FMVSS Noncompliance-Head Impact Protection

THIS BULLETIN IS BEING REVISED TO UPDATE THE SERVICE PROCEDURE AND ADD LABOR OPERATIONS. PLEASE DISCARD CORPORATE BULLETIN NUMBER 06217, ISSUED MARCH 2007.

General Motors has decided that certain 2005-2006 Chevrolet Cobalt Coupe vehicles not equipped with optional roof-mounted side impact airbags fail to conform to Federal Motor Vehicle Safety Standard 201, "Occupant Protection in Interior Impact." In tests at an impact point near the attachment of the sun visor to the roof, the Standard's requirement was exceeded. If a front seat occupant’s head contacts that point in a crash, the occupant's injury could be increased.

Dealers are to install an energy absorbing device between the front headliner and the vehicle roof.

Involved are certain 2005-2006 Chevrolet Cobalt Coupe vehicles without roof-mounted side impact airbags and built within these VIN breakpoints:

Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved.

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 through GM DealerWorld Recall Information. 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 recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall.

Parts required to complete this recall are to be obtained from General Motors Service and 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.

Determine if the vehicle is equipped with side impact air bags. Refer to GMVIS to verify vehicle content.

Tools Required

Hot Glue Gun

Important: Install the energy absorbing (EA) plastic piece into the headliner at both the driver and passenger side A-pillar locations.

1. Remove the A-pillar trim panels. Refer to Windshield Garnish Molding Replacement in SI.
2. Remove the sunshades from the vehicle. Refer to Sunshade Replacement in SI.
3. Remove the assist handle from the vehicle, if equipped. Refer to Assist Handle Replacement in SI.
4. Remove the sunroof finishing lace, if equipped. Refer to Sunroof Finishing Lace Replacement in SI.




Important: The headliner will drop about 203 mm (8 in), which will provide adequate room to install the insert energy absorbing (EA) plastic piece into the headliner. Use GM Care Hot Melt Adhesive Sticks (P/N 12377914) or equivalent to glue the EA plastic piece into the headliner.

5. Locate the installation anchor points (2) for installing the energy absorbing (EA) plastic piece (3) onto the headliner (1).



6. Apply hot glue to the energy absorbing (EA) plastic piece.




Important: Ensure that the energy absorbing (EA) plastic piece is installed properly. The tail ends of the energy absorbing (EA) plastic piece (2) should wrap around the anchor posts (1) of the headliner material. The body of the EA plastic piece should be firmly attached to the headliner.

7. Insert the energy absorbing (EA) plastic piece to the headliner trim with hot glue.
8. Tuck headliner in place to ensure proper fit with the A-pillar trim panels and sunshades.
9. nstall the A-pillar trim panels. Refer to Windshield Garnish Molding Replacement in SI.
10. Install the sunshades. Refer to Sunshade Replacement in SI.
11. Install the assist handle from the vehicle, if equipped. Refer to Assist Handle Replacement in SI.
12. Install the sunroof finishing lace, if equipped. Refer to Sunroof Finishing Lace Replacement in SI.

The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines.

Submit a Product Recall Claim with the information indicated below:

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

General Motors will notify customers of this recall on their vehicle (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 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 to provide 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 notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

This bulletin is notice to you that the new motor vehicles included in this recall 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 recall 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 recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall 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. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall 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 recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear General Motors 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 2005 and 2006 model year Chevrolet Cobalt Coupe vehicles not equipped with the optional roof-mounted side impact airbags fail to conform to Federal Motor Vehicle Safety Standard 201, "Occupant Protection in Interior Impact". As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products.

In tests on a vehicle similar to yours, there was an impact point near the attachment of the sun visor to the roof in which the Standard’s requirement was exceeded. If a front seat occupant’s head contacts that point in a crash, the occupant’s injury could be increased.

Your GM dealer will install an energy absorbing device between the front headliner and the vehicle roof. This service will be performed for you at no charge . It is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 50 minutes because of service scheduling requirements.

If your vehicle is within the New Vehicle Limited Warranty your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner’s Manual and your dealer for details on courtesy transportation.

You should contact your GM dealer to arrange a service appointment as soon as possible. Bring the enclosed customer reply form with you when you visit your dealer. The form identifies the repairs required. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us.

If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about this recall can be found at the Owner Center at MyGMLink, http://www.gm.com/recall

If after contacting your dealer and the Customer Assistance Center, you are still not satisfied 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 St., SW, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov.

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

Scott Lawson

General Director,

Customer and Relationship Services

Enclosure

06217