CAMPAIGN: HIGH EFFORT OR BINDING ACCEL. CONTROL CABLES

Subject: PRODUCT SAFETY CAMPAIGN 93-C-07 HIGH EFFORT OR BINDING ACCELERATOR CONTROL CABLES

Models Affected: 1992-93 PONTIAC SUNBIRD MODELS EQUIPPED WITH 4-CYLINDER ENGINES (RPO LE4)

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 1992-93 Pontiac Sunbird models. The accelerator control cable on some vehicles may develop a high effort and/or binding condition in very cold weather.

Under certain conditions, water may enter the cable conduit. In very cold weather the water may freeze in the cable conduit, resulting in high accelerator pedal effort or binding of the accelerator control cable. If the accelerator control cable requires high effort or binds, loss of normal throttle control may result, or the throttle may not return to idle when the accelerator pedal is released. If this were to occur while the vehicle was in motion, a vehicle crash could occur without prior warning.

To prevent this condition from occurring, dealers are to replace the accelerator control cable assembly.

VEHICLES INVOLVED

Involved are certain 1992-93 Pontiac Sunbird model vehicles built within the following VIN breakpoints:

Up To And Year Plant Beginning Including ---- ----- --------- --------- 1992 Lordstown N7500002 N7600508 1993 Lordstown P7500001 P7570124

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 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

General Motors Service Parts Operations (GMPSO) will pre-ship 50% of required parts to complete this campaign to affected dealers on December 1, 1993. Pre-shipped parts will be charged to the dealer's parts open account. Any additional parts required to complete this campaign are to be obtained from 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).

Part Quantity Description Number Per Vehicle ----------- ------ ----------- Cable Assembly-Accelerator Control 22593226 1 Without Cruise Control

Cable Assembly-Accelerator Control 22593227 1 With Cruise Control (RPO K34)

SERVICE PROCEDURE

1. Open hood and support using hood support rod.

2. Remove two screws and two nuts from the left side lower sound insulator panel. Disconnect the courtesy lamp connector and remove the sound insulator panel. See Figure 1.

3. Release the accelerator cable retainer from the accelerator pedal lever assembly. See Figure 2.

4. Depress the accelerator cable locking tabs and carefully push the cable housing forward through the cowl toward the engine compartment.

5. On vehicles equipped with cruise control, observe the routing of the cruise control cable from the accelerator control bracket to the cruise control servo bracket.

On 1992 vehicles with cruise control, the cruise control cable is routed through a retainer on the brake booster assembly and then routed to the cruise control servo bracket.

On 1993 vehicles equipped with cruise control, the cruise control cable is retained to the accelerator control cable with a tie strap, and routed directly over the brake booster assembly to the cruise control servo bracket. There is no retainer on the brake booster assembly.

Both 1992 and 1993 vehicles equipped with cruise control will be serviced using the 1993 routing. The new (replacement) cruise control cable should not be routed through the retainer on the brake booster assembly.

6. On 1992 vehicles equipped with cruise control, disengage the cruise control servo cable from the retaining clip mounted on the inboard side of the brake vacuum booster assembly.

Some 1992 vehicles may also have the accelerator cable retained in the booster-mounted clip. Disengage the accelerator cable from the retaining clip if it is routed through the clip.

7. Disengage the accelerator control cable cross slug from the throttle body pulley/cam. on vehicles equipped with cruise control, disengage the cruise control servo cable from the throttle body lever by removing the cable retaining clip.

8. Depress the accelerator/cruise control cable locking tabs and disengage the cable assembly from the engine accelerator control cable bracket.

9. On vehicles equipped with cruise control, disengage the cruise control servo cable from the servo by removing the cable retaining clip. Depress the cruise control cable locking tabs and disengage the cruise control cable from the cruise control servo bracket.

10. Remove the old cable assembly from the vehicle.

11. Position the new accelerator control cable assembly to the engine accelerator control cable bracket, partially routing the accelerator cable under the fuel feed and return pipes and the heater hose. See Figures 3 and 4.

12. Attach the accelerator control cable assembly to the accelerator control cable bracket by pushing the cable fitting into the bracket until the locking tabs are fully engaged in the bracket.

13. Slide the accelerator control cable cross slug into the throttle body pulley/cam, and properly position the cable in the pulley/cam channel.

14. On vehicles equipped with cruise control, position the fitting end of the cruise control servo cable to the throttle body lever stud and secure by installing the cable retaining clip.

15. From the accelerator control cable bracket, route the accelerator control cable under the fuel feed and return pipes/hoses and the heater hose, inboard of the brake master cylinder and brake booster assembly, and through the accelerator cable opening in the cowl. See Figures 3 and 4. on vehicles equipped with automatic transmission, the accelerator cable should be routed between the brake master cylinder and the transaxle fluid fill tube.

16. Make sure that the cable housing is not kinked, twisted, or damaged in any way. Secure the accelerator control cable assembly to the cowl by pushing the cable fitting into the cowl opening until the locking tabs are fully engaged.

17. Position the accelerator control cable in the slot in the accelerator pedal lever assembly, and install the plastic cable retainer to the accelerator pedal lever. Make sure the cable retainer is fully seated in the accelerator pedal lever.

18. Check for proper, unrestricted operation of the throttle linkage. The linkage must operate freely between idle and full wide open throttle.

19. On vehicles equipped with cruise control, route the cruise control cable inboard of and over the top of the brake vacuum booster to the cruise control servo bracket.

20. Attach the cruise control cable to the cruise control servo bracket by pushing the cable fitting into the bracket until the locking tabs are fully engaged in the bracket. Make sure that the cruise control cable is not twisted, kinked, or damaged in any way.

21. Adjust the cruise control cable, and secure the cable to the servo assembly using the following procedure:

A. Both ends of the cable must be completely engaged in their brackets, and the cruise control cable must be attached to the throttle body lever stud with the retainer installed.

B. Pull the servo end of the cruise control cable toward the servo without moving the throttle body lever.

C. If one of the six (6) holes in the servo assembly tab lines up with the cable pin, connect the pin to the tab and secure by installing the cable retaining clip.

D. If a tab hole does not line up with the cable pin, move the cable away from the servo assembly until the next closest tab hole lines up with the cable pin. Connect the pin to the tab and secure by installing the cable retaining clip. See Figure 3.

IMPORTANT: DO NOT STRETCH THE CRUISE CONTROL CABLE TO MAKE A PARTICULAR TAB HOLE CONNECT TO THE CRUISE CONTROL CABLE PIN. THIS WILL PREVENT THE ENGINE FROM RETURNING TO IDLE.

22. After the cruise control cable is completely installed, remove the shipping clip from the end of the cable near the servo. See Figure 3.

23. Check for proper operation of the throttle and cruise control linkages. The linkages must operate freely between the idle and full wide open throttle positions.

24. Reconnect the courtesy lamp and reinstall the left side sound insulator panel.

25. 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 --------- ------- --------- ----- ------ Replace Accelerator Cable 96 V8360 0.4 0.1 Without Cruise Control

Replace Accelerator Cable 96 V8361 0.5 0.1 With Cruise Control

* 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 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.

Dear Pontiac Sunbird 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 1992-93 Pontiac Sunbird models. The accelerator control cable on some vehicles may develop a high effort and/or binding condition in very cold weather.

Under certain conditions, water may enter the cable conduit. In very cold weather the water may freeze in the cable conduit, resulting in high accelerator pedal effort or binding of the accelerator control cable. If the accelerator control cable requires high effort or binds, loss of normal throttle control may result, or the throttle may not return to idle when the accelerator pedal is released. If this were to occur while the vehicle was in motion, a vehicle crash could occur without prior warning.

WHAT WE WILL DO

To prevent this condition from occurring, dealers are to replace the accelerator control cable assembly.

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 currently available. The labor time necessary to perform this service is approximately one (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.