Service Procedure

Service Procedure

Tools, Equipment and Materials
- Dust Mask
- Hair Dryer or Heat Gun
- Hand File
- Orbtial Sander*
- Hack-Saw
- Protective Eyewear
- Protective Work Gloves
- Bubble Wrap
- Shop Cloth
- Masking Tape
- Sandpaper - 400 Grit
- Reciprocating Saw*
- Scribe
- Air Saw
- Standard Hand Tools
- Tech 2(R)
- Torque Wrench
- Workbench with Vise

* Dealers will be allowed to purchase one orbital sander and one reciprocating saw. Refer to the tool information below.

Gas Pedal Template & Gauges (shipped from the WPC)

ALLDATA EDITORS NOTE
All templates shown in this bulletin are not to scale.

Cutting Template

Shape Gauge

Tibia Marking Gauge

All-Weather Floor Mat Inspection

Determine if the vehicle is equipped with GM All-Weather Floor Mats (AWFM).

- If the vehicle is equipped with Pontiac Vibe AWFM, remove the driver-side floor mat and install the new design driver's floor mat. The new design mat will be available July 16, 2010. If this recall is performed before the new design mat is available, place the driver-side floor mat in the trunk of the vehicle. Inform the customer to leave the floor mat in the trunk of the vehicle and to contact the dealership on or after July 16, 2010, to exchange the old design floor mat for a new design floor mat. Proceed to the Remove and Cut the Accelerator Pedal procedure below.
- If the vehicle is not equipped with Pontiac Vibe AWFM, the mat does not require replacement and can be reinstalled after this recall has been completed. Proceed to the Remove and Cut the Accelerator Pedal procedure below.

Remove and Cut the Accelerator Pedal

Note
There are service repair videos available at GMTraining.com (US), gmprocanada.com under the "resources" menu (Canada). These videos will demonstrate the key service repair steps in this bulletin. It is advised that all technicians review these videos before performing this repair.

Note
Do NOT modify the second design accelerator pedal, P/N 19205346. Second design pedals do NOT require the pedal modifications provided in safety recall bulletins 10018 and 10038. To determine if the vehicle is equipped with a second design accelerator pedal, measure the length of the accelerator pedal in the area indicated in the arrow span. Refer to the illustration.
- If the length of the accelerator pedal in the arrow span area is 70 mm (2.76 in), the accelerator pedal has been modified or is a second design pedal. Do NOT modify the accelerator pedal. Proceed to the Floor Carpet Modification procedure in this bulletin.
- If the length of the accelerator pedal in the arrow span area is longer than 70 mm (2.76 in), the accelerator pedal has NOT been modified and is a first design accelerator pedal. Proceed to the next step.

Caution: Accelerator Pedal Handling Notes

- DO NOT drop.
- Avoid vibration and shock.
- DO NOT place sensor in vise.
- Cover and uncover the sensor while in the vehicle to prevent damage and debris from entering.
- DO NOT reuse an accelerator pedal that has been dropped.

Note

- For additional information on accelerator pedal removal, please refer to SI.
- Be sure to use bubble wrap to protect the sensor.
- Be sure to seal the bubble wrap with masking tape to prevent damage to the sensor, and cutting debris from entering the pedal's movable lock.
- DO NOT reuse the bubble wrap.

1. Remove the accelerator pedal assembly.

1. Disconnect the accelerator pedal connector.
2. Remove the 2 bolts.
3. While still inside the vehicle, use bubble wrap (1) and masking tape (2) to cover and protect the sensor.

Note

- DO NOT mark the area beyond the template.
- Use a flat tip screwdriver or marker if a scribe is not available.
- Never cut or sand the pedal while the template is on the pedal.

2. Mark the area to be cut. Firmly set the template (2) to the pedal and scribe guidelines (1) to outline the area to be cut.

Note

- DO NOT place the sensor in the vise to avoid damage.
- Firmly secure the pedal to prevent it from moving.
- DO NOT over tighten the vise.

Upper View

Tip Side View

Side View
3. Set the pedal in the vise at a right angle using a shop cloth while avoiding the sensor.

Note

- Always wear protective eyewear and gloves when cutting and sanding.
- Guide cut must be straight and clean.

4. Cut lower section accelerator pedal assembly.

1. The cut line (1) is slightly outside from the scribed line and it makes 90 degree to the pedal foot pad as shown in the illustration.

2. Use a hack-saw (2) and cut the pedal 5 mm (0.2 in) deep (1) as guide groove for reciprocating saw.

Note

- Always wear protective eyewear and gloves when cutting and sanding.
- The cut must be straight and clean.
- Apply consistent pressure during cutting.
- Do not stop during the cutting process.

3. Use a reciprocating saw and cut off the lower section of the pedal as shown in the illustration.

Cut Line

Cut Area

Reciprocating Saw

Note
Do not cut at the scribed line. This area will be sanded later.

5. Cut corners of accelerator pedal assembly.

Note

- Always wear protective eyewear and gloves when cutting and sanding.
- Guide cut must be straight and clean.

1. Turn the pedal over in the vise with the foot pad facing up.
2. The cut line (1) is 3 mm (0.12 in) outside from the scribed line as shown in the illustration.
3. Use a hack-saw and cut the pedal 5 mm (0.2 in) deep as a guide groove (1) for the reciprocating saw.

Note

- Always wear protective eyewear and gloves when cutting and sanding.
- The cut must be straight and clean.
- Apply consistent pressure during cutting.
- Do not stop during the cutting process.

Cut Area

Cut Line
4. Use a reciprocating saw and cut off the accelerator pedal's corners as shown in the illustration.

6. Sand the top surface.

Note

- Always wear protective eyewear and gloves when cutting and sanding.
- Guide cut must be straight and clean.

Using orbital sander, sand to the scribed line on the top surface and remove any sharp edges and burrs. Be sure to sand the foot pad round and not flat.

7. Sand the radius line.

Note

- Always wear protective eyewear and gloves when cutting and sanding.
- Guide cut must be straight and clean.

Using orbital sander, sand to the scribed radius line and remove any sharp edges and burrs.

Caution
DO NOT sand pedal stopper area (circled) as shown in illustration.

8. Sand the lower corner near pedal stopper.

1. Remove the pedal from the vise. Turn the pedal over with the foot pad facing down and set pedal in the vise using a shop cloth while avoiding the sensor.

Note
Always wear protective eyewear and gloves when sanding.

2. Using an orbital sander and hand file, sand the lower corner near pedal stopper.

9. Remove all burrs from the cut surfaces.

Note

- Always wear protective eyewear and gloves when sanding or filing.
- DO NOT place the sensor in the vise to avoid damage.
- Firmly secure the pedal to prevent it from moving.
- DO NOT over tighten the vise.

1. Remove the pedal from the vise
2. Turn the pedal over with the foot pad facing up and set the pedal in the vise using a shop cloth while avoiding the sensor.
3. Using an orbital sander and file, remove all burrs from the cut surfaces. The cut edges along the foot pad should be rounded and not square.
4. Finish the cut surface and all edges with 400 grit sandpaper.

OK

No Good

Cutting Template

Cutting Surface

Clearance

Shape Gauge
10. Check the shape of the pedal.

Note

- Always wear protective eyewear and gloves when sanding or filing.
- A tolerance of -1.0 mm is permissible between the final cut surface and the template.
- Regarding the pin hole, the key point of judgment is a "smooth pedal surface".

1. Using the correct cutting template and shape gauge, check the shape of the pedal.
2. If the shape does NOT match the template and/or gauge, continue filing.
3. If the shape matches the template and gauge, touch the cut surface with your hand to verify it is smooth and free of burrs.

OK

No Good

No Rib

Rib

Pin Hole

Chip or Nick
4. Check for a rib as shown. If there is a rib, file it until it is gone.
5. Check for any chips or nicks on the finished surface edge. If there are any chips or nicks, file the edge to the make them smooth.
6. Accelerator pedal modification is now complete.

Floor Carpet Modification