CAMPAIGN: INCORRECT BUMPER IMPACT BARS SUP. 'A'

Models: 1985 Grand AM

TO ALL GM DEALERS

THIS BULLETIN SUPPLEMENT REPLACES THE ORIGINAL 5A10 BULLETIN ISSUED IN MAY, 1985.

THe previously released campaign parts did not readily fit the affected vehicles and required some rework of the attachement notes.

This rework could affect the compliance to the Canadian WVSS that require bumpers to meet an 8 Kph impact standard. It has been decided to recampaign all vehicles previously campaigned.

A new listing is being sent to affected Dealers covering all vehicles originally involved, broken down as follows: -

Suffix A - Vehicles previously completed require,(FRONT IMPACT BAR ONLY).

Suffix B - On completed vehicles that require (FRONT AND REAR IMPACT BARS).

VEHICLES IWOLVED:

Certain 1985 Pontiac Grand Ams within the following breakpoints: -

PLANT ----- FC701676 to FC708276

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:

Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, 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 in the future, you should take the steps necessary to be sure the campaign correction has been made reselling 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 modification according to instructions contained in this bulletin.

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. The listings provided are for campaign activity only and should not be used for any other purpose.

PARTS INFORMATION:

Parts required to perform this modification should be ordered through regular channels: -

P/N DESCRIPTION QUANTITY --- ----------- -------- 10041162 FRONT IMPACT BAR 1 PER VEHICLE 10040172 SINGLE STUD UPPER PLATE -FRT 2 PER VEHICLE 10040171 LOWER STUD PLATE - FRT 2 PER VEHICLE 22054764 ABSORBER ASM - LH - FRT 1 PER VEHICLE 22054765 ABSORBER ASM - RH - FRT 1 PER VEHICLE 10029337 REAR IMPACT BAR 1 PER VEHICLE

PARTS AND LABOUR CLAIM INFORMATION:

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

Repair Code Operation Time Allowance ----------- --------- ---------------

2A Remove and Replace 1.1 Front Bumper Impact Bar

3A Remove and Replace 1.9 Front and Rear Bumper Impact Bars.

This 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

FRONT BUMPER

1. Place a jack stand below the facia assembly to prevent it from dropping down when the attaching bolts are removed.

2. From underneath of vehicle, remove front filler panel from each side of vehicle. (Figure 1)

3. Remove four (4) nuts from each side valance panel support. (Figure 2)

4. Remove four (4) nuts (each side) attaching bumper assembly to energy absorbing bracket.

5. Pull facia ends and supporting bracket away from fenders and bring the assambly forward until the parking lamp sockets can be removed.

6. Remove three (3) bolt/screws attaching energy absorbing bracket, shims (on some vehicles) and reinforcement plate to body.

7. Replace energy absorbing bracket with energy absorber P/N 22054764/5 RL using bolt/screws removed in previous step.

8. Remove reinforcement bar assembly from facia by removing ten (10) retainers. (Figure 3)

9. Remove absorber from reinforcement bar by drilling out six (6) pop rivets.

10. Replace reinforcement bar with part number 10041162. This replacement bar has a three (3) slot mount which requires a single stud upper plate (P/N 10040172) in place of the existing double stud upper plate. As well, a new longer stud plate P/N 10040171 will need to be used.

11. Install absorber onto reinforcement bar with rivets or nuts, bolts and locking washers.

12. To reinstall bumper assembly reverse the above procedure.

REAR BUMPER

1. Place a jack stand below facia assembly.

2. From inside rear compartment, remove two (2) nuts at each end of facia. (Figure 4)

3. Remove two (2) facia retaining nuts at rear of each wheel opening.

4. Remove eight (8) bumper bracket retaining bolts - two (2) from inside rear compartment and six (6) from underneath of vehicle.

5. Full facia ends end supports away from fender and remove facia assembly.

6. Remove reinforcement bar and energy absorber assembly from facia by removing the thirteen (13) retainers. (Figure 5)

7. Remove retainers from absorber and remove absorber from 'V' bar.

8. Replace reinforcement bar with part number 10029337 and install absorber with retainers.

9. To reinstall bumper, reverse the above procedure.

INSTALLATION OF CAMPAICN IDENTIFICATION LABEL

Clean surface of radiater 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 campaiqn has been completed.

Dear General Motors Customer:

This letter is sent to you in accordance with the Canada Motor Vehicle Safety Act.

General Motors of Canada has determined that certain 1985 Pontiac Grand AM, models produced for sale in Canada were assembled with front and rear bumper impact bars which do not meet the CMVSS 8 KPH (5 mph) impact requirements.

Although you have previously been notified of this condition, and may have had the correction performed by your Dealer, further modifications are required.

The front bumper impact bar will be replaced on those vehicles previously repaired and the front and rear bumper impact bars will be replaced on the others. Please contact your GM dealer to arrange a service appointment.

The labour time required to perform this modification is 1 to 2 hours. Please allow your dealer additional time to process your vehicle. This correction will be made at no cost to you.

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.

Further assistance, if required, may be obtained from the General Motors Zone Office nearest you. Your vehicle Owner's Manual provides the location and phone number of each respective Zone Office.

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

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.