CAMPAIGN: CATALYTIC CONVERTER BEAD REPLACEMENT
PRODUCT EMISSION CAMPAIGN
SUBJECT: 96022 - CATALYTIC CONVERTER BEAD REPLACEMENT --------------------------------------------
MODELS: 1992 C,K TRUCKS, G VANS EQUIPPED WITH 5.OL (LO3); AND C,K TRUCKS ----------------------------------------------------------------- (EXCEPT 4WD SUBURBANS), G VANS EQUIPPED WITH 5.7L (LO5) ENGINES AND --------------------------------------------------------------------- LIGHT-DUTY EMISSIONS EQUIPMENT (BELOW 8500 GVW - RPO NA1) [CALIFORNIA --------------------------------------------------------------------- VEHICLES ONLY] --------------
THIS BULLETIN SUPPLEMENTS BULLETIN 92-C-53 ISSUED JULY, 1996. THIS SUPPLEMENT CONTAINS CHANGES IN THE "VEHICLES INVOLVED", "CUSTOMER NOTIFICATION", "SERVICE PROCEDURE", AND "CLAIM INFORMATION" SECTIONS. CHANGES OR ADDITIONS ARE SHOWN IN BOLD AND ITALIC TYPE. ADDITIONALLY, A NEW OWNER'S LETTER WILL BE SENT TO CUSTOMERS THAT ARE NOT REGISTERED IN THE STATE OF CALIFORNIA. A COPY OF THE NEW LETTER IS ATTACHED. THIS SUPPLEMENT SHOULD BE FILED WITH BULLETIN 92-C-53.
Certain 1992 C,K Trucks, and G Vans equipped with 5.OL engines (RPO L03 - VIN Code H) and California emissions equipment (RPO NB2); C,K Trucks (except 4WD Suburbans) and G Vans equipped with 5.7L engines (RPO L05 - VIN Code K) and Light-Duty emissions equipment (below 8500 lbs. GVW - RPO NA1) and California emissions equipment (RPO NB2) may be emitting non-methane hydrocarbons in excess of California emission standards. Excess emissions may cause a vehicle to fail state mandated emission tests.
To correct this condition, dealers are to replace the catalytic converter catalyst beads.
VEHICLES INVOLVED
This recall campaign applies only to vehicles registered in California. Vehicles registered outside California may have this campaign closed by returning a reply card (see owner notification section), or the Chevrolet/GMC dealer in their state may close (see "Claim Information" section). If a vehicle is registered outside of California, but will be registered in California in the future, the campaign should remain open until the vehicle is registered in California. The customer should be instructed to have the service procedure performed at a Chevrolet/GMC dealer located in California.
Involved are certain 1992 C,K Trucks, and G Vans equipped with 5.OL engines (RPO L03 - VIN Code H) and California emissions equipment (RPO NB2); C,K Trucks (except 4WD Suburbans) and G Vans equipped with 5.7L engines (RPO L05 - VIN Code K) and Light-Duty emissions equipment (below 8500 lbs. GVW - RPO NA1) and California emissions equipment (RPO NB2) and built within the following VIN breakpoints:
PLANT YEAR DIVISION MODEL PLANT CODE FROM THROUGH
1992 Chevrolet C,K Oshawa "1" SOP EOP 1992 Chevrolet C,K Pontiac "E" SOP EOP 1992 Chevrolet C,K Fort Wayne "Z" SOP EOP 1992 Chevrolet C,K Janesville "J" SOP EOP 1992 Chevrolet G Scarborough "4" SOP EOP 1992 Chevrolet G Lordstown "7" SOP EOP 1992 GMC C,K Oshawa "1" SOP EOP 1992 GMC C,K Pontiac "E" SOP EOP 1992 GMC C,K Fort Wayne "Z" SOP EOP 1992 GMC C,K Janesville "J" SOP EOP 1992 GMC G Scarborough "4" SOP EOP 1992 GMC G Lordstown "7" SOP EOP
NOTICE: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) or ServiceNet (GMC only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved]
CUSTOMER NOTIFICATION
Customers will be notified of this campaign on their vehicles by General Motors (see copy of divisional customer letter(s) included with this bulletin).
Owners of vehicles registered outside the state of California will receive a second letter advising them that this campaign is not required on their vehicle unless they are planning to register in California in the future. A reply card will be enclosed that may be returned to close the campaign on such vehicles (see copy attached).
In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance, and that the vehicle may fail a state or local emission inspection test if the recall work is not completed.
Notice: Catalyst removal tool J-29132-1 will require modification for use on 4WD vehicles.
Use a ball peen hammer to put an indentation (1) on the top edge of the catalyst remover toll J29132-1. See drawing below for illustration of location of indentation.
I. BEAD REMOVAL
2. On C,K trucks only, install a transmission support stand on the front edge of the transmission oil pan and remove the transmission cross member (five bolts) to allow access to the converter fill plug.
4. On 4WD vehicles - loosen the rear catalyst hanger (3 bolts). To obtain clearance for the catalyst removal tool J29132-1, pry the converter inboard (away from the frame rail) and install a wood block (2 x 4) between the frame rail and the exhaust pipe.
Install the catalyst remover tool J-29132-1 to fill plug opening and secure to exhaust system by wrapping the retaining chain over exhaust system. Fasten the loose end of the chain to the remover, see figure (4).
The remover can be rotated in any direction if interference is encountered.
On 4 WD vehicles - Install the catalyst remover tool with the outlet pointing towards the driver side of the vehicle., and secure as necessary. The indentation in the catalyst remover tool is required to allow clearance to the transmission pan.
NOTICE: The catalyst remover must be held tightly in place against the converter.
II. BEAD INSTALLATION
9. Disconnect the air supply to the aspirator and remove it from the tail pipe. On 4WD vehicles - Remove the wooden block (2 x 4) and install the converter hanger ( three bolts - torque to 33 lb. ft.145 nm.).
CLAIM INFORMATION
Submit a Product Campaign Claim with the information indicated below:
* REPAIR PERFORMED PART FAILED PARTS LABOR LABOR NET COUNT PART NO. ALLOW CC-FC 0P HOURS ITEM --------------------- ----- -------- ----- ----- ----- ----- ---- a) Replace Catalyst Beads- G Van 1 25175232 ** MA-96 V9897 0.7 -
b) Replace Catalyst 0.9 Beads - C/K Truck
Inspect Only- Vehicle - - - - V9898 0.2 - Registered Outside of California
* 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 30% for the catalyst bead kit needed to complete the repair.
Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission.
October, 1996
Dear GM Customer:
In July 1996, General Motors notified you by letter that your 1992 truck was involved in recall campaign 92-C-53, Catalytic Converter Bead Replacement. Because your vehicle is registered outside the state of California and the recall only applies to vehicles registered in California, it is not necessary that you have the service performed. Your vehicle complies to all Federal Environmental Protection Agency requirements and does not require catalytic converter bead replacement.
If you intend to continue to register your vehicle outside California, you are requested to complete the enclosed reply card and retum it to Chevrolet/GMC. This will remove your vehicle from this recall campaign. However, if you intend to register your vehicle in California in the future, do not return the card. Before you register your vehicle in Califomia, contact a California Chevrolet/GMC dealer and they will perform the required service to complete this recall at no charge to you.
We are sorry for any inconvem"ence these notifications have caused you.
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.
