SPECIAL POLICY: CATALYTIC CONVERTER REPLACEMENT-CA ONLY

MODELS: 1985-86 PONTIAC FIREBIRD WITH 2.8L ENGINE AND CALIFORNIA EMISSIONS

General Motors has determined that some 1985-86 Pontiac Firebird model vehicles with 2.8L engines and California Emissions ONLY may exhibit a catalytic converter related performance problem. Vehicles with this condition may experience symptoms of excessive and continuous loss of power and/or a rattle in the catalytic converter area (center of vehicle under passenger seat) during acceleration.

VEHICLES INVOLVED

Involved are certain 1985-86 Pontiac Firebird model vehicles with 2.8L engines and California Emissions ONLY within the following VIN break- points:

Up To And Model Year Plant Beginning Including ----- ---- ----- --------- ---------- F 1985 Van Nuys FL200009 FL654601 F 1986 Van Nuys GL200058 GL259097

SPECIAL POLICY ADJUSTMENT

This special policy covers the condition described above for 7 years/70,000 miles, whichever occurs first, from date vehicle was originally placed in service regardless of ownership. Correction will consist of performing a diagnostic check on vehicles with catalytic converter problems to identify "upstream" malfunctioning components, and replace defective components (including catalytic converter) at no charge to the customer. Also, vehicles which are not found to have catalytic converter problems will have certain upstream components checked, and, if faulty, replaced to prevent possible converter replacement in the, future.

This "Special Policy Adjustment Bulletin" should be filed in the three ring binder previously furnished to dealers by General Motors.

OWNER NOTIFICATION

Owners will be notified of this Special Policy on their vehicles by Pontiac Division (see copy of owner letter included with this bulletin).

REIMBURSEMENT

Customer claims for reimbursement on previously paid catalytic converter replacement are to be submitted in the following manner: Use the special "Owner Reimbursement" labor operation listed under the Claim Information Section of this bulletin. Reimbursement amounts of $150.00 or less can be processed by the dealer. If the amount exceeds $150.00 an Owner Reimbursement Form 7201-039 (Rev. 6/88) must be forwarded to and processed by the Zone Office.

All expenses concerning previous repairs must be listed on a separate claim and entered in the net items column of the warranty claim.

SERVICE PROCEDURE Perform all steps appropriate to customers described symptoms.

1. Customer's described symptom is an excessive and continuous loss of power, and no other causes for condition are found.

a. Pressure check catalytic converter for plugging following procedure in Chart 1 on page 3 of this bulletin. If plugging is found, replace converter.

b. If converter is found to be plugged, it is likely that plugging was caused by a rich fuel or misfire condition which must be corrected. Using proper service manuals, check for malfunctioning components such as spark plugs, spark plug wires, mass air flow sensor and ignition coil. Replace only the above components which are determined to be faulty by diagnosis.

2. Customer's described symptom is a rattle in the catalytic converter area (center of vehicle under passenger seat) during acceleration.

a. Check converter using a rubber or brass mallet (or other convenient method) to verify that the converter has internally deteriorated. If it has deteriorated, replace converter.

b. If converter has deteriorated internally, use procedure from Step 1.b. to determine cause of rich fuel or misfire condition which is likely to have caused the deterioration.

3. If neither of Steps 1.a. or 2.a. show that vehicle has a plugged or deteriorated converter, it is still necessary to determine if a rich fuel condition exists by using the procedure described in Step 1.b. above.

RESTRICTED EXHAUST SYSTEM CHECK ALL ENGINES

Proper diagnosis for a restricted exhaust system is essential before any components are replaced. Either of the following procedures may be used for diagnosis, depending upon engine or tool used:

CHECK AT A.I.R. PIPE:

1. Remove the rubber hose at the exhaust manifold A.I.R. pipe check valve. Remove check valve.

2. Connect a fuel pump pressure gauge to a hose and nipple from a Propane Enrichment Device (J26911) (see illustration).

3. Insert the nipple into the exhaust manifold A.I.R. pipe.

CHECK AT 02 SENSOR:

1. Carefully remove 02 sensor.

2. Install Borroughs Exhaust Backpressure Tester (BT 8515 or BT 8603) or equivalent in place Of 02 sensor (see illustration).

3. After completing test described below, be sure to coat threads of 02 sensor with anti-seize compound P/N 5613695 or equivalent prior to re-installation.

DIAGNOSIS:

1. With the engine idling at normal operating temperature, observe the exhaust system backpressure reading on the gauge. Reading should not exceed 1 14 psi (8.6 kPa).

2. Accelerate engine to 2000 RPM and observe gauge. Reading should not exceed 3 psi (20.7 kPa).

3. If the backpressure, at either RPM, exceeds specification, a restricted exhaust system is indicated.

4. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler failure.

5. If there are no obvious reasons for the excessive backpressure, a restricted catalytic converter should be suspected and replaced using current recommended procedures.

PARTS INFORMATION

Parts are to be obtained from General Motors Service Parts Operation (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered on a "C.I.O." order with no special instruction code, but on an advise code (2).

Part Quantity/ Number Description Vehicle ------ ----------- ------- 25104586 Catalytic Converter 1

25007557 MAF Sensor 1

1115315 Ignition Coil 1

10495089 Pick-Up Coil 1

5614168 Spark Plugs 6

12073926 Spark Plug Wires (Set) 1

CLAIM INFORMATION

A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.

DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS: Other Failed Parts Labor Labor Labor Repair Performed PC Part No. Allow FC Operation Hours Hours

Perform Diagnostic * ** 95 T1595 0.8 *** Check/Repair As Necessary

Owner Reimbursement 95 T1596 **** for Previous Repairs

* Part Number of prry failed part.

**The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% handling allowance of all parts (see list above) required for repairs performed in accordance with this bulletin.

***"Other Labor Hours" should contain the sum of all labor hours (see listing on next page) for repairs performed in accordance with this bulletin.

****Total reimbursement amount requested should be shown in the sublet column. Other Labor Repair Performed Hours ----------------- ------ Replace Catalytic Converter 0.4

Replace Mass Air Flow Sensor 0.2

Replace Ignition Coil 0.4

Replace Pick-Up Coil 0.8

Replace Spark Plugs - All 0.4

Replace Spark Plug Wires - All 0.3

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.