FMVSS Noncompliance - Installation of Rear Seat Center Belt Anchor Reinforcement Plate

Important: Saturn Retailers in Canada: The Canadian version of this bulletin follows the U.S. version.

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 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 letter, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

Saturn has decided that 2002-2004 Saturn L-Series wagon vehicles were built with a center and passenger side rear seat belt anchor that fails to conform to Federal Motor Vehicle Safety Standard (FMVSS) 210, "Seat Belt Assembly Anchorages." The seat belt anchor may separate from the floor of the vehicle before holding the required test load for the required time. If a separation occurred in a crash, the right and center rear seat occupants may not be properly restrained, increasing the risk of personal injury.

To correct this condition, Saturn retailers will install a rear seat center belt anchor reinforcement plate to the floor pan of the vehicle. This service will be performed at no cost to the owner.

2002-2004 model year Saturn L-Series wagon vehicles within the following VIN range will require this recall.

2Y500039 - 2Y600755

3Y500095 - 3Y581210

4Y500021 - 4Y521105

You must verify recall involvement through your AS400 system. It is important to note that recall claims will only be paid on involved vehicles.

Owners of all involved vehicles located within areas covered by the US National Traffic and Motor Vehicle Safety Act will be notified of this recall by Saturn. (Refer to the owner letter included in this bulletin.)

All unsold new vehicles in Retailers' 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.

Retailers 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.

Owners who have recently purchased vehicles sold from your vehicle inventory are to be contacted by the retailer and arrangements are to be made to make the required correction according to the procedure contained in this bulletin.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your retail facility for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

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.

Saturn vehicles that have been sold to you, which may be closer in proximity to another Saturn Retailer, may still appear on your Facility VIN Listing. If either you or the vehicle owner determines that it is more desirable for a vehicle on your Facility VIN Listing to be serviced by another Saturn Retailer, or if the customer’s address has recently changed, recall responsibility may be transferred by completing the following:

A copy of the Recall Vehicle Action Report is included for your reference. Additional copies can be ordered from Saturn Publications (win.wallace.com/saturn or 1-800-828-2112, prompt 3, Item # S03 2002RVAR). All changes to recall responsibility will be reflected in your next Unfixed VIN Report.

All other changes in vehicle status (e.g., scrapped, stolen, etc.) are to be made in accordance with section 4.4.3 of the Retailer Service Policies & Procedures Manual, "Notifying Saturn of Vehicle Status Change."

1. A shipment of the required parts to perform this program will be automatically sent to involved Retailers from Saturn Service Parts Operations (SSPO).
2. Should you require any additional parts, please contact your Parts Support Analyst (PSA) to expedite parts shipment.

*Do not use the replacement bolts included in Kit #15810645. Instead, use the original bolts that are removed from the vehicle during disassembly.

Important: DO NOT Use Threadlocker - Loctite 242® on the M12 bolt, which is larger than the two M8 bolts and required to anchor the seat belt to the child seat anchor plate assembly . Threadlocker - Loctite 242® should only be added to the two smaller M8 bolts that were removed from the child seat anchor plate assembly.

NOTE: All material prices are retailer cost plus 40%.

** One tube will service 10 vehicles. One tube $9.93/10 vehicles = $ 1.00 per vehicle.

Total Material Allowance is $ 1.00 per vehicle.

Disposition of Replaced Parts

Retailers will scrap all replaced parts in a manner that ensures that they cannot be reused, remanufactured, or otherwise entered into the stream of commerce in the future.

As you know, Saturn’s success hinges upon our ability to execute superior customer support throughout the ownership experience, especially when important corrective actions such as this are required.

It is imperative that every effort is made to accommodate the affected owners. Additionally, priority should be given to customer vehicles over retail inventory vehicles. If you have any questions, please coordinate with the Saturn Customer Assistance Center to help ensure customer satisfaction.

In order to install the rear seat center belt anchor reinforcement plate to the floor pan of the vehicle, removal of the following interior parts is required: rear seat cushion, passenger side rear folding seat back, two 8 mm (0.315 in) child seat anchor plate assembly bolts, one 11.11 mm (7/16 in) seat belt anchor bolt, and a fiber retainer (if applicable) and buckle/latch assembly. No special tools are required to perform the service procedures in this bulletin.

Refer to the illustration below to view the floor pan, child seat anchor plate, and rear seat center belt anchor reinforcement plate.

Important: There are two rear seat cushion retainer straps, which are located on the bottom of the driver’s and passenger’s side of the rear seat cushion. If they are not exposed, insert a finger between the bottom of the rear seat cushion and the floor to locate them.

1. Remove rear seat cushion.

1.1.	Pull on rear seat cushion retainer strap while puling up on cushion to disengage rear seat cushion forward attachment. Perform the same operation for the other side of the seat cushion.

1.2.	Push rear seat cushion rearward to disengage rear attachment.

1.3.	Route seat belts through rear seat cushion opening and lift rear seat cushion out of vehicle.

2. Remove passenger's side rear folding seat back.

2.1.	Push up on seat back foam with your hand to expose seat bracket outer retainer.

2.2.	Unlatch rear seat back. Leave seat in upward position.





Notice: Rear seat back attachments have an "Easyload" outer bracket that allows the rear seat back to snap into position upon installation. It is necessary to pry on the bottom of the bracket (where the large pivot pin goes into the seat bracket) to disengage the rear seat back attachment.

2.3.	Gently pry on the bottom of the bracket (1) while pulling upward on the seat back to disengage outer bracket from pivot pin (2).

2.4.	Tilt seat back down to align inner pivot tabs then pull seat back outward to remove seat back.




3. Remove buckle/latch assembly, fiber retainer, seat belt bolt, child seat anchor plate assembly bolts, and install the rear seat center belt anchor reinforcement plate (part of kit, P/N 15810645) .

3.1.	Remove 11.11 mm (7/16 in) seat belt bolt and fiber retainer (if applicable) from the buckle/latch assembly. Save this bolt for reassembly.

3.2.	Remove the two 8 mm (0.315 in) bolts from the child seat anchor plate assembly. Save these bolts for reassembly.

3.3.	Slide the rear seat center belt anchor reinforcement plate (part of kit, P/N 15810645) under the child seat anchor plate assembly.

Caution: APPLY LOCTITE 242 THREADLOCKER® (OR EQUIVALENT) ON 8 MM (0.315 in) BOLTS BEFORE INSTALLATION.

3.4.	Install the two 8 mm (0.315 in) child seat anchor plate assembly bolts at the pivot bracket. Use the two 8 mm (0.315 in) bolts removed in step 3.2.

Tighten
Tighten child seat anchor plate assembly bolts to 25 ± 5 N·m (18 lb-ft ± [44 in-lbs]).

Notice: Ensure the belt is not twisted by buckling the center and outboard seating positions after the seat back assembly and seat cushion have been installed. Push and pull on the seat belt system to ensure it is secure.

Important: DO NOT use Threadlocker [horbar] Loctite 242® on 11.11 mm (7/16 in) seat belt bolt.

3.5.	Install buckle/latch assembly and the 11.11 mm (7/16 in) seat belt bolt removed in step 3.1.

Tighten
Tighten seat belt bolt to 42 ± 6 N·m (31 lb-ft ± [53 in-lbs]).




4. Install passenger's side rear folding seat back.

4.1.	Guide seat back assembly onto center pivot pin.

4.2.	Align outer pivot pin with the lead in ramp on the "Easyload" bracket.

4.3.	Push downward on the seat back to engage "Easyload" bracket.

4.4.	Raise seat back and secure seat back latch.




5. Install rear seat cushion.

5.1.	Position rear seat cushion over rear seat floor area.

5.2.	Route rear seat belts through cushion openings.

5.3.	Slide rear seat cushion frame into rear attachment brackets.

5.4.	Push downward on rear seat cushion forward retainers to lock rear seat cushion to floor brackets.

5.5.	Check seat belt for proper routing through cushion.

1. To receive credit, submit a claim with the information below:

Claiming Loctite 242 Threadlocker® Material

It will be necessary to sell these materials to the CSO as "material" using net item code "M" per the chart in the Parts Information section of this bulletin. Claims received in the amount of $1.00 will be accepted. Claims exceeding the amount of $1.00 will be returned with Return Reason 143 - material/reimbursement > maximum allowed.

2. To receive credit for loaner/rental vehicle costs incurred while owner awaits program repair, submit a claim with the information below:

3. Check your Saturn SERVICELINE.XL Claim Memorandum daily. Remember to code the claim as a WC sale type, and VC case type. Contact your field representative if you need assistance.

4. All labor operations claimed in this bulletin must be submitted on individual (unrelated) CSO lines. Refer to the Customer Service Order Preparation Manual for details on Bulletin Claim Submission.

Complete this worksheet and attach it to the hard copy of the Customer Service Order (CSO) to document all loaner/rental reimbursement claims submitted to Saturn.

VIN #____________________

Vehicle Loaner/Rental Allowance Explanation: $_________

____________________________________________________________

____________________________________________________________

____________________________________________________________

MODELS: 2002-2004 SATURN L-SERIES WAGON VEHICLES

Attention: General Motors of Canada Ltd. Saturn Retailers

Saturn has decided that 2002-2004 Saturn L-Series wagon vehicles were built with a centre and passenger side rear seat belt anchor that fails to conform to Canada Motor Vehicle Safety Standard (CMVSS) 210, "Seat Belt Assembly Anchorages." The seat belt anchor may separate from the floor of the vehicle before holding the required test load for the required time. If a separation occurred in a crash, the right and centre rear seat occupants may not be properly restrained, increasing the risk of personal injury.

To correct this condition, Saturn retailers will install a rear seat centre belt anchor reinforcement plate to the floor pan of the vehicle. This service will be performed at no cost to the owner.

Involved are certain 2002-2004 model year Saturn L-Series Wagon vehicles built within these VIN breakpoints:

Important: Retailers 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 retailers 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 GMinfoNet Recall Reports. Retailers will not have a report available if they have no involved vehicles currently assigned.

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 purpose other than follow-up necessary to complete this recall 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 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.

*Do not use the replacement bolts included in Kit #15810645. Instead, use the original bolts that are removed from the vehicle during disassembly.

Important: DO NOT Use Threadlocker - Loctite 242® on the M12 bolt, which is larger than the two M8 bolts and required to anchor the seat belt to the child seat anchor plate assembly . Threadlocker - Loctite 242® should only be added to the two smaller M8 bolts that were removed from the child seat anchor plate assembly.

** One tube will service 10 vehicles. One tube $3.99/10 vehicles = $0.40 per vehicle.

Total Material Allowance is $0.40 per vehicle.

In order to install the rear seat centre belt anchor reinforcement plate to the floor pan of the vehicle, removal of the following interior parts is required: rear seat cushion, passenger side rear folding seat back, two 8 mm (0.315 in) child seat anchor plate assembly bolts, one 11.11 mm (7/16 in) seat belt anchor bolt, and a fiber retainer (if applicable) and buckle/latch assembly. No special tools are required to perform the service procedures in this bulletin.

Refer to the illustration below to view the floor pan, child seat anchor plate, and rear seat centre belt anchor reinforcement plate.

Important: There are two rear seat cushion retainer straps, which are located on the bottom of the driver’s and passenger’s side of the rear seat cushion. If they are not exposed, insert a finger between the bottom of the rear seat cushion and the floor to locate them.

1. Remove rear seat cushion.

1.1.	Pull on rear seat cushion retainer strap while pulling up on cushion to disengage rear seat cushion forward attachment. Perform the same operation for the other side of the seat cushion.

1.2.	Push rear seat cushion rearward to disengage rear attachment.

1.3.	Route seat belts through rear seat cushion opening and lift rear seat cushion out of vehicle.

2. Remove passenger's side rear folding seat back.

2.1.	Push up on seat back foam with your hand to expose seat bracket outer retainer.

2.2.	Unlatch rear seat back. Leave seat in upward position.





Notice: Rear seat back attachments have an "Easyload" outer bracket that allows the rear seat back to snap into position upon installation. It is necessary to pry on the bottom of the bracket (where the large pivot pin goes into the seat bracket) to disengage the rear seat back attachment.

2.3.	Gently pry on the bottom of the bracket (1) while pulling upward on the seat back to disengage outer bracket from pivot pin (2).

2.4.	Tilt seat back down to align inner pivot tabs then pull seat back outward to remove seat back.




3. Remove buckle/latch assembly, fibre retainer, seat belt bolt, child seat anchor plate assembly bolts, and install the rear seat centre belt anchor reinforcement plate (P/N 15796153 [included in kit, P/N 15810645]).

3.1.	Remove 11.11 mm (7/16 in) seat belt bolt and fibre retainer (if applicable) from the buckle/latch assembly. Save this bolt for reassembly.

3.2.	Remove the two 8 mm (0.315 in) bolts from the child seat anchor plate assembly. Save these bolts for reassembly.

3.3.	Slide the rear seat centre belt anchor reinforcement plate (P/N 15796153 [included in kit, P/N 15810645]) under the child seat anchor plate assembly.

Caution: APPLY LOCTITE 242 THREADLOCKER® (OR EQUIVALENT) ON 8 MM (0.315 in) BOLTS BEFORE INSTALLATION.

3.4.	Install the two 8 mm (0.315 in) child seat anchor plate assembly bolts at the pivot bracket. Use the two 8 mm (0.315 in) bolts removed in step 3.2.

Tighten
Tighten child seat anchor plate assembly bolts to 25 ± 5 N·m (18 lb-ft ± [44 in-lbs]).

Notice: Ensure the belt is not twisted by buckling the center and outboard seating positions after the seat back assembly and seat cushion have been installed. Push and pull on the seat belt system to ensure it is secure.

Important: DO NOT use Threadlocker [horbar] Loctite 242® on 11.11 mm (7/16 in) seat belt bolt.

3.5.	Install buckle/latch assembly and the 11.11 mm (7/16 in) seat belt bolt removed in step 3.1.

Tighten
Tighten seat belt bolt to 42 ± 6 N·m (31 lb-ft ± [53 in-lbs]).




4. Install passenger's side rear folding seat back.

4.1.	Guide seat back assembly onto center pivot pin.

4.2.	Align outer pivot pin with the lead in ramp on the "Easyload" bracket.

4.3.	Push downward on the seat back to engage "Easyload" bracket.

4.4.	Raise seat back and secure seat back latch.




5. Install rear seat cushion.

5.1.	Position rear seat cushion over rear seat floor area.

5.2.	Route rear seat belts through cushion openings.

5.3.	Slide rear seat cushion frame into rear attachment brackets.

5.4.	Push downward on rear seat cushion forward retainers to lock rear seat cushion to floor brackets.

5.5.	Check seat belt for proper routing through cushion.

Submit a Product Recall Claim with the information indicated below:

* The "Parts Allowance" should be the sum total of the current GMSPO Retailer Net price plus applicable mark-up for the seal needed to complete the repair.

** One tube (part no. 10953489) will service 10 vehicles. One tube $3.99/10 vehicles=$0.40 per vehicle. Total Material Allowance is $0.40 per vehicle.

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

Customer Notification

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

Retailer Recall Responsibility

All unsold new vehicles in Retailers' 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.

Retailers 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 Retailer listing, are to be contacted by the Retailer. 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 retail facility for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear Saturn Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Saturn has decided that 2002-2004 Saturn L-Series wagon vehicles were built with a center and passenger side rear seat belt anchor that fails to conform to Federal Motor Vehicle Safety Standard (FMVSS) 210, "Seat Belt Assembly Anchorages." The seat belt anchor may separate from the floor of the vehicle before holding the required test load for the required time. If a separation occurred in a crash, the right and center rear seat occupants may not be properly restrained, increasing the risk of personal injury.

What Saturn will do:

To correct this condition, Saturn retailers will install a rear seat center belt anchor reinforcement plate to the floor pan of the vehicle.

Repairs will take about 60 minutes, although some additional time may be required due to service scheduling requirements, paperwork and processing. This service will be performed at no charge to you.

What you should do:

Contact your Saturn Retailer as soon as possible to arrange to have this service performed.

The enclosed reply card identifies your vehicle and will facilitate completion of the service when presented to your Saturn retail facility. If your address has changed, please provide the new information in the space provided. This will assist us in ensuring that all affected vehicles are corrected.

Your Retailer is prepared to perform this service promptly and with minimal inconvenience to you. However, if your car is provided to the Retailer on the agreed service date and the condition is not remedied on that date, or within a reasonable time, please contact the Saturn Customer Assistance Center at 1-800-972-8876, or for the hearing impaired, 1-800-833-6000. We will assist you and the Retailer in getting your car serviced.

If, after contacting your Saturn Retailer and the Saturn Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 7th St., SW, Washington, DC 20590, or call 1-888-327-4236.

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 sincerely regret any inconvenience or concern this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your Saturn provides you many miles of enjoyable and safe driving.

Sincerely,

Saturn

05041

Enclosures