CAMPAIGN:SEAT BELT - BUCKLE ASSEMBLY. Geo Tracker - 4WD 1990

For 1990-2009 cars

# CAMPAIGN:SEAT BELT - BUCKLE ASSEMBLY

#### Subject: PRODUCT SAFETY CAMPAIGN 9lC52 - SEAT BELT BUCKLE ASSEMBLY ---------------------------------------------------------

Model/Year: 1989-91 GEO METRO & TRACKER AND 1990-91 GEO STORM -------------------------------------------------

#### To: All Chevrolet Geo Dealers

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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 Chevrolet 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

The National Highway Traffic Safety Administration (NHTSA), in cooperation with General Motors, has decided that a defect which relates to motor vehicle safety exists in some 1989-91 GEO Metro & Tracker and 1990-91 GEO Storm model vehicles.

Some of these vehicles may exhibit a condition in which the driver and/or passenger front seat belt buckle release button may be chipped or cracked. If this were to occur, it could interfere with the proper operation of latching mechanism. These buckle malfunctions could prevent a person from using the seat belt system, and risk of injury to an unbelted person in an accident would be increased.

To correct this condition, all involved vehicles will have the release button with spring replaced and have a new buckle housing cover installed. Also, any buckle assemblies which are found not to function correctly will be replaced.

Buckle assemblies which are found not to function correctly in the future - no matter when - will also be repaired.

#### VEHICLES INVOLVED

Involved are certain 1989-91 GEO Metro & Tracker and 1990-91 GEO Storm model vehicles built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ----- ---- --------

1989 "M" Car Kosai "K" KK700118 KK770493 1989 "J" Trk. Iwata "W" KW825033 KW835059 1990 "M" Car Kosai "K" LK700022 LK772986 1990 "M" Car Ingersoll "6" L6000053 L6028121 1990 "R" Car Fujisawa "7" L7500165 L7583091 1990 "J" Trk. Ingersoll "6" L6200057 L6235055 1991 "M" Car Kosai "K" MK600002 MK620830 1991 "M" Car Ingersoll "6" M6700001 M6817792 1991 "R" Car Fujisawa "7" M7500519 M7595301 1991 "J" Trk. Ingersoll "6" M6900006 M6940658

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.

#### PARTS INFORMATION

#### Notice: A pre-shipment of push button repair kits (part number 91173033, 91173104, 91173032, 91173103, 97141901, 97141902), will be sent to involved dealers the week of May 6, 1996. Pre-shipment parts will be charged to the dealers' open parts account. Please refer to your "Involved Vehicle Listing" prior to ordering additional requirements.

Additional parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Normal orders should be placed on a DRO=Daily Replenishment Order. An emergency requirement should be ordered on a CSO=Customer Special Order.

PUSH BUTTON REPAIR KITS (ONE PER VEHICLE) (OVER 90% OF VEHICLES WILL BE REPAIRED USING THESE PUSH BUTTON KITS)

Quantity/ Part Number Description Vehicle ----------- ------------ ---------- STORM 97141901 Push Button Kit, Blue As Required 97141902 Push Button Kit, Gray As Required

TRACKER 91173033 Push Button Kit, Black As Required

METRO 91173032 Push Button Kit, Black As Required 91173104 Push Button Kit, Gray As Required 91173103 Push Button Kit, Blue As Required

ONE KIT IS REQUIRED PER VEHICLE. EACH KIT WILL REPAIR THE DRIVERS BUCKLE ASSEMBLY AND THE FRONT PASSENGERS BUCKLE ASSEMBLY.

Each kit Includes:

2 - Release Buttons with Springs 2 - Buckle Housing Covers

#### REPLACEMENT BUCKLE ASSEMBLIES

DUE TO THE SMALL PERCENTAGE OF VEHICLES THAT WILL REQUIRE THIS REPAIR (LESS THAN 10%) AND VERY LIMITED PARTS AVAILABILITY, DEALERS ARE NOT TO ORDER REPLACEMENT BUCKLE ASSEMBLIES FOR USE AS SHELF STOCK. ONLY ORDER REPLACEMENT BUCKLE ASSEMBLIES IF THEY ARE REQUIRED TO REPAIR A VEHICLE WITH AN INOPERATIVE BUCKLE IASSEMBLY.

For those vehicles which experience inoperative buckle assemblies, dealers will need to order buckle assemblies as listed below. TO ENSURE EXACT COLOR MATCH, BOTH BUCKLE ASSEMBLIES (DRIVER & PASSENGER) MUST BE ORDERED WHEN EITHER BUCKLE ASSEMBLY REQUIRES REPLACEMENT.

Quantity/ Left Hand P/N Right Hand P/N Description Vehicle ------------- -------------- ----------- ---------- STORM 97141907 97141904 Blue As Required 97141908 97141905 Gray "

TRACKER 96059626 96059621 Black "

METRO 91173192 91173191 Black " 91173196 91173193 Slate Gray 91173197 91173194 Med. Smoke Gray 91173198 91173195 Blue "

#### OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin). Mailing of owner letters will be scheduled on a phased basis (commencing with the oldest vehicles first) as parts become available.

#### 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 enters your vehicle inventory, or 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.

#### SPECIAL INSTRUCTIONAL VIDEO

Each dealer will be shipped an instructional video during the week of May 6, 1996. Mechanics should be certain to view this video tape before attempting to perform the following service procedure.

#### SERVICE PROCEDURE

#### IMPORTANT: THIS PROCEDURE MUST BE PERFORMED ON BOTH FRONT SEAT BELT BUCKLE ASSEMBLIES TO COMPLETE THE CAMPAIGN.

#### INSPECTION PROCEDURE (BOTH FRONT SEATS)

#### IMPORTANT: IF CUSTOMER COMPLAINS OF LATCHING PROBLEMS WITH EITHER FRONT SEAT BELT BUCKLE, BOTH BUCKLES WILL REQUIRE REPLACEMENT TO ENSURE EXACT COLOR MATCH.

A LOT NUMBER INSPECTION WILL BE REQUIRED ON ALL 1991 MODEL VEHICLES.

1. Slide front seat to the most rearward position and place clean shop cloth on seat and console. Ensure shop cloth allows access to seat belt buckle assemblies.

2. FOR 1991 VEHICLES ONLY: Inspect BOTH front seat belt buckle assemblies for the lot number markings (See Figure 1) to determine if involved in recall. Using a pen-light will help with this inspection.

3. If lot number markings indicate that it IS NOT necessary to perform the recall procedure, proceed to Step 27. If lot number markings indicate it IS necessary to perform the recall procedure, proceed to Step 4.

4. Disconnect driver side seat belt buckle switch connector (located under seat).

5. Using a small pair of wire cutters, carefully cut plastic outer cover long separation line between the two covers as shown in Figure 2 & 2A.

6. Using a medium screwdriver or other suitable tool, carefully separate the two halves of the outer cover by placing the screwdriver into the slot between the edges of the two covers as shown in Figure 3 below. Do not pry in the middle of the buckle, as this may damage the switch (e.g. driver side).

7. FOR DRIVER SIDE BUCKLES ONLY: Using the wire cutters, cut the three plastic tabs retaining the switch too the cover. Cut the bottom pin first, slide the switch down, then cut the top two retaining pins shown in Figure 4 below.

8. FOR DRIVER SIDE BUCKLES ONLY: Use a small blade flat screwdriver to separate the switch from the cover (see Figure 5).

9. Depress seat belt push button and release the bottom loop of the latch spring using a small screwdriver (see Figure 6).

10. Remove button and spring by applying slight upward force while pulling button out of buckle assembly (see Figure 7). BUTTON AND SPRING WILL NOT BE REUSED.

11. Inspect buckle assembly for dirt, dust or foreign material. If buckle is contaminated with any form of sticky material, replace both buckle assemblies. DO NOT ATTEMPT TO CLEAN BUCKLE OF STICKY MATERIAL.

12. Remove any loose dirt, dust or foreign material using a dry compressed air. BE CAREFUL NOT TO DAMAGE OR DISLODGE ANY PARTS DURING THIS PROCESS. SAFETY GOGGLES MUST BE WORN DURING THIS STEP.

13. Check for proper position of the ejector mechanism, springs and rails (see Figure 8 on page 11).

14. Install the NEW button onto the buckle assembly. Depress the release button and hold. Hook the end of the latch spring to the latch plate using a small screwdriver (see Figure 9).

15. Check operation of the button and that the spring is attached correctly by pressing the button several times to confirm free travel.

16. TEST the operation of the buckle. Insert seat belt latch plate into buckle and check to see that it latches properly by tugging on the seat belt latch plate while firmly holding the buckle. Repeat this step three (3) times. If it DOES NOT latch, the buckle assembly should be replaced.

17. Install new upper cover to the base (see Figure 10).

18. FOR DRIVER SIDE BUCKLES ONLY: Carefully install switch onto lower cover half by inserting the bottom portion first (A) and then by applying pressure to the top corners (B) of the

19. Press the switch wires into the clamps provided in the lower cover (see Figure 12).

20. Slide the switch upwards (away from wires) to its original position (see Figure 13.)

21. Push the buckle release button and carefully assemble the two halves together by first inserting the top tabs of the lower cover into the button half of the cover (see Figure 14).

22. Firmly push the two halves together until a snap is heard and/or felt.

23. Check the operation of the buckle. Insert the seat belt latch plate into the buckle. Be sure there is a positive locking sound and check to see that it latches properly by tugging on the seat belt latch plate while firmly holding the buckle. Repeat this step three (3) times. If it DOES NOT latch, both buckle assemblies should be replaced.

24. Connect the drivers side seat belt buckle switch connector and check for proper operation.

25. Return seat to its original starting position.

26. Remove shop cloth from seats and console.

27. Install Campaign Identification Label.

#### CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected 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 and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner. When using the new campaign identification label, be sure to install the clear protective covering. Additional "Campaign Identification Labels" can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday through Friday 8:00 a.m. to 4:30 p.m. EST). Ask for Item Number S-1015 when ordering. Apply "Campaign Identification Label" only on a clean, dry surface.

#### CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

PARTS FAILED PARTS LABOR LABOR REPAIR PERFORMED COUNT PART NO. ALLOW CC-FC OP HOURS ---------------- ----- -------- ----- ----- ----- ------

Inspect - DO NOT - -- ** MA-96 V9900 0.2 REPLACE - Front Seat Belt Buttons Only 1991 Models

Replace Both 1 91173104 ** MA-96 V9901 0.4 Front Seat Belt Buttons - Metro

Storm & Tracker 0.5

(Includes Time To Inspect 1991 Vehicles)

Replace Both 2 97141905 MA-96 V9902 0.3 Front Seat Belt Buckles - ALL MODELS

* For Campaign Administrative Allowance, add 0.1 hours to the "Labor Hours".

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30%(1989-91) of all parts required for the repair.

Refer to the General Motors Claims Processing Manual for details on Product Campaign Claim Submission.

May, 1996

Dear Geo 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

Our records indicate that you are the owner of a 1989-91 Geo Metro, Geo Tracker or 1990-91 Geo Storm model vehicle. We at General Motors, in cooperation with the National Highway Traffic Safety Administration (NHTSA), want to notify you that some of these vehicles may exhibit a condition in which the driver and/or passenger front seat belt buckle release button may be chipped or cracked. If this were to occur, it could interfere with the proper operation of latching mechanism. These buckle malfunctions could prevent a person from using the seat belt system, and risk of injury to an unbelted person in an accident would be increased.

WHAT WE WILL DO

To correct this condition, all involved vehicles will have the front seat belt buckle release buttons and springs replaced and have new buckle housing covers installed. Also, any front seat belt buckle assemblies which are found not to function correctly will be replaced. This service will be performed for you at no charge. The release buttons in the rear seat belt buckles are made of a different material, and they are not subject to this campaign.

In addition, if you ever have a problem with the front seat belt buckle assemblies in the future - no matter when - contact your Chevrolet/Geo dealer for buckle repair.

WHAT YOU SHOULD DO

Please contact your Chevrolet/Geo dealer as soon as possible to arrange a service date.

Also, please tell them the interior color of your car so they may order the necessary parts for the repair.

Instructions for making this correction have been sent to your dealer and parts are available. The labor time necessary to perform this service correction is approximately 15 to 30 minutes. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

Your Chevrolet Geo 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 Chevrolet Customer Assistance Center by calling 1-800-222-1020.

After contacting your dealer and the 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, D.C. 20590 or call 1-800-424-9393 (Washington D.C. residents use 202-366-0123).

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 safety and continued satisfaction with our products.

Chevrolet Motor 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.