Product Safety 99044 - Airbag Sensing and Diagnostic Modules (SDM). Chevrolet Lumina 1999

Subject:

99044 -- Airbag Sensing and Diagnostic Modules (SDM)

Models:

1999 Chevrolet Rear-Wheel Drive Lumina

Defect Involved

General Motors has decided that certain 1999 Chevrolet Rear-Wheel Drive Lumina model vehicles may have suspect Sensing and Diagnostic Module (SDM) located under the centre console assembly. This could cause an unnecessary air bag deployment.

To correct this condition, dealers will need to inspect, and if necessary, replace the suspect SDM with an improved SDM.

Vehicles Involved

Involved are certain 1999 Chevrolet Rear-Wheel Drive Lumina model vehicles built within the following VIN breakpoints:

Year	Division	Model	Plant	From	Through
1999	Chevrolet	Lumina	Holden	XL367025	XL413138

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

Parts Information

Important: An initial supply of SDMs, equivalent to 40% of involved vehicles, required to complete this campaign was pre-shipped at no charge to involved dealers of record, as well as one TORX bit tool. This pre-shipment occurred the week of May 10, 1999.

Important: If additional TORX bit tools, Tool No. ETX30H, are required, please contact your Regional Marketing Office.

Additional SDMs, if required, are to be obtained from Holden Service Parts Operation (HSPO) using the attached order form. Please refer to your "involved vehicles listing" prior to ordering requirements.

Part Number	Description	Quantity/ Vehicle	Subgroup Identifier on Initiation Detail Report
92057981	SDM Version 6.2 Driver Air Bag	1	A
92057980	SDM Version 6.2 Driver and Passenger Air Bag	1	B
92053352	SDM Version 6.2 No Air Bag Fitted	1	C

Customer Notification

The attached suggested dealer letter is recommended and should be sent by dealers.

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 customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin.

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.

Service Procedure

Remove the centre console assembly using the following steps:

1.1.	Remove the four screws securing the centre console to the transmission tunnel and slide the front seats forward to gain access to the rear screws.

1.2.	Remove the screws securing the centre fascia side extensions and remove the centre fascia side extensions.

Note that there are three screws for the left-hand side extension and two screws for the right-hand side extension.

1.3.	Open the centre console bin and pull the rubber insert out from the console bin. Remove the two retaining nuts.

1.4.	For vehicles with manual transmissions, remove the gearshift knob by rotating it clockwise. Pry the gearshift boot from the centre console.

1.5.	Remove the rubber cap from the transmission console and remove the two screws from the transmission console. Pry out the transmission console, disconnecting the power window harness where fitted.

1.6.	Remove the two screws attaching the storage compartment to the instrument console and remove the storage compartment. Remove the four screws attaching the centre console to the instrument panel.

1.7.	Partially remove the centre console and disconnect the wiring harness to the centre console. Fully remove the centre console by lifting the rear end up and pulling the assembly out.

Make an inspection for the SDM Serial Number using these steps:

Figure 1


(1)	Holden Part Number-First 8 Digits
(2)	SDM Serial Number-First 9 Digits

2.1.	Check the SDM part number and the serial number as shown in Figure 1.

Important: The part number shown on the SDM fitted to the vehicle may not correspond to the replacement part number.

2.2.	If the serial number falls within the affected range of serial numbers shown for that part number, then the SDM must be replaced with a new one. Refer to the table at the end of this Service Procedure. Proceed to Step 3.

If the SDM serial number does not fall within the affected range, proceed to Step 6.

Remove the SDM using the following steps:

Caution: The SDM can maintain sufficient voltage to cause SRS deployment for up to 10 seconds after the ignition switch is turned OFF or the battery is disconnected.

3.1.	Disable the SRS system by disconnecting both the battery ground and the power leads. Wait at least 10 seconds before performing any work on the vehicle.

Figure 2

3.2.	Using a number T30H TORX bit, Tool No. ETX30H and a suitable holder, such as Tool No. J 25359-8, loosen and remove the SDM-to-floor attaching screw (1) with the ground lead attached to it. Refer to Figure 2.

3.3.	Lift up the SRS wiring harness connector locking lever (2) and pull the harness connector (3) out of the SDM. Refer to Figure 2.

3.4.	Using the number T30H TORX bit, Tool No. ETX30H and a suitable holder, such as Tool No. J 25359-8, loosen and remove the remaining two SDM-to-floor attaching screws

3.5.	Remove the SDM.

Install the replacement SDM. Installation of the new SDM is the reverse of the removal procedures, noting the following points:

•	Ensure that the directional arrow on the SDM identification label is pointing towards the front of the vehicle. Refer to Figure 2.

•	Install the SRS wiring harness ground lead to the left-hand rear SDM retaining screw.

•	Using a number T30H TORX bit, Tool No. ETX30H and a suitable holder, such as Tool No. J 25359-8, tighten the SDM to the floor attaching screws between 7-11 N·m (10-16 lb ft).

•	Connect the SRS wiring harness connector, ensuring that the connector is fully seated into the SDM module and the locking lever is locked down.

Enable the SRS using these steps:

5.1.	Reconnect both the battery power and the ground leads.

5.2.	Switch the ignition ON. Observe the SRS warning lamp in the instrument cluster. The warning lamp should be illuminated for approximately 5 seconds. During this period, the SDM performs a wiring and self-check.

If no system faults are detected, the SRS warning lamp will be switched off.

If the warning lamp remains illuminated and an audible alarm chimes, or the warming lamp illuminates for 2 seconds after it was originally switched off, an SRS fault is present. Refer to the relevant volume of the 1999 Lumina Service Manual, 12M Supplemental Restraint System Section 3-Diagnostics.

Refit the centre console by reversing the removal procedure.

Install the Campaign Identification Label.

Affected Batches of SDM Serial Numbers for Each Part Number

SDM Part Number	Affected SDM Serial Number From	Affected SDM Serial Number To
92075492	982510001	982880542
92075493	982400001	982930028
92075494	982450001	982940183
92057976	981920001	982930003

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 by the customer for periodic servicing. Additional Campaign Identification Labels can be obtained from your Regional Marketing Office.

Apply the "Campaign Identification Label" only on a clean, dry surface.

Claim Information

Submit a Product Campaign Claim with the information indicated below.

Repair Performed	Part Count	Part No.	Parts Allow	CC-FC	Labour Op	Labour Hours*
Inspect SDM-Does Not Need Replacement	--	--	**	MA-96	V0366	0.7 hr
Replace SDM	1	92057980	**	MA-96	V0367	0.9 hr
* -- For Campaign Administrative Allowance, add 0.1 hours to the "Labour Hours". ** -- The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus landed cost mark-up.

Repair Performed

Part Count

Part No.

Parts Allow

CC-FC

Labour Op

Labour Hours*

Inspect SDM-Does Not Need Replacement

MA-96

V0366

0.7 hr

Replace SDM

92057980

MA-96

V0367

0.9 hr

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

** -- The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus landed cost mark-up.

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

TO: EXPORT MANAGER Material Order Form 1999 Chevrolet Lumina Sensing and Diagnostic Modules Fax No.: 613 9797 7342 Attention: Russell Thiele
This dealership wishes to order additional Sensing and Diagnostic Modules for completion of Campaign 99044 (Hold #99-H-04). Please dispatch the parts detailed below, to this dealership, as soon as possible.
Part No.	Description	Amount
92057981	SDM version 6.2 Driver Air Bag
92057980	SDM version 6.2 Driver and Passenger Air Bags
92053352	SDM version 8.1 No Air Bags Fitted
From Dealer Code:
Date:
Dealership Name:
Dealership Service Manager (please PRINT your name):
Fax This Form To: HSPO Export Manager

Suggested Dealer Letter

General Motors has decided that certain 1999 Chevrolet Rear-Wheel Drive Lumina model vehicles may have suspect Sensing and Diagnostic Module (SDM) located under the centre console assembly. This could cause an unnecessary air bag deployment.

To correct this condition, we will need to inspect, and if necessary, replace the suspect SDM with an improved SDM.

This service will be provided for you at no charge.

Please contact us as soon as possible to arrange a service date.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our procedures.

GMODC

General Motors Corporation