CAMPAIGN: LOSS OF HEADLIGHT OPERATION. Pontiac Grand Prix 1991

PRODUCT SAFETY CAMPAIGN - LOSS OF HEADLAMP OPERATION

1991 PONTIAC GRAND PRIX COUPE

TO: ALL PONTIAC 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 PONTIAC 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 DETERMINED THAT A DEFECT WHICH RELATES TO MOTOR VEHICLE SAFETY EXISTS IN CERTAIN 1991 PONTIAC GRAND PRIX COUPE MODEL VEHICLES. THESE VEHICLES EXHIBIT A CONDITION IN WHICH THE FOG LAMPS, LOW BEAM HEADLAMPS AND HIGH BEAM HEADLAMPS CAN BE OPERATED SIMULTANEOUSLY. THIS CONDITION VIOLATES LAWS IN SOME STATES WHICH ONLY PERMIT THE OPERATION OF FOUR (4) WHITE LIGHTS AT THE SAME TIME.

ADDITIONALLY, ALL THREE SETS OF HEADLAMPS OPERATING SIMULTANEOUSLY MAY CAUSE THE HEADLAMP CIRCUIT BREAKER TO BECOME OVERLOADED AND "TRIP" RESULTING IN THE LOSS OF HEADLAMP (HIGH AND LOW BEAM) AND FOG LAMP OPERATION.

TO CORRECT THIS CONDITION, DEALERS ARE TO INSTALL A NEW FOG LAMP RELAY, NEW CIRCUIT BREAKER AND NEW CIRCUIT BREAKER TERMINALS. THE VEHICLE CIRCUITRY WILL ALSO BE MODIFIED TO PREVENT THE FOG LAMPS AND HIGH BEAM HEADLAMPS FROM OPERATING SIMULTANEOUSLY.

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1991 PONTIAC GRAND PRIX COUPE MODEL VEHICLES BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS:

PLANT YEAR MODEL PLANT CODE FROM THROUGH

1991 W-CAR FAIRFAX "F" MF284000 MF301210

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.

OWNER NOTIFICATION

OWNERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY PONTIAC 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 ARE TO BE CONTACTED BY THE DEALER, AND ARRANGEMENTS MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO INSTRUCTIONS CONTAINED IN 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, PLEASE TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE.

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).

QUANTITY/ PART NUMBER DESCRIPTION VEHICLE

12141644 HEADLAMP REPAIR KIT 1

KIT INCLUDES: 1 - 20 AMP FUSE 1 - FOG LAMP RELAY 1 - CIRCUIT BREAKER # - WIRE TERMINALS # - WIRE SPLICE CLIPS

SERVICE PROCEDURE

1. OPEN HOOD AND PERFORM THE FOLLOWING STEPS:

1A. DISCONNECT NEGATIVE BATTERY CABLE AND REMOVE AIR CLEANER.

1B. REMOVE OVERFLOW BOTTLE AND SET ON TOP OF ENGINE.

1C. REMOVE 2 SCREWS FROM FORWARD LIGHT RELAY CENTER LOCATED BELOW RIGHT SIDE ELECTRICAL CENTER (SEE FIGURE 1) AND PULL OUT FORWARD LIGHT RELAY CENTER FOR ACCESS.

1D. REPLACE FOG LAMP RELAY WITH NEW RELAY FROM KIT.

1E. REMOVE BACK OF RELAY CENTER.

1F. CUT DARK GREEN WIRE FROM BACK OF FUSE, LEAVING AT LEAST 4" OF WIRE ATTACHED TO THE FUSE. TAPE THE HARNESS END OF WIRE. SEE FIGURE 2.

1G. SPLICE GREEN WIRE INTO ONE OF TWO ORANGE WIRES FROM BACK OF HORN RELAY. EITHER ORANGE WIRE CAN BE USED. USE SPLICE CLIP FROM KIT, SOLDER, AND TAPE CONNECTION.

1H. REPLACE BACK OF RELAY CENTER, AND REINSTALL IT TO FRAME RAIL.

2. OPEN RIGHT HAND DOOR, AND PERFORM THE FOLLOWING STEPS:

2A. OPEN GLOVE BOX DOOR, REMOVE FUSE PANEL COVER, AND REPLACE 15 AMP "HORN" FUSE WITH 20 AMP FUSE FROM KIT. REPLACE FUSE PANEL COVER AND CLOSE THE GLOVE BOX DOOR.

2B. REMOVE RIGHT HAND SOUND INSULATOR PANEL.

2C. REMOVE COMPONENT CENTER (SEE FIGURE 3). THERE ARE TWO (2) 5.5 MM SCREWS UNDERNEATH. REMOVE FRONT SCREW AND LOOSEN THE REAR SCREW. SLIDE COMPONENT CENTER OUT AND SLIDE BACK OF CENTER OFF TO EXPOSE WIRES.

2D. LOCATE AND REMOVE 20 AMP HEADLIGHT CIRCUIT BREAKER. THERE ARE TWO DARK GREEN AND ONE RED WIRE GOING TO THIS BREAKER.

2E. REMOVE TWO TERMINALS FROM COMPONENT CENTER. CUT WIRES AS CLOSE TO TERMINALS AS POSSIBLE. STRIP WIRES, AND CRIMP AND SOLDER TWO NEW TERMINALS FROM KIT TO WIRES. REINSTALL CONNECTORS INTO COMPONENT CENTER. IF NECESSARY, PULL ON HARNESS TO GAIN EXTRA WIRE LENGTH SO THE WIRES ARE NOT STRETCHED.

NOTICE: IT IS VERY IMPORTANT THAT NEW TERMINALS BE SOLDERED. A CIRCUIT BREAKER OPERATES BY OPENING WHEN HEAT BUILDS UP TO A CERTAIN LEVEL. THE TERMINALS AND WIRE ARE USED AS A HEAT SINK FOR THE CIRCUIT BREAKER. UNSOLDERED TERMINALS MAY BUILD UP HEAT, OPENING THE CIRCUIT BREAKER, AND CAUSING THE HEADLIGHTS TO FLASH.

2F. INSTALL NEW CIRCUIT BREAKER.

2G. REINSTALL COMPONENT CENTER. USING REAR SCREW AS A GUIDE, SLIDE CENTER ONTO SCREW, POSITION CENTER AND INSTALL FRONT SCREW. TIGHTEN BOTH SCREWS SECURELY.

3. CONNECT NEGATIVE BATTERY CABLE AND VERIFY THAT FOG LAMPS AND HORN OPERATE PROPERLY.

- OPERATE HORN. - TURN HEADLAMPS ON LOW BEAM. - TURN FOG LAMP SWITCH ON. FOG LAMPS SHOULD LIGHT. - TURN HEADLAMPS TO ON HIGH BEAM. FOG LAMPS SHOULD GO OUT. - TURN HEADLAMPS BACK TO LOW BEAM. FOG LAMPS SHOULD COME BACK ON. - TURN FOG LAMP SWITCH OFF. FOG LAMPS SHOULD GO OFF.

4. REINSTALL AIR CLEANER AND OVERFLOW BOTTLE. MAKE CERTAIN COOLANT HOSE IS CORRECTLY LOCATED AND IS NOT CLOSE TO ENGINE PULLEYS OR BELTS.

5. REINSTALL RIGHT HAND SOUND INSULATOR PANEL.

6. PERFORM IDLE LEARN PROCEDURE AS FOLLOWS:

6A. PLACE TRANSAXLE IN PARK OR NEUTRAL.

6B. CONNECT TECH 1 "SCAN" TOOL.

6C. SELECT "IAC SYSTEM", THEN SELECT "IDLE LEARN" IN "MISC. TEST" MODE.

6D. PROCEED WITH IDLE LEARN AS DIRECTED.

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 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. 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:

_________________________________________________________________ * FAILURE LABOR LAB OTH REPAIR PERFORMED CODE OP HRS HRS _________________________________________________________________

INSTALL HEADLAMP 96 V7750 1.1 0.1 REPAIR KIT _________________________________________________________________

* 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 PONTIAC CLAIMS PROCESSING MANUAL FOR DETAILS ON PRODUCT CAMPAIGN CLAIM SUBMISSION.

(NOTIFICATION USED BY PONTIAC MOTOR DIVISION)

________ __, 1992

DEAR PONTIAC GRAND PRIX COUPE 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

WHAT WE WILL DO

TO CORRECT THIS CONDITION, YOUR DEALER WILL INSTALL A NEW FOG LAMP RELAY, NEW CIRCUIT BREAKER AND NEW CIRCUIT BREAKER TERMINALS. THE VEHICLE CIRCUITRY WILL ALSO BE MODIFIED TO PREVENT THE FOG LAMPS AND HIGH BEAM HEAD LAMPS FROM OPERATING SIMULTANEOUSLY. THIS SERVICE WILL BE PERFORMED FOR YOU AT NO CHARGE.

WHAT YOU SHOULD DO

PLEASE CONTACT YOUR PONTIAC 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 _____. PLEASE ASK YOUR DEALER IF YOU WISH TO KNOW HOW MUCH ADDITIONAL TIME WILL BE NEEDED TO SCHEDULE AND PROCESS YOUR VEHICLE.

YOUR PONTIAC 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 PONTIAC 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 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.

PONTIAC MOTOR DIVISION GENERAL MOTORS CORPORATION

ENCLOSURE

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.