Product Safety - Body-Color Roof Adhesive Separation

This bulletin is being revised to include (30) 2007 model year vehicles (U.S. and Export). Discard all copies of bulletin 06041B, issued November 2006.

This recall was released in phases. As each phase was released, Customer Satisfaction Program 05112 was cancelled. Vehicles that were not repaired under Customer Satisfaction Program 05112 were transferred into this safety recall. In addition, vehicles that had the roof replaced, and according to the repair order did not have the adhesive foam applied, were called back for the adhesive installation. Vehicles that had the temporary roof installed (T5641) were also called backed for roof replacement.

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2005-2007 Chevrolet Corvette vehicles equipped with a body-color roof. Some of these vehicles have a condition in which the adhesive between the roof panel and the frame may separate. If there is a partial separation, the occupant may notice one or more symptoms, such as a snapping noise when driving over bumps, wind noise, poor roof panel fit, roof panel movement/bounce when a door or hatch is closed, or a water leak in the headliner. If there is a complete separation, the roof panel may detach from the vehicle. If this were to occur while the vehicle was being driven, it could strike a following vehicle and cause injury and property damage.

Dealers are to apply adhesive foam to the roof panel to ensure the proper adhesion, or, if signs of separation are found, install a new design roof panel.

Involved are certain 2005-2007 Chevrolet Corvette vehicles equipped with a body-color roof 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 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

--Export dealers - sent directly to dealers

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 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.

Beginning the week of February 13, 2006, each dealer was shipped a Two-Part Adhesive Applicator Gun, BO 48206 for use in Customer Satisfaction Program 05112. That gun will be required for this recall. The tool was furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657.

Z06 Vehicles

Important Information: Inspect the roof panel before performing the service procedure below. Determine if the roof panel is manufactured with polycarbonate or SMC material. The interior side of the roof panel is either black or white. Roof panels manufactured with polycarbonate material are black and roof panels manufactured with SMC material are white. Carefully lower the rear edge of the headliner to view the interior side of the roof panel.

1. Remove the rear roof bow trim panel. Refer to the Rear Roof Bow Trim Panel Replacement procedure in SI.
2. Pry down on the edge of the headliner to loosen it from the vehicle roof panel.

Important: A flashlight may be required to view the interior side of the roof panel.

3. Pull the edge of the headliner down about 51 mm (2 in) to view the color of the interior side of the roof panel.

•	If the roof panel is manufactured with SMC material (white), do NOT perform the service procedure below. Re-install the rear roof bow trim panel. No further action is required.

•	If the roof panel is manufactured with polycarbonate material (black), refer to the Roof Panel Adhesion Inspection and Foam Fill Procedure for Z06 Vehicles procedure found in this bulletin.

Roof Panel Inspection and Foam Fill Procedure for Z06 Vehicles

Tools Required

BO 48206 Two-Part Applicator Gun

Notice: Carefully remove the sunshade bezel to avoid damaging it. DO NOT DISCARD THE BEZEL AS INSTRUCTED IN SI; IT WILL BE REUSED. If the bezel is difficult to remove, use a screwdriver wrapped with tape to remove it.

1. Remove the driver and passenger side sun visor and sun visor clamp. Refer to the Sun Shade Replacement procedure in SI.
2. Disconnect the rear view mirror electrical connector. Refer to the Rear View Mirror Replacement procedure in SI.
3. Remove the windshield side garnish molding. Refer to the Windshield Side Garnish Molding Replacement procedure in SI.

Important: The rear roof bow trim panel holds the rear of the headliner in place.

4. Remove the rear roof bow trim panel. Refer to the Rear Roof Bow Trim Panel Replacement procedure in SI.



5. Remove the headliner from the vehicle.

5.1.	Ensure that the sunshade and rear view mirror electrical connectors have been disconnected.

5.2.	Pry down on the edge of the headliner to loosen it from the vehicle roof panel.

5.3.	Lower the headliner and route it through the rear hatch.

6. Remove the bolts on all four corners of the roof panel and the center rear bracket.
7. Remove the roof panel from the vehicle. Discard the 10 roof panel fasteners.




Important: Note the orientation and number of shims on the driver and passenger side of the roof panel assembly contact points and the center rear bracket.

Notice: Protect the painted surface of the roof panel from damage.

8. Place the roof panel, painted surface down, on a glass stand, bench, or other suitable area.



9. Inspect for proper adhesion by inserting a 0.254 mm (.010 in) feeler gage between the panel and the frame. If the feeler gage fits between the panel and the frame, and the depth is 19.05 mm (.750 in) or greater, the roof panel is separated from the frame.

•	If the feeler gage does not identify any area of the roof panel with separation, proceed to Step 10.

•	If the feeler gage identifies areas of roof panel separation, replace and paint the roof panel. Refer to Step 20.

10. Prepare the roof panel for foam adhesive injection.




Important: Use tape with strong adhesion. It is difficult to clean the foam off of visible surfaces. Ensure that the tape covers holes 1, 2, and 3.

10.1.

Cut four pieces of tape to cover holes 1, 2, and 3. Tape length: 76 mm (3 in); Tape width: 76 mm (3 in).

10.2.

Place the tape near the roof panel holes 1, 2, and 3. Two pieces of tape are required for roof panel hole #1.

10.3.

Insert the two removed bolts from the rear center attachment into the holes (finger tight) until the washer is touching the roof inner panel. This it to prevent foam from filling the location where the bolts are to be when the roof is reinstalled.

Standard Coupe Vehicle (non Z06)

Important Information: Inspect the roof panel before performing the service procedure below. Determine if the roof panel is manufactured with polycarbonate or SMC material. The interior side of the roof panel is either black or white. Roof panels manufactured with polycarbonate material are black and roof panels manufactured with SMC material are white. Carefully remove an edge of the headliner to view the interior side of the roof panel.

1. Remove the roof panel from the vehicle.

Notice: Be sure to protect the painted surface of the panel from damage.

2. With the painted surface down, support the roof panel horizontally on a glass stand, bench, or other suitable area.
3. Pull the edge of the headliner back about 51 mm (2 in) to view the color of the interior side of the roof panel.

•	If the roof panel is manufactured with SMC material (whtie), do NOT perform the service procedure below. Re-install the roof panel. No further action is required.

•	If the roof panel is manufactured with polycarbonate material (black), refer to the Roof Panel Adhesion Inspection and Foam Fill Procedure fo Standard Coupe Vehicles (non Z06) procedure found in this bulletin.

Roof Panel Inspection and Foam Fill Procedure for Standard Coupe Vehicles (non-Z06)

Tools Required

BO-48206 Two-Part Applicator Gun

1. Remove the roof panel from the vehicle.

Notice: Be sure to protect the painted surface of the panel from damage

2. With the painted surface down, support the roof panel horizontally on a glass stand, bench, or other suitable area.
3. Lift the edge of the headliner in the areas indicated for inspection in the next step.



4. Inspect for proper adhesion by inserting a 0.254 mm (.010 in) feeler gage between the panel and the frame. Particular attention should be paid to the areas around the rear latch and the front corners. If the feeler gage fits between the panel and the frame, and the depth is 19.05 mm (.750 in) or greater, the roof panel has some degree of separation.

•	If the feeler gage does not identify any area of the roof panel with separation, proceed to Step 7.

•	If the feeler gage identifies area of roof panel separation, replace the roof panel. The SI procedures below may be used.

-	Headliner Replacement - Roof Lift Off Panel

-	Roof Lift Off Panel Rear Latch Replacement

-	Roof Lift Off Panel Front Latch Handle Replacement

-	Roof Lift Off Panel Molding Replacement

-	Roof Lift Off Panel Rear Locator Pin Replacement

-	Roof Lift Off Panel Adjustment




5. Remove the rear latch trim screws (1) and the trim (2).



6. Remove the rear latch attaching bolts (3) and the rear latch assembly (4).
7. Install the rear latch attaching bolts (3) to the frame.



8. Remove the front corner brackets (5).





9. Tape off the rear latch and the front bracket areas.

Important: Cover the area completely with tape that has strong adhesion. It is difficult to clean the foam off of visible surfaces.

10. Using a pen or small knife, cut holes in the tape to inject foam.

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 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).

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.

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.

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 a defect that relates to motor vehicle safety exists in certain 2005, 2006 and 2007 model year Chevrolet Corvette vehicles equipped with a body-color roof. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we have taken this action for your safety and continued satisfaction with our products.

Your vehicle may have a condition in which the adhesive between the roof panel and the frame may separate. If there is a partial separation, you may notice one or more symptoms, such as a snapping noise when driving over bumps, wind noise, poor roof panel fit, roof panel movement/bounce when a door or hatch is closed, or a water leak in the headliner. If there is a complete separation, the roof panel may detach from the vehicle. If this were to occur while the vehicle was being driven, it could strike a following vehicle and cause injury and property damage.

Your GM dealer will apply adhesive foam to ensure the proper adhesion, or, if signs of separation are found, your dealer will install a new design roof panel.

If you have already taken your vehicle to your GM dealer for this condition and the roof panel was replaced, we still need you to bring your vehicle in for an inspection.

This service will be performed for you at no charge . Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual inspection and service correction time of approximately 25 minutes to 2½ hours, depending on the service required.

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

06041