F/CMVSS Noncompliance - Accelerator Pedal Sticking

General Motors has decided that certain 2003 model year Chevrolet Malibu, Oldsmobile Alero, and Pontiac Grand Am vehicles equipped with a V6 engine (RPO LA1/LG8) fail to conform to Federal/Canada Motor Vehicle Safety Standard 124, Acceleration Control Systems. In some of these vehicles, the accelerator pedal may not return to the engine idle position when the driver removes force from the pedal because of interference caused by expansion of the pedal arm when it is exposed to heat. If the pedal does not return to the engine idle position, the engine speed will not slow as intended. This could cause increased stopping distance and a vehicle crash.

Dealers are to inspect the accelerator pedal assembly for proper clearance, and replace it if necessary.

Involved are certain 2003 model year Chevrolet Malibu, Oldsmobile Alero, and Pontiac Grand Am vehicles equipped with a V6 engine (RPO LA1/LG8) and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

For US

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld.

For Canada

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a Campaign Initiation Detail Report.

For Export

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin.

The Campaign Initiation Detail Report 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 report to the follow-up necessary to complete this program.

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 inspecting, and if necessary, replacing the accelerator/brake pedal assembly.

Inspection

1. Turn the ignition switch to the OFF position.
2. Open the hood.
3. Have an assistant hold the throttle linkage (cam) in the wide-open throttle position.




Important: In the next steps, you are checking to see if the accelerator pedal is binding in the bracket assembly.

4. With the throttle being held in the wide-open throttle position, from under the instrument panel, move the accelerator pedal to the idle position (1) or fully towards the rear of the vehicle.
5. Release (let go of) the accelerator pedal assembly.

•	If the accelerator pedal falls (moves freely) towards the front of the vehicle (2), then no repairs are needed. Proceed to the next step.

•	If the accelerator pedal stays or sticks at the idle position and doesn't move, then the accelerator/brake pedal assembly must be replaced. Proceed to the section titled, "Replacement."

•	If you move the accelerator pedal to any position and it stays or sticks there (won't move unless you help it), then the accelerator/brake pedal assembly must be replaced. Proceed to section titled, "Replacement."

6. Release the linkage at the throttle body assembly.
7. Close the hood.

Replacement

1. Disconnect the accelerator and cruise control cables from the accelerator cable bracket.



2. From inside of the vehicle, remove the pushpin retainer for the left side outboard instrument panel insulator.
3. Disengage the outboard insulator tab from the inboard insulator, pull the insulator off the stud, and remove.



4. Remove the three screws attaching the left side inboard insulator panel.
5. Slide the insulator panel from the HVAC module, disconnect the defroster duct, and remove the insulator.



6. Remove the brake switch (5) and the cruise control switch (7) from the bracket (1) on the pedal assembly.
7. Disconnect the electrical connectors (3, 4, 6) from the switches.
8. Disconnect the two push-in clips that attach the wiring harness to the bracket.



9. Remove the clip and bushing that attaches the brake pedal pushrod (1) to the brake pedal (2).
10. Remove the pushrod from the pedal.
11. Remove the four nuts that attach the bracket assembly to the body.

Important: The use of a 15mm swivel socket or the right combination of a flex (universal) joint and socket are required to remove the upper bracket to the body nut in the next step.

12. Remove the one upper nut that attaches the upper part of the bracket assembly to the body.
13. Lower the pedal assembly.
14. Squeeze the tabs on the white bushing inwards and remove the bushing and cable from the accelerator pedal.

Important: The mounting locations of the brake and cruise control switches and retainers may be reversed when being installed in the new pedal assembly in the next step.

15. Transfer the retainers for the brake switch and cruise control switch from the original pedal assembly to the new pedal assembly.
16. Install the new pedal assembly to the body and install the four forward nuts.

Tighten
Tighten the four nuts to 27 N·m (20 lb ft).

17. Install the upper nut.

Tighten
Tighten the four nuts to 27 N·m (20 lb ft).

18. Connect the accelerator cable and bushing to the accelerator pedal.
19. Install the pushrod on the brake pedal and install the bushing and retaining clip.
20. Connect the electrical connectors to the brake and cruise control switches.
21. Install the switches in the brackets and adjust as necessary.
22. Attach the wiring harness clips to the bracket.
23. Attach the defroster duct to the inboard insulator and slide the insulator to the HVAC module.
24. Install the three insulator screws.

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

25. Position the outboard insulator on the stud and engage the tab to the inboard insulator.
26. Align the outboard insulator and install the push-in retainer.
27. Connect the accelerator and cruise control cables to the accelerator cable bracket on the throttle body assembly.
28. Close the hood.

All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers.

A General Motors Product Recall Customer Reimbursement Procedure Form is included with the customer letter.

Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.

Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted by December 31, 2005.

All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

When a customer requests reimbursement, they must provide the following:

Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS.

Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification.

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:

Note: Canadian dealers should refer to the Canadian distribution of the bulletin for detailed claim information.

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

General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that 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 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.

This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, 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 recall correction, your dealership may be subject to a civil penalty for each such sale.

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.

If you have paid to have this condition corrected by replacing the upper intake manifold/gasket, throttle body nuts, or throttle body gasket before August 8, 2003, you may be eligible to receive reimbursement.

Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

Your claim will be acted upon within 60 days of receipt.

If your claim is:

Please follow the instructions on the Claim Form provided on the reverse side to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center:

Please mail this claim form and the required documents to:

General Motors Corporation

P.O. Box 33170

Detroit, MI 48232-5170

All recall reimbursement questions should be directed to the following number: 1-800-204-0261.

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 certain 2003 model year Chevrolet Malibu, Oldsmobile Alero, and Pontiac Grand Am vehicles equipped with a V6 engine (RPO LA1/LG8) fail to conform to Federal/Canada Motor Vehicle Safety Standard 124, Acceleration Control Systems. In some of these vehicles, the accelerator pedal may not return to the engine idle position when the driver removes force from the pedal because of interference caused by expansion of the pedal arm when it is exposed to heat. If the pedal does not return to the engine idle position, the engine speed will not slow as intended. This could cause increased stopping distance and a vehicle crash.

Your GM dealer will inspect the accelerator pedal assembly for proper clearance, and replace it if necessary. This service will be performed for you at no charge .

This inspection will take approximately 15 minutes. If the pedal requires replacement, an additional 30 minutes will be needed. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that any necessary parts will be available on your scheduled appointment date. 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. The Customer Assistance Center’s hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

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 enclosed customer reply form identifies your vehicle. Presentation of this form 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 form and mailing it back to us.

The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for this condition.

If your vehicle is within the New Vehicle Limited Warranty your dealer may 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.

This free online service offers vehicle and ownership related information and tools tailored to your specific vehicle. To join, visit www.mygmlink.com , and enter your vehicle's 17-character vehicle identification number (VIN) shown on the enclosed customer reply form to get the most personalized information for your vehicle.

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

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

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