CAMPAIGN:SEAT BELT BUCKLES

Subject: PRODUCT SAFETY CAMPAIGN 90-C-13 SEAT BELT BUCKLES

Models Affected: 1988-90 PONTIAC LEMANS

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 1988-90 Pontiac LeMans model vehicles. Some seat belt buckle assemblies in affected vehicles may not latch, or may not release, due to fracture of the red push button which can occur during seat belt connection or disconnection. These buckle malfunctions would prevent a person from using the seat belt system, and the risk of injury to an unbelted person in an accident would be increased.

To correct this condition, all involved vehicles will have the pushbutton assemblies replaced. Also, any buckle assemblies which are found not to function correctly, or which have fractured pushbuttons, will be replaced.

VEHICLES INVOLVED

Involved are certain 1988-90 LeMans model vehicles built within the following VIN breakpoints:

Up To And Year Plant Beginning Including ---- ----- --------- --------- 1988 Pupyong JB300029 JB385149 1989 Pupyong KB300010 KB368546 1990 Pupyong LB300245 LB334503

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listing 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 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 is taken into your new or used vehicle inventory, or it 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

Dealers who have involved vehicles in this campaign will be preshipped 10 vehicle pushbutton kits on December 8, 1993. These parts will be charged to the dealer's open parts account.

Additional parts required are to be obtained from General Motors Service Parts Operation (GMSPO). To ensure that these parts are obtained as soon as possible, they should be ordered from GMSPO on a C.I.O. order with no special instruction code, but on advise code (2).

Quantity Description Part Number Per Vehicle ----------- ----------- ----------- Vehicle Pushbutton Kit 10259113 1 Contains: 5 Pushbuttons 5 Button Springs

DEALERS ARE TO RETURN ALL SERVICE INVENTORY OF PART 90245578, 902455799 90245580 AND 90245581. PLEASE IDENTIFY AS A SPECIAL RETURN ON YOU PC659 DOCUMENT.

For those vehicles which experience pushbutton fractures, dealers will need to order individual buckle assemblies and related parts as listed below:

Quantity Description Part Number Per Vehicle ----------- ----------- ----------- R. H. Front Buckle Assembly 90384314 As Required L. H. Front Buckle Assembly 10258236 As Required L. H. or R. H. Rear Buckle Assembly 90384297 As Required Center Rear Buckle Assembly 90384298 As Required Front Seat Track Retaining Bolt 90196045 4 Per Front (Package Contains 80 Pcs. - Enough Buckle Replaced For 160 Buckle Replacements - Order Accordingly) Tie Strap NPN 1

SPECIAL TOOL AND INSTRUCTIONAL VIDEO

To perform the service procedure, dealers will be required to use the Pushbutton Removal Kit J-38886 furnished to dealers for product safety campaign 90-C-03. Additional kits, if needed, may be purchased by contacting Kent-Moore Tool Company at 1-800-345-2233.

Each Kit Includes: J-38886-1 Pushbutton Removal Tool J-38886-2 Spring Installation Tool

On December 7, 1993 dealers were sent an instructional video tape through the Express One Mail, Attn: Service Manager, which demonstrates the service procedure. Mechanics should be certain to view this video tape before attempting to perform the service procedure.

SERVICE PROCEDURE

PERFORM INSPECTION/CORRECTION PROCEDURE AS SHOWN HERE: ----------------------------------------------------- 0 1988-89 LeMans - All Seating Positions (2 Front, 3 Rear)

0 1990 LeMans - 3 Rear Seating Positions Only

1. Inspect appropriate buckle assemblies per above chart for the following:

0 Improper Function - Fasten seat belt by inserting latchplate into buckle. Pull on belt webbing to ensure proper latching. Release latch. Repeat five times for each buckle to insure proper operation.

0 Missing Or Fractured Red Pushbutton - Figure #1 below illustrates a typical fracture.

BE CERTAIN TO CHECK ALL NECESSARY BUCKLES PER MODEL YEAR REQUIREMENTS SHOWN ABOVE.

2. If a buckle does not function correctly, or if a red pushbutton is broken replacement of that buckle assembly is required. See Body Service Manual for procedure (seat belt section). If a buckle assembly is replaced, no further action for that buckle is required.

If buckle does function properly and pushbutton broken, continue to step 3.

3. Remove pushbutton by inserting pushbutton removal tool (J-38886-1) under edge of pushbutton in a horizontal position and then rotate tool to a vertical position. See Figure 3.

NOTICE: Pushbutton may fracture at this time - this is acceptable.

4. Finger tighten screw until screw head has bottomed out on tool. Be certain to keep tool as vertical as possible.

NOTICE: Pushbutton may fracture at this time - this is acceptable.

5. Gently rock tool in a side-to-side motion as shown in Figure 3 to dislodge pushbutton cap. DO NOT PRY TOOL ON EDGE OF BUCKLE.

6. Inspect removed pushbutton for any fractures. Figure 2 illustrates a typical pushbutton fracture.

0 If pushbutton is not fractured, continue to step 7.

0 If pushbutton is fractured, locate fractured piece and assure that it is not lodged in the buckle mechanism as it may interfere with buckle operation when reassembled. Continue on to step 7 when this is completed.

7. Discard removed pushbutton (and any fractured pieces).

NOTICE: In the event that a removed pushbutton becomes mixed with the new pushbuttons from the pushbutton kit, note that the removal tool leaves a circular "witness mark" on top of removed pushbuttons. Use this mark to distinguish between old and new pushbuttons. DO NOT REUSE REMOVED PUSHBUTTONS. THEY ARE TO BE DISCARDED.

8. Inspect pushbutton spring inside buckle to determine if it is still secured under pushbutton retainer (black) as shown in Figure 4.

0 If pushbutton spring is secure, skip to step 12.

0 If pushbutton spring is not secure, reposition original spring following the procedure in steps 9 through 11. A replacement spring from kit must be installed if original is lost or damaged in removal of pushbutton cap.

9. Install pushbutton spring on spring installation tool (J-38886-2) as illustrated in Figure 5.

10. Raise pushbutton retainer using opposite end of spring installation tool as a hook (see Figure 6 below). This may not be necessary if retainer is already in proper position.

11. Install pushbutton spring on detent lever. Note that there are two different detent lever designs using either one or two retaining nubs - Figure 7. Pushbutton spring must be positioned over retaining nub(s) on detent lever and 3ecured under the pushbutton - Figure 8.

12. Install a new pushbutton from the service kit by inserting spring installation tool between buckle cover and pushbutton retainer to keep the new pushbutton away from the cover during installation - see Figure 9.

13. Locate new red pushbutton to pushbutton retainer and push into position until an audible "CLICK is hear. Remove spring installation tool from buckle assembly.

14. Work pushbutton to assure it moves up and down freely. If it does not, repeat steps 3 through 13 to remove and reinstall pushbutton.

15. Perform final inspection of safety belt by inserting latchplate into buckle assembly and pulling on safety belt webbing to assure proper latching. Use approximately 30 lbs. of pulling force.

Unlatch and repeat this step five times to verify proper operation.

16. Install Campaign Identification Label.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified 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, the five digit dealer code of the dealer performing the campaign service, and the date the vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. Install the label only on a clean, dry surface of the radiator baffle where it is readily visible. (Additional campaign labels are available on stationery order as Form 7201-709.)

CLAIM INFORMATION

A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.

DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:

For 1988-89 model year vehicles a labor operation for the front seat belts and a labor operation for the rear seat belts should be listed on the warranty claim. For 1990 model year vehicles only a rear seat belt labor operation should be listed on the warranty claim.

*Other Failure Labor Labor Labor Operation Code Operation Hours Hours ---------------------------------------------------------------------------- FRONT SEAT BELT COMBINATIONS ---------------------------- Replace 2 Pushbuttons 1988-89 LeMans 96 V8230 0.1 ---

Replace 1 Pushbutton and 1 Buckle 1988-89 LeMans 96 V8231 0.5 ---

Replace 2 Buckles 1988-89 LeMans 96 V8232 0.8 ---

REAR SEAT BELT COMBINATIONS

Replace 3 Pushbuttons 1988-89 LeMans 96 V8233 0.1 0.1 1990 LeMans 0.2 0.1

Replace Any Combination of Pushbuttons/Buckles 1988-89 LeMans 96 V8234 0.2 0.1 1990 LeMans 0.3 0.1

* In addition dealerships will receive 0.1 hours credit for dealer administrative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with the rear seat belt labor operation for credit. This entry will not require authorization.

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

Parts required are to be listed in your warranty claim in the normal manner. Parts will be credited at dealer net plus 30% dealer handling allowance.

Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the labor operation as outlined.

RECORDING COMPLETION

Repairs submitted for vehicles not involved in the campaign will not be paid.

Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS." Owners are being asked to present the owner reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.

Dear Pontiac 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 a defect which relates to motor vehicle safety exists in certain 1988-90 Pontiac LeMans model vehicles. Some seat belt buckle assemblies in affected vehicles may not latch, or may not release, due to a fracture of the red push button which can occur during seat belt connection or disconnection. These buckle malfunctions would prevent a person from using the seat belt system, and the risk of injury to an unbelted person in an accident would be increased.

WHAT WE WILL DO

To correct this condition, your dealer will replace the pushbutton assemblies on your vehicle. Also, any buckle assemblies which are found not to function correctly, or which have fractured pushbuttons, will be replaced. 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 an appointment and so the dealer may order the necessary parts for the repair.

Instructions for making this correction have been sent to your Pontiac Dealer and parts are available. The labor time necessary to perform this service correction is approximately 1 hour. 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: 1-800-762-2737.

After contacting your dealer and the Pontiac 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, DC 20590 or call 1-800-424-9393 (Washington, DC residents use 366-0123).

The enclosed Campaign 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 Owner 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 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.