CAMPAIGN: CATALYTIC CONVERTER WELDED INTO EXHAUST PIPE
SUBJECT: PRODUCT EMISSION CAMPAIGN 96-C-21 - CATALYTIC CONVERTER WELDED INTO EXHAUST PIPE BACKWARDS -------------------------------------------------------
ModeL/Year: 1996 C/K TRUCKS WITH HEAVY DUTY EXHAUST EMISSIONS --------------------------------------------------
To: All Chevrolet/Geo Dealers
-------------------------
General Motors has decided that some 1996 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. In this configuration, the engine may not meet the configuration specified in the emissions Application for Certification.
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 some 1996 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:
PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ------ ----- ----- ---- -------
1996 C/K Flint "F" TF000001 TF003266 1996 C/K Pontiac East "E" TE104283 TE120739 1996 C/K Fort Wayne "Z" TZ100139 TZ108797
Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identif- ication Number, owner name and address data, and are furnished to 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 has no involved vehicles currently assigned.
OWNER NOTIFICATION
Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin).
DEALER CAMPAIGN RESPONSIBILITY
All unsold new vehicles in dealers' 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 service all vehicles subject to this campaign at no charge to owners, regardless of mileage, 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 the instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owners 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 enters your 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.
PARTS INFORMATION
Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "Involved Vehicle Listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment order. An emergency requirement should be ordered on a CSO = Customer Special Order.
Part Quantity/ Number Description Model Vehicle ------ ------------ ----- ---------
15733227 Exhaust Crossover With Converter K2-3 With 1 L29 & MW3
15733228 Exhaust Crossover With Converter K2-3 With 1 L31 & MW3
C2-3 With L29 & MT1 15733230 Exhaust Crossover With Converter or MW3 1 K2-3 With L29 & MT1
C2-3 With L31 & MT1 lS733231 Exhaust Crossover With Converter or MW3 1 K2-3 With L31 & MT1
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 of the vehicle).
- If converter 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 trans jack.
6. Remove transmission crossmember bolts, transmount 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 Nm (48 lb. ft.) (Figure 1, Item 6).
13. Install left crossover pipe at manifold and torque nuts to 65 Nm (48 lb. ft.) (Figure 1, Item 5).
14. Re-install bolts from catalytic converter to exhaust pipe flange and torque to 48 Nm (35 lb. ft.) (Figure 1, Item 4).
15. Reposition and reinstall transmission crossmember and torque bolts to 77 Nm (57 lb. ft.) and trans mount nut torque nut to 52 Nm (38 lb. ft.).
16. Remove transmission jack.
17. Re-install right side oxygen sensor, including electrical connector, (Figure 1, Item 3) and torque to 41 Nm (30 lb. ft.).
18. Re-install left side oxygen sensor, including electrical connector, (Figure 1, Item 2) and torque to 41 Nm (30 lb. ft.).
19. Lower vehicle.
20. Install Campaign Identification Label.
SERVICE PROCEDURE
Inspection And Repair Procedure For "K" Model (4 Wheel Drive) :
1. Raise vehicle.
2. Inspect configuration of drivers 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 Nm (48 lb. ft.) (Figure 1, Item 6).
12. Install left crossover pipe at manifold and torque nuts to 65 Nm (48 lb. ft.) (Figure 1, Item 5).
13. Re-install bolts from catalytic converter to exhaust pipe flange and torque to 48 Nm (35 lb. ft.) (Figure 1, Item 4).
14. Re-install transmission pan shield.
15. Re-install right side oxygen sensor, including electrical connector (Figure 1, Item 3) and torque to 41 Nm (30 lb. ft.).
16. Re-install left side oxygen sensor, including electrical connector (Figure 1, Item 2) or equivalent and torque to 41 Nm (30 lb. ft.).
17. Lower vehicle.
18. Install Campaign Identification Label.
CAMPAIGN IDENTIFICATION LABEL
Each vehicle corrected 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 campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point 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. When installing the new Campaign Identification Label, be sure to install the clear protective covering. Additional Campaign Identification Labels can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday-Friday, 8:00 a.m. to 4:30 p.m. EST). Ask for Item Number S-1015 when ordering.
Apply "Campaign Identification Label", only on a clean, dry surface.
CLAIM INFORMATION
Submit a Product Campaign Claim with the information indicated below:
PART FAILED PARTS LABOR LABOR REPAIR PERFORMED COUNT PART NO. ALLOW CC-FC OP HOURS ---------------- ---- ------- ------- ----- ----- ------
C/K Truck - Crossover Pipe/ - -- -- MA-96 V910 0.3 Converter Inspect only
C Truck Crossover 1 # ** MA-96 V9911 1.0 Pipe/Converter Inspect & Replace
K Truck - Crossover 1 # ** MA-96 V9912 0.8 Pipe/Converter Inspect & Replace
* For Campaign Administrative Allowance, add 0. 1 hours to the "Labor Hours'.
** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 40% of all parts required for the repair.
# Use appropriate Part Number shown in "Parts Information" section of this bulletin.
Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission.
April, 1996
Dear Chevrolet Customer:
This notice is sent to inform you that Chevrolet Motor Division is conducting an emission recall campaign that includes your vehicle.
REASON FOR THIS RECALL
General Motors has decided that some 1996 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. In this configuration, the engine may not meet the configuration specified in the emissions Application for Certification.
WHAT WE WILL DO
To correct this condition, your 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 performed for you at no charge.
WHAT YOU SHOULD DO
Please contact your Chevrolet dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle.
The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us. Should your dealer not schedule a service date within a reasonable time, you should contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020.
If your dealer and the Customer Assistance Center are unable to remedy this condition within a reasonable time, you may wish to advise the Environmental Protection Agency at the following address: Director, Manufacturers Operations Division (6405J) , United States Environmental Protection Agency, 401 M Street. S.W., Washington, D.C. 20460.
To ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished.
IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS
The California Air Resources Board (CARB) requires vehicle emission recall campaigns be completed prior to California registration renewal. Uncorrected emission recall campaigns will result in your not being able to renew your California vehicle registration.
At the time of emission campaign completion, your California dealer will issue a "Campaign Certificate Of Completion". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of campaign completion.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.
Chevrolet Motor Division GENERAL MOTORS CORPORATION
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.
