CAMPAIGN: OMITTED WELDS - FRT. SUSPENSION LOWER ARM CONTROL

SUBJECT: OMITTED WELDS - FRONT SUSPENSION LOWER CONTROL ARM

Models: 1995 Chevrolet Cavalier and Pontiac Sunfire

TO: ALL GENERAL MOTORS DEALERS

General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1995 Chevrolet Cavalier and Pontiac Sunfire models. Some of these vehicles have been built with welds omitted from the front suspension lower control arm assemblies. This condition could cause excessive loads on existing control arm welds, and could result in separation of the front bushing-sleeve subassembly from the control arm. Separation of the front bushing-sleeve assembly from the control arm may result in reduced steering control. If this were to occur while the vehicle was in motion, a vehicle crash could occur without prior warning.

To prevent this condition from occurring, dealers are to inspect both LH and RH front suspension lower control arm assemblies and replace all control arm assemblies found with omitted welds.

VEHICLES INVOLVED:

Involved are the following 1995 Chevrolet Cavalier and Pontiac Sunfire vehicles:

Chevrolet Cavalier Vehicles

Year Model Plant Plant Code From Through

1995 J Lordstown 7 S7100001 S7117124 1995 J Ramos Arizpe S SS800001 SS812990

Pontiac Sunfire Vehicles

Year Model Plant Plant Code From Through

1995 J Lordstown 7 S7500001 S7504875 1995 J Ramos Arizpe S SS800001 SS812984

NOTE: PLEASE CHECK DCS SCREEN 45 OR YOUR V.I.N. LIS BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

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 kilometers traveled, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner letter accompanying this bulletin. Campaign follow- up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.

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:

NOTICE: ESTIMATES INDICATE THAT A VERY SMALL NUMBER OF CONTROL ARM ASSEMBLIES WILL REQUIRE REPLACEMENT. AS A RESULT OF THIS ESTIMATE, G.M.S.P.O. IS N 0 T INCREASING INVENTORY LEVELS OF THESE CONTROL ARM ASSEMBLIES, AND AVAILABILITY WILL BE EXTREMELY LIMITED. DEALERS SHOULD NOT ATTEMPT TO STOCK ADDITIONAL PARTS FOR THIS CAMPAIGN. EXCESSIVE DEALER STOCKING OF CONTROL ARM ASSEMBLIES COULD LEAD TO UNNECESSARY PARTS SHORTAGES AND CUSTOMER INCONVENIENCE.

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

Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 22649351 Front Suspension Lower Control Arm Assembly - RH 1 As Required 22649352 Front Suspension Lower Control Arm Assembly - LH 1 As Required 12337997 Cotter Pin 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 ----------- ----------- -------------- 2A Inspect LH & RH Control Arm Assemlies. 1.7 Set Vehicle Toe-In. 3A Inspect LH & RH Control Arm Assemblies. 1.8 Replace 1 Control Arm Assembly. Set Vehicle Toe-In. 4A Inspect LH & RH Control Arm Assemblies. 1.8 Replace Both Control Arm Assemblies. Set Vehicle Toe-In. *T2010 Fuel Top Off - (Up to $20.00) - NOT for dealer inventory vehicles *T2011 Wash Vehicle - (Up to $7.00) - NOT for dealer inventory vehicles **T2012 Courtesy Transportation (max. $35.00 per day - up to 5 days) 6 or more days requires Zone (DSM) approval

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 40% to cover parts handling.

* These services should be clearly noted on the repair order and marked "NO CHARGE." This should then be presented to the owner as a gesture of appreciation from the dealership for their cooperation and inconvenience. These services can be charged by submitting a Warranty Claim and the amounts entered in the "Net Item/Sublet Amount" column using appropriate "T" labour operations.

** Labour Operation T-2012 should represent the cost of courtesy transportation following the guidelines as per the Service Policies and Procedures Manual, Article 1.4.16 Courtesy Transportation Program.

SERVICE PROCEDURE:

IMPORTANT: WELDS CANNOT BE INSPECTED WHILE INSTALLED IN THE VEHICLE. SERVICE PROCEDURE MUST BE FOLLOWED STEP BY STEP.

1. Raise vehicle on frame type hoist. See Section OA of appropriate Service Manual.

2. Remove lower bolt from right engine strut and loosen upper bolt. Move strut to gain access to right front control arm bolt.

3. Remove suspension support brace (two bolts) to gain access to left front control arm bolt.

4. Remove front tire and wheel assembly.

5. Unclip antilock brake system speed sensor harness from control arm at two locations on front edge of control arm.

6. Disconnect lower suspension ball joint from steering knuckle using tool J38892.

7. Remove front stabilizer bar link.

8. Remove lower control arm front attaching bolt (horizontal).

9. Loosen lower control arm rear fastener (vertical). Do not remove bolt.

10. Pull the front of the control arm assembly outward and clear of the suspension support pocket.

11. Clean the control arm to assure accurate inspection of all weld positions.

12. Inspect the ball joint attachment to the control arm to verify that all three (3) rivets are fully seated.

13. Carefully inspect the control arm for the presence of all twenty (20) welds. See illustration.

Welds fill slots shown as XXX on illustration.

On the left (driver's) side, seventeen (17) of the welds will be located on the underside of the control arm assembly, with three (3) of the welds located on the top side of the control arm.

On the right (passenger's) side, seventeen (17) of the welds will be located on the top of the control arm assembly, with three (3) of the welds located on the bottom side of die control arm.

IMPORTANT: THE WELDS THAT ATTACH THE FRONT BUSHING SLEEVE TO THE CONTROL ARM MUST BE VERY CAREFULLY INSPECTED FOR PRESENCE ON ALL THREE SIDES (WELDS RIGHT 5, 6 AND 7, OR LEFT 8, 9 AND 10). SEE ILLUSTRATION.

14. If any welds are missing, or if any ball joint rivets are not fully seated, the control arm assembly must be replaced following the procedure in Section 3C of the 1995 Service Manual with the following torque values:

Control arm front fastener 120 N.m (89 Lbs-Ft) + 180 degree (1/2 turn) Control arm rear fastener 170 N.m (125 Lbs-Ft) Ball joint to knuckle 60 N.m (44 Lbs-Ft); (align cotter pin holes by tightening only) Stabilizer link 17 N.m (13 Lbs-Ft)

15. Reattach ABS harness to control arms at two (2) locations.

16. Install wheel and tire assembly. Tighten torque wheel nuts to 125 N.m (92 Lbs-Ft) using torque stick J39544-15.

17. Repeat Steps 4 through 15 for the opposite side of the vehicle.

18. Reinstall suspension support brace. Tighten bolts to 66 N.m (48 Lbs-Ft).

19. Reinstall lower attaching bolt to engine strut. Tighten bolts to 120 N.m (89 Lbs-Ft).

20. Lower vehicle.

21. Set vehicle toe-in to 0.10 total toe-in (0.10 sum toe), making sure the steering wheel is correctly set to straight ahead position.

22. Install Campaign Identification Label.

23. Wash vehicle and fill fuel tank before returning to owner.

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 a defect which relates to motor vehicle safety exists in certain 1995 Chevrolet Cavalier and Pontiac Sunfire models. Some of these vehicles have been built with welds omitted from the front suspension lower control arm assemblies. This condition could cause excessive loads on existing control arm welds, and could result in separation of the front bushing-sleeve subassembly from the control arm. Separation of the front bushing-sleeve assembly from the control arm may result in reduced steering control. If this were to occur while the vehicle was in motion, a vehicle crash could occur without prior warning.

To prevent this condition from occurring, your dealer will inspect both LH and RH front suspension lower control arm assemblies and replace all control arm assemblies found with omitted welds.

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.