Noncompliance 00043 - Daytime Running Lights Height Compliance

General Motors has decided that certain 1998 4WD S10 pickup trucks, Sonoma pickup trucks, and Blazer SUVs equipped with the ZR2 suspension package, may have been built with headlamp assemblies that do not meet the mounting height requirements of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment." These vehicles use the high beam, at reduced voltage, for the daytime running lights (DRLs), resulting in the potential for glare in the rearview mirror of drivers being followed by these vehicles.

Dealers are to install a revised wiring harness that changes the DRLs from high beam to low beam DRLs, and install new long-life low beam bulbs. In addition, customers will be sent an insert for their Owner's Manual with the new long-life bulb replacement part number.

Involved are certain 1998 4WD S10 pickup trucks, Sonoma pickup trucks, and Blazer SUV equipped with the ZR2 suspension package and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.]

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.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

1. Disconnect the negative battery cable.
2. Remove the fresh air intake duct.
3. Remove the air cleaner and the air cleaner housing.
4. Remove the grille.
5. Remove both of the composite headlamps and disconnect the wiring. Set the lamps in a safe place.
6. Disconnect the wiring harness from the other lamps.
7. Disconnect the wiring harness from the radiator core support.
8. Remove the cover from the underhood bussed electrical center (UBEC).
9. Disconnect the positive wire from the UBEC.
10. Remove the three 10 mm screws holding the UBEC to the vehicle.
11. Turn the UBEC over and disconnect the green connector from the bottom of the UBEC.
12. If the vehicle is equipped with a power steering oil cooler, remove the four screws supporting the cooler and lines to the front of the radiator support.
13. Remove the wiring harness from the vehicle by pulling the wiring harness through the opening in the core support into the engine compartment. It will be necessary to feed each piece through the opening, with the white parking lamp bulb holders being last. To gain additional clearance needed for the parking lamp sockets to fit through the hole in the core support, carefully reposition the cooler lines, moving them forward and to the left side of the vehicle.
14. Install the new wiring harness to the vehicle. Reverse the previous step, starting with the white parking lamp sockets.
15. Install the new green connector to the UBEC.

Tighten
Tighten the retaining screw to 7 N·m (62 lb in).

16. Reposition the UBEC and install the three 10 mm screws.

Tighten
Tighten the screws to 7 N·m (62 lb in).

17. Reconnect the positive wire to the UBEC.

Tighten
Tighten the 7 mm screw to 10 N·m (88 lb in).

18. Remove the 5-prong DRL relay from the UBEC.




Important: The 5-prong DRL relay will be replaced with a 4-prong relay and a plug for the 5th hole.

19. Modify the plug supplied in the kit by cutting off a single prong (1) as shown. Install the modified single prong plug in the 5th hole.
20. Install the new 4-prong relay in the UBEC.
21. Using a clean, dry cloth, wipe dirt, oil, etc. from the inside of the UBEC cover. Install the service label, included in the kit, over the existing label.
22. Install the cover to the UBEC.
23. Reinstall the air cleaner assembly and the air cleaner.
24. Replace the fresh air intake tube to the air cleaner and throttle body.
25. Properly route the wiring harness to the radiator core support and install all retainers in the original locations.
26. Connect the wiring harness to all of the lamps.
27. Replace the low beam bulbs in the composite headlamp assemblies (the outside lamps) with the new bulbs.
28. Install the wiring to the headlamps and install in the vehicle.
29. Install the grille.
30. Reconnect the negative battery cable.
31. Program the Body Control Module with calibration number 09389527, found on TIS 2000 CD #16, per the following procedure:

•	Call the Techline Customer Support Center (TCSC) at 10800-828-6860 (English) or 1-800-503-3222 (French).

•

Inform the TCSC specialist that you need programming assistance per Campaign Bulletin Number 00043. You will need the full 17 digit vehicle identification number (VIN) when you call. TCSC will provide you with a VCI number to be used for programming the Body Control Module and instructions for its use. THIS NUMBER IS UNIQUE TO THE VEHICLE BEING PROGRAMMED AND CANNOT BE USED ON MULTIPLE VEHICLES.

32. For used vehicles in dealer inventory, copy the owner insert at the back of this bulletin and place in Section 6, "Service and Appearance Care," of the Owner's Manual.
33. Install the GM Campaign Identification Label.

Place a Campaign Identification Label on each vehicle in accordance with the instructions outlined in this Product Campaign Bulletin. 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.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Submit a Product Campaign Claim with the information indicated below:

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

Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin).

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty 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 customer 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 these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall campaign notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the campaign is not completed within a reasonable time.

This bulletin is notice to you that the new motor vehicles included in this campaign may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the campaign correction, your dealership may be subject to a civil penalty for each such sale.

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. Campaign follow-up cards should not be used for this purpose, since the customer 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.

Dear Chevrolet/GMC Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

General Motors has decided that certain 1998 4WD S10 pickup trucks, Sonoma pickup trucks, and Blazer SUVs equipped with the ZR2 suspension package, may have been built with headlamp assemblies that do not meet the mounting height requirements of Federal Motor Safety Standard (FMVSS) 108, "Lamps, Reflective Devices, and Associated Equipment." These vehicles use the high beam, at reduced voltage, for the daytime running lights (DRLs), resulting in the potential for glare in the rearview mirror of drivers being followed by these vehicles.

Your Chevrolet/GMC dealer will install a revised wiring harness that changes the DRLs from high beam to low beam DRLs, and install new long-life low beam bulbs. This service will be performed for you at no charge . In addition, we have included an insert for your Owner's Manual with the new long-life bulb replacement part number. Please place this insert in Section 6, "Service and Appearance Care," of your Owner's Manual.

The length of time required to perform this service correction is approximately 1 hour and 40 minutes. Additional time may be required to schedule and process your vehicle. If you dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed schedule, process, and repair your vehicle.

Please contact your Chevrolet/GMC dealer as soon as possible to arrange a service date. Parts are available and instructions for making this correction have been sent to your dealer.

Your Chevrolet/GMC dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the number listed below:

If, after contacting the appropriate customer assistance center, 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 SW, Washington, DC 20590 or call 1-800-424-9393 (Washington, DC residents use 202-366-0123).

The attached customer 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 no longer own this vehicle, please let us know by completing the attached and mailing it in the postage paid envelope.

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/Pontiac-GMC Division

General Motors Corporation

Enclosure