SB-10045039-5059

Program Bulletin

Bulletin No.: 12026
Date: June 2012

CUSTOMER SATISFACTION PROGRAM
SUBJECT:

Front Seat Wiring Connector Corrosion

MODELS:

2011-2012 Chevrolet Caprice Police Vehicles
U.S. Vehicles

THIS PROGRAM IS IN EFFECT UNTIL JUNE 30, 2014.
CONDITION
Certain 2011 and 2012 model year Chevrolet Caprice police vehicles, equipped with vinyl
interior floors, may have a condition where the front seat wiring connectors may corrode. If
large amounts of water or snow accumulate in the front seat foot-wells and splashes rearward
under the front seats, it could enter the wiring connectors. If sufficient water enters the
connectors, corrosion and a short circuit could occur and cause the airbag light to illuminate.
CORRECTION
Dealers are to replace and relocate the connectors.
VEHICLES INVOLVED
All involved vehicles are identified by Vehicle Identification Number on the Investigate Vehicle
History screen in GM Global Warranty Management system. Dealership service personnel
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs. It is important to routinely use this tool to verify eligibility because
not all similar vehicles may be involved regardless of description or option content.
For dealers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and
will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have
a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle
Registration Records. The use of such motor vehicle registration data for any purpose other
than follow-up necessary to complete this program is a violation of law in several
Copyright 2012 General Motors. All Rights Reserved.

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June 2012

Bulletin No.: 12026

states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
PART INFORMATION
Parts required to complete this program are to be obtained from General Motors Customer Care
and Aftersales (GMCC&A), unless otherwise noted. 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.
Part Number
92457427
92457428
92457429
1089482
(Obtain from Kent
Automotive*)
Obtain Locally

Description
Seat Kit (LH and RH)
Body Harness Kit LH
Body Harness Kit RH
Kent Automotive Coroplast 837 X
Anti-Abrasive Tape
(will service 2 vehicles)
Molex Hand Crimp Tool 63811-1000

Quantity/Vehicle
1
1
1
As Needed
(submit in Net Item)
1 - to be purchased one
time (reusable)

* Contact Kent Automotive at 1-888-937-5368 or www.kent-automotive.com. Do not order from
GMCC&A. We believe this source and their products to be reliable. There may be additional
manufacturers of such products/materials. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or material from this firm or for
any such items that may be available from other sources.
All terminals and crimps required to perform this repair are contained in the kits above.
However, in the rare event that damage occurs during the repair, the part numbers are listed
below.
Part Number
19299667
19299668
19299669

Description
TERMINAL,WRG HARN (0.50mm)
(seat connector circuit)
TERMINAL,WRG HARN (0.50mm)
(Seatside SIAB &
Seatside Pretensioner circuits)
TERMINAL,WRG HARN (1.25mm)
(Seat connector circuit)

Quantity/Vehicle
As Needed
(if damaged during install)
As Needed
(if damaged during install)
As Needed
(if damaged during install)

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SERVICE PROCEDURE
Tools/Miscellaneous Materials Required


Molex Hand Crimp Tool 63811-1000



Service Crimp Tool J 38125-7



Service Crimp Tool J 38125-6



Butane Soldering Iron with:
 Standard Tip for Soldering
 Heat Deflector Tip for Heat Shrink Application



High Flow Solder (Lead Free Only)



Wire Cutters



Wire Stripper - Knipex



10mm and 16mm Sockets and Driver



T40 Torx Socket



Headrest Removal Probe



Scrivet Removal Tool



Long Nosed Pliers



2.50mm Punch



1.40mm Precision Screw Driver



Rivet Gun (Pneumatic or Easy Squeeze Type Recommended)



Measuring Tape



Electrical Tape



Kent Automotive Coroplast 837 X Anti-Abrasive Tape

Bulletin No.: 12026

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Service Kits
All parts required for this rework will be supplied as part of the following three kits:
Seat Kit (LH and RH) - Part Number 92457427

2839292

Seat Kit as packaged Two-way Connectors Three-way Connectors 16-way Connector with Plugs
Rivets Tie Straps Seat Brackets
Body Harness Kit LH - Part Number 92457428

2839304

Body Harness Kit LH as packaged Heat Shrink Tube Splice Terminals 16-way
Three-way Connector Two-way Connector Bar Clip Tie Stand-off Clip Tie

Connector

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Body Harness Kit RH - Part Number 92457429

2839312

Body Harness Kit RH as packaged Three-way Connector 16-way Connector Two-way Connector
Heat Shrink Tube Splice Terminals Bar Clip Tie Stand-off Clip Tie
Crimp Tool Uses
The following details the crimp tools and associated jaws required for each terminal/seal crimp
throughout the rework. These must be adhered to.
2-Way and 3-Way Connector Terminals and Seals (Common - Seat Side Only)

2839317

Molex 63811-10000: Use 1.6 mm crimp jaw to crimp stripped wire to terminal. Service Tool J381256: Use Jaw number 1 to crimp wire seal to terminal.

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16-Way Connector Terminals and Seals (Seat Side Only)

2839328

Molex

63811-10000: Use 1.6 mm crimp jaw to crimp stripped wire to terminal. Service Tool
J38125-6: Use Jaw number 2 to crimp wire seal to terminals. Use Jaw number 5 to crimp wire seal to
terminal.

Splice Terminals (Body Side Only)

2839404

Large terminal. Use Jaw B of Service Tool J38125-7 to crimp over large splice terminals (2.00 mm).
Small terminal. Use Jaw C of Service Tool J38125-7 to crimp over small splice terminals (0.30/0.50 mm).

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Bulletin No.: 12026

Service Procedure

2839427

1.

Using the vertical seat adjuster, raise both seats to their maximum vertical heights. Also tilt
both seats backwards approximately 45 degrees using the electric tilt adjuster. Some
vehicles may have a manual adjuster knob for tilt.

Note: Do not attempt any other reworks that require electrical power in parallel with this rework.
2.

Disconnect both vehicle negative battery terminals using a 10mm socket. Both vehicle
batteries are located in the vehicle's rear compartment (boot/trunk).

2839444

3.

Remove the seat outer adjuster finish cover.
3.1 Remove the rear section first by sliding the seat all the way forward, unclipping the rear
clip and removing the trim.
3.2 To remove front section, unclip the rear trim clip first, then slide seat back, lever the
rear of the front section in an upward direction until all clips are unsecured and slide
forward.
3.3 Check for damaged clips on the removed trims. If broken clips are found, replace the
affected component.

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2839450

Connectors Connector Carrier
4.

Locate and remove seat connectors.
4.1 Locate the group of four (five on the passenger side) connectors at the base of the
front outer seat rail housed within a carrier.
4.2 Carefully disconnect and remove the connectors from the carrier and discard the
carrier.

2839456

5.

Remove the front side door sill trim plate.
5.1 Unclip the front side door sill trim plate starting from the front and work back.
5.2 Check for damaged clips on the removed trim. If broken clips are found, replace the
affected component.

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2839459

6.

Remove front seat.
6.1 Remove the front seat retaining bolts using a 16mm socket. Bolts are located on the
rear side of the seat. Access to the bolts is via the rear passenger door.
6.2 Fully extend head restraint out of the head restraint guides.
6.3 Insert a suitably sized probe into the hole in the left-hand restraint guide.
6.4 Depress the right-hand head restraint sleeve height adjuster lock.
6.5 Remove the head restraint out of the guides. Note that the seat may need to be tilted so
that the headrest can clear the headliner.

2839460

6.6 Remove the seat belt buckle latch located on the seat by sliding down the buckle
cover and using a T40 torx driver to loosen the screw.
6.7 Using a probe or punch, push the screw out from the opposite side  and pull the belt
out of the latch.
6.8 Remove the front seat, by lifting and tilting the seat forward, and then lifting and pulling
the seat rearwards to disengage the front hooks. The seat can be removed via the front
door. Use caution not to scratch any trim upon removal of the seat.

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2839470

6.9 Place the seat on an appropriate table with the seat airbag label facing towards the
ceiling.

2839471

7.

Free the seat harness.
7.1 Detach the two harness clips retaining the airbag circuits to the seat as well as the
single clip retaining the remaining seat circuits.
7.2 Carefully cut the clips off the wires one at a time and replace each with the cable tray
clips provided in the exact location as the clip that was removed. Make use of the
visible crimp left behind by the removed tie to help locate the new tie.

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2839475

8.

Attach seat bracket.
8.1 Attach the correct sided seat bracket to the seat using the rivets provided. Note that the
two safety circuit bracket clips will always be located towards the front of the vehicle
regardless of side.
8.2 Rivet the bracket in the two locations shown.

2839478

9.

Clip seat harnesses to bracket and cable tray.
9.1 Refit the harness retaining clips that were attached in Step 7 to the attached seat
bracket in the following order:

2 way pre-tensioner harness (closest to front of vehicle)
 3 way SIAB harness (2nd closest from front of vehicle)
Remaining bundle (3rd closest from front of vehicle)

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2839480

Note: Attach clip to cable tray hole bracket side.
9.2 Attach the supplied cable-tie clip over both safety circuit harnesses at a distance of
220mm (8.60 in) from the pre-tensioner harness clip and press into the cable tray in
the position shown.
10. Replace pre-tensioner (2P male) and SIAB (3P male) connectors.

2839481

Note: Cut both harnesses 76 mm (3 in) post retaining clip.
10.1 Using a measuring tape, measure 76 mm (3 in) of harness from the harness retaining
clips towards the connectors and cut the harnesses off using wire cutters.

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2839899

10.2 Strip back the black outer insulation of both leads 30.0mm (1.20 in) using a wire
stripping tool to expose the 5 colored circuits.
10.3 Slide 0.50mm wire seals onto all 5 leads in the orientation shown and back enough to
enable removal of the insulation.
10.4 Strip all wires back 4.0mm (0.16 in).

2839904

10.5 Position the 0.50mm MALE terminals onto the wires. Caution must be used not to
position the wire too far forward as it may interfere with the mating portion of the
terminal. Crimp the terminals onto the bare wire using Molex Tool 63811-1000 Jaw
1.6mm.

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Bulletin No.: 12026

WARNING: To avoid personal injury or part damage, review the information below.
 DO NOT use soldering equipment that is battery or electric powered. These types of soldering
irons can induce voltage into the circuit, which may cause inflator module deployment and/or
damage to electrical components. Use only a butane fueled soldering iron when working on SIR
circuits.
 Ensure that the wire seals are distant from the crimp before applying solder. This will avoid
melting the seals.
 When soldering, hold the iron tip on the underside of the terminal and allow solder to flow
through the crimp from the top.

2839910

10.6 Solder all terminals at the wire crimp.

2839918

10.7

Position the wire seal to the terminal and crimp the seal and insulation using
Service Tool J38125-6 Jaw #1.

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2839928

10.8 Insert the terminals into the rear of the 2-way pre-tensioner housing as follows.
GN – PIN1
GY – PIN2
Listen for an audible "click" sound indicating that the terminals are inserted. Perform a
push-pull test to ensure the terminals are fully inserted.

2839938

10.9

Using a 1.4mm precision screwdriver, push the internal purple locking tab from
left to right in the orientation shown to lock the terminals in.

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