CAMPAIGN: BRAKE BOOSTER ASSY. INSPECTION/REPLACEMENT. Saturn Saturn 1993

For 1990-2009 cars

# CAMPAIGN: BRAKE BOOSTER ASSY. INSPECTION/REPLACEMENT

#### SUBJECT: BRAKE BOOSTER ASSEMBLY INSPECTION/REPLACEMENT

YEAR and MODEL: 1993 SATURN (ALL MODELS)

#### TO: ALL SATURN RETAILERS and AUTHORIZED SERVICE PROVIDERS

The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a product campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure, to adequately 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 repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge, or 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 owner letter, owners are being instructed to contact the Saturn Assistance Center if their Retailer does not remedy the condition within five (5) days of the service date. If the condition is not remedied within a reasonable time, owners are instructed how to contact the National Highway Traffic Safety Administration.

DEFECT INVOLVED

Saturn has determined that a defect which relates to motor vehicle safety exists in certain 1993 model year Saturn vehicles produced during early February, 1993. Some of the vehicles involved in this campaign will require inspection only. The brake booster assemblies on the remaining vehicles were improperly manufactured by the supplier, which could cause the brake booster housing to come apart during a high effort braking maneuver. If this occurs, the driver may experience a loss of brake apply, which could result in a vehicle crash without prior warning. The action being taken is to inspect the brake booster assemblies on these vehicles and replace them, if necessary.

Most of the affected vehicles are in Retailer inventory and have not been delivered to customers. However, we are contacting owners of affected, delivered vehicles and asking them to make arrangements with a Saturn Retailer for service, or to have their vehicle transported to a Saturn Retail Facility for inspection, and replacement of the brake booster assembly if necessary.

VEHICLES INVOLVED

About 3,700 U.S. 1993 Saturn vehicles are involved. All 1993 Saturn vehicles in the following VIN range will require this campaign, except for the VIN's on the listing included in this bulletin (refer to "Non - Involved Vehicles within VIN Range"): PZ215200 through PZ219322

Also, the following VIN's not in the above range are to be included in this campaign: PZ214920, PZ214930, PZ215038, PZ215049 and PZ215069

Because Saturn builds in sequence order, which does not always match VIN order, there are some non-involved vehicles within the VIN range that do not require this campaign. It is important to note that campaign claims will only be paid on involved vehicles.

OWNER NOTIFICATION

Owners of vehicles involved will be notified of this campaign by Saturn. Saturn will also notify owners of 1993 vehicles, not affected by this condition, that their cars are not involved in this campaign. This will alleviate any concerns these customers may have regarding this issue. (Refer to the involved and non-involved owner letters included in this bulletin.)

FACILITY VIN LISTING

A list of vehicles assigned to you (Facility VIN Listing), which our records indicate were sold by or shipped to you, is enclosed for your follow-up program. The Facility VIN Listing contains:

o Complete Vehicle Identification Number; o Owner name, address and telephone number; and o VIN's of vehicles, which according to Saturn records are in retail stock.

The Facility VIN Listing (with owner information) is furnished to involved Retailers with the Product Campaign Bulletin. Although these vehicles are assigned to your facility, it is important to note that owners can take their vehicles to the Saturn Retail Facility of their choice to have this campaign performed.

Those Retailers not involved initially in this campaign will receive a message at the top of a blank Facility VIN Listing that states: NO VEHICLES ASSIGNED AT THIS TIME FOR CAMPAIGN 93C03.

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 the law in several states. Accordingly, you are urged to limit the use of this listing to the follow up necessary to complete this campaign. Those records updated with California DMV registration information will have the following message printed adjacent to the appropriate VIN: "OWNER INFORMATION UPDATED BY CALIFORNIA DMV, PUBLICATION PROHIBITED."

REMOTE OWNER STRATEGY

In order to minimize customer inconvenience and ensure the highest level of customer satisfaction, owners who live in a remote location from an open Saturn Retail Facility will be contacted by Saturn to arrange to have their vehicles serviced in a manner convenient to them. Therefore, you may notice that not all vehicles which were sold by you are on your Facility VIN Listing.

SERVICELINE CAMPAIGN IDENTIFICATION

All vehicles in for service at a Saturn Retail Facility will have the VIN checked for possible outstanding campaigns by the Saturn Retailer System. The SERVICELINE portion of the Saturn Retailer System compares the VIN from the vehicle in for service to a list of VIN ranges (Campaign Parameter File) that was set up for this campaign. Although the Campaign Parameter File is designed to be as discriminating as possible, it should only be used as a tool to aid the Retailer in identifying vehicles that may possibly be subject to this campaign.

The information provided in the "VEHICLES INVOLVED" section of this bulletin is the definitive information to be used to identify vehicles involved in this campaign.

RETAILER RESPONSIBILITY

All unsold new vehicles in Retailers possession and subject to this campaign must be held at the retail facility and inspected/repaired per the service procedure of this campaign bulletin before owners take possession of these vehicles.

Retailers 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 are to be contacted by the Retailer, and arrangements made to make the required correction according to instructions contained in this bulletin.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your retail facility 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.

TRANSFER OF CAMPAIGN RESPONSIBILITY

Saturn vehicles that have been sold by you, which may be closer in proximity to another Saturn Retailer, may still appear on your Facility VIN Listing. If either you or the vehicle owner determines that it is more desirable for a vehicle on your Facility VIN Listing to be serviced by another Saturn Retailer, campaign responsibility may be transferred by 1) contacting the Saturn Assistance Center (1 - 800 - 828 - 2112, prompt 6); 2) submitting a Campaign Vehicle Action Report to your field representative. A copy of the Campaign Vehicle Action Report can be found in your Service Support Activities Folder; or 3) submitting an update in owner information to the Saturn Owner of Record system, via SERVICELINE, for field organization review and approval. All change's to campaign responsibility will be reflected in your next monthly Unfixed VIN Report.

All other changes in vehicle status (e.g., scrapped, stolen, etc.) are to be made in accordance with section 4.4.3 of the Retailer Service Reference Guide (Notifying Saturn of Vehicle Status Change).

UPDATING SATURN OWNER INFORMATION

When reviewing the Unfixed VIN Report or entering claims into the SERVICELINE system, please compare your owner information to the Saturn provided information. If changes are required, please make them promptly. Variations in the Retailer's customer name information should be corrected using the methods listed below:

A. Change in Current Owner Information

1. Select [CMD-3] key for "Change Customer Data" and access the Customer File Maintenance Screen. Make the appropriate changes. 2. Select [CMD-5] key to save the updated customer information and return to the Service Vehicle Master Maintenance Screen. 3. Enter vehicle mileage and select the [CMD-5] key to open a Customer Service Order (CSO).

B. New Owner Information

1. Choose vehicle by the VIN and not by the customer's name. 2. Select the [CMD-2] key to access the Customer File and Maintenance Screen. Enter the new owner's name and address information, and enter "Y" in the "New Owner" field to prompt the update. 3. Select the [CMD-5] key to save the updated information. 4. Enter vehicle mileage and select the [CMD-5] key to open a Customer Service Order (CSO).

PARTS INFORMATION 1. A pre-shipment of parts required to perform this campaign has been automatically sent to you from Saturn Service Parts Operations (SSPO). The initial shipment will be followed up with recommended stocking policies . . . so Retailers will not need to order parts. 2. Parts questions may be directed to your Saturn Parts Support Analyst.

Required Parts Quantity Required Part Number Description Per Vehicle

21010181 BOOSTER - P/B ASM 1 25524798 NUT-BRK M/CYL 2 25524798 NUT-P/B BOOS 4

DISPOSITION OF REPLACED PARTS

Retailers will scrap all replaced parts in a manner that ensures that they cannot be reused, remanufactured, or otherwise entered into the stream of commerce in the future.

SUGGESTIONS FOR ENSURING CUSTOMER SATISFACTION

As you know, Saturn's success hinges upon our ability to execute superior customer support throughout the ownership experience, especially when important corrective actions such as this are required.

Retailers should have an aggressive "action plan" so that they can quickly complete the campaign ... and minimize customer inconvenience. Some thought starters include:

1. Immediately contact owners to schedule appointments, so that this important service can be completed as quickly and conveniently as possible. 2. Coordinate with Saturn Roadside Assistance, as necessary, to pick-up and return vehicles for those owners who choose not to drive in. 3. Provide loaner or rental vehicles to owners, as required, until the repair can be performed. 4. Utilize additional Retailer resources to minimize owner wait time and to reduce inconvenience (e.g., leveraged service capacity). 5. Give priority to customer owned vehicles over retail inventory vehicles.

Again, whatever "action plan" you choose, it is imperative that every effort is made to accommodate the owner. If you have any questions, please coordinate with the Saturn Assistance Center to help ensure customer satisfaction.

SERVICE PROCEDURES (FOR ABS AND NON-ABS EQUIPPED VEHICLES)

I. DATE CODE TAG INSPECTION

1. Using a bright light, inspect the date code tag on the power brake booster assembly. If the date code tag is present, but the date code cannot be easily read, blacken the date code area of the tag with a black felt tip marker, wipe off with your thumb and try reading the date code tag using a bright light.

#### IMPORTANT: If the master cylinder obstructs the view of the date code tag, proceed to step 2 below.

a. If the last three digits in the code ARE NOT 034 or 035, the power brake booster assembly is not suspect and DOES NOT need to be replaced. The only possible date codes in this group of vehicles are: 015, 016, 019, 020, 021, 022, 023, 025, 026, 027, 028, 029, 030, 032, 033, 034, 035, 039, 040, 041 and 042. Proceed to "Campaign Completion Label" procedure in this bulletin. b. If the last three digits in the code ARE 034 or 035 (e.g. 63034, as shown below), the power brake booster assembly must be replaced using the "Brake Booster Assembly" removal and installation procedures beginning on the next page of this bulletin. If you find any date codes other than those mentioned in this bulletin, call the Technical Assistance Center (TAC).

c.If the date code tag is missing, damaged or otherwise unreadable, the power brake booster assembly must be replaced using the "Brake Booster Assembly removal and installation procedures beginning on the next page of this bulletin. (see figure 1).

#### NOTE: For figure 1, the type style used for numbers on date code tag may vary in appearance.

2. If the date code label cannot be seen, perform steps 7 through 9 of the "Brake Booster Assembly" removal procedures outlined on page 6 of this bulletin to gain visual access. 3. a. If the last three digits in the code ARE NOT 034 or 035, the power brake booster assembly is not defective. Reusing the same master cylinder nuts, completely reassemble using steps 6 and 7 on the "Installation" procedure outlined on Page 8 of this bulletin. Apply the Campaign Completion Label. b. Otherwise, proceed to steps 1b. and 1c. above.

#### NOTE: Use the retailer brake booster inspection worksheet to aid in record keeping and claims processing. This inspection worksheet can be found on the last page of this bulletin. Make enough copies to properly record the inspection of each vehicle assigned to your Facility (see Facility VIN Listing). After all claims have been paid, these worksheets may be discarded.

II. BRAKE BOOSTER ASSEMBLY REMOVAL

#### CAUTION:

THE NEGATIVE BATTERY CABLE MUST BE DISCONNECTED FIRST TO PREVENT ARCING.

(See figure 2 for steps 1-3)

1. Disconnect battery cables. 2. Remove front air intake duct assembly and air cleaner assembly. 3. On vehicles equipped with an SOHC engine, remove air cleaner assembly support bracket from engine support bracket.

#### IMPORTANT: Two of the battery tray support assembly bolts are located in the fenderwell.

(See figure 3 for steps 4-6)

4. Remove the battery shield, battery and battery tray support assembly. 5. Disconnect brake fluid level sensor connector. 6. If equipped with ABS, disconnect the two ABS solenoid connectors.

(See figure 4 for steps 7-9)

7. Remove two brake master cylinder nuts. 8. Remove positive battery cable clip attached to power brake booster assembly mounting stud.

#### NOTICE: Do not bend/kink brake lines.

9. Move brake master cylinder away from power brake booster assembly, far enough that power brake booster assembly can be removed. 10. Disconnect vacuum hose and power brake booster check valve from power brake booster assembly. Remove power brake booster check valve from vacuum hose and discard. 11. Remove four power brake booster nuts attaching power brake booster assembly to body. 12. Remove brake pedal push rod retainer and washer from brake pedal, then remove power brake booster push rod from brake pedal pushrod pin.

#### NOTICE: The power brake booster assembly and pushpin are a matched set. Power brake booster assemblies are measured during manufacture and a pushpin of the correct length is selected and fitted to the power brake booster assembly. Power brake boosters and pushpins are not interchangeable and must always be installed as a set.

13. Remove power brake booster assembly from vehicle.

III. BRAKE BOOSTER ASSEMBLY INSTALLATION

1. Position power brake booster assembly in vehicle, according to orientation shown in figure 5. Do not install fasteners at this time. 2. Install power brake booster push rod onto brake pedal pushrod pin and secure with brake pedal pushrod retainer and washer. 3. Install four new power brake booster nuts.

Torque: 27 Nm (20 ft lbs)

4. Connect vacuum hose to power brake booster check valve. 5. Remove plastic shipping pushpin retainer from power brake booster assembly. Check to be sure pushpin is present and in position.

#### NOTICE: Be careful not to bend/kink brake lines.

(See figure 6 for steps 6-9)

6. Position brake master cylinder onto power brake booster assembly. 7. Position positive battery cable clip onto power brake booster assembly mounting stud and install two new brake master cylinder nuts.

Torque: 27 Nm (20 ft lbs)

8. Connect brake fluid level sensor electrical connector. 9. If equipped with ABS brakes, connect the two ABS solenoid electrical connectors.

#### IMPORTANT: Two of the battery tray support assembly bolts are located in the fenderwell.

(See figure 7 for steps 10-12)

10. Install battery tray support assembly and fasteners.

Torque: 7 Nm (62 in lbs)

11. Install battery, battery shield and fasteners.

Torque: 7 Nm (62 in lbs)

#### CAUTION:

THE POSITIVE BATTERY CABLE MUST BE CONNECTED FIRST TO PREVENT ARCING.

12. Connect battery cables.

Torque: 17 Nm (151 in lbs)

(see figure 8 for steps 13-16)

13. On vehicles equipped with an SOHC engine, install air cleaner assembly support bracket to engine support bracket.

Torque: 10 Nm (89 in lbs)

14. Install air cleaner assembly.

Torque: 10 Nm (89 in lbs)

15. Install front air intake duct assembly.

Torque: 7 Nm (62 in lbs)

#### NOTICE: Stop lamp switch adjustment must be checked whenever a vacuum booster is replaced.

16. Proceed to "Stop Lamp Switch Adjustment Check" on the next page.

IV. STOP LAMP SWITCH ADJUSTMENT CHECK

1. Install stop lamp switch adjustment gage (SA 9303BR) between the switch and the switch actuator pad on the brake pedal arm being sure that the plunger protrudes through the slot in the gage. (see figure 9). 2. With the pedal released and the adjustment gage position, tap the gage side-to-side: (see figure 10) a. If the gage swings freely side - to - side, proceed to Step 3. b. If the gage sticks or does not swing freely, adjust the switch using the following "Stop Lamp Switch Adjustment" procedure. 3. With the adjustment gage in position, pull up on the brake pedal with very light force (approximately 2 lbs.) and tap the, gage side-to-side: (see figure 11) a. If the gage swings freely, adjust the switch using the following "Stop Lamp Switch Adjustment" procedure. b. If the gage sticks and/or does not swing freely, the switch is properly adjusted.

V. STOP LAMP SWITCH ADJUSTMENT

(see figure 12 for steps 1-3)

1. Loosen the stop lamp switch mounting nut sufficiently to allow the switch to move forward and rearward in the adjustment slot. 2. Install stop lamp switch adjustment gage (SA 9303BR) between the switch and the switch actuator pad on the brake pedal arm being sure that the plunger protrudes through the slot in the gage. 3. While pulling up with moderate force on the brake pedal assembly, push the switch forward against the gage.

#### IMPORTANT: Hold the switch perpendicular to the actuator pad on the brake pedal arm to prevent the switch from rotating out of alignment when tightening the mounting nut.

4. Tighten the switch mounting nut.

Torque: 10 Nm (89 in lbs)

(see figure 13 for steps 5-6)

5. Release the brake pedal assembly. 6. With the pedal released and the adjustment gage still in position, tap the gage side-to-side: a. If the gage swings freely side-to-side, proceed to Step 7. b. If the gage sticks or does not swing freely, repeat Steps 1 through 6. 7. With the adjustment gage in position, pull up on the brake pedal with very light force (approximately 2 lbs.) and tap the gage side - to - side: (see figure 14) a. If the gage swings freely, repeat Steps 1 through 7. b. If the gage sticks and/or does not swing freely, the switch is properly adjusted.

CAMPAIGN COMPLETION LABEL

Upon completion of the campaign, a Campaign Completion Label should be affixed on a clean, dry surface of the radiator core support in an area clearly visible when the hood is raised. Each label provides a space to print in ink (or type) the campaign number (93C03) and the five (5) digit facility code of the Retailer performing the campaign service.

As a reminder, additional labels may be obtained from your Service Support Activities Folder (provided to each facility as part of their "start-up" package) or may be ordered from GM Photo (1 - 800 - 828 - 2112 prompt 3, Item # S03 00013).

CREDIT

1. To receive credit for inspecting or replacing the brake booster assembly, submit a claim with the information below:

Failed Parts Sale Case Labor Labor Add Repair Performed Part # Allow. Type Type OP Hours Hrs.* ---------------- -------- ------ ---- ---- ----- ------ ----- Booster Inspection N/A N/A WC VC V7970 0.2 0.1

Booster-Inspect, Remove 21010181 ** WC VC V7971 1.1*** 0.1 and Replace

2. To receive credit for loaner/rental car costs incurred while owner awaits campaign repair or other goodwill expenses, submit a claim with the information below:

Sale Case Labor Net Item Net Item # Days Repair Performed Type Type OP Amount Code Rental ---------------- ---- ---- ----- -------- -------- ------ Loaner Reimbursement WC VC T 9569 **** C ***** Other/Goodwill WC VC T 9569 **** R N/A

3. Check your Saturn SERVICELINE Claim Memorandum daily. Remember to code the claim as a WC sale type, and VC case type. Contact your field representative if you need assistance.

4. Refer to the Customer Service Order Preparation Manual for details on Product Campaign Claim Submission.

* Campaign administrative allowance

** The parts allowance should be the sum total of the current SSPO Retailer net price plus 30% of all parts required for the repair.

*** Add 0.2 hrs for stop lamps switch adjustment as necessary

**** Net Item amounts must be submitted as a miscellaneous sale ... Loaner reimbursement not to exceed $30/day.

***** Enter number of days vehicle was rented.

NON-INVOLVED VEHICLES WITHIN VIN RANGE

PZ216278 PZ217523 PZ217563 PZ217920 PZ217961 PZ216393 PZ217524 PZ217566 PZ217922 PZ217962 PZ216615 PZ217525 PZ217567 PZ217923 PZ217963 PZ216819 PZ217526 PZ217568 PZ217924 PZ217964 PZ216909 PZ217527 PZ217569 PZ217925 PZ217965 PZ216989 PZ217528 PZ217623 PZ217927 PZ217966 PZ217037 PZ217529 PZ217789 PZ217928 PZ217967 PZ217139 PZ217530 PZ217843 PZ217929 PZ217968 PZ217156 PZ217531 PZ217886 PZ217930 PZ217969 PZ217480 PZ217532 PZ217890 PZ217931 PZ218014 PZ217481 PZ217533 PZ217891 PZ217932 PZ218313 PZ217491 PZ217534 PZ217892 PZ217933 PZ218463 PZ217499 PZ217535 PZ217893 PZ217934 PZ218464 PZ217500 PZ217536 PZ217895 PZ217936 PZ218465 PZ217501 PZ217537 PZ217896 PZ217937 PZ218466 PZ217502 PZ217538 PZ217898 PZ217940 PZ218467 PZ217503 PZ217539 PZ217899 PZ217941 PZ218468 PZ217504 PZ217540 PZ217900 PZ217942 PZ218469 PZ217505 PZ217541 PZ217901 PZ217943 PZ218470 PZ217506 PZ217542 PZ217902 PZ217944 PZ218471 PZ217507 PZ217544 PZ217903 PZ217945 PZ218472 PZ217509 PZ217545 PZ217904 PZ217947 PZ218473 PZ217510 PZ217546 PZ217905 PZ217948 PZ218474 PZ217511 PZ217547 PZ217906 PZ217950 PZ218475 PZ217512 PZ217549 PZ217907 PZ217951 PZ218476 PZ217513 PZ217550 PZ217909 PZ217952 PZ218477 PZ217515 PZ217551 PZ217910 PZ217953 PZ218478 PZ217516 PZ217552 PZ217911 PZ217954 PZ218479 PZ217517 PZ217553 PZ217912 PZ217955 PZ218480 PZ217518 PZ217554 PZ217913 PZ217956 PZ218481 PZ217519 PZ217555 PZ217914 PZ217957 PZ218482 PZ217520 PZ217558 PZ217915 PZ217958 PZ218832 PZ217521 PZ217560 PZ217916 PZ217959 PZ218928 PZ217522 PZ217562 PA217917 PZ217960 PZ219000 PZ219010

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.