CAMPAIGN: SHOULDER BELT GUIDE LOOP CRACKING-NEW P/N RELEASED

Subject: PRODUCT SAFETY CAMPAIGN 91-C-07 SHOULDER BELT GUIDE LOOP CRACKING

MODELS AFFECTED: 1991 SUNBIRD AND GRAND PRIX -----------------------------------------------------------------------------

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 adequately 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 certain 1991 Pontiac Sunbird and Grand Prix model vehicles fail to comply to Federal Motor Vehicle Safety Standard (FMVSS) 208 "Occupant Crash Protection." Some of these vehicles have been built with cracked front door shoulder belt guide loops which may not provide front seat occupants with proper protection in the event of a vehicle crash.

DEALER ACTION

To correct this condition, dealers are to inspect the front door shoulder belt guide loops for possible cracks. If a cracked guide loop is found, both front door guide loops will have reinforcing plates installed.

VEHICLES INVOLVED

Involved are certain 1991 Pontiac Sunbird and Grand Prix model vehicles built within the following VIN breakpoints:

Up To And Year Model Plant Beginning Including

1991 Grand Prix Fairfax MF200001 MF246454

1991 Sunbird Lordstown M7500001 M7590841

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identifica- tion Number, owner name and address data, and are furnished to the 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

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.

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, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle.

Owners of vehicles recently sold from your new vehicle inventory are to be con- tacted by the dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.

This bulletin is notice to you that the new motor vehicles included in this campaign may not comply with the standard identified above. Under Section 108 of the National Traffic and Motor Vehicle Safety Act, 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 campaign correction, your dealership may be subject to a civil penalty up to $1,000 for each such sale.

PARTS INFORMATION

Parts required to complete this campaign 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).

NOTICE: During the early stages of this product safety campaign, GMSPO may restrict the number of kits which may be requested on any one order due to available parts quantities.

IF GUIDE LOOP IS NOT CRACKED

Part Quantity/ Description Number Vehicle ----------- ------ -------- Guide Loop Nut - Grand Prix 10115018 2 Guide Loop Nut - Sunbird 22551133 2 (Guide Loop nuts are serviced in merchandized packages of 6.)

NOTICE: If P/N 22551133 for Sunbird can not be obtained, the nuts removed from the car can be reused if thread locking compound is applied. The nut for the Grand Prix is not to be reused under any circumstances.

IF GUIDE LOOP IS CRACKED

Part Quantity/ Description Number Vehicle ----------- ------ --------- Guide Loop Reinforcement Kit - Grand Prix 10216391 1 Guide Loop Reinforcement Kit - Sunbird 22582246 1

Each Kit Contains: 2 Reinforcing Plates, 2 Nuts & An Instruction Sheet

NOTICE: It is anticipated that less than 3% of vehicles will require the guide loop reinforcement kit to complete this campaign. Please order parts accordingly.

SPECIAL TOOLS AND INSTRUCTIONAL VIDEO

Each dealer will be shipped a Guide Loop Inspection/Drilling Fixture J39425-4, T-Handle Cutting Tool J39425-1, a Bulb PT7190-12 with metal dust and an Instructional Video Tape, during the week of January 20, 1992. This package is being furnished to dealers at no charge. Each package will be identified with Pontiac Campaign Number 91-C-07. Additional tools, if required, may be ordered from Kent-Moore. Mechanics should be certain to view the. video tape before attempting to perform the service procedure.

INSPECTION PROCEDURE

1. Lower front door window glass and remove plastic shoulder belt guide loop plug cover (Grand Prix) or plastic shoulder belt guide loop anchor cover (Sunbird), nut and rubber washer (Grand Prix). DO NOT USE POWER TOOLS TO REMOVE GUIDE LOOP NUT.

2. Pull guide loop outside of vehicle and place in Guide Loop Inspection/ Drilling Fixture (J39425-4) (see View A). Use "Magnetic Inspection" side of fixture for this step.

3. Apply small amount of metal dust to guide loop (see View B).

4. With guide loop still in fixture, gently shake dust from side to side to highlight any possible crack.

5. Inspect guide loop for cracks. If guide loop is cracked, metal dust will have been drawn to crack line (see Views C & D) and a guide loop reinforcement kit must be installed on both sides of vehicle.

If guide loop does not have a crack, perform steps 1 through 5 on the opposite front door guide loop to determine if that guide loop is cracked. Do Not Reinstall First Guide Loop Until Both Sides Have Been Inspected.

6. Remove all traces of dust from guide loop(s) and from magnetic fixture by brushing or blowing.

7. If cracks were not found, reinstall guide loop, rubber washer (Grand Prix) and a new guide loop nut (to be ordered separately). For Sunbirds only, the the old nut may be reused after a small amount of Locktite 242 thread locking compound (GM P/N 12345382) or equivalent is applied to the threads. The old Grand Prix nut can not to be reused under any circum- stances.

Torque nut to 28 N.m (21 lb. ft.). Reinstall nut cover (Grand Prix) or anchor cover (Sunbird) and install Campaign Identification Label.

Notice: Use only guide loop nut P/N 10115018 on Grand Prix. DO NOT SUBSTITUTE OR REUSE OLD NUT.

Notice: Use only guide 1 loop nut P/N 22551133 on Sunbird. DO NOT SUBSTITUTE. If this nut can not be obtained, reuse the old nut after a small amount of Locktite 242 thread locking compound (GM P/N 12345382) or equivalent is applied to the threads.

8 . If cracks were found on guide loop, a reinforcement plate must be installed following the "Installing Reinforcement Assemblies" procedure below.

INSTALLING REINFORCEMENT ASSEMBLIES

(To Be Performed On BOTH Front Door Guide Loops When EITHER Front Door Guide Loop Is Cracked) ----------------------------------------------

1. Using "Drilling Operation" side of Guide Loop Inspection/Drilling Fixture (J39425-4), place guide loop in fixture (see View E).

2. Locate two holes in guide loop plate on either side of threaded stud. While holding guide loop in fixture with palm, use 3/16" (5mm) drill bit to drill through black plastic material (see View F).

3. Using T-Handle Cutting Tool (J39425-1) to remove all black plastic material from in and around holes in guide loop as illustrated in View G. This creates two circular cutouts in lower corners of triangular area on back side of guide loop.

NOTICE: Turning handle back and forth while applying downward pressure has been determined to do a better cleaning job than full rotation of the handle.

4. Install reinforcement plate studs into holes in guide loop. Ensure reinforcement plate is completely seated by firmly pressing plate into guide loop cutout area (see View H).

5. Reinstall guide loop (with reinforcement assembly in place) using rubber washer removed previously (Grand Prix Only) and new nut supplied in reinforcement kit. Torque nut to 28 N.m (21 lb. ft.). Reinstall nut cover (Grand Prix) or anchor cover (Sunbird). See View I for Grand Prix assembly. See View J for Sunbird assembly.

6. Repeat reinforcement assembly installation on opposite front door guide loop.

7. 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:

*Other Failure Labor Labor Labor Operation Code Operation Hours Hours --------- ------- --------- ----- ----- Inspect - No Reinforcement Kit Required 96 V7261 0.3 0.1

Inspect/Install Reinforcement Kit 96 V7262 0.5 0.1

* In addition dealerships will receive 0.1 hours credit for dealer adminis- trative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed 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.

Notification Used by Pontiac

January, 1992

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 certain 1991 Pontiac Sunbird and Grand Prix model vehicles fail to comply to Federal Motor Vehicle Safety Standard (FMVSS) 208, "Occupant Crash Protection." Some of these vehicles have been built with cracked front door shoulder belt guide loops which may not provide front seat occupants proper protection in the event of a vehicle crash.

WHAT WE WILL DO

To correct this condition, your Pontiac dealer will inspect the front door shoulder belt guide loops on your vehicle for possible cracks. If a cracked guide loop is found, both front door shoulder belt guide loops will have reinforcing plates installed. 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. Instruc- tions for making this correction have been sent to your Pontiac Dealer and parts are available. The labor time necessary to perform this service inspection/correction is approximately twenty minutes. Please ask your dealer if you wish to know how much additional time will be needed to 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.

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.