CAMPAIGN:STARTER MOTOR PINION STOP. Pontiac Sunbird 1994

Subject: CUSTOMER SATISFACTION CAMPAIGN 94-C-03 STARTER MOTOR PINION STOP

Models Affected: 1994 PONTIAC TRANS SPORT, GRAND PRIX, SUNBIRD, GRAND AM AND BONNEVILLE

TO: ALL PONTIAC DEALERS

DEFECT INVOLVED

General Motors has determined that certain 1994 Pontiac Trans Sport, Grand Prix, Sunbird, Grand Am and Bonneville model vehicles may have improperly heat treated starter motor pinion stop collars. This condition may result in a part failure causing slow engine crank speeds or an engine no start condition.

To prevent these conditions from occurring, dealers are to inspect and repair certain starter motors on vehicles indicated in the vehicles involved section. Starter motors with date codes of N093, N103, N113, N123, N133, N153, and N163 are to be repaired by replacing the pinion stop collar and retaining ring. No repairs are necessary on motors that fall outside of these date codes.

VEHICLES INVOLVED

Involved are certain 1994 vehicles built within the following VIN breakpoints:

Engine Up To And Year Model Code Beginning Including ---- ----- ------ --------- ---------

1994 Sunbird H R7533174 R7537617 1994 Sunbird T R7532469 R7536865 1994 Grand Am 3 RC725472 RC732555 1994 Grand Am 3 RM525434 RM531965 1994 Grand Am D RC725515 RC732542 1994 Grand Am A RC725755 RC732540 1994 Grand Am M RC722782 RC730539 1994 Grand Am M RM522859 RM529729 1994 Grand Prix M,X RF238407 RF239686 1994 Bonneville L,1 R4213098 R4218880 1994 Trans Sport D,L RT210924 RT213304

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 names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purposes 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 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 owner 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

Parts required to complete the 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 an advise code (2).

Part Quantity Description Number Per Vehicle ----------- ------ ----------- Pinion Stop Collar 1927849 1 As Required Retaining Ring 1927848 1 As Required

IMPORTANT: GMSPO has limited quantities of parts which are in merchandised packages of 10 pieces each. Please do not over order so that GMSPO will have parts for all involved vehicles.

SERVICE PROCEDURE

INSPECTION

1. All vehicles within the breakpoints should be inspected to determine the starter motor date codes. The date codes are imprinted on the upper half of a tag located on the motor end of the starter. The tag information is read upside down as viewed from the bottom. (See illustration.)

2.a. Most vehicles may be inspected by utilizing a mirror, flashlight and/or use of a pliable material such as modeling clay or similar material to make an impression of the date code. After making an impression, read the code in a mirror.

b. Grand Prix vehicles with L82 engines may require removal of the oil filter drip pan to gain access to read the date codes.

c. Sunbird vehicles equipped with oil coolers and 2.OL (LE4) engines will require starter motor removal to read the date codes per section 6D2 of the service manual.

3. Remove all starters with date codes of N093, N103, N113, N123, N133, N153 and N163 and perform service procedure to replace pinion stop collar. Starter removal instructions in section 6D2 of the service manuals should be followed.

IMPORTANT: Remove negative cable from battery.

4. Reinstall starter motors per instructions in service manual, section 6D2.

5. Install campaign identification label on all vehicles inspected and/or serviced.

SERVICE PROCEDURE TO REPLACE PINION STOP COLLAR

1. With starter motor removed, remove field lead attaching screw, from solenoid terminal.

2. Loosen, but do not remove through bolts in the starter motor assembly. Do not separate the commutator end and frame.

3. Separate the frame with the armature inside from the housing.

4. Remove the thrust collar from the end of the shaft if it is not stuck to the housing.

5. Remove the pinion stop retaining ring first prying the pinion stop collar off the ring. Pry the pinion stop ring off the armature with a small screw driver. Bend ring enough to avoid scratching or damaging armature surface as ring is removed. Discard ring.

6. Remove pinion stop collar from armature shaft. Discard collar.

7. Install new pinion stop collar on armature shaft. Flat side goes towards pinion.

8. Install new retaining ring onto armature shaft and seat it in the shaft groove. Use care not to damage the armature shaft.

9. Install thrust collar onto armature shaft with small flange toward retaining ring. Use two pliers to move pinion stop collar and the thrust collar to snap pinion stop collar over retaining ring.

10. Assemble the frame, armature, and drive assembly into the housing. Ensure the shift lever is engaged with the drive assembly. Ensure the armature shaft is engaged with the housing bearing. Tighten the through bolts.

11. Install starter field lead to solenoid. Return to step 4 of Inspection.

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 Starter Motor Date Code (No Parts Removed) 96 V8530 0.2 0.1

Inspect Starter Where Starter Requires Removal 96 V8531 0.7 0.1

Inspect Date Code and Replace Pinion Stop Collar 96 V8532 1.2 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 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 40% 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:

We, at Pontiac Division, are committed to improving the Pontiac customer ownership experience. We have discovered a condition that could develop on your vehicle and are writing to you today with our action to resolve this condition.

CUSTOMER SATISFACTION RECALL FOR:

ACTION:

------ To prevent these conditions from occurring, dealers will inspect and repair starter motors with suspect date codes. This service will be performed for you at no charge.

CONTACTING YOUR PONTIAC DEALER:

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. Instructions for performing this service have been sent to your dealer and parts are available. Please ask your dealer if you wish to know how much time will be needed to schedule and process your vehicle.

OWNER REPLY CARD:

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid 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 continued satisfaction with our products.

Pontiac Division GENERAL MOTORS CORPORATION

Object Number: 77836 Size: FS

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.