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Service Campaign - Catalytic Converter Corrosion (SC-02 NOV 90 (R 3/89))

Publication date: 1990-11-01
Reference number: SC-02 NOV 90 (R 3/89)

SERVICE CAMPAIGN - CATALYTIC CONVERTER CORROSION

SERVICE CAMPAIGN - CATALYTIC CONVERTER CORROSION

TECHNICAL SERVICE BULLETIN

Reference Number(s): SC-02 NOV 90 (R 3/89), Date of Issue:  November 1990
Superceded Bulletin(s): SC-02, Date of Issue:  March 1989

SERVICE CAMPAIGN NO. K2 - CATALYTIC CONVERTER CORRODED/LOOSE

Model(s): 1986-87 Suzuki Samurai

Section Title: Exhaust System

Division: Automotive

Category: Campaign

Bulletin No.: SC-02 Nov 90 (R 3/89)

Date: November 1990

NOTE: This bulletin revises SC-02 dated March 1989.

To assure owner satisfaction, ASMC initiated on March 1, 1989 a Service Campaign to install a new exhaust center pipe (converter) on affected Samurai vehicles.

APPLICABLE VEHICLES

All 1986-87 Suzuki Samurai

APPLICABLE VEHICLE VIN RANGE

Model VIN Range
1986 MP Convertible JS3JC51C0G4100007 - JS3JC51C0G4128965
1986 TR Convertible JS4JC51C0G4100042 - JS4JC51C0G4128969
1986 MP Van JS3JC51V0G4100010 - JS3JC51V0G4111063
1986 TR Van J43JC51V0G4100054 - JS4JC51V0G4111065
1987 MP Convertible JS3JC51CXH4130004 - JS3JC51C8H4185079
1987 TR Convertible JS4JC51CXH4130001 - JS4JC51C1H4185081
1987 MP Van JS3JC51V6H4115002 - JS3JC51V2H4133450
1987 TR Van JS4JC51VXH4115001 - JS4JC51V9H4133456
NOTE: Vehicles in the above VIN ranges that previously received an improved converter were excluded.

OWNER NOTIFICATION

Owners of affected vehicles, whose name and address were on file at ASMC, were notified by mail (see OWNER NOTIFICATION LETTER) beginning on March 15, 1989. Excluded were owners of vehicles that, according to ASMC records, previously received an improved converter.

MATERIALS

Campaign Kit #14150-83840 can be ordered through ASMC Parts Department following established ordering procedures.

REIMBURSEMENT

Dealer claim reimbursement follows regular reimbursement schedules except an automatic deduction of $6.10 for recycle value is made.

RECYCLING OF REPLACED CENTER PIPE

For recycling/collectors contact your nearest collection center of Multimetco Inc.

Multimetco Inc. Stockton, CA 1-800-922-2668

Multimetco Inc. Houston, TX 1-800-255-4875

Multimetco Inc. Anniston, AL 1-800-824-5092

Multimetco Inc. Portstown, PA 1-800-525-0494

If you are unable to recycle through Multimetco use any of your local Recyclers/Collectors.

Recyclers/Collectors pay an approx. of $8.00 for a full unit, and $3.00 to $4.00 for a unit not full (rattling).

In consideration that most campaign replacements will involve full converters, an automatic average reimbursement deduction of $6.10 will be made for all replacement claims.

SPECIAL CASES

For special cases such as owner reimbursement, additional repair scope, replacement away from dealer, etc. contact the ASMC Warranty Department for authorization and claim instructions. Call 1-800-877-6900, Ext. 467. Have all details at hand before calling.

DEALER RECORD KEEPING

Your dealer repair order serves as a source document to record campaign completion for all variations JA - JK. Therefore, you must prepare a repair order for any variation you report to ASMC and record all events including owner statements that are the basis for the variation you are reporting.

OWNER NOTIFICATION LETTER

SUBJECT: Service Campaign #K2

Dear Mr/Mrs/Ms

Your vehicle may be releasing air pollutants which exceed Federal and California standards. Therefore, Suzuki has started a voluntary emission-related Service Campaign #K2 which includes your Suzuki Samurai.

Problem:

The catalytic converter on certain 1986/87 model Suzuki Samurai vehicles may loosen under certain driving conditions. You may notice a rattling noise or a drop in engine power or both.

What you should do:

To make sure that a replacement converter is in dealer stock at the time you bring your vehicle to the dealer, please make an appointment by contacting your nearest Suzuki dealer.

What Suzuki dealers will do:

Suzuki dealers will inspect your vehicle and, if necessary, replace your converter.

Previous repairs/refunds:

Also contact a Suzuki dealer if, before this notification your converter was replaced under warranty or you paid for such a replacement, you may qualify for A), B), or both:

  1. Free installation of a new converter.
  2. Refund for reasonable charges for a replacement if the replacement was made before this notice and the replacement was made because for a defect in the converter. Ask your Suzuki dealer for full details.

Suzuki dealers have been notified of the above procedures. If you are unable to have your vehicle repaired in a reasonable time, please call Suzuki at, 1-800-877-6900 ext. 455. Suzuki is concerned with your continued satisfaction with our product. Thank you for purchasing a Suzuki.

William A. Charles Director of Service Operations

SERVICE PROCEDURE

Inspection/Repair/Vehicle Marking Procedures

  1. Verify that the vehicle is within the specified VIN ranges. Refer to APPLICABLE VEHICLE VIN RANGE TABLE  .
    • If No, Stop.
    • If Yes, proceed to next step.
  2. Verify that the campaign was not previously completed. Check for Sticker K2 under the hood next to the emission control system label. See Fig 1 .
    • If No, Stop.
    • If Yes, proceed to next step.
  3. Verify the type of converter on the vehicle. See Fig 2 .
    • If NEW TYPE, apply sticker K2 (see Fig 1 ) and report variation JA.
    • If OLD TYPE, proceed to next step.
  4. Install kit and apply sticker. Refer to PARTS INFORMATION.

INSTALLATION INSTRUCTIONS

WARNING: To avoid danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool.
WARNING: When lifting the vehicle use a frame contact hoist and follow safety procedures in the shop manual.

Remove the converter's two (2) front spring loaded bolts at the front flange. Alternate several turns on each bolt to reduce the possibility of thread damage. Penetrating oil on the exposed bolt thread may assist removal.

While supporting the converter,

  1. Remove the two (2) bolts and nuts at the rear flange.
  2. Remove the front and rear hanger mounting bolts.
  3. Remove the converter.

Remove the bracket and insulator from the old converter. Install the old insulator on the new converter together with the new bracket and nuts supplied with the kit.

While supporting the converter,

  1. Install the front and rear hanger mounting bolts.
  2. Install the two (2) bolts, nuts, and gasket at the rear flange.
  3. Install the two (2) front mounting bolts, springs, and sealing rings. To prevent thread damage alternately turn each bolt until tight. Verify alignment and sealing condition.
TIGHTENING TORQUE

Item Torque
Flange bolts (front) 40-60 N-m 29.0-43.0 ft.lb
Flange bolts (rear) 18-28 N-m 13.5-20.0 ft.lb
Hanger bolts (front & rear) 18 N-m 13.0 ft.lb
Bracket nuts 18-28 N-m 13.5-20 ft.lb

Mark Vehicle

Put your dealer code on the marking sticker with a non-erasable inkpen and apply to marking sticker under the hood. See Fig 1 . Make sure the surface is clean to assure proper adhesion.

- Dispose of old converter by recycling. Refer to RECYCLING OF REPLACED CENTER PIPE

PARTS INFORMATION

Refer to Fig 3 for Campaign Kit illustration.

CAMPAIGN KIT #14150-83840 CONTENTS

Item Part Number Qty.
Converter #14150-83060 *  1
Sealing Ring #14183-82601 1
Gasket #14699-83000 1
Bracket #14284-83020 1
Nut #08316-16083 2
Sticker #99963-01501-037 under this part number. 1
  • - Not available separately through regular parts channels

REPORTING/CLAIM PROCEDURES

The below listed variations apply to campaign #K2. You must report campaign completion status as follows.

CLAIM REPORTING CODE

Camp Code Var. Code Labor Op. Time Part # Qty Description/ Reporting
K2 JA DA9999 0.1 - 1 Inspection & mark vehicle only. Vehicle has new type converter no repair necessary.
  • Report via SCAT
K2 JB DA14R0 0.5 - 14100- 83840 1 Install campaign kit & mark vehicle Campaign Kit
  • Report via SCAT
K2 JC - - - - Vehicle scrapped.
  • Report via SCAT
K2 JD - - - - Vehicle stolen.
  • Report via SCAT
K2 JE - - - - Vehicle exported.
  • Report via SCAT
K2 JF - - - - Owner moved address unknown.
  • Report via SCAT
K2 JG - - - - Owner states; will not comply with notification or dealer follow-up.
  • Report via SCAT
K2 JH - - - - Vehicle ineligible for campaign due to alteration/misuse. Special Procedures (Manual Claim)
K2 JI - - - - Owner reimbursement for previous repair. Special Procedures (Manual Claim)
K2 JJ - - - - Owner reimbursement for previous repair & installation of campaign kit & mark vehicle. Special Procedures (Manual Claim)
K2 JK - - - - Unspecified variations such as additional repair scope, vehicle in remote area, etc. Special Procedures (Manual Claim)
  • - Refer to SCAT Instructions for Claims.

(1  ) -For Special Procedures\authorization contact the ASMC Warranty Department. Call 1-800-877-6900, ext. 467
Fig 1: Campaign Sticker Location
G95E54050
Fig 2: Old & New Converter Configurations
G95F54051
Fig 3: Converter Campaign Kit Parts Identification
G95G54052
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