INSPECTION AND REPLACEMENT OF CATALYTIC CONVERTER (IF NECESSARY). Saturn Saturn 1994

For 1990-2009 cars

# INSPECTION AND REPLACEMENT OF CATALYTIC CONVERTER (IF NECESSARY)

Subject: | Inspection and Replacement of Catalytic Converter (If Necessary)

Models: | 1994 Saturn S-Series Vehicles Registered in California Equipped with DOHC Engines (RPO LLO) and California Emissions (RPO NB6)

All Saturn Retailers and Authorized Service Providers

### Defect Involved

Saturn has decided that certain 1994 Saturn DOHC (dual overhead cam) vehicles with California emission package (NB6) may fail to meet California emission standards due to internal catalytic converter damage. These catalytic converters manufactured during the first quarter of the 1994 model year were produced with an internal mat material that may degrade when exposed to extreme temperatures and/or excessive mechanical forces. Degradation of converter mat material could result in vehicle symptoms such as underbody rattles, exhaust noise, and/or hesitation on acceleration.

### Vehicles Involved

Only selected 1994 model year S-Series Saturn vehicles within the VIN range RZ100016-RZ159813 will require this campaign. A VIN listing of the involved vehicles is included in this bulletin for your reference.

You must verify campaign involvement through your AS400 system or with the listing attached to this bulletin. It is important to note that campaign claims will only be paid on involved vehicles.

### Owner Notification

Owners of all involved vehicles will be notified of this campaign by Saturn. Refer to the owner letter included in this bulletin.

### Facility VIN Listing

A list of vehicles assigned to you (Facility VIN Listing), which our records indicate were sold by or shipped to you, or are located in close proximity to your facility, is enclosed. Only vehicles registered in California are involved in this campaign.

This listing contains:

• | Owner's name with address and telephone number; and

• | Complete vehicle identification number (VIN).

The Facility VIN Listing, with owner information, is furnished to involved Retailers with the Product Campaign Bulletin. Although these vehicles are assigned to your facility, it is important to note that owners may elect to have their vehicle serviced at the Saturn Retail Facility of their choice.

Only Retailers with California registered vehicles will receive Facility VIN Listings. Those Retailers not involved initially in this campaign will receive a message at the top of a blank Facility VIN Listing that states: NO VEHICLES ASSIGNED AT THIS TIME FOR CAMPAIGN 99E01.

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 the law in several states. Accordingly, you are urged to limit the use of this listing to the follow up necessary to complete this campaign. Those records updated with California DMV registration information will have the following message printed adjacent to the appropriate VIN: "OWNER INFORMATION UPDATED BY CALIFORNIA DMV; PUBLICATION PROHIBITED."

### Retailer Responsibility

All vehicles in Retailers' possession and subject to this campaign must be held at the retail facility and repaired per the service procedure of this campaign bulletin before owners take possession of these vehicles.

Retailers 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.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your retail facility 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.

### Transfer of campaign Responsibility

Saturn vehicles that have been sold by you, which may be closer in proximity to another Saturn Retailer, may still appear on your Facility VIN Listing. If either you or the vehicle owner determines that it is more desirable for a vehicle on your Facility VIN Listing to be serviced by another Saturn Retailer, or if the customer's address has recently changed, campaign responsibility may be transferred by completing the following:

• | Submit a Campaign Vehicle Action Report to your Customer Assistance Manager (CAM) at the Saturn Customer Assistance Center.

| OR

• | Submit an update in owner information to the Saturn Owner of Record system, via SERVICELINE XL, for Saturn Customer Assistance Center review and approval.

A copy of the Campaign Vehicle Action Report is included for your reference. Additional copies can be ordered from Saturn Publications, 1-800-828-2112, prompt 3, Item # S0397050. All changes to campaign responsibility will be reflected in your next Unfixed VIN Report.

All other changes in vehicle status (e.g., scrapped, stolen, etc.) are to be made in accordance with section 4.4.3 of the Retailer Service Reference Guide , Notifying Saturn of Vehicle Status Change.

### Parts Information

1. A pre-shipment of catalytic converters and clamps required to perform this campaign has been automatically sent to you from Saturn Service parts Operations (SSPO). These initial shipments are to aid in the Retailer in campaign preparation and ensure minimal customer inconvenience.
2. Should additional parts be required, please order as needed.
3. Required Parts:

Part Number | Description | Qty
--- | --- | ---
21006671 | Catalytic Converter Kit | 1
15595048 | Exhaust System Clamp | 1

### Disposition of Replaced Parts

Retailers are to fill out the Yellow Core Return Tag provided with each catalytic converter. Return the replaced catalytic converter, along with the Yellow Core Return Tag, using the existing core return program. All replaced catalytic converters, Saturn original or non-Saturn part, must be returned in the SSPO box to receive core credit. If you have any questions on how to process a core return, refer to Parts and Accessories Bulletin 98-PA-07, or contact your Parts Support Analyst at 1-800-828-2112, prompt 2.

### Suggestions for Ensuring Customer Satisfaction

As you know, Saturn's success hinges upon our ability to execute superior customer support throughout the ownership experience, especially when important corrective actions such as this are required.

It is imperative that every effort is made to accommodate the affected owners. Additionally, priority should be given to customer vehicles over retail inventory vehicles. If you have any questions, please coordinate with the Saturn Customer Assistance Center to help ensure customer satisfaction.

### Service Procedure

#### Inspection and Replacement of Catalytic Converter

Caution: Make sure vehicle is properly supported and squarely positioned on hoist. to help avoid personal injury, provide additional support to opposite end of vehicle that components will be removed from. Ensure hoist does not contact fuel or brake lines.

1. Raise vehicle on hoist.

Important: If catalytic converter has previously been replaced with a non-Saturn part, continue to step 4.

2. Inspect catalytic converter date code stamp in area (A) indicated in illustration. Date code stamp is a six digit number on passenger side and will be facing downward.

• | If date code stamp cannot be read or catalytic converter has previously been replaced with a non-Saturn part, continue to step 4.

• | When read from left to right, if fourth digit of date code stamp is 4 or greater, no further repair is necessary. Affix Campaign Completion Label.

• | When read from left to right, if fourth digit of date code stamp is 3, continue to step 3.

3. Inspect first three digits of date code stamp.

• | When read from left to right, if first three digits of date code stamp are greater than or equal to 272, no further repair is necessary. Affix Campaign Completion Label.

• | When read from left to right, if first three digits of date code stamp are less than 727, continue to step 4.

Notice: Always use a chain cutter to cut stainless steel exhaust system pipes. A torch leaves a rough edge and warps end of pipe, preventing good exhaust system sealing.

4. Using chain cutter SA9168NE, or equivalent, cut catalytic converter inlet pipe off approximately 19 mm (3/4 in) from front edge of hanger bracket.

Specification
(A) 19 mm (3/4 in)

5. Remove three catalytic converter to intermediate pipe nuts and remove converter from vehicle.
6. Remove catalytic converter isolators.
7. Obtain the following service replacement parts:

• | Catalytic converter kit (P/N 21006671)

• | One exhaust system clamp (P/N 15595048)

8. File burrs from inside front exhaust pipe.
9. Clean converter flange surface on intermediate pipe with a wire brush.

Important: The sleeve included with replacement catalytic converter is only required if a service front exhaust pipe is installed on vehicle.

10. Install new bolts and gasket onto outlet flange of replacement catalytic converter.
11. Install exhaust system clamp on converter inlet.
12. Position catalytic converter under vehicle with drain holes facing down.
13. Slide end of converter inlet over front exhaust pipe.
14. Install catalytic converter outlet flange to intermediate pipe and ensure converter is properly located.
15. Install catalytic converter to intermediate pipe nuts.

Tighten
Tighten the nuts to 31 N·m (23 lb ft).

16. Install two catalytic converter isolators.
17. Check exhaust system alignment.

Important: Always use correct size exhaust system clamp to prevent exhaust leaks.

18. Position exhaust system clamp 19 mm (3/4 in) from cut edge of front pipe.
19. Rotate and position clamp on pipe to ensure no contact with heat shield.
20. Tighten clamp nuts evenly.

Tighten
Tighten nuts to 60 N·m (44 lb ft).

21. Start vehicle and check entire exhaust system for exhaust leaks.
22. Affix Campaign Completion Label.

### Campaign Completion Label

Upon completion of the campaign, a Campaign Completion Label and a Clear Protective Cover should be affixed on a clean, dry surface of the radiator core support in an area clearly visible when the hood is raised. each label provides a space to print in ink (or type) the campaign number (99E01) and the five (5) digit facility code of the Retailer performing the campaign service.

As a reminder, additional labels may be ordered from Saturn Publications, 1-800-828-2112, prompt 3, item # S03 00013A for the Campaign Completion Label, and Item # S03 00013B for the Clear Protective Cover.

### Credit

1. To receive credit for inspecting and replacing catalytic converter, if necessary, submit a claim with the information below:

Repair Performed | Failed Part No. | Parts Allow. | Sale Type | Case Type | Labor Op | Labor Hours | Admin Hours**
--- | --- | --- | --- | --- | --- | --- | ---
Inspect Date Code on Catalytic Converter | N/A | * | WC | VC | V0399 | 0.2 | 0.1
Add: A: Replace Catalytic Converter if Necessary (Core # 21013083) | 21006671 |  |  |  |  | 0.5 |
* The parts allowance should be the sum total of the current SSPO Retailer net price plus 30% of all parts required for the repair. ** Campaign administrative allowance

2. To receive credit for loaner/rental car costs incurred while owner awaits campaign repair or other goodwill expenses, submit a claim with the information below:

Repair Performed | Sale Type | Case Type | Labor Op | Net Item Amount | Net Item Code | # Days Rental
--- | --- | --- | --- | --- | --- | ---
Loaner Reimbursement | WC | VC | Z4060 | *** | C | ****
Other Goodwill | WC | VC | Z4061 | *** | R | N/A
Customer Reimbursement | WC | VC | Z4062 | *** | R | N/A
*** Net amount must be submitted as a miscellaneous sale. . .Loaner reimbursement not to exceed $30/day. **** Enter number of days vehicle was rented. . .Not to exceed 1 day.

Retailer are empowered to use good judgement regarding loaner/rental cars or any other good will expenses deemed necessary. It will not be necessary to call the Saturn Customer Assistance Center for authorization of goodwill. The Goodwill Worksheet, printed towards the back of this bulletin, must be used to document goodwill expenses. The completed Goodwill Worksheet must be attached to the hard copy of the CSO. Retailers are to make sufficient copies of the blank Goodwill Worksheet to document goodwill expenses.

Customer requests for reimbursement of previously paid repairs, performed at a non-Saturn facility, to replace the catalytic converter must be accompanied by the original paid receipts/invoices verifying the repair, proof of payment, and proof of ownership of the vehicle at the time of repair.

Check your Saturn SERVICLINE.XL Claim Memorandum daily. Remember to code the claim as a WC sale type, and VC case type. Contact your field representative if you need assistance.

All labor operations claimed in this bulletin must be submitted on individual (unrelated) CSO lines. Refer to the Customer Service Order Preparation manual for details on Product Campaign Claim Submission.

### 99-E-01 GOODWILL WORKSHEET

As stated in the "Credit" section of this bulletin, Retailers are empowered to use good judgement regarding loaner/rental cars or other goodwill expenses that might become necessary for customer satisfaction.

Complete this worksheet and attach it to the hard copy of the Customer Service Order (CSO) to document all campaign goodwill claims submitted to Saturn.

VIN #

A. Vehicle Loaner/Rental Allowance Explanation: | $
Repair Performed | Sale Type | Case Type | Labor OP | Net Item Code | # Days Rental
Loaner Reimbursement | WC | VC | Z4060 | C | *
* Not to exceed $30/day for 1 day
B. Other/Goodwill Allowance Explanation (Attach original paid receipts/invoices verifying the repair, proof of payment, and proof of vehicle ownership at time of repair): | $
Repair Performed | Sale Type | Case Type | Labor OP | Net Item Code | # Days Rental
Other Goodwill | WC | VC | Z4061 | R | N/A
C. Customer Reimbursement Explanation (Specify what was done and why): | $
Repair Performed | Sale Type | Case Type | Labor OP | Net Item Code | # Days Rental
Other/Goodwill | WC | VC | Z4062 | R | N/A
Authorized Retailer Signature
(Please copy this form as necessary)

November, 1999

Dear Saturn Owner:

This notice is sent to inform you that Saturn is conducting a voluntary emission recall campaign that affects vehicles registered in the state of California.

Saturn has decided that certain 1994 Saturn DOHC (dual overhead cam) vehicles with California emission package (NB6) may fail to meet California emissions standards due to internal catalytic converter damage. These catalytic converters manufactured during the first quarter of the 1994 model year were produced with an internal mat material that may degrade when exposed to extreme temperatures and/or excessive mechanical forces. Degradation of converter mat material could result in vehicle symptoms such as underbody rattles, exhaust noise, and/or hesitation on acceleration.

### What Saturn will do:

We will inspect and if necessary, replace your vehicle's catalytic converter at no charge to you. We will also reimburse you for any catalytic converter replacement expense you have incurred on your vehicle during your ownership. If required, replacement of your catalytic converter will take about one (1) hour, although some additional time may be required for paperwork and processing.

### What you should do:

Contact your Saturn Retailer to arrange for a vehicle inspection and possible catalytic converter replacement, as well as any appropriate reimbursement for past expense you have incurred.

Your Saturn retailer will have the knowledge and all the necessary paperwork required for processing any reimbursement to you. If a reimbursable repair was performed by a non-Saturn facility, your Retailer will require specific documentation including original copies of paid receipts or invoices verifying the repair, proof of payment, and proof of ownership of the vehicle at the time of the repair. It is important that you contact your Saturn Retailer at your earliest convenience to have your vehicle inspected and repaired if necessary, regardless of any previous replacement of your vehicle's catalytic converter.

The enclosed Campaign Replay card identifies your vehicle, and will facilitate completion of the repairs when presented to your Saturn retail facility. If your address has changed, please provide the new information in the space provided. If you no longer own the vehicle, please complete this postage-paid reply card and return it to us. This will assist us in ensuring that all affected vehicles are corrected.

IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires that vehicle emission recall campaigns be completed prior to California registration renewal. Uncorrected emission recall campaigns will result in the inability to renew your California vehicle registration. At the time of emission campaign completion, your retailer will issue a "Vehicle Emission Recall Proof of Correction." Keep this certificate and, if required, present it to the Department of Motor Vehicles as proof of campaign completion when renewing your California registration.

Your Retailer is prepared to perform this service promptly and with minimal inconvenience to you. However, if your car is provided to the Retailer on the agreed service date and the condition is not remedied within a reasonable amount of time, please contact the Saturn Customer Assistance Center at 1-800-553-6000 prompt 3, or for the hearing impaired, 1-800-833-6000. We will assist you and the Retailer in getting your car serviced.

If, after contacting your Saturn Retailer and the Saturn Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to advise the State of California at the following address: State of California Air Resources Board, Mobile Source Operations Division, PO Box 8001, El Monte, California 91731-2990.

### Emission Law Information:

In order to ensure your full protection under the emission warranty provisions made applicable to your vehicle by California Law, and your right to participate in future recall campaigns, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as a lack of proper vehicle maintenance. Also, your vehicle may fail a state or local emission inspection if the recall campaign is not completed.

Again, we sincerely regret any inconvenience or concern this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your Saturn provides you many miles of enjoyable driving.

Sincerely,

Saturn Corporation

99E01