CAMPAIGN: FRT. DOOR INTERLOCK STRIKER STUD REPLACEMENT. Pontiac Sunbird 1991

Models: 1991 Chevrolet Cavalier and Pontiac Sunbird (Except Convertibles)

General Motors of Canada has determined that certain 1991 Chevrolet Cavalier and Pontiac Sunbird model vehicles fail to conform to the requirements of Canada Motor Vehicle Safety Standard (CMVSS) 210, "Seat Belt Assembly Anchorages." If a vehicle crash should occur, the front door interlock striker stud may fail, which could cause the door frame to collapse. Collapse of the door frame could result in failure of the shoulder belt to provide sufficient restraint to the occupant.

To prevent this condition from occurring, dealers are to replace the passive restraint interlock striker studs on involved vehicles.

VEHICLES INVOLVED:

Involved are certain 1991 Chevrolet, Cavalier and Pontiac Sunbird model vehicles built within the following VIN breakpoints:

Year Model Plant Plant Code From Through ---- -------- -------- ---------- -------- -------- 1991 Cavalier Lordstown "7" M7160183 M7185111

1991 Cavalier Janesville "J" MJ187660 MJ202174

1991 Sunbird Lordstown "7" M7574021 M7590841

(Convertibles are not involved in this campaign action.)

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

DEALER CAMPAIGN RESPONSIBILITY:

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, 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, you are to ensure the campaign correction has been made before selling or releasing the vehicle.

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

CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors. The listings provided are for campaign activity only and should not be used for any other purpose.

PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- --------------------------- ---------------- 22571850 Door Interlock Striker Stud 2

PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ------------ ------------------- -------------- 2A R & R Striker Stud .5

Time allowance includes 0. 1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 30% to cover parts handling.

SERVICE PROCEDURE:

(PERFORM PROCEDURE ON BOTH FRONT DOORS OF INVOLVED VEHICLES)

TOOLS REQUIRED: - 9mm hex head (Allen head) driver. - Thin-blade putty knife. - Pointed drift, or drift with a relatively small tip. - Ball peen hammer (approx. 24 oz.).

1. Lower front door glass and remove plastic cover from shoulder belt upper guide loop anchor. See illustration on page 4.

2. Mask off inside surface of vertical leg of door frame to prevent damage to painted surfaces. See illustration on page 4.

3. Using a 9mm hex driver, loosen interlock striker until there is a 2mm gap between base of striker and the door frame.

4. Strike loosened striker with hammer until stud is dislodged from door frame.

NOTICE: The interlock striker stud is'press-fit' into the door frame, and several blows may be required to dislodge it. It is recommended that several moderate blows be used, rather than trying to dislodge the stud with one or two very heavy blows. Use of excessive force may result in damage to door frame.

5. Remove interlock striker. Do not discard striker, it will be reinstalled on new interlock striker stud.

6. With the door open, position tip of drift in depression at end of striker stud, and finish driving stud out of door frame by striking drift with hammer.

7. Working from inside of door frame, carefully disengage run channel weatherstrip from door frame using a thin-blade putty knife to disengage upper clip. Upper clip is located about 2.5 cm. above top edge of shoulder belt anchor. See illustration on page 4.

8. Carefully disengage enough of run channel weatherstrip from door frame to allow retrieval of interlock striker stud. It may be necessary to use a "magnet-on-a-stick," or needle nose pliers to retrieve stud.

9. Using needle nose pliers, position replacement stud in hole in door frame, and install striker onto stud finger tight. Align base of stud so that long edges of stud are parallel to channel in door frame (see illustration on page 4). Using a 9mm hex driver, torque striker to 35 N.m (26 lb. ft.). Make sure that new stud is pulled fully into hole, and that base of stud is flush against inside of door frame.

10. Push run channel weatherstrip back into door frame, making sure that it is properly positioned for sealing and appearance. Be sure to re-engage upper run channel weatherstrip clip to door frame.

11. Reinstall plastic cover to shoulder belt upper guide loop anchor.

12. Check window for proper up/down operation.

13. Remove masking tape.

14. Repeat above steps, 1-13 for opposite front door of vehicle.

15. Install Campaign Identification Label.

INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure die correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

Dear General Motors Customer:

To prevent this condition from occurring, your General Motors dealer will replace the passive restraint interlock striker studs on the front doors of your vehicle. This service will be performed for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

Subsequent to contacting your dealer, further assistance, if required, may be obtained from our Customer Assistance Centre, toll free, by calling 1-800-263-3777 (English), or 1-800-263-7854 (French).

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Object Number: 88415 Size: MF

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.