CAMPAIGN: RESTRICTED EXHAUST PLUGGED CATALYTIC CONVERTER
1981 BONNEVILLE AND CATALINA MODELS WITH 5.0L V-8 GASOLINE ENGINE (VIN CODE Y)
CONDITION
General Motors has determined that some 1981 Pontiac Bonneville/ Catalina models equipped with a 5.0L V-8 gasoline engine may develop a restricted exhaust due to the catalytic converter becoming plugged.
VEHICLES INVOLVED
Involved are all 1981 Bonneville/Catalina models equipped with a 5.0L V-8 gasoline engine (VIN Code Y).
Vehicles that have had the catalytic converter replaced since approximately June 1, 1983 with the new type basketed converter assembly or that have had the converter kit part number listed in this bulletin and in Dealer Technical Bulletin 81-T-70 installed, need not have this campaign performed.
DEALER ACTION
To correct this condition on vehicles involved the catalytic converter will require replacement.
Dealers are to service all vehicles subject to this campaign at no charge to the owner, regardless of mileage, age of vehicle, or ownership, from this time forward.
Whenever a vehicle subject to this campaign is taken into your dealer 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 before reselling or releasing the vehicle.
Owners of vehicles recently sold from your vehicle inventory are to be contacted by the dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.
PARTS INFORMATION
Parts are to be obtained from WDDGM using the following part numbers.
Description Part Number ----------- ----------- Converter with Upper Beads 25057007
(Includes fill hole plug)
Lower Bed Bead Package* 25056895 (If needed to fill Converter)
Converter Front Exhaust Clamp 1259609 (If needed)
To ensure these parts willl be obtained as soon as possible, they should be ordered from GM Parts (WDDGM) on a C.I.O. order with NO special instruction code, but ordered on an advise code (2).
*A lower Bed Bead Package, when used along with the beads removed from the old converter, will complete approximately 10 vehicles.
Additional fill hole plugs, if required, may be ordered using part number 8998202.
PART I - SERVICE PROCEDURE
1. Raise the vehicle on a hoist.
Inspection: The converter need not be replaced:
If it is one of the new-type basketed converter assemblies part number 25056622.
If it is one of the converters used in Dealer Technical Bulletin 81-T-70, part number 25057007.
The part numbers are stamped on the bottom of the inboard flange near the converter inlet. Refer to Figure 1. Proceed to Part II if replacement of the converter is not required.
2. If the converter is of the original type, remove both converter clamps and brackets.
3. Remove the A.I.R. clamp and pipe.
4. Remove the converter (using a torch to heat the joints).
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.
5. Stand the old converter upright on the inlet end and pour 16 ounces of water into the outlet end to control catalyst dust.
6. Using a hammer and chisel, remove the fill hole plug from the lower bed. (The smooth side of the converter is the lower bed side.) See Figure 1.
7. Hold the converter over a clean pan (J-34155-2) and empty the catalyst beads by shaking. It may be necessary to tap the converter belt flange with a hammer to loosen the beads.
8. Pour the beads into a sifting pan (J-34155-1) and sift to remove undersized beads.
9. Prop the new converter up at a 45 degree angle with the lower bed fill hole at the top.
10. Using funnel J-34155-3, pour the sifted beads into the lower bed of the new converter. If additional beads are required to completely fill the lower bed, it will be necessary to obtain a lower bed bead kit from the parts department. Excess beads from the kit should be saved in a clean container for future use.
11. Lay the converter down on a flat surface with the lower bed fill hole on top. Figure 1.
12. Insert the fill plug into the lower bed fill hole. The fill plug outer rim must rest against the converter body.
13. Insert the plug installer tool (J-34118) into the fill plug and tighten to a torque of 47 N.m (35 lb. ft.). See Figure 2.
14. Install the converter on the vehicle by reversing steps 1 through 4 of this procedure.
PART II - INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL
Each vehicle modified in accordance with the instructions outlined herein will require a Campaign Identification Label. Each label provides a space to include the campaign number, the five (5) digit Dealer Code of the dealer performing the campaign service and the date vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. When installing label, clean the surface of the fan shroud and apply the campaign label.
Additional campaign labels are available on stationery order as Form 7201-709.
DISPOSITION OF REPLACED CONVERTERS
Replaced converters must be held for disposition per normal scrapping procedures approved by Pontiac for your dealership.
ENCLOSED WITH THE COPY OF THIS BULLETIN
A list of those vehicles involved which our records indicate are in your geographical area is attached for your follow-up. Advise the zone if vehicles appearing on the attached list are not in your area. If a list of vehicles is not attached, our records indicate no affected vehicle(s) in your area.
If a vehicle has been transferred or sold to another location, please forward the new name and address of the vehicle to your Pontiac zone office.
RECORDING COMPLETION
Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS". Owners are being asked to present the owner reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.
DEALERS SHOULD STILL SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:
(A completed warranty claim is to be kept as a permanent record of completion.)
WARRANTY CREDIT
A separate repair order must be used for each vehicle.
OTHER* FAILURE LABOR LABOR LABOR DESCRIPTION CODE OPERATION HOURS HOURS ------------ ---- --------- ----- ----- Inspection Only 96 V23io 0.2 Hr. 0.1 Hr. Inspect and Replace 96 V2371 0.9 Hr. 0.1 Hr. Converter
"In addition, dealerships will receive 0.1 hour credit for dealer administrative services associated with thie campaign. The 0.2 hour allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed for credit. This entry will not require zone authorization."
Part(s) required are to be listed on your warranty claim in the normal manner. Parts will be credited at the dealer net plus 30% dealer handling allowance.
(CREDITING)
Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claims must contain all information required and should list the labor operation as outlined.
Repair submitted for vehicles not involved in the campaign will not be paid.
Dear Pontiac Owner:
General Motors has determined that certain 1981 Pontiac Bonneville/Catalina models equipped with a 5.0L engine 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 your vehicle.
If you have recently had your catalytic converter replaced with a new type catalytic converter assembly or catalytic converter kit you need not have this campaign performed.
Instructions for making this correction have been sent to your Pontiac Dealer.
Please contact your dealer to arrange a service date to have this modification performed. The labor time required to perform this modification is approximately one hour. Please allow additional time for the dealer to process your vehicle.
The enclosed owner reply card identifies your vehicle. Presentation of this car to your dealer will assist in making the necessary correction to your vehicle in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage-paid owner reply card and returning it to us.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.
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.
