CAMPAIGN: BATTERY POSITIVE/ NEGATIVE POST INTERNAL WELD

Subject: PRODUCT SAFETY CAMPAIGN 95-C-59 - BATTERY POSITIVE/NEGATIVE POST INTERNAL WELD

Model and Year: 1995 GEO PRIZM

To: All Chevrolet/Geo 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. 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 a defect which relates to motor vehicle safety exists in certain 1995 Geo Prizm model vehicles. These vehicles have been assembled with batteries that may have been improperly welded. This condition could result in a "no start" or the remote possibility of "ignition of gases in the battery". The ignition of battery gases could cause the battery to explode without prior warning, resulting in injury to persons standing nearby.

To correct this condition, dealers will inspect the battery for the involved date code and replace those found suspect.

VEHICLES INVOLVED

Involved are certain 1995 Geo Prizm models built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ----------------------------------------------------------- 1995 "S" Car Fremont "Z" SZ091845 SZ098298

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification 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.

PARTS INFORMATION

Batteries required to complete this campaign are to be obtained from your local AC Delco battery supplier.

Quantity/ Part Number Description Vehicle ------------------------------------------------------ 35-60 (A/C Delco P/N) 525 CCA Battery 1 (1983S80 GMSPO P/N)

NOTICE

BATTERIES REMOVED FROM VEHICLES SHOULD BE ISOLATED, IDENTIFIED AS A DEFECTIVE PART BY COVERING THE MAJORITY OF THE CASE WITH A BRIGHT COLOR PAINT AND LABELED "DO NOT USE". FOLLOW YOUR NORMAL DISPOSAL PROCEDURES TO ARRANGE FOR PICK UP.

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

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 owners take possession of these vehicles.

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.

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 the instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owners 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 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.

SERVICE PROCEDURE

WARNING:

------- All lead-acid batteries generate hydrogen gas which is highly flammable. If ignited by a spark or flame, the gas may explode violently, causing spraying of acid and/or fragmentation of the battery, and personal injury could result. Wear safety glasses when working near batteries. In case of contact with acid, flush area immediately with water.

1. Inspect top of battery for suspect date code of "5FC6" OR "5FC21" (see Figure on page 4). If CORRECT battery is installed, proceed to step 15. If INCORRECT battery is installed, proceed to step 2.

2. Make sure ignition switch is in OFF position.

3. Make sure ALL Lights, and other electrical devices are OFF (including headlights, interior lights, underhood lights, etc.).

NOTICE: Preset radio stations should be recorded prior to battery disconnect.

4. Disconnect negative battery (Ground) cable at transaxle attachment.

5. Ensure loose end of negative battery (ground) cable is covered (i.e. electrical tape) to keep from inadvertently grounding battery during removal process.

6. Disconnect negative battery (ground) cable from battery.

7. Disconnect positive battery cable from battery.

8. Remove battery hold-down bracket.

9. Carefully remove battery from vehicle, tag "DO NOT USE" and identify as defective by painting the cover a bright color.

10. Install new battery in vehicle.

11. Install battery hold-down bracket nut & bolt and torque to 8 Nm (71 lb. in.).

12. Install positive battery cable to terminal and torque to 15 Nm (11 lb. ft.).

13. Install negative battery cable to terminal and torque to 15 Nm (11 lb. ft.).

14. Install negative battery cable to transaxle and torque to 13 Nm (115 lb. in.) Return radio stations to preset positions and reset clock.

15. Install Campaign Identification Label.

16. FOLLOW YOUR NORMAL DISPOSAL PROCEDURES TO ARRANGE FOR BATTERY PICK UP.

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 for periodic servicing by the owner. When using the new campaign identification label, be sure to install the clear protective covering. Additional "Campaign Identification Labels" can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday through Friday 8:00 a.m. to 4:30 p.m. EST) Ask for Item Number S-1015 when ordering.

Apply "Campaign Identification Label" only on a clean, dry surface.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

PARTS FAILED PARTS LABOR LABOR OPERATION COUNT PART NO. ALLOW CC-FC OPERATION HOURS ---------------------------------------------------------------- Inspect, DO NOT - - - MA-96 V9760 0.2* Replace Battery

Inspect, Replace 1 1983580 ** MA-96 V9761 0.3* Battery

* For Campaign Administrative Allowance, add 0.1 hours to the "Labor Hours".

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 40% of all parts required for the repair.

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

Dear Geo Prizm 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 decided that a defect which relates to motor vehicle safety exists in certain 1995 Geo Prizm model vehicles. These vehicles have been assembled with batteries that may have been improperly welded. This condition could result in a "no start" or the remote possibility of "ignition of gases in the battery". The ignition of battery gases could cause the battery to explode without prior warning, resulting in injury to persons standing nearby.

WHAT WE WILL DO

To correct this condition, your dealer will inspect the battery for the involved date code and replace those found suspect. This service will be performed for you at no charge.

WHAT YOU SHOULD DO

Please contact your Chevrolet/Geo dealer as soon as possible to arrange a service date and so the dealer may order the necessary parts for the repair. Instructions for making this correction have been sent to your dealer and parts are available. The labor time necessary to perform this service correction is approximately 15 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 202-366-0123).

The enclosed owner 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 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.

Chevrolet Motor Division GENERAL MOTORS CORPORATION

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.