CAMPAIGN: WELDS MIS-LOCATED LH ROCKER INNER REINFORCEMENT
THE GM OF CANADA VERSION OF 98012 IS LOCATED BELOW THE U.S. VERSION ______________________________________________________________________ PRODUCT CAMPAIGNS 98012 MARCH, 1998
PRODUCT RECALL CAMPAIGN
FMVSS NON-COMPLIANCE CAMPAIGN
SUBJECT: 98012 - WELDS MIS-LOCATED - LH ROCKER INNER REINFORCEMENT PANEL TO BODY SIDE RING
MODELS: CERTAIN 1997 CHEVROLET CAVALIER AND PONTIAC SUNFIRE SEDANS BUILT AT LORDSTOWN ASSEMBLY
THE HIGHWAY 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 CUSTOMER 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 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. AS YOU WILL SEE IN READING THE ATTACHED COPY OF THE DIVISIONAL LETTER THAT IS BEING SENT TO CUSTOMERS, THE CUSTOMERS ARE BEING INSTRUCTED TO CONTACT THE APPROPRIATE 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 DECIDED THAT CERTAIN 1997 CHEVROLET CAVALIER AND PONTIAC SUNFIRE SEDAN MODEL VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD (FMVSS) 214, "SIDE IMPACT PROTECTION". THESE VEHICLES MAY HAVE BEEN MANUFACTURED WITH MIS-LOCATED WELDS AT THE JOINT BETWEEN THE LEFT ROCKER PANEL INNER REINFORCEMENT AND THE BODY SIDE RING. IN THE EVENT OF A VEHICLE CRASH, THE SHEET METAL STRUCTURE MAY NOT PERFORM AS DESIGNED. THIS COULD RESULT IN REDUCED LEVELS OF OCCUPANT PROTECTION. TO PREVENT THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO INSPECT FOR THE MIS-LOCATED WELDS AND, IF NECESSARY, PLACE UP TO FIVE WELDS BETWEEN THE INVOLVED PANELS AND APPLY PRIMER AND TOPCOAT FINISH MATERIALS.
VEHICLES INVOLVED
INVOLVED ARE THE FOLLOWING 1997 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES MANUFACTURED AT THE LORDSTOWN, OHIO ASSEMBLY PLANT:
1G1JC5242V7292895 1G2JB5242V7591253 1G1JC5246V7292897 1G1JC5244V7293224 1G1JF5244V7293263 1G1JC5241V7293620 1G1JC5240V7293415 1G1JC5244V7294423 1G1JF5245V7293689 1G2JB5242V7591494 1G1JF5244V7294445 1G2JB5240V7591154
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 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.
PARTS INFORMATION MATERIALS REQUIRED TO COMPLETE THIS CAMPAIGN ARE LISTED BELOW: 3M SCOTCH BRITE CLEAN 'N STRIP DISC (P/N 07460, 3M WHEEL MANDREL P/N 07491) DP90 TWO-PART ANTICORROSION PRIMER OR EQUIVALENT TOPCOAT MATERIAL PER GM REFINISH MANUAL #4901M-D
CUSTOMER NOTIFICATION
CUSTOMERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY GENERAL MOTORS (SEE COPY OF TYPICAL CUSTOMER LETTER INCLUDED WITH THIS BULLETIN - ACTUAL DIVISIONAL LETTER MAY VARY SLIGHTLY).
DEALER CAMPAIGN RESPONSIBILITY
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 APPROPRIATE DIVISIONAL 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.
THIS BULLETIN IS NOTICE TO YOU THAT THE NEW MOTOR VEHICLES INCLUDED IN THIS CAMPAIGN MAY NOT COMPLY WITH THE STANDARD IDENTIFIED ABOVE. UNDER 49 U.S.C. SECTION 30112 OF THE HIGHWAY SAFETY ACT AS AMENDED, 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 $1,100 FOR EACH SUCH SALE.
SERVICE PROCEDURE
1. RECORD RADIO STATION PRESETS.
2. DISCONNECT BATTERY.
3. RAISE VEHICLE ON HOIST.
4. IF THE VEHICLE IS EQUIPPED WITH A ROCKER MOLDING, REMOVE THE ROCKER MOLDING (3 SCREWS; 8 CLIPS).
5. CLEAN THE AREA SHOWN IN FIGURE 1 AS REQUIRED TO ALLOW THOROUGH INSPECTION. INSPECT FOR FLANGE ALIGNMENT AND WELD LOCATION. IF THE FLANGES ARE CORRECTLY ALIGNED AND THE WELDS ARE PROPERLY PLACED, PROCEED TO STEP 16 OF THIS SERVICE PROCEDURE. IF THE FLANGES ARE NOT PROPERLY ALIGNED AND THE WELDS ARE NOT PROPERLY PLACED (SEE FIGURE 2), PROCEED TO STEP 6 OF THIS SERVICE PROCEDURE.
6. STRIP AREAS TO BE WELDED TO BARE METAL USING A DIE GRINDER EQUIPPED WITH 3M SCOTCH BRITE CLEAN 'N STRIP DISC (DISC P/N 07460, 3M WHEEL MANDREL P/N 07491) OR EQUIVALENT. SEE FIGURE 3.
INNER AND OUTER FLANGES CORRECTLY ALIGNED SO THAT SPOT WELDS FASTEN INNER AND OUTER FLANGES
FIGURE 1
7. REMOVE PARK BRAKE CABLE RETENTION CLIP AND MOVE CABLE CLEAR FROM AREA TO BE WELDED.
8. USING A LOCKING PLIERS OR OTHER APPROPRIATE CLAMPING DEVICE, CLAMP A PIECE OF 13 MM (1/2") THICK BRASS OR COPPER BEHIND THE FLANGES TO SERVE AS A HEAT SINK.
CAUTION
PROTECT THE FUEL LINE THAT IS ROUTED NEAR THE LH RAIL WITH APPROPRIATE WELD/HEAT SHIELDING MATERIAL. BEFORE PROCEEDING WITH WELDING, MAKE SURE THAT NO FLAMMABLE LIQUIDS OR VAPORS ARE PRESENT. ANY FUEL LEAKS MUST BE CORRECTED BEFORE ANY WELDING IS PERFORMED.
IMPORTANT
TO MINIMIZE THE CHANCE OF BURN-THRU, SOME SAMPLE WELDS SHOULD BE TRIED ON SOME SCRAP PIECES OF SIMILAR THICKNESS. ADJUST THE MIG WELDER TO THE LOWEST POSSIBLE HEAT SETTING THAT WILL ALLOW GOOD WELDS.
INNER FLANGE LOW, WITH WELDS MIS-LOCATED SO THAT FLANGES ARE NOT WELDED TOGETHER.
FIGURE 2
9. PLACE FIVE, TWENTY (20) MM (25/32") LONG MIG WELDS AT THE FLANGES AS SHOWN IN FIGURE 3. THE MIG WELDS SHOULD BE LOCATED TO LINE UP WITH THE FIVE (5) MIS-LOCATED SPOT WELDS.
10. REMOVE THE CLAMPS AND HEAT SINK FROM THE FLANGES. TO ASSURE PROPER PRIMER ADHESION, CLEAN AND PREPARE ALL WELDED SURFACES USING 3M SCOTCH BRITE CLEAN 'N STRIP DISC (DISC P/N 07460, 3M WHEEL MANDREL P/N 07491) OR EQUIVALENT.
11. FEATHEREDGE REPAIR AREA USING 150 GRIT SANDPAPER ON A DUAL ACTION SANDER. APPLY TWO-PART, ANTI-CORROSION PRIMER SUCH AS DP90 TO BARE SHEET METAL. REFER TO GM REFINISH MANUAL #4901M-D FOR A LISTING OF APPROVED PRODUCTS.
12. APPLY TOPCOAT AS SPECIFIED BY GM REFINISH MANUAL #4901M-D FOR A LISTING OF APPROVED PRODUCTS.
13. REPOSITION PARK BRAKE CABLE AND INSTALL RETAINER CLIP.
14. IF THE VEHICLE IS EQUIPPED WITH A ROCKER MOLDING, RE-INSTALL THE ROCKER MOLDING (3 SCREWS; 8 CLIPS).
15. LOWER VEHICLE.
16. CONNECT BATTERY.
17. RESET RADIO STATION PRESETS.
18. INSTALL THE GM CAMPAIGN IDENTIFICATION LABEL.
FIGURE 3
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 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.
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 BY THE CUSTOMER FOR PERIODIC SERVICING. WHEN INSTALLING THE CAMPAIGN IDENTIFICATION LABEL, BE SURE TO PULL THE TAB TO ALLOW ADHESION OF THE CLEAR PROTECTIVE COVERING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM VISPAC INCORPORATED BY CALLING 1-800-269-5100 (MONDAY-FRIDAY, 8:00 A.M. TO 4:30 P.M. EST). ASK FOR ITEM NUMBER S-1015 WHEN ORDERING.
APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE.
CLAIM INFORMATION
SUBMIT A PRODUCT CAMPAIGN CLAIM WITH THE INFORMATION INDICATED BELOW:
PART FAILED PARTS LABOR LABOR NET REPAIR PERFORMED COUNT PART NO. ALLOW CC-FC OP * HOURS ITEM
INSPECT ONLY - - MA-96 V0145 0.4 -
INSPECT AND REPAIR MIS-LOCATED WELDS - - MA-96 V0146 2.2 ***
FOR VEHICLES EQUIPPED WITH ROCKER PANEL MOLDINGS, ADD 0.2 HOURS TO LABOR HOURS LISTED ABOVE.
* FOR CAMPAIGN ADMINISTRATIVE ALLOWANCE, ADD 0.1 HOURS TO THE "LABOR HOURS".
*** THE AMOUNT IDENTIFIED IN THE "NET ITEM" COLUMN SHOULD REPRESENT THE SUM TOTAL OF THE CURRENT RETAIL PRICE FOR MATERIALS REQUIRED TO PERFORM THE REQUIRED INSPECTION AND REPAIR (NOT TO EXCEED $24.78).
REFER TO THE GENERAL MOTORS CORPORATION CLAIMS PROCESSING MANUAL FOR DETAILS ON PRODUCT CAMPAIGN CLAIM SUBMISSION.
FIGURES: 3
GM BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THESE 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 TOOLS, EQUIPMENT, 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 YOUR DEALER/RETAILER FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.
WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION
98012-S
(SAMPLE OF NOTIFICATION USED)
MARCH, 1998
DEAR [CHEVROLET CAVALIER/PONTIAC SUNFIRE] CUSTOMER:
THIS NOTICE IS SENT TO YOU IN ACCORDANCE WITH THE REQUIREMENTS OF THE NATIONAL TRAFFIC AND MOTOR VEHICLE SAFETY ACT.
REASON FOR THIS RECALL: GENERAL MOTORS HAS DECIDED THAT CERTAIN 1997 CHEVROLET CAVALIER AND PONTIAC SUNFIRE SEDAN MODEL VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD (FMVSS) 214, "SIDE IMPACT PROTECTION". THESE VEHICLES MAY HAVE BEEN MANUFACTURED WITH MIS-LOCATED WELDS AT THE JOINT BETWEEN THE LEFT ROCKER PANEL INNER REINFORCEMENT AND THE BODY SIDE RING. IN THE EVENT OF A VEHICLE CRASH, THE SHEET METAL STRUCTURE MAY NOT PERFORM AS DESIGNED. THIS COULD RESULT IN REDUCED LEVELS OF OCCUPANT PROTECTION.
WHAT WILL BE DONE: TO PREVENT THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO INSPECT FOR THE MIS-LOCATED WELDS AND, IF NECESSARY, PLACE UP TO FIVE WELDS BETWEEN THE INVOLVED PANELS AND APPLY PRIMER AND TOPCOAT FINISH MATERIALS.
HOW LONG WILL THE REPAIR TAKE? THE LENGTH OF TIME REQUIRED TO PERFORM THIS INSPECTION AND SERVICE CORRECTION IS APPROXIMATELY THREE HOURS. 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.
CONTACTING YOUR DEALER: PLEASE CONTACT YOUR DEALER AS SOON AS POSSIBLE TO ARRANGE A SERVICE DATE. PARTS ARE AVAILABLE AND INSTRUCTIONS FOR MAKING THIS CORRECTION HAVE BEEN SENT TO YOUR DEALER. PLEASE ASK YOUR DEALER IF YOU WISH TO KNOW HOW MUCH TIME WILL BE NEEDED TO SCHEDULE, PROCESS AND REPAIR YOUR VEHICLE. YOUR <DIVISION> DEALER IS BEST EQUIPPED TO OBTAIN PARTS AND PROVIDE SERVICES TO CORRECT YOUR VEHICLE AS PROMPTLY AS POSSIBLE. SHOULD YOUR DEALER BE UNABLE TO SCHEDULE A SERVICE DATE WITHIN A REASONABLE TIME, YOU SHOULD CONTACT THE APPROPRIATE CUSTOMER ASSISTANCE CENTER AT THE LISTED NUMBER BELOW:
DIVISION
NUMBER DEAF, HEARING IMPAIRED OR SPEECH IMPAIRED *
CHEVROLET 1-800-222-1020 1-800-833-2438
PONTIAC 1-800-762-2737 1-800-833-7668
* UTILIZES TELECOMMUNICATION DEVICES FOR THE DEAF/TEXT TELEPHONES (TDD/TTY)
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 1-800-424-9393 (WASHINGTON, DC RESIDENTS USE 202-366-0123).
CUSTOMER REPLY CARD: THE ENCLOSED 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 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 PRODUCTS.
CHEVROLET/PONTIAC MOTOR DIVISION GENERAL MOTORS CORPORATION
ENCLOSURE
COPYRIGHT 1998 GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.
********************************************************************** *** GM OF CANADA VERSION *** **********************************************************************
PRODUCT CAMPAIGNS 98012 MARCH 1998
PRODUCT RECALL CAMPAIGN
CMVSS NON-COMPLIANCE CAMPAIGN
SUBJECT: CAMPAIGN 98012 WELDS MIS-LOCATED LH ROCKER INNER REINFORCEMENT PANEL TO BODY SIDE RING
MODELS: 1997 'J' SEDANS BUILT AT LORDSTOWN ASSEMBLY
DEFECT INVOLVED
GENERAL MOTORS OF CANADA LIMITED HAS DECIDED THAT CERTAIN 1997 'J' SEDAN MODEL VEHICLES FAIL TO CONFORM TO CANADA MOTOR VEHICLE SAFETY STANDARD (CMVSS) 214, "SIDE DOOR STRENGTH". THESE VEHICLES MAY HAVE BEEN MANUFACTURED WITH MIS-LOCATED WELDS AT THE JOINT BETWEEN THE LEFT ROCKER PANEL INNER REINFORCEMENT AND THE BODY SIDE RING. IN THE EVENT OF A VEHICLE CRASH, THE SHEET METAL STRUCTURE MAY NOT PERFORM AS DESIGNED. THIS COULD RESULT IN REDUCED LEVELS OF OCCUPANT PROTECTION.
TO PREVENT THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO INSPECT FOR THE MIS-LOCATED WELDS AND, IF NECESSARY, PLACE UP TO FIVE WELDS BETWEEN THE INVOLVED PANELS AND APPLY PRIMER AND TOPCOAT FINISH MATERIALS.
VEHICLES INVOLVED
INVOLVED ARE THE FOLLOWING FOUR (4) 1997 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES MANUFACTURED AT THE LORDSTOWN, OHIO ASSEMBLY PLANT:
CHEVROLET CAVALIER VEHICLES (2 TOTAL) PONTIAC SUNFIRE VEHICLES (2 TOTAL) 1G1JC5241V7293620 1G2JB5240V7591154 1G1JC5244V7294423 1G2JB5242V7591494
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 THE INTER-PROVINCIAL RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF PROVINCIAL LAWS. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN.
PARTS INFORMATION
MATERIALS REQUIRED TO COMPLETE THIS CAMPAIGN ARE LISTED BELOW:
3M SCOTCH BRITE CLEAN 'N STRIP DISC (P/N 07460, 3M WHEEL MANDREL P/N 07491)
DP90 TWO-PART ANTICORROSION PRIMER OR EQUIVALENT
TOPCOAT MATERIAL PER GM REFINISH MANUAL #4901M-D
CUSTOMER NOTIFICATION
ALL CUSTOMERS 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 CUSTOMER LETTER INCLUDED WITH THIS BULLETIN).
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 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 APPROPRIATE CUSTOMER LETTER ACCOMPANYING THIS BULLETIN.
IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, YOU MUST TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE.
SERVICE PROCEDURE
1. RECORD RADIO STATION PRESETS.
2. DISCONNECT BATTERY.
3. RAISE VEHICLE ON HOIST.
4. IF THE VEHICLE IS EQUIPPED WITH A ROCKER MOULDING, REMOVE THE ROCKER MOULDING (3 SCREWS; 8 CLIPS).
5. CLEAN THE AREA SHOWN IN FIGURE 1 AS REQUIRED TO ALLOW THOROUGH INSPECTION. INSPECT FOR FLANGE ALIGNMENT AND WELD LOCATION.
IF THE FLANGES ARE CORRECTLY ALIGNED AND THE WELDS ARE PROPERLY PLACED, PROCEED TO STEP 16 OF THIS SERVICE PROCEDURE.
IF THE FLANGES ARE NOT PROPERLY ALIGNED AND THE WELDS ARE NOT PROPERLY PLACED (SEE FIGURE 2), PROCEED TO STEP 6 OF THIS SERVICE PROCEDURE.
6. STRIP AREAS TO BE WELDED TO BARE METAL USING A DIE GRINDER EQUIPPED WITH 3M SCOTCH BRITE CLEAN 'N STRIP DISC (DISC P/N 07460, 3M WHEEL MANDREL P/N 07491) OR EQUIVALENT. SEE FIGURE 3.
INNER AND OUTER FLANGES CORRECTLY ALIGNED SO THAT SPOT WELDS FASTEN INNER AND OUTER FLANGES
FIGURE 1
7. REMOVE PARK BRAKE CABLE RETENTION CLIP AND MOVE CABLE CLEAR FROM AREA TO BE WELDED.
8. USING A LOCKING PLIERS OR OTHER APPROPRIATE CLAMPING DEVICE, CLAMP A PIECE OF 13 MM ( ") THICK BRASS OR COPPER BEHIND THE FLANGES TO SERVE AS A HEAT SINK.
CAUTION
PROTECT THE FUEL LINE THAT IS ROUTED NEAR THE LH RAIL WITH APPROPRIATE WELD/HEAT SHIELDING MATERIAL.
BEFORE PROCEEDING WITH WELDING, MAKE SURE THAT NO FLAMMABLE LIQUIDS OR VAPORS ARE PRESENT. ANY FUEL LEAKS MUST BE CORRECTED BEFORE ANY WELDING IS PERFORMED.
IMPORTANT
TO MINIMIZE THE CHANCE OF BURN-THROUGH, SOME SAMPLE WELDS SHOULD BE TRIED ON SOME SCRAP PIECES OF SIMILAR THICKNESS. ADJUST THE MIG WELDER TO THE LOWEST POSSIBLE HEAT SETTING THAT WILL ALLOW GOOD WELDS.
INNER FLANGE LOW, WITH WELDS MIS-LOCATED SO THAT FLANGES ARE NOT WELDED TOGETHER.
FIGURE 2
9. PLACE FIVE, TWENTY (20) MM (25/32") LONG MIG WELDS AT THE FLANGES AS SHOWN IN FIGURE 3. THE MIG WELDS SHOULD BE LOCATED TO LINE UP WITH THE FIVE (5) MIS-LOCATED SPOT WELDS.
10. REMOVE THE CLAMPS AND HEAT SINK FROM THE FLANGES. TO ASSURE PROPER PRIMER ADHESION, CLEAN AND PREPARE ALL WELDED SURFACES USING 3M SCOTCH BRITE CLEAN 'N STRIP DISC (DISC P/N 07460, 3M WHEEL MANDREL P/N 07491) OR EQUIVALENT.
11. FEATHEREDGE REPAIR AREA USING 150 GRIT SANDPAPER ON A DUAL ACTION SANDER. APPLY TWO-PART, ANTI- CORROSION PRIMER SUCH AS DP90 TO BARE SHEET METAL. REFER TO GM REFINISH MANUAL #4901M-D FOR A LISTING OF APPROVED PRODUCTS.
12. APPLY TOPCOAT AS SPECIFIED BY GM REFINISH MANUAL #4901M-D FOR A LISTING OF APPROVED PRODUCTS.
13. REPOSITION PARK BRAKE CABLE AND INSTALL RETAINER CLIP.
14. IF THE VEHICLE IS EQUIPPED WITH A ROCKER MOULDING, REINSTALL THE ROCKER MOULDING (3 SCREWS; 8 CLIPS).
15. LOWER VEHICLE.
16. CONNECT BATTERY.
17. RESET RADIO STATION PRESETS.
18. INSTALL CAMPAIGN IDENTIFICATION LABEL.
FIGURE 3
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 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.
INSERT CAMPAIGN NUMBER
INSERT DEALER CODE
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 BY THE CUSTOMER FOR PERIODIC SERVICING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM DGN BY CALLING 1-800-668-5539 (MONDAY-FRIDAY, 8:00 A.M. TO 5:00 P.M. EST). ASK FOR ITEM NUMBER GMP 91 WHEN ORDERING.
APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE.
CLAIM INFORMATION
SUBMIT A PRODUCT CAMPAIGN CLAIM WITH THE INFORMATION INDICATED BELOW:
PART FAILED PARTS LABOR LABOR NET REPAIR PERFORMED COUNT PART NO. ALLOW CC-FC OP * HOURS ITEM
INSPECT ONLY -- -- -- MA-96 V0145 0.4 --
INSPECT AND REPAIR MIS-LOCATED WELDS - - -- MA-96 V0146 2.2 **
* FOR CAMPAIGN ADMINISTRATIVE ALLOWANCE, ADD 0.1 HOURS TO THE "LABOUR HOURS".
** THE AMOUNT IDENTIFIED IN THE "NET ITEM" COLUMN SHOULD REPRESENT THE SUM TOTAL OF THE CURRENT RETAIL PRICE FOR MATERIALS REQUIRED TO PERFORM THE REQUIRED INSPECTION AND REPAIR (NOT TO EXCEED $24.78).
REFER TO THE GENERAL MOTORS CLAIMS PROCESSING MANUAL FOR DETAILS ON PRODUCT CAMPAIGN CLAIM SUBMISSION.
FIGURES: 3
GM BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THESE 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 TOOLS, EQUIPMENT, 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 YOUR DEALER/RETAILER FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.
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