Recall - Headlight/DRL Malfunction: Overview
SAFETYBulletin No.: 12155
Date: September 04, 2012
Subject: -12155 Headlight and/or DRL (Daytime Running Light) Malfunction
Models:
2004-2006 Chevrolet Optra (Canada Only)
Condition
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-2006 model year Chevrolet Optra vehicles sold in Canada. Some of these vehicles may experience a loss of headlamp function as a result of a melted instrument panel harness connector. Loss of headlamp function could lead to reduced driver visibility while driving at night, which may result in a crash.
Correction
Dealers are to remove the SP201 splice pack harness connector and reconnect the affected wires with two heat-shrink splices.
Vehicles Involved
All involved vehicles are identified by Vehicle Identification Number on the Investigate Vehicle History screen in GM Global Warranty Management system. Dealership service personnel should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content.
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 to Canadian dealers through the GM GlobalConnect 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 states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall.
Parts Information
Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A). 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
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.
5. Locate the two light blue wires. Cut the wires as close to the splice pack as possible. Strip away 20 mm of insulation from each wire and splice together all the sky blue wires (remove any damaged or burnt wire before stripping the insulation). Crimp the wires together with a splice sleeve and shrink the crimp connector with heat gun. DO NOT use an open flame.
6. Locate the three to five light green wires. Cut the wires as close to the splice pack as possible. Strip away 20 mm of insulation from each wire and splice together all the light green wires (remove any damaged or burnt wire before stripping the insulation). Crimp the wires together with a splice sleeve and shrink the crimp connector with heat gun. DO NOT use an open flame.
7. If recall 07240 has not been completed, repeat step 6 for the three purple wires.
8. 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 9.
9. Install the instrument panel cluster and trim. Refer to Instrument Panel Cluster (IPC) Replacement in SI.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI.
11. Verify that the headlamps, Daytime Running Lamps, and the DRL indicator light in the instrument panel are fully operational.
Customer Reimbursement
Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by September 30, 2013.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair.
All reasonable and customary costs to correct the condition described in this bulletin should be considered for reimbursement. Any questions or concerns should be reviewed with your GM Service representative prior to processing the request.
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 Warranties. 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.
Warranty Transaction Information
Submit a transaction using the table below.
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer.
Customer Notification
General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).
Dealer Recall Responsibility
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.
Disclaimer