CAMPAIGN: 2-WAY MANUAL SEAT ADJ.BUILT AT RAMOS ARIZPE

SUBJECT: INCORRECT DRIVER'S SEAT ADJUSTER MECHANISM INSTALLED CANADA ONLY

MODELS: 1993 Chevrolet Cavalier and Pontiac Sunbird Sedans (4-Door Models) with 2-Way Manual Seat Adjusters Built at Ramos Arizpe

TO: ALL GENERAL MOTORS DEALERS

General Motors of Canada Limited has determined that certain 1993 Chevrolet Cavalier and Pontiac Sunbird Sedan models may not comply with Canadian Motor Vehicle Safety Standard (CMVSS) 210 (Seat Belt Assembly Anchorage). These vehicles may have been built with an incorrect driver's seat adjuster assembly. At this most rearward seat position, the shoulder belt contact point is out of the certification compliance zone.

To prevent the possibility of this condition occurring, dealers are to inspect the driver's side seat adjuster mechanism for the presence of an incorrect inner seat adjuster track, and if necessary, replace the inner track of the driver's side seat adjuster assembly.

VEHICLES INVOLVED:

NOTE: PLEASE CHECK DCS BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

Involved are CERTAIN, 1993 Chevrolet Cavalier and Pontiac Sunbird models within the following VIN breakpoints:

Year Model Plant From Through ---- ----- ----- ---- ------- 1993 Chevrolet Cavalier Ramos Arizpe PS800001 PS807891 1993 Pontiac Sunbird Ramos Arizpe PS800002 PS807890

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

DEALER CAMPAIGN RESPONSIBILITY:

All unsold new vehicles in dealer's possession and subject to this campaign must be held and inspected/repaired per the Service Procedure of this Campaign Bulletin before owners take possession of these vehicles.

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, 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 it is in your dealership for service, you are to ensure the campaign correction has been made before selling or releasing the vehicle.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin.

In summary, 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, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors (see copy of owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.

PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 16608888 Track Assembly - Seat Adjuster Inner 1

16609637 Cap/Cover - Seat Mounting Stud 2

PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ----------- -------------- 1A Inspect - No Further Action Required .3

2A Inspect and Replace Seat Track Assembly .7

Time allowance includes 0. 1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 30% to cover parts handling.

SERVICE PROCEDURE:

1. Inspect the driver's side seat adjuster assembly for correct or incorrect inner track assembly as follows:

a. Adjust the seat to the full-rearward locked position.

b. Using a scale/ruler, measure the amount of exposed lower channel as shown in the illustration.

c. If the amount of exposed lower channel is measured at approximately 99mm (3.9 in.), the correct adjuster assembly is installed and no further action is required. Install Campaign Identification Label and return vehicle to customer or to dealer stock.

d. If the amount of exposed lower channel is measured at approximately 109mm (4.3 in.), an incorrect adjuster assembly has been installed, and must be replaced.

2. Move the seat to the full-forward position and remove the screw from the rear of the outboard seat track cover. Remove the outboard seat track cover. Set aside for reinstallation.

3. Remove and discard the plastic stud cover from the inboard rear seat mounting stud. Remove the nuts from the rear seat mounting studs.

4. Move the seat to the full-rearward position. Remove and discard the plastic stud cover from the inboard front seat mounting stud. Remove the nuts from the front seat mounting studs.

5. Using a small screwdriver or other appropriate tool, disconnect the safety belt warning harness connector located under the seat.

6. Remove the seat from the vehicle and place it on a work bench or table in an inverted position.

NOTICE: Be sure that the surface of the work bench or table is clean and/or properly covered to prevent soiling or damage to the seat covering material.

7. Remove the safety belt buckle assembly from the inner seat track (1 bolt). Set aside for reinstallation.

8. Release the fore/aft adjustment handle and move the adjuster tracks so that the seat is in the full-forward position. The lower channels should be in the extreme rearward position and the adjuster spring should be in its unloaded state for the seat to be in the full-forward position.

9. Remove the alignment bar/brace (4 screws/bolts) from the seat adjuster assembly. Set aside for reinstallation.

10. Carefully remove the link rod that connects the adjuster tracks and set aside for reinstallation.

11. Remove the spring from the adjuster assembly and set aside for reinstallation.

12. Remove the inner seat adjuster track from the seat frame assembly (2 bolts). Set the bolts aside for reinstallation.

13. Loosen, but do not remove, the front mounting bolt from the outer seat adjuster rail.

14. Position and loosely assemble the new inner seat adjuster track to the seat frame. Tighten the rear attaching bolt to 24 N.m (15 lbs. ft.). Do not tighten the front bolt at this time.

15. Position the new inner seat adjuster track so that the lower rail is in the full-rearward position (seat in full-forward position).

16. Position and loosely assemble the alignment bar/brace to the inner and outer seat adjuster tracks. Tighten the 4 screws/bolts to 10 N.m (7.4 lbs. ft.).

17. Tighten the two front seat adjuster track attaching bolts to 24 N.m (15 lbs. ft.).

18. Reinstall the link rod to the seat adjuster assembly.

19. Make sure that both the inner and outer seat adjuster tracks are in the full-rearward position (seat in full-forward position), and reinstall the spring to the adjuster assembly.

20. Reinstall the safety belt buckle assembly to the inner seat track. Tighten to 27 N.m (20 lbs. ft.).

21. Route/position the safety belt warning harness between the seat frame and the inner seat adjuster track.

22. With the seat adjuster tracks in the full-rearward locked position (seat in full-forward position), carefully place the seat assembly back into the vehicle and over the seat mounting studs.

23. Install the rear seat mounting nuts and tighten to 29 N.m (21 lbs. ft.).

IMPORTANT: THE REAR SEAT MOUNTING NUTS SHOULD BE FULLY TIGHTENED BEFORE THE FORE/AFT ADJUSTMENT HANDLE IS RELEASED.

24. Release the adjuster handle and move the seat rearward far enough to gain access to the front seat mounting studs, but not all the way back against the rear stops. Release the adjuster handle and verify that both sides of the seat adjuster locking mechanism are fully engaged by pushing the seat forward and rearward on the outboard side.

25. Install the front seat mounting nuts and tighten to 29 N.m (21 lbs. ft.).

26. Reconnect the safety belt connector located under the seat.

27. Verify correct function by sitting in the seat and moving the seat to several fore/aft positions and checking for any fore/aft motion after the adjuster handle is released.

28. Install new plastic stud covers, P/N 16609637, to the inboard seat mounting studs.

29. Position the seat to the full-forward position and reinstall the outboard seat track cover (1 screw). Tighten the screw to 2 N.m (1.5 lbs. ft. or 18 lbs. in.).

30. Verify proper function of the safety belt warning system as follows:

a. While sitting in the driver's seat with the vehicle doors closed and the safety belt not buckled, turn the ignition key to the "on" position. The safety belt warning system should activate the instrument panel telltale lamp and the warning chime.

b. Buckle the safety belt while the warning system is activated (lamp on; chime sounding). The warning lamp and chime should both be deactivated by buckling the safety belt.

If the safety belt warning system does not function properly, check the under-seat connector for proper engagement.

31. Install Campaign Identification Label.

INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

Dear General Motors Customer.

General Motors of Canada Limited has determined that certain 1993 Chevrolet Cavalier and Pontiac Sunbird model vehicles may not comply with Canadian Motor Vehicle Safety Standard (CMVSS) 210 (Seat Belt Assembly Anchorages). These vehicles may have been built with an incorrect driver's seat adjuster assembly. At this most rearward seat position, the shoulder belt contact point is out of the certification compliance zone.

To prevent the possibility of this condition occurring, your dealer will inspect the driver's side seat adjuster mechanism for the presence of an incorrect inner seat adjuster track, and if necessary, replace the inner track of the driver's side seat adjuster assembly.

This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department General Motors of Canada Limited

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.