F/CMVSS Noncompliance - Passenger-Side Rear Safety Belt Anchorage Compliance

General Motors has decided that certain 2004 model year Chevrolet Cavalier and Pontiac Sunfire vehicles fail to conform to Federal/Canada Motor Vehicle Safety Standard 209, Seat Belt Assemblies, and Standard 210, Seat Belt Assembly Anchorages. On some of these vehicles, the passenger side rear safety belt may have been installed with an incorrect nut and bolt. In a severe crash, the upper seat belt anchorage may separate. The effectiveness of the seat belt could then be reduced and the occupant could receive greater injuries.

Dealers are to inspect the safety belt anchorage, and if necessary, install a new nut and bolt.

Involved are certain 2004 model year Chevrolet Cavalier and Pontiac Sunfire vehicles built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

For US

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld.

For Canada

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a Campaign Initiation Detail Report.

The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program.

Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

*Adhesive will service several dozen vehicles.

The following service procedure provides instructions for inspecting the size of the weld nut and bolt that attaches the RIGHT rear shoulder belt retractor to the rear panel located between the rear seat back and the back glass. Instructions are also included for replacing the weld nut and bolt if the results of the inspection indicate that replacement is required.

Inspection

There are two ways to determine if the weld nut and bolt on the RIGHT side are correct. One way is to measure the outside diameter of the weld nut and compare it to the one used on the LEFT side, the other way is to compare the diameter of the bolt hole in the RIGHT weld nut to the hole found in the LEFT side weld nut.

1. Open the rear (trunk) compartment lid.



2. From inside the trunk, reposition the trim and locate the weld nut (1) that attaches the RIGHT rear shoulder belt retractor to the rear panel.
3. Reposition the trim on the opposite side and locate the weld nut that attaches the LEFT rear shoulder belt retractor to the rear panel.
4. Measure and compare the outside diameter of the RIGHT and LEFT weld nuts or, measure and compare the diameter of the bolt holes to each other.

•	If the RIGHT side (diameter or hole) is about 2 mm (1/16 in) SMALLER than the left side (diameter or hole), the RIGHT side weld nut and bolt must be replaced. Proceed to the section titled "Weld Nut and Bolt Replacement".

•	If the RIGHT side (diameter or hole) is the SAME size as the left side (diameter or hole), NO repair is required. Reposition the trim and close the rear compartment lid.

Weld Nut and Bolt Replacement

This replacement procedure should only be performed is the results of the inspection procedure indicate that the replacement of the weld nut and bolt is required. Perform this procedure only if the diameter is 2 mm (1/16 in) smaller on the RIGHT side.

Two-Door Coupe Model

1. Release both rear seat backs by pulling on the straps.



2. From inside the vehicle, release the center seat belt retractor latch plate (5) from the seat belt buckle.
3. Remove the rear seat cushion.
4. Remove the 2 nuts and 2 bolts attaching the rear seat backs and mounting bracket to the vehicle, and remove the seat back and bracket assembly.



5. Unsnap the driver and passenger front shoulder belt bolt covers (5) and remove the bolts (1).
6. Remove both coat hooks and attaching screws.
7. Loosen the rear of both door opening carpet retainers (sill plates).



8. Remove the rear push-in retainer (5) from the quarter panel extension (4).

Important: It is not necessary to remove the front seat belt webbing material from the rear quarter trim panel in the next step.

9. Remove the rear quarter panel by pulling firmly and evenly to disengage the retainers. Once the retainers are released, reposition the panel as necessary to remove the rear shelf trim panel.



10. Lift up, unsnap, and remove the bezels (2) for the child tether anchors and the bezel (1) for the center seat back retractor.
11. Remove the rear shelf trim panel (3) and route the seat belt webbing material through the slots.



12. Remove the bolt (1) attaching the right side retractor to the rear shelf panel.
13. Lift up and reposition the right seat belt retractor.



14. From inside the trunk, remove the 8 mm weld nut (1) from the underside of the shelf panel.
15. Position the right seat belt retractor back to the original mounting location.
16. Apply threadlocker to the threads of the new bolt and insert the bolt through the seat belt retractor and the hole in the shelf panel.
17. From inside the rear compartment, install the NEW nut on the bolt.

Tighten
Tighten the bolt to 28 N·m (21 lb ft).

18. Route the seat belt webbing material through the slots and install the rear shelf trim panel.
19. Install the bezels for the child tether anchors and the center seat belt retractor.
20. Install the rear quarter trim panels on both sides of the vehicle. Align the retainers and press firmly and evenly to engage.
21. Install the rear push-in retainer in the quarter panel extension.
22. Press both carpet retainers into position.
23. Install the coat hooks and attaching screws.

Tighten
Tighten the screws to 2 N·m (18 lb in).

24. Install the driver and passenger front shoulder belt bolts to the pillars.

Tighten
Tighten to 41 N·m (30 lb ft).

25. Install the shoulder belt bolt covers and press firmly until fully seated.
26. Install the rear seat back and mounting bracket assembly to the vehicle and install the nuts and bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

27. Remove the rear seat cushion retainers from the brackets on the floor and install them to the frame on the bottom of the seat cushion as shown (3).
28. Install the rear seat cushion to the vehicle and press firmly until the retainers are fully seated.
29. Connect the center seat belt retractor latch plate to the seat belt buckle.
30. Close the rear compartment lid.

Four Door Sedan Model

1. From the rear seat, release the center seat belt retractor latch plate (5) from the seat belt buckle.
2. From the trunk, release both rear seat backs by pulling on the straps and allowing the seat backs to fold forward and lay flat.



3. From the rear seat, remove the rear quarter upper trim (1) and insulator on both sides of the vehicle by pulling firmly and evenly to disengage the retainers securing the panel.



4. Remove the push-in retainer (1) from the lower quarter trim panel (2) on both sides of the vehicle and pull firmly and evenly to disengage the retainers securing the trim panel.



5. Lift up, unsnap, and remove the bezels (2) for the child tether anchors and the bezel (1) for the center seat belt retractor.
6. Remove the rear shelf trim panel (3) and route the seat belt webbing material through the slots.



7. Remove the bolt (1) attaching the right side retractor to the rear shelf panel.
8. Lift up and reposition the right seat belt retractor.



9. From inside the trunk, remove the 8 mm weld nut (1) from the underside of the shelf panel.
10. Position the right seat belt retractor back to the original mounting location.
11. Apply threadlocker to the threads of the new bolt and insert the bolt through the seat belt retractor and hole in the shelf panel.
12. From inside the rear compartment, install the NEW nut on the bolt.

Tighten
Tighten the bolt to 28 N·m (21 lb ft).

13. Route the seat belt webbing material through the slots and install the rear shelf trim panel.
14. Install the bezels for the child tether anchors and the center seat belt retractor.
15. Position the lower quarter trim panels on both sides of the vehicle. Align the retainers and press firmly and evenly to engage.
16. Install the push-in retainer in each lower quarter trim panel.
17. Install the rear quarter upper trim and insulators on both sides of the vehicle and press firmly and evenly to engage the retainers.
18. Return both rear seat backs to the upright and locked position.
19. Reconnect the center seat belt retractor latch plate to the seat belt buckle.
20. Close the rear compartment lid.

The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

Submit a Product Recall Claim with the information indicated below:

Refer to the General Motors WINS Claim Processing Manual for details on Product Recall Claim Submission.

General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale.

All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

General Motors has decided that certain 2004 model year Chevrolet Cavalier and Pontiac Sunfire vehicles fail to conform to Federal/Canada Motor Vehicle Safety Standard 209, Seat Belt Assemblies, and Standard 210, Seat Belt Assembly Anchorages. On some of these vehicles, the passenger side rear safety belt may have been installed with an incorrect nut and bolt. In a severe crash, the upper seat belt anchorage may separate. The effectiveness of the seat belt could then be reduced and the occupant could receive greater injuries.

Your GM dealer will inspect the safety belt anchorage, and if necessary, install a new nut and bolt. This service will be performed for you at no charge .

This service correction will take approximately 25 to 45 minutes. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

To limit any possible inconvenience, we recommend that you contact your GM dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date.

Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the number listed below. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday

If, after contacting the appropriate customer assistance center, you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street SW, Washington, DC 20590 or call 1-888-327-4236.

The enclosed customer reply form identifies your vehicle. Presentation of this form to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us.

If your vehicle is within the New Vehicle Limited Warranty your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation.

More information about this recall (including answers to frequently asked questions) is available online at the Owner Center at My GMLink. This free online service offers vehicle and ownership related information and tools tailored to your specific vehicle. To join, visit www.mygmlink.com and enter your vehicle's 17-character vehicle identification number (VIN) shown on the enclosed form to get the most personalized information for your vehicle.

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

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

General Motors Corporation

Enclosure

04056