Recall - Ignition Switch Fire Hazard: Overview

File In Section: Product Recalls

Bulletin No.: 02008B

Date: October, 2002

PRODUCT SAFETY RECALL

THIS BULLETIN SUPERCEDES RECALL BULLETIN 02008A, ISSUED MAY 2002, PLEASE DISCARD ALL COPIES OF 02008A. THE PARTS TABLE, SERVICE PROCEDURE, AND CLAIM TABLE HAVE BEEN REVISED TO ADDRESS CORROSION OF THE STARTER SOLENOID "S" TERMINAL STUD.

SUBJECT:
02008B - IGNITION CIRCUIT THERMAL EVENTS

MODELS:
1995-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE
1996-97 BUICK SKYLARK, OLDSMOBILE ACHIEVA AND PONTIAC GRAND AM

CONDITION

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1995-1997 Chevrolet Cavalier and Pontiac Sunfire model cars, and 1996-1997 Buick Skylark, Oldsmobile Achieva, and Pontiac Grand Am model cars. If the engine fails to start and the driver holds the key in the "start" position for an extended period, high current flows through the ignition switch, and sometimes produces enough heat to melt internal switch parts. If the switch is damaged, a fire could occur in the steering column, even with the engine off and the key removed. The fire could spread to the interior of the car which could injure occupants of the car or cause damage to adjoining structures.

CORRECTION

Dealers are to install a relay kit and verify that the vehicle will start with a properly charged battery in good operating condition (adequate reserve capacity, or cold cranking amps).

VEHICLES INVOLVED

Involved are certain 1995-1997 Chevrolet Cavalier and Pontiac Sunfire model cars, and 1996-1997 Buick Skylark, Oldsmobile Achieva, and Pontiac Grand Am model cars built within the VIN breakpoints shown.

IMPORTANT:
Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin.

The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall.

PARTS INFORMATION

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.

Important:
It is estimated that only 5% of involved vehicles will require ignition switch and tilt lever replacement. Please order parts accordingly.

RECALL IDENTIFICATION LABEL - For US and IPC

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the RECALL vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering.

CUSTOMER REIMBURSEMENT

Previous ignition switch replacement and related wiring repair should be considered for possible reimbursement on a case-by-case basis. Dealers should confirm why the ignition switch was replaced and related wiring repaired (i.e., heat damage, fuse blown, etc.) and that there were no other contributing factors (i.e., after market remote starters, alarm systems, etc.). Customers requesting reimbursement for previous ignition switch replacement and related wiring repair must provide proof of ownership at time of repair and the original paid receipt. Such reimbursement should be limited to reasonable and customary charges for this type of service. If deemed appropriate, reimbursement expense should be identified in the "Net Item" column under labor operation V0851. Note that reimbursement for replacement of a steering column tilt lever is allowable since the lever may have been damaged when the ignition switch was replaced. Reimbursement for battery replacement and/or the repair of other starting system components are not covered by this recall.

Customers from the States of California, Connecticut, Virginia, and Wisconsin must submit requests for reimbursement directly to General motors.

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.

CLAIM INFORMATION

CUSTOMER NOTIFICATION For US and CANADA

Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter shown in this bulletin).

To coordinate customer requests for this service with the anticipated availability of harness kits, customer notification letters ask 6 cylinder N-Car owners to contact their dealers immediately. The owners of 4 cylinder N-Cars and J-Cars will be asked to contact their dealers in phases during May, June and July.

CUSTOMER NOTIFICATION - For IPC

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 sample letter shown.

DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions)

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.

DEALER RECALL RESPONSIBILITY - ALL

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. This could be done by mailing to such customers, a copy of the customer letter accompanying this bulletin. 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