Product Safety - Headlight and/or DRL (Daytime Running Light) Malfunction

Step 10 of the service procedure in this bulletin has been revised. Please discard all copies of bulletin 07240A, issued November 2007.

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-2006 Chevrolet Optra model vehicles sold in Canada. Some of these vehicles may experience a loss of headlamp low beam or DRL (Daytime Running Light) function as a result of a melted instrument panel harness connector. Low beam failure would lead to reduced visibility during hours of darkness. DRL failure may render the vehicle less visible to other motorists and pedestrians during daylight hours. Both cases could lead to a vehicle crash.

This condition may be caused by a poor electrical contact of the terminals in the wiring harness splice pack (SP201), resulting in an electrical-arc and melting of the splice pack housing. The melted plastic material may remain inside the terminal contact area breaking the low beam headlamps and DRL circuits. The SP201 splice pack connects common wires for the headlamp and DRL systems.

Dealers are to inspect the SP201 splice pack for thermal damage and/or poor connections and repair by removing the three affected wires from the splice pack and crimping them together with a separate splice.

Involved are certain 2004-2006 Chevrolet Optra vehicles 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 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 recall is a violation of law in several provinces. 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.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI.





2. Remove the instrument panel trim and cluster. Refer to Instrument Panel Cluster (IPC) Replacement in SI.



3. Detach the SP201 splice pack from the tie bar located on the left hand side of the steering wheel. The splice pack anchor is located under the dash panel to the left of the steering column. Release the anchor of the splice pack by squeezing the anchor catches and pushing the anchor through the hole.



4. Pull the splice pack out from in between the A/C duct and dash support structure. Inspect the splice pack for the three purple wires shown above. Cut the three purple wires indicated by callouts 1 through 3 well away from any melted or damaged areas close to the splice pack. The two inboard wires may be found in the cavities indicated by either callout 2 or 3. (Wires in illustration above are shown at position of callout 2.)



5. Strip approximately 20 mm (0.75 in) of insulation from the ends of the three purple wires and splice using blue splice (P/N 19168447). Insert the wire from callout 1 into one end of the splice and the remaining purple wires from callout 2 or 3 in the other end. Crimp the connector using a standard crimping tool and seal the splice sleeve using Ultra Torch or another approved heating tool. Refer to Splicing Copper Wire Using Splice Sleeves in SI.
6. Temporarily connect the three IP connectors to the instrument cluster. Connect the negative battery terminal and test the headlights. The key must be on for the headlights to operate. If the headlights do not operate, further diagnosis is required. If the headlights operate properly, turn off the ignition, disconnect the battery, and continue with step 7.
7. Reattach the splice pack to its original position on the tie bar to prevent dash rattles.
8. Install the instrument panel cluster and trim. Refer to Instrument Panel Cluster (IPC) Replacement in SI.
9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI.
10. Verify that the headlamps, Daytime Running Lamps, and the DRL indicator light in the instrument panel are fully operational.

Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by October 31, 2008.

All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

When a customer requests reimbursement, they must provide the following:

Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS.

Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification.

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).

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:

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-2006 Chevrolet Optra model vehicles sold in Canada. As a result, GM is conducting a safety recall.

Some of these vehicles may experience a loss of headlamp low beam or DRL (Daytime Running Light) function as a result of a melted instrument panel harness connector. Low beam failure would lead to reduced visibility during hours of darkness. DRL failure may render the vehicle less visible to other motorists and pedestrians during daylight hours. Both cases could lead to a vehicle crash.

Your GM dealer will inspect and repair the instrument panel wiring harness. This service will be performed for you at no charge .

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.

If you have already paid for some or all of the cost to correct the condition in this recall, and you have not received reimbursement under a Vehicle Service Contract, you should contact your dealer to seek reimbursement. Please provide your dealer with your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair. Your request for reimbursement, including the information and documents mentioned above, must be received by your dealer by October 31, 2008. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products.

Customer Support Department

General Motors of Canada Limited

07240