Product Safety - Ignition Switch High Electrical Current

THIS CAMPAIGN BULLETIN SUPERSEDES AND REPLACES CAMPAIGN BULLETIN 00079A ISSUED MARCH 2001. THIS BULLETIN IS BEING REVISED TO CORRECT THE "VEHICLES INVOLVED" TABLE. A PAPER COPY OF THIS CAMPAIGN BULLETIN WILL NOT BE ISSUED AS DCS654 (AD. MSG. WIA20010003) ADDRESSED THIS ISSUE.

General Motors has decided that a defect which relates to motor vehicle safety exists and may manifest itself in 1994-1995 Buick Skylark, Oldsmobile Achieva, and Pontiac Grand Am model vehicles. If the engine starter fails to engage and the driver holds the key in the "start " position for an extended period, high current flows through the ignition switch, and sometimes produces enough heat to melt internal switch parts. If the switch is damaged, a fire could occur in the steering column, even with the engine off and the key removed. The fire could spread to the interior of the car which could injure occupants of the car or cause damage to adjoining structures.

Dealers are to install a relay kit and verify that the vehicle will start with a properly charged battery in good operating condition (adequate reserve capacity, or cold cranking amps). This campaign does not cover battery replacement or unrelated starting system or electrical system repairs.

Involved are all 1994-1995 Buick Skylark, Oldsmobile Achieva, and Pontiac Grand Am model vehicles built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC Only) before beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings 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 listing to the follow-up necessary to complete this campaign.

Parts required to complete this campaign 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.

Important: It is estimated that only 5% of involved vehicles will require ignition switch and tilt lever replacement. Please order parts accordingly.

1. Open the hood and install fender covers.
2. Check the battery state of health using the J 4200 Midtronics Digital Battery Tester or suitable equivalent. If the tester displays "Replace Battery," attach a battery charger to the battery while performing this repair, as the test at the end will require cranking/starting the engine six times in succession. A low battery state of charge may affect the outcome of the test.

Important: If the battery fails the test (does not have sufficient reserve capacity or cold cranking amps required), the customer should be advised that the battery is not functioning properly and should be replaced. The customer should be informed that battery replacement is not covered under this campaign, and that a replacement battery may be purchased from the dealership or another source.

3. Disconnect the negative battery cable.
4. Select either the V6 procedure or the L4 procedure, whichever is correct for the vehicle being repaired.

V6 Service Procedure

1. Locate the square cut-out hole in the back side of the radiator support upper bar, just to the right (passenger side) of the airbag sensor mounting bracket, and install the J-nut.
2. Attach the relay bracket to the radiator tie bar, using the J-nut previously installed and the hex head cap screw from the kit.

Tighten
Tighten the screw to 10 N·m (89 lb in).

3. Select the short black wire with a ring terminal on one end from the kit. Attach the ring terminal end of the wire to the weld nut on the upper surface of the radiator support, just to the left (driver's side) of the air bag support bracket, using the bolt from the kit.

Tighten
Tighten the nut to 10 N·m (89 lb in).

4. Route the new wiring harness to the transmission cooler lines. Secure the harness to the cooler lines using the clips on the wiring harness.
5. Raise the vehicle.

Caution: The oil filter, the exhaust manifold and the exhaust pipe may be hot. Use care to avoid personal injury.

6. Remove the nut from the starter solenoid "S" terminal. Remove all wires from the solenoid stud.
7. Remove the nut from the "B" terminal of the starter and disconnect the cable from the terminal.
8. Cut the ring terminal from the vehicle's wiring harness purple wire which was removed from the "S" terminal.
9. Strip the insulation back about 1/4-inch (6.35mm) on the purple wires of the vehicle harness and the kit harness.
10. Using the appropriate crimping tool from the electrical repair kit, install the butt connector over the original purple wire and the purple wire from the service kit; crimp the wires together firmly.
11. Heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.
12. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter to the starter solenoid cap. Clean the small ring terminal from the service relay (red wire) to the starter "S" terminal and install to the "S" terminal. Reinstall the nut.

Tighten
Tighten the nut to 2.5 N·m (22 lb in).

13. Thoroughly clean the interface surfaces of the "B" terminal. Install the 5/16 inch (7.94mm) ring terminal (blue, blue/grey, or green fuse link attached to the red wire) and the battery cable to the "B" terminal and reinstall the nut.

Tighten
Tighten the nut to 12 N·m (9 lb ft).

14. Lower the vehicle.

Important: Do not use a remote starter device for this test. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition.

•	If the starter cranks the engine six times in a row, go to Step 16.

•	If the starter will not crank the engine, skip to Procedure A>

15. Start the engine a minimum of six times.
16. Install the GM Campaign Identification Label.

L4 Service Procedure

1. Remove the fresh air duct from the air cleaner to the throttle body.
2. Remove the fresh air duct muffler assembly.
3. Remove the top starter bolt.
4. Raise the vehicle.
5. Remove the oil filter.
6. Remove the bottom starter bolt and remove the starter.
7. Remove the nut from the starter solenoid "S" terminal and remove all the wires from the solenoid stud.
8. Remove the nut from the "B" terminal of the starter and disconnect all the wires and the cable from the terminal.

Important: When performing the next step in this procedure, make sure the ring terminal is carefully secured in a vice to prevent movement/rotation while enlarging the eyelet.

9. Carefully secure the large ring terminal from the service kit wiring harness (blue, blue/grey, or green fuse link attached to the red wire) in a vice. Using a 10mm (13/32 inch) drill bit, carefully engage the eyelet inside diameter to 10mm (13/32 inch).
10. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal.
11. Strip the insulation back about 1/4 inch (6.35mm) on the purple wires of the vehicle harness and the kit harness.
12. Using the appropriate crimping tool from the electrical repair kit, install the butt connector over the original purple wire and the purple wire from the service kit. Crimp the wires together firmly.
13. Heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.
14. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap. Clean the small ring terminal from the service relay (red wire) and install to the "S" terminal. Reinstall the nut.

Tighten
Tighten the nut to 2.5 N·m (22 lb in).

Important: In the next step, make sure the battery cable is the last cable positioned on the "B" terminal so that the nut is tightened against the battery cable.

15. Thoroughly clean the interface surfaces of the "B" terminal. Clean all fuse link/wire terminals and reinstall to the "B" terminal. Clean and install 10mm (13/32 inch) ring terminal (blue, blue/grey, or green fuse link attached to the red wire) and battery cable to the "B" terminal and reinstall the nut.

Tighten
Tighten the nut to 12 N·m (9 lb ft).

16. Reinstall the starter and loosely install the bottom starter bolt.
17. Route the service relay wiring to the transaxle cooler lines and clip into position.
18. Lower the vehicle.
19. Locate the square cut-out hole in the back side of the radiator support upper bar closest to the right end of the radiator support and install the J-nut to this cutout location.
20. Attach the relay/bracket assembly and ground wire to the radiator support, using the next head cap screw from the kit and the J-nut previously installed.

Tighten
Tighten the nut to 10 N·m (89 lb in).

Important: This will position the relay so that it will not have contact with the A/C refrigerant line.

21. Install the upper starter retaining bolt.

Tighten
Tighten the bolt to 90 N·m (66 lb ft).

22. Raise the vehicle and tighten the lower starter retaining bolt.

Tighten
Tighten the bolt to 90 N·m (66 lb ft).

23. Install a new oil filter.
24. Lower the vehicle.
25. Reinstall the fresh air muffler/air duct components.
26. Reinstall the negative battery cable.

Tighten
Tighten the battery (negative) cable terminal bolt to 15 N·m (11 lb ft).

Important: Do not use a remote starter for this test. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition.

•	If the starter cranks the engine six times in a row, proceed to Step 29.

•	If the starter will not crank the engine, skip to Procedure A below.

27. Start the engine a minimum of six times. During one start, make sure to let the engine run long enough to circulate engine oil into the new oil filter.
28. Check the engine oil and top up as required.
29. Install the GM Campaign Identification Label.

Procedure A

1. Remove the fuse panel trim plate from the I/P and remove the 15-amp airbag fuse.
2. Remove the left side dash lower insulator panel.
3. Disconnect the yellow air bag connector at the base of the steering column.
4. Remove the left side knee bolster trim panel.
5. Remove the tilt lever from the steering column.
6. Remove the bezel around the key lock cylinder.
7. Remove the screws that hold the steering column trim in place.
8. Remove both halves of the steering column trim.
9. Disconnect the wiring from the ignition switch.

Notice: The ignition switch mounting screws and the screws that secure the upper and lower halves of the steering column covers are self-tapping screws. In order to prevent stripping the screws when securing the new ignition switch and the steering column cover, the following procedure should be used:

•	Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction.

•	When the original thread is located, the screw will drop slightly. Reverse direction and tighten the screw.

10. Remove the two (2) screws holding the ignition switch to the steering column. Remove the ignition switch from the steering column.
11. Make sure the ignition switch is properly positioned by checking for proper location of the tab.

Tighten
Tighten both screws to 1.4 N·m (12 lb in).

12. Attach the wiring harness connectors to the ignition switch.
13. Reinstall the upper and the lower steering column covers.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

14. Reinstall the knee bolster trim.

Tighten
Tighten the fasteners to 2 N·m (17 lb in).

15. Reconnect the yellow air bag connector at the base of the steering column.
16. Reinstall the sound insulator panel.

Tighten
Tighten the fasteners to 2 N·m (17 lb in).

17. Reinstall the 15-amp airbag fuse into the fuse box and replace the I/P trim cover.
18. Install the GM Campaign Identification Label.

FOR US AND IPC

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels for US dealers can be obtained from Dealer Support Material by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Additional Campaign Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

FOR CANADA

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering.

Submit a Product Campaign Claim with the information indicated below:

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

FOR US AND CANADA

Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin).

FOR IPC

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached suggested dealer letter.

FOR US AND IPC (US States, Territories, and Possessions)

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall campaign 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 to provide 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 campaign notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the campaign is not completed within a reasonable time.

FOR ALL

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

Dealers are to service all vehicles subject to this campaign 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. Campaign 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 campaign enters your 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.

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 a defect which relates to motor vehicle safety exists and may manifest itself in 1994-1995 Buick Skylark, Oldsmobile Achieva, and Pontiac Grand Am model vehicles. If the engine starter fails to engage and the driver holds the key in the "start" position for an extended period, high current flows through the ignition switch, and sometimes produces enough heat to melt internal switch parts. If the switch is damaged, a fire could occur in the steering column, even with the engine off and the key removed. The fire could spread to the interior which could injure occupants of the car or cause damage to adjoining structures.

The purpose of this letter is to explain this product safety issue, what GM is doing to correct it, and what you can do immediately to reduce the potential for a fire and its consequences. We have received about 95 reports out of nearly 700,000 affected vehicles. There are no reports of a fire caused by this problem while these cars are being driven. Customers who have experienced this problem usually report that they recently had problems starting their cars. While most of the fires occurred within minutes of an unsuccessful attempt to start the car, other occurred after the car had been unattended for a longer time. If you are experiencing problems starting your car, have it repaired promptly and do not leave the car in a building.

Please know that we understand the concern this product safety issue may cause and the need to correct it as quickly as we can. Until we are able to install a relay kit in your car that will prevent high current from flowing through the ignition switch, there are two very important precautions you can take to reduce the potential for a fire:

When parts are available, your dealer will (1) install a relay kit that will prevent high current from flowing through the ignition switch and (2) check that your car will start with a properly charged battery and, if necessary, replace the ignition switch. These services will be performed for you at no charge . Battery replacement and other normal maintenance, however, are not covered by this campaign.

GM is working with its suppliers as quickly as it can to obtain the relay kits for these cars. Based on the anticipated schedule, we are asking customers to contact their dealers in specific months. We expect to have a kit available for your car in [February 2001 for Buick and Oldsmobile; March 2001 for Pontiac]. Please save this letter and make a note on your calendar to call your dealer in [February 2001 for Buick and Oldsmobile; March 2001 for Pontiac] to arrange a service date. If your dealer is then unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the listed number below:

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 length of time required to perform this service correction is approximately one (1) hour. Additional time may be required to schedule and process your vehicle. If your dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed to schedule, process and repair your vehicle.

The attached customer reply card identifies your vehicle. Presentation of this card 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 attached and mailing it in the postage paid envelope.

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