CAMPAIGN: FRT. DOOR INTERLOCK STRIKER STUD REPLACEMENT. Chevrolet Cavalier 1991

Subject: PRODUCT SAFETY CAMPAIGN 9lC24 FRONT DOOR INTERLOCK STRIKER STUD

Model and Year: 1991 CAVALIER (EXCEPT CONVERTIBLES)

The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to repair within sixty (60) 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 owner 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 solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter that is being sent to owners, the owners are being instructed to contact the Chevrolet Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.

DEFECT INVOLVED

General Motors has determined that certain 1991 Chevrolet Cavalier model vehicles fail to conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 210, "Seat Belt Assembly Anchorages". If a vehicle crash should occur, the front door interlock striker stud may fail, which could cause the door frame to collapse. Collapse of the door frame could result in failure of the shoulder belt to provide sufficient restraint to the occupant.

To prevent this condition from occurring, dealers are to replace the passive restraint interlock striker studs on involved vehicles.

VEHICLES INVOLVED

Involved are certain 1991 "J" vehicles built within the following VIN breakpoints: PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ------ ------- ----- -------- -------- 1991 J-Car Lordstown "7" M7160183 M7185111

1991 J-Car Janesville "J" MJ187660 MJ202174

1991 J-Car Ramos Arizpe "S" MS103160 MS117299

(Convertibles are not involved in this campaign action.)

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin).

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 before 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 correction according to instructions contained in this bulletin.

This bulletin is notice to you that the new motor vehicles included in this campaign may not comply with the standard identified above. Under Section 108 of the National Traf f ic and Motor Vehicle Safety Act, 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 campaign correction, your dealership may be subject to a civil penalty up to $1000 for each such sale.

PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO) . To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).

Quantity/ Part Number Description Vehicle ---------- ---------------------- -------- 22571850 Door Interlock Striker Stud 2

SERVICE PROCEDURE

(PERFORM PROCEDURE ON BOTH FRONT DOORS OF INVOLVED VEHICLES)

TOOLS REQUIRED: - 9 mm hex head (allen head) driver - Thin-blade putty knife - Pointed drift or drift with a relatively small tip - Ball peen hammer (approx. 24 oz.)

1. Lower front door glass and remove plastic cover from shoulder belt upper guide loop anchor. See illustration, next page.

2. Mask off inside surface of vertical leg of door frame to prevent damage to painted surfaces. See illustration, next page.

3. Using a 9 mm hex driver, loosen interlock striker until there is a 2 mm gap between base of striker and the door frame.

4. Strike loosened striker with hammer until stud is dislodged from door frame.

NOTICE: The interlock striker stud is 'press-fit' into the door frame, and several blows may be required to dislodge it. It is recommended that several moderate blows be used, rather than trying to dislodge the stud with one or two very heavy blows. Use of excessive force may result in damage to door frame.

5. Remove interlock striker. Do not discard striker as it will be re-installed on new interlock striker stud.

6. With door open, position tip of drift in depression at end of striker stud and finish driving stud out of door frame by striking drift with hammer.

7. Working from inside of door frame, carefully disengage run channel weatherstrip from door frame using a thin-blade putty knife to disengage upper clip. Upper clip is located about 1 inch above top edge of shoulder belt anchor. See illustration, below.

8. Carefully disengage enough of run channel weather strip from door frame to allow retrieval of interlock striker stud. It may be necessary to use a 'magnet-on-a-stick',or needle nose pliers to retrieve stud.

9. Using needle-nose pliers, position replacement stud in hole in door frame, and install striker onto stud finger tight. Align base of stud so long edges of stud are parallel to channel in door frame (see illustration, below). Using a 9 mm hex driver, torque striker to 35 Nm (26 lb. ft.) . Make sure new stud is pulled fully into hole, and that base of stud is flush against inside of door frame.

10. Push run channel weatherstrip back into door frame, making sure it is properly positioned for sealing and appearance. Be sure to re-engage upper run channel weatherstrip clip to door frame.

11. Re-install plastic cover to shoulder belt upper guide loop anchor.

12. Check window for proper up/down operation.

13. Remove masking tape.

14. Repeat above steps, 1-13 for opposite front door of vehicle.

15. Install Campaign Identification Label.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label." Each label provides a space to include the f ive (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in f or periodic servicing by the owner. Additional "Campaign Identification Labels" can be obtained from DAC.

Apply "Campaign Identification Label" only on a clean, dry surface.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below: * FAILED PARTS CC-FC LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS -------------- -- --------- ----- ------ ------ --- --- Install New 2 22571850 SK-00 V6900 0.4 0.1 Striker Stud

* Campaign Administrative Allowance.

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.

Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim Submission.

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

REASON FOR THIS RECALL

WHAT WE WILL DO

To prevent this condition from occurring, your Chevrolet dealer will replace the passive restraint interlock striker studs on the front doors of your Cavalier. This service will be performed for you at no charge.

WHAT YOU SHOULD DO

Please contact your Chevrolet dealer as soon as possible to arrange a service date and so the dealer may order the necessary parts for the repair. Instructions for making this correction have been sent to your dealer and parts are available. The labor time necessary to perform this service correction is approximately 25 minutes. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

Your Chevrolet dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within five (5) days, we recommend you contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020.

After contacting your dealer and the Customer Assistance Center, if 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, S.W., Washington, D.C. 20590 or call 1-800-424-9393 (Washington D.C. residents use 366-0123).

The enclosed owner 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 have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us. 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

Object Number: 88741 Size: MF

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.