Customer Satisfaction - A/C System Wiring and Dual Stage Airbag Module Wiring

THIS BULLETIN IS BEING REVISED TO INCLUDE ADDITIONAL LABOR TIME IN THE EVENT THAT THE VEHICLE IS BROUGHT IN WITH AN INOPERATIVE A/C SYSTEM. DISCARD ALL COPIES OF BULLETIN 05046 ISSUED MAY 2005.

On certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles equipped with a 2.2L engine (L61) and air conditioning (C67), voltage spikes from abnormal fan switching can damage the air conditioning pressure sensor transducer, resulting in a loss of air conditioning. Damage is more likely to occur if the abnormal fan switching occurs when the vehicle is being driven in city traffic and when the outside temperatures are 70 °F (21 °C) or higher. The spikes can also cause the engine to operate in a reduced power mode. If this occurs, the Driver Information Center will display "ENG PWR REDUCED", and the maximum throttle opening will permit a speed of about 30 mph (48 km/h).

In addition, the steering column mounted airbag module wiring is reversed on these vehicles. The driver's air bag will deploy under the same conditions (see "When Should An Air Bag Inflate?" in your owner's manual) and the vehicle meets the occupant protection requirements of the Motor Vehicle Safety Standards. In the event of a moderate frontal impact, however, the airbag will deploy fully instead of at the reduced level described in your owner's manual

Dealers are to install wiring to isolate the voltage spike and modify the circuitry to the airbag module.

Involved are certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles equipped with a 2.2L engine (L61) and air conditioning (C67), and built within these VIN breakpoints:

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

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned.

The Campaign Initiation Detail Report 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 states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program.

Important: An initial supply of harnesses required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of May 2, 2005, and will be approximately 10% of each dealer’s involved vehicles. Pre-shipped parts will be charged to dealer’s open parts account.

Additional parts, if required, 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.

Airbag Wiring Procedure

1. Remove the SIR fuse from the BCM.
2. With a flat-bladed tool, separate the outer trim cover from the I/P.
3. Pull the outer trim cover rearward from the I/P to disengage the locating tabs.
4. Remove the outer trim cover from the I/P.
5. Disconnect the electrical connector from the trim cover.
6. Remove the connector position assurance (CPA) clip from the connector.
7. Disconnect the connector.
8. Carefully peel back about 2 inches (50 mm) of tape from the male side of the connector.
9. Remove the terminal position assurance (TPA) clip from the male side of the connector.
10. Remove the TPA.
11. Back out the BROWN and PINK wires and swap their positions. (BROWN goes into cavity B1, and PINK goes into cavity A1).
12. Back out the TAN and WHITE wires and swap their positions. (TAN goes into cavity B2 and WHITE goes into cavity A2).
13. Install the TPA clip to the male terminal.
14. Rewrap the wiring.
15. Connect the connector and insert the CPA clip.
16. Connect the connector to the trim cover.
17. Align the outer trim cover locating tabs to the opening in the I/P.
18. Push the outer trim cover locating tabs into the I/P until fully engaged.
19. Press the outer trim cover into the I/P until fully secured.
20. Install the fuse for the airbag.
21. Proceed to the A/C Wiring (Jumper) Procedure below.

A/C Wiring (Jumper) Procedure

Important: If the vehicle is brought in with an inoperative A/C system, replace the A/C refrigerant pressure sensor using the appropriate procedure in SI and then perform the repair below.

1. Open the hood.
2. Remove the engine sight shield.

Notice: DO NOT pull on the wiring clip to remove it from the fan shroud. The fan shroud may be damaged. Use a prying tool between the clip and the ear on the shroud or use diagonal cutters to cut the retainer.

3. Remove the wire retainer from the fan shroud and unplug the electrical connector from the fan.
4. Plug the new jumper into the fan and plug the original fan wiring into the jumper.
5. Press the wiring retainer on the jumper into the hole in the fan shroud where the original wire clip was located. Route the wiring so that it will not come into contact with other parts.
6. Install the engine sight shield.
7. Close the hood.

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 program 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 Program Claim with the information indicated below.

General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin).

All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles.

Dealers are to service all vehicles subject to this program 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. Program 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 program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

This notice is sent to inform you that GM is conducting a customer satisfaction program that affects certain 2005 model year Chevrolet Cobalt and Pontiac Pursuit vehicles equipped with a 2.2L engine and air conditioning.

Voltage spikes from abnormal fan switching can damage the air conditioning pressure sensor transducer, resulting in a loss of air conditioning. Damage is more likely to occur if the abnormal fan switching occurs when the vehicle is being driven in city traffic and when the outside temperatures are 70 °F (21 °C) or higher. The spikes can also cause the engine to operate in a reduced power mode. If this occurs, the Driver Information Center will display "ENG PWR REDUCED", and the maximum throttle opening will permit a speed of about 30 mph (48 km/h).

In addition, your vehicle was built with the steering column mounted airbag module wiring reversed. The driver's air bag will deploy under the same conditions (see "When Should An Air Bag Inflate?" in your owner's manual) and the vehicle meets the occupant protection requirements of the Motor Vehicle Safety Standards. In the event of a moderate frontal impact, however, the airbag will deploy fully instead of at the reduced level described in your owner's manual.

Your GM dealer will install wiring to isolate the voltage spike and modify the circuitry to the airbag module. These services will be performed for you at no charge .

We recommend that you contact your dealer to arrange a service date. Presenting the enclosed customer reply form to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please check the appropriate box and provide the new owner information, if available.

The enclosed customer reply form identifies your vehicle. Presentation of this form 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 form and mailing it back to us.

If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. The Customer Assistance Center’s hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

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.

This free online service offers vehicle and ownership related information and tools tailored to your specific vehicle. To get the most personalized information for your vehicle, visit www.mygmlink.com , and enter your vehicle's 17-character vehicle identification number (VIN) shown on the enclosed customer reply form.

We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your Chevrolet vehicle provides you many miles of enjoyable driving.

General Motors Corporation

Enclosure

05046