Customer Satisfaction -- Coolant Leak

THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2008.

On certain 2008 model year Chevrolet Cobalt and Pontiac G5 vehicles, the hose connecting the surge tank to the thermostat cover may not seal sufficiently. This could result in a coolant leak at the thermostat cover. If enough coolant leaks out, the engine coolant temperature warning light will illuminate. If the vehicle is driven with the light illuminated, it could result in engine damage.

Dealers are to install an additional clamp to the hose at the thermostat cover.

Involved are certain 2008 model year Chevrolet Cobalt and Pontiac G5 vehicles built within these VIN breakpoints:

Important:  Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (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 the applicable system listed below. Dealers will not have a report available if they have no involved vehicles currently assigned.

-- US dealers - GM DealerWorld Recall Information

-- Canadian dealers - GMinfoNet Recall Reports

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

Parts required to complete this program 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.

1. Remove the engine cover.

1.1.	Unscrew the oil cap.

1.2.	Pull upward on the cover to unseat the cover from the pins.




2. Open the spring clamp (1) and push the hose fully down to the thermostat cover housing.



3. Install the hose clamp (2).

3.1.	Open the hose clamp (2) fully, disengaging the worm screw.

3.2.	Slide the hose clamp (2) over the surge tank outlet hose.

3.3.	Hand-start the worm screw to engage the hose clamp over the hose.

3.4.	Position the hose clamp (2) along the top of the existing spring clamp (1). The screw head should be on the outboard side of the hose and facing forward.

3.5.	Tighten the hose clamp. Keep the two clamps beside each other but with no overlap.




4. If the surge tank fluid level is below the cold full line, top it off to the line with coolant.
5. Wipe any spilled or leaked coolant from the engine and engine compartment.



6. Reinstall the engine cover.

6.1.	Engage the two pins.

6.2.	Reinstall the oil cap.

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 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 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, through October 31, 2008.

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 through October 31, 2008, 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:

We have learned that the hose connecting the surge tank to the thermostat cover on your 2008 model year Chevrolet Cobalt or Pontiac G5 vehicle may not seal sufficiently. This could result in a coolant leak at the thermostat cover. If enough coolant leaks out, the engine coolant temperature warning light will illuminate. If the vehicle is driven with the light illuminated, it could result in engine damage.

Your satisfaction with your 2008 model year Chevrolet Cobalt or Pontiac G5 vehicle is very important to us, so we are announcing a program to prevent this condition or, if it has occurred, to fix it.

What We Will Do: To prevent this condition from occurring, your GM dealer will install an additional clamp to the hose at the thermostat cover. This service will be performed for you at no charge until October 31, 2008.

What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date.

Customer Reply Form: 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.

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 GM vehicle provides you many miles of enjoyable driving.

Scott Lawson

General Director,

Customer and Relationship Services

Enclosure

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