Campaign - Air Bag, A/C Wiring Installation: Overview
A/C System Wiring and Dual Stage Airbag Module Wiring# 05046A - (Jul 22, 2005)
Model:
2005 CHEVROLET COBALT
2005 PONTIAC PURSUIT
EQUIPPED WITH A 2.2L ENGINE (L61) AND AIR CONDITIONING (C67)
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.
Condition
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 owners 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
Correction
Dealers are to install wiring to isolate the voltage spike and modify the circuitry to the airbag module.
Vehicles Involved
Involved are certain 2005 Chevrolet Cobalt and Pontiac Pursuit vehicles equipped with a 2.2L engine (L61) and air conditioning (C67), and built within the VIN breakpoints shown.
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.
Parts Information
Important:
An initial supply of harnesses required to complete this recall will be preshipped 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. Preshipped 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.
Service Procedure
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.
Courtesy Transportation
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.
Claim Information
Submit a Product Program Claim with the information shown.
Customer Notification
General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin).
Dealer Program Responsibility
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 shown 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.
Disclaimer