Product Safety - Front Safety Belt Buckles

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2003 model year Chevrolet Express and GMC Savana vehicles with a GVW less than 8500 pounds (3856 kg). During a vehicle crash of sufficient severity to deploy the safety belt pretensioner, the front safety belt buckles in some of these vehicles may not release after the vehicle crash, or alternately may eject the front safety belt latches during the vehicle crash, resulting in increased risk of personal injury.

Dealers are to replace the front driver and passenger side safety belt buckles.

Involved are certain 2003 model year Chevrolet Express and GMC Savana vehicles with a GVW less than 8500 pounds (3856 kg) and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) before beginning recall 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 recall bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this recall. Any dealer not receiving a computer listing with the recall 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 recall.

Parts required to complete this recall 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.

The following service procedure provides instructions for replacing the driver and front passenger seat belt pretensioner and buckle assemblies. The steps for SIR disabling/enabling are different than that found in the service manual because in this procedure it is not necessary to disconnect the steering wheel or instrument panel air bag modules. Note that the labor time allowance is for replacement of both assemblies and includes the time necessary for deployment of the removed pretensioners.

1. Turn the ignition switch to the OFF position and remove the AIR BAG fuse.



2. Remove the CPA from the driver's seat belt pretensioner (1) yellow 2-way connector (3) located under the driver's seat, and disconnect the connector.



3. Remove the screws (1) from the driver's seat pretensioner trim cover (2) and remove the cover.
4. Remove the pretensioner attaching bolt (2).
5. Disconnect the pretensioner electrical connector.

Important: Note the wire routing before removal in the next step in order to route the wiring properly during installation of the new pretensioner.

6. Route the wiring as necessary and remove the pretensioner from the seat.
7. Route the connector and wiring of the new pretensioner in the driver's seat.
8. Position the pretensioner to the seat and install the attaching bolt.

Tighten
Tighten the bolt to 40 N·m (30 lb ft).

9. Position the pretensioner trim cover to the seat and install the attaching screws.

Tighten
Tighten the screws to 2 N·m (18 lb in).

10. Connect the pretensioner electrical connectors under the driver's seat and install the CPA.
11. Remove the CPA from the passenger seat belt pretensioner yellow 2-way connector (3) located under the passenger seat, and disconnect the connector.
12. Remove the screws from the passenger seat pretensioner trim cover and remove the cover.
13. Remove the pretensioner attaching bolt.
14. Disconnect the pretensioner electrical connector.

Important: Note the wire routing before removal in the next step in order to route the wiring properly during installation of the new pretensioner.

15. Route the wiring as necessary and remove the pretensioner from the seat.
16. Route the connector and wiring of the new pretensioner in the passenger seat.
17. Position the pretensioner to the seat and install the attaching bolt.

Tighten
Tighten the bolt to 40 N·m (30 lb ft).

18. Position the pretensioner trim cover to the seat and install the attaching screws.

Tighten
Tighten the screws to 2 N·m (18 lb in).

19. Connect the pretensioner electrical connectors under the passenger seat and install the CPA.
20. Install the AIR BAG fuse.
21. Turn the ignition switch to the ON position and verify that the AIR BAG indicator flashes seven times and goes out.
22. Install the GM Recall Identification Label.
23. Follow the service manual procedures for deployment of the removed pretensioner assemblies.

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

Put the Recall 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 Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

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

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

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

The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

Submit a Product Recall Claim with the information indicated below:

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

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

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

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

Dealers are to service all vehicles subject to this recall 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. Recall 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 recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall 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 in certain 2003 model year Chevrolet Express and GMC Savana vehicles. During a vehicle crash of sufficient severity to deploy the safety belt pretensioner, the front safety belt buckles in some of these vehicles may not release after the vehicle crash, or alternately may eject the front safety belt latches during the vehicle crash, resulting in increased risk of personal injury.

Your GM dealer will replace the front driver and passenger side safety belt buckles. This service will be performed for you at no charge .

The length of time required to perform this service correction is approximately 45 minutes. Additional time may be required to schedule and process your vehicle. If you 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.

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.

Your 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 number listed 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 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.

If your vehicle is within the New Vehicle Limited Warranty your dealer will provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation.

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