZ503068 1996 Chevrolet C/K Truck Flint F TFOOOOOI TF003266 1996 Chevrolet C/K Truck Pontiac East E TE104283 TE120739 1996 Chevrolet C/K Truck Fort Wayne Z TZ100139 TZ108797
NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID
All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.
DEALER CAMPAIGN RESPONSIBILITY:
All unsold new vehicles in dealer's possession and subject to this campaign must be held and inspected/repaired per the Service Procedure of this Campaign Bulletin before owners take possession of these vehicles.
Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, age of vehicle, or ownership, from this time forward.
Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.
CAMPAIGN PROCEDURE:
Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.
OWNER NOTIFICATION:
All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors (see copy of owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.
PARTS INFORMATION:
Parts required to complete this campaign should be ordered through regular channels, as follows:
Part Number Description Quantity/Vehicle ----------- ----------- ----------------
15733227 Exhaust Crossover With Converter 1 K2, 3 With L29, MW3
15733228 Exhaust Crossover With Converter 1 K2, 3 With L3 1, MW3
15733230 Exhaust Crossover With Converter 1 C2,3 With L29 & MT1 or MW3 K2,3 With L29 & MT1
15733231 Exhaust Crossover With Converter 1 C2,3 With L31 & MT1 or MW3 K2,3 WITH L31 & MT1
PARTS AND LABOUR CLAIM INFORMATION:
Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:
Repair Code Description Time Allowance ----------- ----------- --------------
1A C/K Truck Inspect Crossover Pipe/ Converter 0.4
2A C Truck Inspect & Replace Crossover Pipe/Converter 1.1
3A K Truck Inspect & Replace Crossover Pipe/Converter 0.9
Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus appropriate model year parts handling allowance.
SERVICE PROCEDURE:
Inspection And Repair Procedure For "C" Model (2 Wheel Drive):
1. Raise vehicle.
2. Inspect configuration of driver's side forward catalytic converter (Figure 1, Item 1). Stamped "AC" logo on converter must be located on the downstream end of converter (i.e. towards the rear of the vehicle). - Ifconverter is configured properly, proceed to step #19. - If converter is installed backwards, proceed to step #3.
3. Remove left side oxygen sensor, including electrical connector (Figure 1, Item 2).
4. Remove right side oxygen sensor, including electrical connector (Figure 1, Item 3).
5. Support transmission with transmission jack.
6. Remove transmission crossmember bolts, transmission mount nut, and reposition crossmember rearward.
7. Remove bolts from catalytic converter to exhaust pipe flange (Figure 1, Item 4).
8. Remove left crossover pipe at manifold (Figure 1, Item 5).
9. Remove right crossover pipe at manifold (Figure 1, Item 6).
10. Remove crossover pipe/converter assembly (Figure 1).
11. Install new crossover pipe/converter assembly in position on vehicle (Figure 1).
12. Install right crossover pipe at manifold and torque nuts to 65 N.m (48 lb. ft.) (Figure 1, Item 6).
13. Install left crossover pipe at manifold and torque nuts to 65 N.m (48 lb. ft.) (Figure 1, Item 5).
14. Reinstall bolts in catalytic converter to exhaust pipe flange and torque to 48 N.m (35 lb. ft.) (Figure 1, Item 4).
15. Reposition and reinstall transmission crossmember and torque bolts to 77 N.m (57 lb. ft.) and transmission mount nut torque nut to 52 N.m (38 lb. ft.).
16. Remove transmission jack.
17. Reinstall right side oxygen sensor, including electrical connector, (Figure 1, Item 3) and torque to 41 N.m (30 lb. ft.).
18. Reinstall left side oxygen sensor, including electrical connector, (Figure 1, Item 2) and torque to 41 N.m (30 lb. ft.).
19. Lower vehicle.
20. Install Campaign Identification Label.
Inspection And Repair Procedure For "K" Model (4 Wheel Drive):
1. Raise vehicle.
2. Inspect configuration of driver's side forward catalytic converter (Figure 1, Item 1). Stamped "AC" logo on converter must be located on the downstream end of the converter (i.e., towards the rear of the vehicle.) - If converter is configured properly, proceed to step #17. - If converter is installed backwards, proceed to step #3.
3. Remove left side oxygen sensor, including electrical connector (Figure 1, Item 2).
4. Remove right side oxygen sensor, including electrical connector (Figure 1, Item 3).
5. Remove transmission pan shield.
6. Remove bolts from catalytic converter to exhaust pipe flange (Figure 1, Item 4).
7. Remove left crossover pipe at manifold (Figure 1, Item 5).
8. Remove right crossover pipe at manifold (Figure 1, Item 6).
9. Remove crossover pipe/converter assembly (Figure 1).
10. Install new crossover pipe/converter assembly in position on vehicle (Figure 1).
11. Install right crossover pipe at manifold and torque nuts to 65 N.m (48 lb. ft.) (Figure 1, Item 6).
12. Install left crossover pipe at manifold and torque nuts to 65 N.m (48 lb.ft.) (Figure 1, Item 5).
13. Reinstall bolts in catalytic converter to exhaust pipe flange and torque to 48 N.m (35 lb. ft.) (Figure 1, Item 4).
14. Reinstall transmission pan shield.
15. Reinstall right side oxygen sensor, including electrical connector (Figure 1, Item 3), and torque to 41N.m (30 lb. ft.).
16. Reinstall left side oxygen sensor, including electrical connector (Figure 1, Item 2), and torque to 41N.m (30 lb. ft.).
17. Lower vehicle.
18. Install Campaign Identification Label.
INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL
Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.
April 1996
Dear General Motors Customer:
General Motors of Canada Limited has decided that CERTAIN 1996 GMC and Chevrolet C/K pickups and chassis-cabs with 5.7L or 7.4L gasoline engines and heavy duty exhaust emissions may have been built with catalytic converters that were welded into the exhaust pipe backwards.
To correct this condition, your GM dealer will inspect to see if the catalytic converter is installed in the proper orientation. If not, the exhaust crossover pipe assembly will be replaced.
This service will be provided for you at no charge.
Please contact your GM dealer as soon as possible to arrange a service date.
If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.
This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.
Customer Support Department General Motors of Canada Limited
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.
