Modification to Increase Head Impact Protection (Canadian Vehicles Only)

The service procedure in this bulletin has been revised to clarify the installation of the energy absorbing device. Please discard all copies of bulletin 08016, issued March 2008.

THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2009.

During the 2008 model year, General Motors improved the head impact protection in the Chevrolet HHR vehicles without roof-rail airbags. This added protection will reduce the risk of injury if a front seat occupant's head were to impact a point near the attachment of the sun visor to the roof. General Motors is making similar changes to all 2006-2007 model year and certain 2008 model year Chevrolet HHR vehicles without roof rail airbags that were built before these changes were implemented.

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

Involved are all 2006-2007 model year and certain 2008 model year Chevrolet HHR vehicles without roof-rail airbags and 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 GMinfoNet Recall Reports. 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 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.

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 door weatherstrip (1).




Important: The headliner will drop about 203 mm (8 in), which will provide adequate room to install the insert energy absorbing (EA) plastic piece (2) into the headliner (3). Use GM Care Hot Melt Adhesive Sticks (P/N 12377914) or equivalent to glue the EA plastic piece (2) into the headliner (3).

4. Locate the installation point for installing the energy absorbing (EA) plastic piece (2) onto the A-pillar edge (1) of the headliner (3).






Important: The EA plastic pieces are marked "LH" (2) for left hand (driver’s side) and "RH" for right hand (passenger’s side).

5. Apply hot glue to the energy absorbing (EA) plastic piece pocket areas (1).






Important: Ensure that the energy absorbing (EA) plastic piece (2) is installed properly. The body of the EA plastic piece should be firmly attached to the headliner (3).

6. Insert the energy absorbing (EA) plastic piece to the headliner trim with hot glue.
7. Tuck headliner in place to ensure proper fit with the A-pillar trim panels and sunshades.



8. Install the A-pillar trim panels. Refer to Windshield Garnish Molding Replacement in SI.
9. Install the sunshades. Refer to Sunshade Replacement in SI.



10. Install the door weatherstrip (1).

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 April 30, 2009.

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 April 30, 2009, 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 General Motors is conducting a customer satisfaction program that affects 2006, 2007, and some 2008 model year Chevrolet HHR vehicles without roof-rail airbags.

During the 2008 model year, GM improved the head impact protection in these vehicles. This added protection will reduce the risk of injury if a front seat occupant's head were to impact a point near the attachment of the sun visor to the roof. GM is making similar changes to all 2006 and 2007 model year and certain 2008 model year Chevrolet HHR vehicles without roof-rail airbags that were built before these changes were implemented.

Your GM dealer will install an additional energy absorbing device between the front headliner and the vehicle roof on the driver and passenger side of the vehicle. This service will be performed for you at no charge until April 30, 2009 .

To limit any possible inconvenience, we recommend that you contact your General Motors 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.

You may be contacted by a dealer other than the dealer who sold or is currently servicing your vehicle. Please be advised that you may take your vehicle to the General Motors dealership of your choice to have the recall service work completed.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department

General Motors of Canada Limited

08019