CAMPAIGN: RESTRICTED CATALYTIC CONVERTER. GMC Truck Caballero 1981

For 1990-2009 cars

# CAMPAIGN: RESTRICTED CATALYTIC CONVERTER

#### MODELS: 1981-1982 CABALLEROS W/LC3 3.8L, L39 4.4L, AND LG4 5.0L ENGINES

General Motors has determined that some 1981-1982 Caballeros 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 revise the catalytic converter on the involved vehicles.

INVOLVED VEHICLES

Involved are certain 1981-1982 Caballeros equipped with engine and emission systems within the following vehicle breakpoints:

Federal Emission Systems (RPO NA5)

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

California Emission System (RPO NB2)

Engine RPO's VIN Code ------------- -------- LG4 5.0L 305 H

Plant Model Year From Through ----- ---------- ---- ------- Arlington 1981 SOP EOP 1982 SOP CR501737

The specific vehicles involved in this campaign have been identified by Vehicle Identification Number Computer Listings. These listings are fur- nished to all involved dealers with the campaign bulletin.

DEALER CAMPAIGN RESPONSIBILITY

Dealers are to service all vehicles subject to this campaign 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 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 the vehicle.

On vehicles involved in this campaign that have been recently sold to a retail owner, where no owner's name and address were available to GMC Truck at the time of campaign initiation, the dealer will determine the owner's name and address from the dealership sales records. Please provide this information directly on the second copy of the listing next to the applicable VIN, so that our records may be updated and the appropriate notification mailed to the owner. This second copy should then be submitted to the address listed below in the previously supplied yellow campaign envelopes.

GMC Truck General Motors Corporation 101 Union Street Plymouth, Michigan 48170

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by GMC Truck (see copy of Owner Letter included with this bulletin). A listing of owner names and addresses has been furnished to the involved dealers to enable dealers to follow up with owners involved in this campaign. This listing 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 this campaign.

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 the Service Procedure of this bulletin because of a malfunction should not receive notification or appear on the dealer's computer listing.

#### CAUTION:

The catalytic converter beads contain platinum, palladium and/or rhodium. Additionally, the beads may be finely coated wtih 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 handhng.

SERVICE PROCEDURE

A. Inspection

1. Raise vehicle on hoist.

2. Refer to Figure No. 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. ------- -------------- ------------ 1981-1982 8999586 25056673 Caballero

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.

4. 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 No. 1 for description of upper and lower beds). De- form fill plug until it can be removed with phers.

7. Hold converter over a clean pan (J-34155-2) and empty catalyst beads by shaking and tapping converter belt flange (Figure No. 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 45 DEG angle with upper bed fill hole at top. (See Figure No. 1 for a description of upper and lower beds). Tap funnel (J-34155-3) into converter fill hole with hammer (Figure No. 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 No. 3 for definition of full upper bed.

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".

12. Lay converter down on a flat surface with upper bed on top.

13. 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, remove enough beads so it does.

14. With fill plug in fill hole, insert tool (J-34188) into fill plug (Figure No. 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.

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

16. Hold converter over a clean pan (J-34155-2) and empty catalyst beds by shaking and tapping converter belt flange (Figure No. 1) with rubber mallet.

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

18. Prop new converter up at a 45 DEG angle with lower bed fill hole at top. (See Figure No. 1 for definition of upper and lower beds). Tap funnel (J-34155-3) into converter fill hole with hammer (Figure No. 2).

19. 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 No. 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.

20. Lay converter down on flat surface with lower bed on top and install fill plug using procedure described in Steps 13 and 14.

21. 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). Number Required Description P/N Per Vehicle ----------- ---- ------------ Converter 25056673 1

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

Upper Bed Bead Kit (con- 25056680 As Required tains 700 grams of catalyst beads only)

Lower Bed Bead Kit (con- 25056682 As Required tains 1,000 grams of catalyst beads only)

Clamp, Catalytic Converter 22505116 1 Air Injection Pipe

Bolt (pipe to rear converter) 11502877 2

Bolt (hanger to converter) 11504596 2 1981 Only

Clamp, Exhaust (2-1/4") 1259609 1 Fill Plug 8998202 As Required

SPECIAL TOOLS

A. Converter Bead Replacement Tool Kit

Each GMC 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 (1)

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, MI 48066

B. Converter Plug Installer

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

WARRANTY INFORMATION

Dealers should submit an accurately filled out Warranty Repair Order on each vehicle completed under this campaign.

1981 MODEL YEAR VEHICLES

Labor *Time Operation Allow- Trouble Number Description ance Code ------ ----------- ---- ---- V168000 Inspect catalytic conver- .2 96 ter. If previously replaced with a single bed bead or appropriate dual bed bead converter P/N listed in Service Procedure of this bulletin, no further action required.

V168100 Inspect, replace catalytic .9 96 converter in accordance with the instructions outlined in this campaign bulletin.

1982 MODEL YEAR VEHICLES

Labor *Time Operation Allow- Trouble Number Description ance Code ------ ------------ ---- ---- V1680 Inspect catalytic conver- .2 96 ter. If previously replaced with a single bed bead or appropriate dual bed bead converter P/N listed in Service Procedure of this bulletin, no further action required.

V1681 Inspect, replace catalytic .9 96 converter in accordance with the instructions outlined in this campaign bulletin.

For dealer to receive Administration Time Allowance associated with this campaign, add .1 hour to the Labor Operation Time Allowance.

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 (5) 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

Procedures covering this campaign are outlined in Section V of your dealership's "GMC Truck Claims Processing Manual" issued October, 1981.

Dear GMC Owner:

General Motors has determined that certain 1981-1982 Caballeros 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.

Instructions for making this correction have been sent to your GMC Truck Dealer.

Please contact your dealer to arrange a service date to have these modifications performed. The labor time required to perform these modifications is approximately one hour. Please allow additional time for the dealer to process your vehicle.

The enclosed owner reply card identifies your Caballero. Presentation of this card 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.