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# RETURN OF UNDEPLOYED (SIR) INFLATOR MODULES

#### SUBJECT: RETURN OF UNDEPLOYED SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) INFLATOR MODULES REPLACED UNDER WARRANTY ON ALL VEHICLES EQUIPPED WITH SIR

Undeployed inflator modules replaced under warranty in all vehicles equipped with Supplemental Inflatable Restraint (SIR) are to be returned to Inland Fisher Guide, General Motors Corporation. This bulletin outlines procedures that all dealers must follow for shipping undeployed SIR inflator modules as flammable solids. This bulletin is in effect and should be retained at all times at the dealership until a subsequent bulletin supersedes it.

Only dealers located in the continental United States should return inflator modules. Dealers in Alaska, Hawaii, territories of the United States, and foreign countries should not return inflator modules. Inflator modules replaced outside of the continental United States should be deployed and disposed of through proper channels. Always refer to Pontiac bulletin number 91-9-4 when it is necessary to deploy an inflator module.

If a vehicle is the subject of a Product Liability Report related to the SIR system and is subject to a Preliminary Investigation (GM-1241), DO NOT DEPLOY the inflator module and DO NOT ALTER the SIR system until cleared by the Zone Service Representative. A 1241 investigation is completed upon a complaint that a product malfunction or failure led to bodily injury or property damage.

An inflator module returned following a 1241 investigation must be clearly designated by:

1. Indicating on the repair order copy inside the box "SUBJECT TO 1241".

2. Indicating the VIN and vehicle owner on the repair order.

3. Sending Xerox copies of the repair order copy to:

A. Zone Service Representative

B. GM Legal-MIC Claim Review Unit P.O. Box 33117 Detroit, MI 48232

Questions related to handling of 1241 associated inflator modules may be answered by calling:

GM Legal-MIC Claim Review Unit (313) 974-1389 or (313) 947-1491

The U.S. Department of Transportation's (DOT) Hazardous Materials Regulations classify an inflator module as an explosive power device, class C or B, depending on its size. However, under exemptions issued by the DOT, manufacturers of inflator modules may transport them within the continental United States as flammable solids. General Motors has been made a "party to" these exemptions and may also transport inflator modules as flammable solids. As recipients of packages shipped under the exemption, dealers who receive inflator modules from GM may reship them under the exemption as well.

Reprinted in this bulletin are copies of the DOT exemptions specifying the packaging and shipping requirements for inflator modules (DOT- E8214, DOT-E8236). Copies of these exemptions must be retained by the shipping dealership. Failure to retain copies and to comply with their provisions will result in civil penalties of up to $10,000 per violation or criminal penalties of up to $25,000 per violation and imprisonment. The DOT exemptions are updated at the expiration date as specified on each exemption. The dealers will be responsible for obtaining an up-to-date copy from the Department of Transportation of each exemption that is being used for inflator module shipments.

When it is necessary to return an undeployed inflator module, the following procedure must be followed. Please note that additional packaging and shipping information relating specifically to the inflator module being replaced will be included with the service replacement inflator module.

1. Package the undeployed inflator module and a legible copy of the repair order detailing the reason for replacement in the same carton in which the service replacement inflator module was shipped. Refer to Figure 1. If the carton is severely damaged to the extent that it will not protect its contents, obtain a new shipping carton by contacting Inland Fisher Guide, General Motors Corporation (513) 455-3819.

2. Close the carton and secure with packaging tape. Transparent tape is recommended. All existing labels and markings on the carton must be visible. DO NOT STAPLE CONTAINER. DO NOT COVER ANY PORTION OF THE RED AND WHITE FLAMMABLE SOLID LABEL OR ANY MARKINGS ON THE CARTON.

3. Secure the return address label to the carton.

Return Address: Inland Fisher Guide C/0 Delco Products 2525 Home Avenue Dayton, OH 45417

4. The following information on the shipping papers (United Parcel Service Hazardous Material Label and Shipper's Certification) must be completed with the same information as enclosed with the replacement inflator module when received: proper shipping name, hazard class, "UN" number, DOT exemption number, technical name of material, and emergency response information. A copy of the emergency response guidelines will be enclosed with the replacement inflator module and must be attached to the shipping papers you complete for the inflator module being shipped.

United Parcel Service (UPS) will provide transportation of undeployed inflator modules. Shipments are to be freight prepaid with the shipping expenses to be handled in the same manner as any prepaid freight reimbursement.

If an inflator module is not required to be returned using this return procedure, the inflator module must be deployed prior to disposal. Always refer to Pontiac bulletin number 91-9-4 when it is necessary to deploy inflator modules.

Research and Special Programs DOT-E 8214 Administration (NINTH REVISION)

1. Morton International Inc., Ogden, Utah, is hereby granted an exemption from certain provisions of this Department's Hazardous Materials Regulations to offer packages prescribed herein of air bag inflators and modules for transportation in commerce subject to the limitations and special requirements specified herein. This exemption authorizes the transportation of inflators and modules for passive restraint systems as Flammable solids, n.o.s., and provides no relief from any regulation other than as specifically stated. Each of the following is hereby granted the status of a party to this exemption:

Mercedes-Benz of North America, Inc. (MBNAI) - Montvale, New Jersey - PTE-1. Chrysler Motors Corporation, Center Line, MI - PTE-2. Allied-Signal Inc/Bendex Safety Restraint Division Knoxville, TN - PTE-3. Nissan Motor Corporation in U.S.A., Gardena, CA - PTE-4. Toyota Motor Corporation, Torrance, CA PTE-5. Saab Scania of America, Inc, Orange, CT PTE-6. Mazda Motor of America, Inc, Irvine, CA PTE-7. Mitsubishi Motor Sales of America, Inc., Cypress, CA -PTE-8. Volkswagen of America, Inc., -PTE-9. General Motors Corporation, Warren, MI -PTE-10. Isuzu Motors America, Inc., Whittier, CA -PTE-11.

2. BASIS. This exemption is based on Morton International Inc., formerly Morton Thiokol's application dated January 13, March 17 and 23, and October 28, 1989, submitted in accordance with 49 CFR 107.105 and 107.103 and the public proceeding thereon. The granting of party status is based on the following applications submitted in accordance with 107.111 and the public proceeding thereon:

MBNAI's applications dated January 13, and March 17, 1989. Chrysler Motors Corporation's application dated January 27, 1989. Allied-Signal Inc/Bendex Safety Restraints Division's application dated October 7, 1988. Nissan Motor Corporation's application dated October 18,1988. Toyota Motor Corporation's application dated November 7, 1988. Saab-Scania of America, Inc's application dated January 24, 1989. Mazda Motor of America, Inc's application dated April 4, 1989. Mitsubishi Motor Sales of America's application dated July 20, 1989. Volkswagen of America, Inc.'s application dated August 30, 1989. General Motors Corporation's application dated December 7, 1989. Isuzu Motors America, Inc.'s application dated December 20, 1989.

3. HAZARDOUS MATERIALS (Descriptor and class). Inflators and modules for passive restraint systems classed as flammable solid containing one or more of the following:

a. Not more than 750 grams of a propellant identified as DL-Z113 or DL-Z113A. ----------------------------------------------------------------------------- Continuation of 9th Rev. DOT-E 8214 MAR 9 1990 Page 2

b. Not more than 25 grams of an ignition composition identified as UIX 171, UIX 172, 2A Borony and UIX-8; or not more than 55 grams of UIX-180.

c. A length of ignition fuse identified as Hiveliet No. 817892-1.

d. No more than two electric squibs.

e. A mechanical sensor approved under EX-8411019.

f. Not more than one gram of Du Pont IMR 3030 smokeless powder.

Modules may be installed in the steering wheel center piece.

4. PROPER SHIPPING NAME (49 CFR 172.101). Flammable solid, n.o.s.

5. REGULATION AFFECTED. 49 CFR 171.11 (See paragraph 8.d.) 173.153, 173.154, 175.3.

6. MODES OF TRANSPORTATION AUTHORIZED. Motor vehicle, rail freight, cargo aircraft only and cargo vessel.

7. SAFETY CONTROL MEASURES. Packaging prescribed is:

a. Inflators must be packaged in fiberboard boxes complying with DOT Specification 12B series or as described in Morton International (formerly Morton Thiokol) drawings SK 93115, SK 93116, SK 93225 and UT11008 on file with the Office of Hazardous Materials Transportation (ORMT).

b. Modules must be packaged in a fiberboard boxes complying with DOT Specification 12B series, and cushioned so as to prevent any movement which would cause the package to be unsafe; or the modules must be packed in packagings described in Drawings SK91297 (10-17-78), SK91296 (10-17-78); Drawings UT10097 (3/27/87 and 4/7/87), UT10785 (9/27/88) and UT11157 (5/2/89); G. Lutz Company's Drawings MB-1 and MB-2 or Chrysler's Drawing CC00090 or SAMH-1317 on file with OHMT.

8. SPECIAL PROVISIONS.

a. Persons who receive packages covered by this exemption may reship them pursuant to the provisions of 49 CFR 173.22a.

b. A copy of this exemption must be carried aboard each aircraft or cargo vessel used to transport packages covered by this exemption.

c. An inflator or a module, identified in paragraph 3 above, is exempt from the requirements of 49 CFR Parts 100-199 when installed in a motor vehicle. All other packages shipped under the terms of this exemption must bear FLAMMABLE SOLID labels regardless of net weight of the flammable solid in each inside package.

----------------------------------------------------------------------------- Continuation of 1st Rev. DOT-E 8214 Page 3

d. Domestic shipments via air may be made per the requirements of 49 CFR 171.11. This also constitutes an exemption under Part 1; 1.1 of the ICAO Technical Instructions to authorize the domestic transportation of inflators and modules for passenger vehicle restraint systems on cargo aircraft using the following proper shipping name, hazard class, and UN number, Flammable solid, n.o.s., 4.1, and UN 1325. The inflators and modules must be packaged in accordance with the provisions of the Safety Control Measures prescribed in paragraph 7 of this exemption.

e . The "FLIGHTS OF CARGO-AIRCRAFT ONLY" requirements of Appendix B to 49 CFR Part 107 do not apply to operations subject to this exemption.

f. This exemption does not grant authority to use foreign airspace or airports outside the United States.

9. REPORTING REQUIREMENTS. Any incident involving loss of contents of the package or packaging failure must be reported to the Office of Hazardous Materials Transportation as soon as practicable.

10. EXPIRATION DATE. January 31, 1991.

Issued at Washington, D.C.:

MAR 9 1990 ___________________________________ ___________________ Alan I. Roberts (DATE) Director Office of Hazardous Materials Transportation

Address all inquiries to: Director, Office of Hazardous Materials Transportation, Research and Special Programs Administration, U.S. Department of Transportation, Washington, D.C. 20590. Attention: Exemptions Branch.

Dist: FAA, FHWA, FRA, USCG -----------------------------------------------------------------------------

Research and Special Programs Administration DOT-E 8214 (EXTENSION) NINTH REVISION March 9, 1990

In accordance with 49 CFR 107.105 of the Department of Transportation (DOT) Hazardous Materials Regulations DOT-E 8214 is hereby extended for the party(ies) listed below by changing the expiration date in paragraph 10 to June 30, 1992. This change is effective from the issue date of this extension. All other terms of the exemption remain unchanged.

This extension applies only to party(ies) listed below based on the application(s) received in accordance with 49 CFR 107.105 and the public proceeding thereon. This extension constitutes a necessary part of this exemption and must be attached to it.

JAN 24 1991 __________________________________ ____________ Alan I Roberts (DATE) Associate Administrator for Hazardous Materials Safety

Dist: FHWA FRA USCG FAA

EXEMPTION HOLDER APPLICATION DATE ------------------------------ ------------------- Ford Motor Company June 20, 1990 Dearborn, MI

Morton International, Inc. September 28, 1990 Ogden, UT

Mercedes-Benz of North America, Inc. October 5, 1990 Montvale, NJ

Isuzu motors America, Inc. October 15, 1990 Whittier, CA

Volkswagen of America, Inc. October 17, 1990 Troy, MI

---------------------------------------------------------------------------- CONTINUATION OF DOT-E8214 (EXTENSION) NINTH REVISION March 9, 1990

EXEMPTION HOLDER APPLICATION DATE ------------------------------ ------------------- Nissan Motor Corporation in U.S.A. November 21, 1990 Gardena, CA

Subaru of America November 28, 1990 Cherry Hill, NJ

General Motors Corporation November 29, 1990 Warren, MI

----------------------------------------------------------------------------- DOT-E 8236 (FOURTH REVISION)

1. TRW Incorporated, Mesa, AZ., is hereby granted an exemption from certain provisions of this Department's Hazardous Materials Regulations to offer packages prescribed herein of a passive restraint system, and its inflator, for transportation in commerce subject to the limitations and special requirements specified herein. This exemption authorizes the transportation of inflators and modules for passenger restraining systems as flammable solids, and provides no relief from any regulation other than as specifically stated. Each of the following is hereby granted the status of a party to this exemption:

General Motors Corporation, Warren, MI - PTE-1. Flint packaging, Incorporated, Burton, MI - PTE-2. Ford Motor Company, Dearborn, MI - PTE-3.

2. BASIS. This exemption is based on TRW Incorporated's application dated April 14, 1989, submitted in accordance with 49 CFR 107.105 and the public proceeding thereon, and supplemental letters dated December 21, 1989 and September 28, 1990. The granting of party status is based on the following applications submitted in accordance with 49 CFR 107.111 and the public proceeding thereon:

General motors Corporation's application dated December 9, 1989.

Flint Packaging Incorporated's application dated August 23, 1990.

Ford Motor Company's application dated June 20, 1990.

3. HAZARDOUS MATERIALS- (Descriptor and class).

a. Passive restraint inflators for, and systems generally identified as Part Nos. 91880-1, 91880-3, 91880-7, 98020- 1, 98020-3, 98020-5, E53B-54042B72 and E53B-54043Bl3 containing not to exceed 105 grams of a propellant identified as TAL 1101 and not to exceed 15 grams of a mixture of boron and potassium nitrate identified in Bureau of Explosives report dated June 21, 1968 as Ignition Composition lP60 and not to exceed 150 milligrams of a mixture of titanium and potassium perchlorate identified in Bureau of Explosives letter dated February 27, 1984, as Igniter Part Number 174-00381 (DOT approval June 5, 1984, EX-8406010 Class C Explosive). This passive restraint inflator, and this system are classed as flammable solids".

----------------------------------------------------------------------------- Continuation of 4th Rev. DOT-E 8236 Page 2

b. Inflators for passenger restraint systems deemed to be scrap material may be classed as flammable solid when packed in accordance with paragraph 7.b. of this exemption.

4. PROPER SHIPPING NAME (49 CFR 172.101). Flammable solid, n.o.s.

5. REGULATION AFFECTED. 49 CFR 171.11 (see paragraph 8) 173.153, 173.154, 175.3.

6. MODES OF TRANSPORTATION AUTHORIZED. Motor vehicle, rail freight, cargo vessel, cargo-aircraft only.

7. SAFETY CONTROL MEASURES.

a. Outside packaging prescribed is a DOT Specification 12H or 12B fiberboard box. Packaging of units identified as PIN E53B-54042B72 must, also comply with the packaging description on page 3 and Appendix D of the Ford applications.

b. Scrap inflators may be packed and shipped in a DOT specification 17H drum for disposal purposes only.

8. SPECIAL PROVISIONS

a. Persons who receive packages covered by this exemption may reoffer them for transportation provided no modifications or changes are made to the packages, all terms of this exemption are complied with, and a current copy of this exemption is maintained at each facility from which such reoffering occurs.

b. A copy of this exemption must be carried aboard each vessel and aircraft used to transport packages covered by this exemption.

C. An inflator or a module identified in paragraph 3 above is exempt from the requirements of 49 CFR Parts 100-199 when installed in a motor vehicle. All other packages shipped under the terms of this exemption, must bear FLAMMABLE SOLID labels regardless of net weight of the flammable solid in each inside package. In addition, for cargo vessel shipments only, all vehicles and freight containers containing packages under the terms of this exemption must be placarded FLAMMABLE SOLID.

----------------------------------------------------------------------------- Continuation of 4th Rev. DOT-E 8236 Page 3

d. Domestic shipments via air may be made per the requirements of 49 CFR 171.11. This provision.also constitutes an exemption under Part 1; 1.1 of the ICAO Technical Instructions to authorize the domestic transportation of inflators and modules for passenger vehicle restraint systems on cargo aircraft using the proper shipping name, hazard class, and UN number (Flammable solid, n.o.s., 4.1, and UN 1325). The inflators and modules must be packaged in accordance with the provisions of the Safety Control Measures prescribed in paragraph 7 of this exemption.

e. The "FLIGHTS OF CARGO-AIRCRAFT ONLY" requirements of Appendix B to 49 CFR Part 107 do not apply to operations subject to this exemption.

f. This exemption does not grant authority to use foreign airspace or airports outside the Untied States.

9. REPORTING REQUIREMENTS. Any incident involving loss of packaging contents or packaging failure must be reported to the Associate Administrator for Hazardous Materials Safety as soon as practicable.

10. EXPIRATION DATE. January 31, 1992.

Issued at Washington, D.C.:

OCT 30 1990 ____________________________________ _____________ Alan I. Robert (DATE) Associate Administrator for Hazardous Materials Safety

Address all inquiries to: Associate Administrator for Hazardous Materials Safety, Research and Special Programs Administration, U.S. Department of Transportation, Washington, D.C. 20590. Attention: Exemptions Branch.

Dist: FHWA, FRA, USCG, FAA.

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.