CAMPAIGN: SHOULDER BELT GUIDE LOOP CRACKING-NEW P/N RELEASED
Subject: PRODUCT SAFETY CAMPAIGN 9lC21 - SHOULDER BELT GUIDE LOOP CRACKING
Model and Year: 1991 CHEVROLET LUMINA (SEDAN/COUPE) AND CAVALIER -----------------------------------------------------------------------------
To: All Chevrolet Dealers
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. I f 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 Lumina (Sedan/Coupe) and Cavalier model vehicles fail to comply to Federal Motor Vehicle Safety Standard (FMVSS) 208 "Occupant Crash Protection". Some of these vehicle's have been built with cracked front door shoulder belt guide loops which may not provide front seat occupants with proper protection in the event of a vehicle crash.
To correct this condition, dealers are to inspect the front door shoulder belt guide loops for possible cracks. If a cracked guide loop is found, both front door guide loops will have reinforcing plates installed.
VEHICLES INVOLVED
Involved are certain 1991 Chevrolet Lumina (Sedan/Coupe) and Cavalier model vehicles built within the following VIN breakpoints:
PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ---- ---- ------- 1991 W-Car Oshawa #1 "9" M9100047 M9172754
1991 W-Car Oshawa #2 "1" M1100001 M1125145
1991 J-Car Lordstown "7" M7100001 M7185111
Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identif- ication 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 Traffic 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 $1,000 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).
Notice: During the early stages of this product safety campaign, GMSPO may restrict the number of reinforcement kits which may be requested on any one order due to available parts quantities.
IF GUIDE LOOP IS NOT CRACKED
Quantity/ Part Number Description Vehicle ----------- ----------- --------- 10115018 Guide Loop Nut - W-Car 2 22551133 Guide Loop Nut - J-Car 2 (Guide Loop nuts are serviced in merchandized packages of 6)
NOTICE: If P/N 22551133 (J-Car Nut) can not be obtained, the nuts removed from the car can be reused if thread locking compound is applied. The nut for the W-Car is not to be reused under any circumstances.
IF GUIDE LOOP IS CRACKED
Quantity/ Part Number Description Vehicle ----------- ----------- -------- 10216391 Guide Loop Reinforcement Kit - W-Car 1 22582246 Guide Loop Reinforcement Kit - J-Car 1
Each Kit Contains: 2 Reinforcing Plates, 2 Nuts & An Instruction Sheet
NOTICE: It is anticipated that less than 3% of vehicles will require the guide loop reinforcement kit to complete this campaign. Please order parts accordingly.
SPECIAL TOOLS AND INSTRUCTIONAL VIDEO
Each dealer will be shipped a Guide Loop Inspection/Drilling Fixture (J 39425-4), T-Handle Cutting Tool (J 39425-1), a Bulb with metal dust (PT7190-12), and an Instructional Video Tape, during the week of January 20, 1992. This package is being furnished to dealers at no charge. Each package will be identified with Chevrolet Campaign Number 9lC21. Additional tools, if required, may be ordered from Kent-Moore. Technicians should be certain to view the video tape before attempting to perform the service procedure below.
SERVICE PROCEDURE
Tools Required: J 39425-4 Guide Loop Inspection/Drilling Fixture J 39425-1 T-Handle Cutting Tool PT7190-12 Bulb With Metal Dust
Inspection Procedure (Perform Inspection On Both Front Door Guide Loops) ----------------------------------------------------
1. Lower front door window glass and remove plastic shoulder belt guide loop plug cover (W-Car) or plastic shoulder belt guide loop anchor cover (J-Car), nut and rubber washer (W-Car). DO NOT USE POWER TOOLS TO REMOVE GUIDE LOOP NUT.
2. Pull guide loop outside of vehicle and place in Guide Loop Inspection/Drilling Fixture (J 39425-4) (See View A, below). Use "Magnetic Inspection" side of fixture for this step.
3. Apply small amount of metal dust to guide loop (see View B, page 4).
4. With guide loop still in fixture, gently shake dust from side to side to highlight any possible crack.
5. Inspect guide loop for cracks. If guide loop is cracked, metal dust will have been drawn to crack line (see Views C & D, below) and a guide loop reinforcement kit must be installed on both sides of vehicle.
If guide loop does not have a crack, perform steps 1 through 5 on the opposite front door guide loop to determine if that guide loop is cracked. Do Not Reinstall First Guide Loop Until Both Sides Have Been Inspected.
6. Remove all traces of dust from guide loop(s) and from magnetic fixture by brushing or blowing.
7. If cracks were not found, reinstall guide loop, rubber washer (W-Car) and a new guide loop nut (to be ordered separately). For J-Cars only, the old nut may be reused after a small amount of Locktite 242 thread locking compound (GM P/N 12345382) or equivalent is applied to the threads. The old W-Car nut can not to be reused under any circumstances.
Torque nut to 28 Nm (21 lb. ft.). Reinstall nut cover (W-Car) or anchor cover (J-Car) and install Campaign Identification Label.
Notice: Use only guide loop nut P/N 10115018 on W-car. DO NOT SUBSTITUTE OR REUSE OLD NUT.
Notice: Use only guide loop nut P/N 22551133 on J-Car. DO NOT SUBSTITUTE. If this nut can not be obtained, reuse the old nut after a small amount of Locktite 242 thread locking compound (GM P/N 12345382) or equivalent is applied to the threads.
8. If cracks were found on guide loop, a reinforcement plate must be installed following the "Installing Reinforcement Assemblies" procedure below.
Installing Reinforcement Assemblies (To Be Performed on Both Front Door Guide Loops When Either Front Door Guide Loop Is Cracked) -------------------------------------------------
1. Using "Drilling Operation" side of Guide Loop Inspection/Drilling Fixture (J 39425-4), place guide loop in fixture (see View E, page 7).
2. Locate two holes in guide loop plate on either side of threaded stud. While holding guide loop in fixture with palm, use 3/16" (5mm) drill bit to drill through black plastic material (See View F, below).
3. Using T-Handle Cutting Tool (J 39425-1) to remove all black plastic material from in and around holes in guide loop as illustrated in View G, above. This creates two circular cutouts in lower corners of triangular area on back side of guide loop.
NOTICE: Turning handle back and forth while applying downward pressure has been determined to do a better cleaning job than full rotation of the handle.
4. Install reinforcement plate studs into holes in guide loop. Ensure reinforcement plate is completely seated flush against the guide loop by firmly pressing plate into guide loop cutout area (see View H, below).
5. Reinstall guide loop (with reinforcement assembly in place) using rubber washer removed previously (W-Car Only) and new nut supplied in reinforcement kit. Torque nut to 28 Nm (21 lb. ft.). Reinstall nut cover (W-car) or anchor cover (J-Car). See View I below for W-Car assembly. See View J below for J-Car assembly.
6. Repeat reinforcement assembly installation on opposite front door guide loop.
7. 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 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 for 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 LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW CC-FC OP HRS HRS ---------------- -- -------- ----- ----- ----- --- --- Inspect - No Reinforcement Kit 2 10115018 ** SK-00 V7260 0.3 0.1 Required W-Car
Inspect No Reinforcement Kit 2 22551133 ** SK-00 V7261 0.3 0.1 Required - J-Car
Inspect/Install Reinforcement Kit 1 10216391 ** SK-00 V7262 0.5 0.1 - W-Car
Inspect/ Install Reinforcement Kit 1 22582246 ** SK-00 V7263 0.5 0.1 J-Car
* 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.
Notification Used by Chevrolet Motor Division
Dear Chevrolet owner:
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 determined that certain 1991 Chevrolet Lumina (Sedan/Coupe) and Cavalier model vehicles fail to comply to Federal Motor Vehicle Safety Standard (FMVSS) 208, "Occupant Crash Protection". Some of these vehicle's have been built with cracked front door shoulder belt guide loops which may not provide front seat occupants proper protection in the event of a vehicle crash.
WHAT WE WILL DO
To correct this condition, your Chevrolet dealer will inspect the front door shoulder belt guide loops on your vehicle for possible cracks. If a cracked guide loop is found, both front door shoulder belt guide loops will have reinforcing plates installed. 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. Instructions for making this inspection/correction have been sent to your dealer and parts are available. The labor time necessary to perform this service inspection/correction is approximately 30 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 inspection/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 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.
