Service, Parts & Warranty Information
SERVICE PROCEDURE1. Install seat and fender covers and 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 25056620 25056622; or
^ If it is one of the converters used in Dealer Technical Bulletin 82-T-27, part number 25056905 or 25056894.
FIGURE 1:
The part numbers are stamped on the bottom of the inboard flange near the converter inlet. Refer to Figure 1.
Proceed to Step 15 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.
FIGURE 1:
FIGURE 2:
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 Figures 1 and 2.
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 under sized 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.
FIGURE 2:
11. Lay the converter down on a flat surface with the lower bed fill hole on top. Figure 2.
FIGURE 3:
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 ft.lbs.). Refer to Figure 3.
14. Install the converter on the vehicle by reversing steps 1 through 4 of this procedure.
15. Install a Campaign Identification label. Each vehicle modified in accordance with the instructions outlined in this Service Procedure 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 radiator upper mounting support and apply the campaign label where it is readily visible.
PART INFORMATION
Parts are to be obtained from WDDGM using the following part numbers.
Description Usage Part Number
Converter with Upper Beads 1981-82 4.3L 25056983
(Includes Fill Hole Plug) 1981-82 5.0L 25057007
Lower Bed Bead Package* 4.3L 25056903
(If Needed To Fill Converter) 5.0L 25056895
Converter Front Exhaust Clamp ALL 1259609
(If Needed)
To ensure these parts will 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 order 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.
Parts are to be retained for disposition by zone personnel.
WARRANTY INFORMATION
Converter Kit Failure Labor Labor
Operation Part No. Code Operation Hours
Inspection Only - 96 V2370 . 2
Inspect & Replace ( As Required) 96 V2371 . 9
Catalytic Converter
Parts will be credited at dealer cost plus 30%.
.1 hour for clerical administration may be added to the above operations.