Recall Bulletin
Contents
1. FROM THROUGH 1997 Chevrolet Corvette V5100001 V5109707 1998 Chevrolet Corvette W5100001 W5131069 1999 Chevrolet Corvette X5100001 X5133283 2000 Chevrolet Corvette Y5100001 Y5133610 2001 Chevrolet Corvette 15100001 15135601 2002 Chevrolet Corvette 25100002 25135762 2003 Chevrolet Corvette 35100003 35135465 2004 Chevrolet Corvette 45100001 45120862 IMPORTANT Dealers should confirm vehicle eligibility through GMVIS GM Vehicle Inquiry System prior to beginning recall repairs Not all vehicles within the above breakpoints may be involved For US and Canada For GM dealers Canadian Saab dealers and Canadian Saturn retailers with involved vehicles a Campaign Initiation Detail Report CIDR 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 For US Saturn retailers only the involved vehicles are provided in a Facility VIN List file sent to you at your current email address Dealers retailers will not have a report available if they have no involved vehicles currently assigned For Export 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 is being furnished to involved dealers Dealers will not receive a report with the re2. a NEW steering wheel set nut on the steering column shaft Tighten Tighten the nut to 41 N m 30 Ib ft Install the retaining screws removed from the steering wheel into the backside of the inflatable restraint module Tighten Tighten the screws to 6 N m 53 Ib in Position the inflatable restraint module to the steering wheel and connect the SIR electrical connector the horn wiring harness connector to the steering column and the ground wire to the column Install the inflatable restraint module on the steering wheel by pushing on both the right and left sides of the module until the retaining screws snap into place Connect the passenger yellow 2 way air bag connector located at the base of the steering column and install the CPA Page 13 February 2006 Bulletin No 04006C 49 50 51 52 59 Connect the driver s yellow 2 way air bag connector located at the base of the steering column and install the CPA Position the driver s side lower closeout panel below the IP and install the courtesy lamp Raise the closeout panel to the IP and engage the push in retainers to the IP lower support beam Align the right hand forward edge of the panel to the tab on the accelerator pedal bracket Push up to secure Install the push on retaining nut to the steering column bracket stud Install the SDM fuse Position the kick up panel to the opening in the floor and insert the lower tabs into the slots in the multi
3. for details on Product Recall Claim Submission C G USTOMER NOTIFICATION For US and CANADA eneral Motors will notify customers of this recall on their vehicle see copy of customer letter included with this bulletin C USTOMER 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 attached sample letter Page 28 February 2006 Bulletin No 04006C 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 custome
4. 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 CUSTOMER REIMBURSEMENT For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center not by dealers A General Motors Product Recall Customer Reimbursement Procedure Form is included with the customer letter IMPORTANT Refer to the GM Service Policies and Procedures Manual section 6 1 12 for specific procedures regarding customer reimbursement and the form CUSTOMER REIMBURSEMENT For Canada Customer requests for reimbursement of previously paid repairs for this recall condition are to be submitted to the dealer by September 30 2005 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 e Proof of ownership at time of repair e Original paid receipt confirming the amount of repair expense s that were not reimbursed a description of the repair and the person or entity performing the repair Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS IMPORTANT Refer to the G
5. in retainers from the IP lower support beam 10 Insert the IP courtesy lamp assembly up through the opening in the closeout panel 11 Lower and remove the closeout panel Release the notch in the right hand forward edge of the closeout panel from the tab on the accelerator pedal bracket Page 7 February 2006 Bulletin No 04006C 68614 12 Remove the connector position assurance CPA from the driver s yellow 2 way air bag connector located at the base of the steering column and disconnect the connector 68617 13 Remove the CPA from the passenger yellow 2 way air bag connector also located at the base of the steering column and disconnect the connector 14 Remove the screws attaching the driver s inflator module to the steering wheel 3 and pull the module away from the steering wheel 15 Disconnect the SIR electrical connector 2 from the backside of the module the horn wiring harness connector 6 from the steering column and the ground wire 5 from the steering column Remove the module 16 Remove the nut attaching the steering wheel to the column and discard the nut Page 8 February 2006 Bulletin No 04006C J 42120 70114 17 Using tool J 1859 A Steering Wheel Puller and J 42120 Steering Wheel Puller Legs remove the steering wheel from the column 82174 18 Using a small flat bladed screwdriver release the locking tab from the tilt lever handle and pull the lever straight out Page 9 Febr
6. of the steering column and install the CPA Position the driver s side lower closeout panel below the IP and install the courtesy lamp Raise the closeout panel to the IP and engage the push in retainers to the IP lower support beam Align the right hand forward edge of the panel to the tab on the accelerator pedal bracket Push up to secure Page 26 February 2006 Bulletin No 04006C 48 Install the push on retaining nut to the steering column bracket stud 49 Install the SDM fuse 50 Position the kick up panel to the opening in the floor and insert the lower tabs into the slots in the multi use bracket 51 Close the panel and engage the latches or hook and loop fasteners 52 Connect the negative battery cable 53 Return to the section titled Functional Test of ECL and rerun the test o If the Functional Test fails again you still can hear a ratcheting ticking or scraping sound contact Technical Assistance for additional information 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 recall is very important in maintaining customer satisfaction Dealers are to ensure that these customers understand that shuttle service or some other
7. the ECL lock pin may not withdraw fully and in vehicles where there is abnormally low clearance to the lock plate there may be contact between the pin and lock plate This can cause a noise or ratcheting when the steering wheel is turned or if there is insufficient clearance the steering wheel cannot be turned If one of these conditions occurs a crash could occur without warning Copyright 2006 General Motors Corporation All Rights Reserved Page 2 February 2006 Bulletin No 04006C CORRECTION Dealers are to remove the column lock plate on U S and Canadian vehicles equipped with an automatic transmission and U S vehicles equipped with a manual transmission After the service correction the steering column will no longer lock when the key is removed On Canadian and export vehicles equipped with a manual transmission and export vehicles equipped with an automatic transmission dealers are to 1 reprogram the PCM and 2 verify there is adequate lock plate clearance and if necessary replace the lock plate After the service correction the steering column will continue to lock when the key is removed VEHICLES INVOLVED Involved are certain 1997 2004 Chevrolet Corvettes equipped with a manual transmission 1997 2000 Chevrolet Corvettes equipped with an automatic transmission and 2001 2004 Chevrolet Corvette equipped with automatic transmission European export only built within these VIN breakpoints YEAR DIVISION MODEL
8. 5 0 volt limit for the test Follow the on screen instructions o If you could hear or feel any type of ratcheting ticking or scraping sound that wasn t heard earlier when turning the steering wheel the steering column lock plate retaining ring and steering wheel retaining nut must be replaced Proceed to the section in this bulletin titled Lock Plate Retaining Ring and Nut Replacement o If you could NOT hear or feel any type of ratcheting ticking or scraping sound when turning the steering wheel no further repairs are required Proceed to the next step Press the EXIT button on the Tech 2 as necessary to return to the diagnostic code inquiry screen Disconnect the battery charger from the vehicle and close the hood Important On 1997 models and 1998 models built BEFORE 5 26 98 EL 47728 electronic column lock tester must be removed from the vehicle in the next step If it is not removed the ECL and starter will not operate with the ignition key If the vehicle is a 1997 or 1998 built before 5 26 98 disconnect the EL 47728 from the BCM and the vehicle s wiring harness Then reconnect the vehicle s wiring harness to the BCM Also reassemble the BCM area of the vehicle at this time Important When using EL 47728 some codes may be set in the BCM These codes must be cleared in the next step Using the Tech 2 check and erase any current and history codes that may be stored in the BCM Page 19 Februa
9. 53 SIR MUST be used when removing the retaining ring and lock plate in the next step 27 Using J 23653 SIR 2 remove the retaining ring and the lock plate 1 and discard both Page 11 February 2006 Bulletin No 04006C 1489468 28 Align and position the cam orientation plate 1 included in the kit on the steering column shaft 1489426 Notice When installing the cam orientation plate in the next step a NEW retaining ring must be used Do not reuse the original retaining ring J 23653 SIR and J 42137 MUST be used when installing the cam orientation plate and new retaining ring in the next step Failure to use these tools may result in damage to the cam orientation plate retaining ring or steering column components 29 Using J 23653 SIR 2 and J 42137 1 install the cam orientation plate and the new retaining ring included in the recall kit The cam orientation plate replaces the lock plate removed in the previous step 30 Position the SIR coil on the steering column and install the snap ring 31 Disconnect the electrical connector from the ECL located on the right lower side of the steering column 32 Attach the NEW relay 1 and harness included in the kit to the left IP brace as shown and secure with plastic tie straps 33 Route the NEW relay harness over the knee bolster Page 12 February 2006 Bulletin No 04006C 34 35 36 37 38 39 45 46 47 48 Important The conn
10. CL has been completed Access to this area will be required when installing EL 47728 electronic column lock tester 5 After completion of the reprogramming proceed to the next section titled Functional Test of ECL Functional Test of ECL Procedure 3 Tools Required e EL 47728 Electronic Column Lock Tester for 1997 and 1998 models built before 5 26 98 Important Depending on conditions that may occur during the functional test the Tech 2 may display various messages Sequence Number Definitions for the different sequence messages are at the end of the functional test procedure in this bulletin Important In order to perform the following procedure your Tech 2 must be updated with software version 24 008 or later If your Tech 2 does not have the necessary software you will need to update it before proceeding 1 Raise the vehicle on a suitable lift so that the front wheels are off the ground by a few inches 2 Position the front tires wheels in the straight ahead position Page 17 February 2006 Bulletin No 04006C 3 4 12 13 Open the hood and connect a battery charger to the vehicle Operate the charger at a Low or Medium charge rate Turn the ignition switch to the ON position Important In order to hear a possible interference between the ECL and lock plate in the steering column during the functional test the area in and around the vehicle must be as quiet as possible in the next few steps Close b
11. File In Section Product Recalls Bulletin No O4006C Date February 2006 Recall Bulletin Canada PRODUCT SAFETY RECALL SUBJECT ELECTRONIC COLUMN LOCK SYSTEM MODELS 1997 2004 CHEVROLET CORVETTE EQUIPPED WITH A MANUAL TRANSMISSION 1997 2000 CHEVROLET CORVETTE EQUIPPED WITH AN AUTOMATIC TRANSMISSION 2001 2004 CHEVROLET CORVETTE EQUIPPED WITH AN AUTOMATIC TRANSMISSION EUROPEAN EXPORT ONLY THIS BULLETIN CANCELS AND REPLACES BULLETIN 04006B ISSUED NOVEMBER 2004 THE SERVICE PROCEDURE FOR U S VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION HAS BEEN REVISED PLEASE REVIEW THIS NEW INFORMATION IMMEDIATELY ALL COPIES OF BULLETIN 04006B SHOULD BE DESTROYED CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1997 2004 model year Chevrolet Corvette vehicles When you remove the ignition key the electronic column lock ECL system prevents turning of the steering wheel When the vehicle is started it unlocks the steering Two conditions can prevent steering while the vehicle is moving 1 The vehicle is designed so that if the column fails to unlock when the vehicle is started the fuel supply will be shut off if the driver tries to move the vehicle If voltage at the powertrain control module is low or interrupted however the fuel shut off may not occur and the vehicle can be accelerated while the steering is locked 2 During quick cranks
12. M Service Policies and Procedures Manual section 1 6 2 for specific procedures regarding customer reimbursement verification C Page 27 February 2006 Bulletin No 04006C LAIM INFORMATION Submit a Product Recall Claim with the information indicated below k k PART PARTS LABOR LABOR REPAIR PERFORMED COUNT PART NO ALLOW CC FC OP HOURS Install Wire Kit Only MA 96 V1153 Automatics Except Export Auto Install Wire Kit Only U S MA 96 V1409 Manuals Install Wire Kit Reprogram amp Perform Functional Test All Canadian amp Export Manuals amp Export Auto Add Replace Lock Plate Perform Reprogram amp Functional Test All Canadian amp Export Manuals amp Export Auto Note Inc using EL 47728 on 1997 amp 1998 models built before 5 26 98 Add Replace Lock Plate 3 ze Courtesy Transportation for N A N A N A MA 96 vehicles within the New Vehicle Limited Warranty US amp Canadian Dealers Customer Reimbursement MA 96 V1154 Dealers US CAC The Parts Allowance should be the sum total of the current GMSPO Dealer net price plus applicable Mark Up or Landed Cost Mark Up for IPC for applicable parts needed to complete the repair Submit courtesy transportation using normal labor operations for courtesy transportation as indicated in the GM Service Policies and Procedures Manual for vehicles within the New Vehicle Limited Warranty Refer to the General Motors WINS Claims Processing Manual
13. P courtesy lamp assembly up through the opening in the closeout panel Lower and remove the closeout panel Release the notch in the right hand forward edge of the closeout panel from the tab on the accelerator pedal bracket 68614 Remove the connector position assurance CPA from the driver s yellow 2 way air bag connector located at the base of the steering column and disconnect the connector Remove the CPA from the passenger yellow 2 way air bag connector also located at the base of the steering column and disconnect the connector Remove the screws attaching the driver s inflator module to the steering wheel and pull the module away from the steering wheel Disconnect the SIR electrical connector from the backside of the module the horn wiring harness connector from the steering column and the ground wire from the steering column Remove the module Remove the nut attaching the steering wheel to the column and discard the nut Page 22 February 2006 Bulletin No 04006C J 42120 70114 16 Using tool J 1859 A Steering Wheel Puller and J 42120 Steering Wheel Puller Legs remove the steering wheel from the column 82174 17 Using a small flat bladed screwdriver release the locking tab from the tilt lever handle and pull the lever straight out Page 23 February 2006 Bulletin No 04006C 18 20 21 22 158135 Using a small flat bladed screwdriver pry the lower edge of the combination
14. Turn the ignition switch to the OFF position 3 Open the hood and disconnect the negative battery cable 71195 4 Disengage the upper latches on the front kick up panel on the passenger side 5 Lift the kick up panel s lower edge out of the slots in the relay bracket Important The Electric Column Lock ECL relay described in the next step can be identified by the four wires that connect to it Prior to the modification being done there should be two ORANGE wires one DARK GREEN and one WHITE wire If there is also a purple wire a total of five wires then the Wire and Relay Kit has already been installed and you should proceed to the section titled Service Reprogramming 6 Locate the ECL relay which is above the body control module BCM 7 Remove the connector position assurance CPA clip from the back of the ECL relay connector 8 Remove the ECL relay harness from the backside of the relay assembly Page 15 February 2006 Bulletin No 04006C Important The relay being removed in the next step is a single pole single throw design With the wiring modifications being made in the next steps a single pole double throw relay is required Only the new relay included with the jumper harness can be used once the wiring modifications have been made Remove the ECL relay from the connector and discard the relay Using the appropriate terminal release tool remove the ORANGE wire from position C1 on the ECL relay conne
15. abs Install the lower retaining screws and the screws located behind the combination fog lamp trunk release switch and the inside air temperature sensor grill Tighten Tighten the screws to 1 8 N m 16 lb in Connect the electrical connector to the combination fog lamp trunk release switch and install the assembly into the opening in the IP Press firmly to secure Repeat this step on the inside air temperature sensor grill Slide the tilt lever in the steering column until the locking tab clicks into place Remove pull the two inflatable restraint module retaining screws from the steering wheel Position align and press the steering wheel onto the steering column shaft Tighten Tighten the nut to 41 N m 30 Ib ft Install the two retaining screws removed from the steering wheel into the backside of the inflatable restraint module Tighten Tighten the screws to 6 N m 53 Ib in Position the inflatable restraint module to the steering wheel and connect the SIR electrical connector the horn wiring harness connector to the steering column and the ground wire to the column Install the inflatable restraint module on the steering wheel by pushing on both the right and left sides of the module until the retaining screws snap into place Connect the passenger yellow 2 way air bag connector located at the base of the steering column and install the CPA Connect the driver s side yellow 2 way air bag connector located at the base
16. call bulletin 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 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 Page 3 February 2006 Bulletin No 04006C PARTS INFORMATION Parts required to complete this recall 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 89023816 Harness Kit Strg Whl Theft Dtrnt Lk Shorting U S manuals and all automatics except export vehicles 88952428 Wire Kit Strg Whl Theft Dtrnt Lk 1 If Req d 1998 2000 Canadian and export manuals amp export automatics Ring Strg Shf Lk Plt Ret SERVICE PROCEDURE The required repairs vary depending on the model year build date and whether Customer Satisfaction Program 01044 or Technical Service Bulletin 01 02 35 008 has previously been performed Refer to the chart below to determine the correct repairs for the vehicle you are working on After de
17. ck shorting harness being installed The harness is only for use on Non Export vehicles with automatic transmissions It is NOT for use on manual transmission vehicles or EXPORT automatic transmission vehicles If the harness has been installed it must be removed If the harness is not there replace the ECL Page 20 February 2006 Bulletin No 04006C Lock Plate Retaining Ring and Nut Replacement The following procedure should only be performed if the results of the Functional Test direct you to this section 6 Tools Required J 1859 A Steering Wheel Puller J 42120 Steering Wheel Puller Legs J 23653 SIR Steering Column Lock Plate Compressor Turn the ignition switch to the OFF position Disconnect the negative battery cable _ Bigs fies are 71195 Disengage the upper latches or hook and loop fasteners on the front floor kick up panel on the passenger side Lift the kick up panel s lower edge out of the slots in the relay bracket Remove the SDM fuse from the IP fuse block located behind the kick up panel that was just removed 64671 Using a flat bladed tool carefully pry the IP courtesy lamp assembly from the driver s side lower closeout Page 21 February 2006 Bulletin No 04006C 12 13 14 95689 Remove the push on retaining nut from the steering column bracket stud Release the driver s side lower closeout panel push in retainers from the IP lower support beam Insert the I
18. ctor Using the appropriate terminal release tool remove the WHITE wire from position A2 on the ECL relay connector Swap the two terminal positions and re insert them so that the ORANGE wire is now in position A2 and the WHITE wire is now in position C1 Connect the remaining purple wire and terminal on the jumper harness into position B2 in the ECL relay connector Install the NEW single pole double throw relay included with the jumper harness kit to the ECL connector Release the retainer holding the BCM and reposition the module for access to the electrical connectors 802246 Disconnect the green 16 way connector from the BCM The above illustration is rotated approximately 90 degrees Using the appropriate terminal release tool remove the purple wire and terminal from cavity A6 of the BCM connector Slide the piece of heat shrink tubing on the jumper harness included in kit P N 88952428 Connect the female terminal and wire removed from the BCM connector to the male terminal on the jumper harness Slide the heat shrink tubing over the two terminals that you just connected together and apply heat as necessary to shrink seal the tubing Install the female terminal on the jumper harness into cavity A6 in the BCM connector Reconnect the green 16 way connector to the BCM Position the BCM to the electrical panel and secure with the retainer Attach the new purple wire
19. ectors on the NEW relay harness are specific and MUST be connected correctly in the next steps When connected the new connection becomes J165 P165 Connect one end of the NEW relay harness into the connector on the ECL Connect the other end on the NEW relay harness into the connector that was disconnected from the ECL in Step 31 Install the upper steering column cover and install the attaching screw Tighten Tighten the screw to 1 9 N m 17 Ib in Install the lower steering column and attaching screws Tighten Tighten the screws to 4 N m 35 Ib in If equipped connect the electrical connector to the inside air temperature sensor located on the knee bolster trim panel Install the knee bolster trim panel and press firmly to engage the locking tabs Install the lower retaining screws and the screws located behind the combination fog lamp trunk release switch and the inside air temperature sensor grill Tighten Tighten the screws to 1 8 N m 16 lb in Connect the electrical connector to the combination fog lamp trunk release switch and install the assembly into the opening in the IP Press firmly to secure Repeat this step on the inside air temperature sensor grill Slide the tilt lever in the steering column until the locking tab clicks into place Remove the inflatable restraint module retaining screws from the steering wheel Position align and press the steering wheel onto the steering column shaft Install
20. ence column lock after starting the engine contact your dealer to arrange for repair How Long Will The Repair Take It is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 20 minutes to 1 hour and 40 minutes depending on the type of transmission you have in your vehicle because of service scheduling requirements Contacting Your Dealer To limit any possible inconvenience we recommend that you contact your GM 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 Page 30 February 2006 Bulletin No 04006C available on your scheduled appointment date Should your dealer be unable to schedule a service date within a reasonable time you should contact the appropriate Customer Assistance Center at the listed number below Division Number Text Telephones TTY Chevrolet 1 800 630 2438 1 800 833 2438 Puerto Rico English 1 800 496 9992 Puerto Rico Espanol 1 800 496 9993 Virgin Islands 1 800 496 9994 If after contacting the appropriate Customer Assistance Center you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time you may wish to write the Administrator National Highway Traffic Safety Administration 400 Seventh Street SW Washington DC 20590 or call 1 888 327 4236 Custome
21. ep If the vehicle is a 1997 or 1998 built before 5 26 98 disconnect the upper pink 32 way connector C2 and the lower green 16 way connector C3 from the BCM Attach the tester to the BCM and to the vehicle s wiring harness pink and green connectors Connect the Tech 2 to the vehicle s DLC power it up and press ENTER If necessary refer to up to date Techline equipment user instructions Select DIAGNOSTICS Enter MODEL YEAR followed by PASSENGER CAR followed by BODY Select Y for the product line followed by the appropriate body style coupe convert etc Page 18 February 2006 Bulletin No 04006C 16 Results of Functional Test 20 21 Important The test is only for vehicles with manual transmissions and EXPORT vehicles with automatic transmissions Do NOT use this test on Non Export vehicles with automatic transmissions Select BODY CONTROL MODULE followed by SPECIAL FUNCTIONS followed by OUTPUT CONTROL followed by MISCELLANEOUS TESTS Select STEERING COL LOCK FUNCTIONAL TEST Important The battery voltage must be maintained between 13 0 and 15 0 volts when performing the functional test in the next steps Because the engine is NOT to be running during the test a battery charger must be connected to the vehicle in the next step The battery charger should be operated at a Low or Medium charge rate Do NOT operate the charger on a Fast Charge or HIGH charge rate Doing so may exceed the 1
22. fog lamp trunk release switch to release the locking tab Disconnect the electrical connector from the switch Repeat this step on the inside air temperature sensor grill located to the right side of the steering column 95692 Important When removing the driver s side knee bolster trim panel as described below care must be taken not to damage the console trim plate as the knee bolster trim panel tucks in behind the console trim plate Remove the driver s side knee bolster trim panel retaining screw located behind the area where the combination fog lamp trunk release switch is installed Repeat this step on the screw located in the inside air temperature sensor cavity Remove the driver s side knee bolster trim panel lower retaining screws Grasp the trim panel at the side edges and firmly pull rearward to release the locking tabs and remove the panel If equipped disconnect the electrical connector from the inside air temperature sensor Page 24 February 2006 Bulletin No 04006C 23 24 25 26 27 28 29 73209 Remove the two screws that attach the lower steering column cover 3 to the upper 1 Remove the one screw that attaches the upper steering column cover to the column and remove the upper cover Remove the snap ring and SIR coil from the steering column Notice Only tool J 23653 SIR can be used for removing and installing the retaining ring and lock plate in the next steps Use of any ot
23. ge at the powertrain control module PCM is low or interrupted however the fuel shut off may not occur and the vehicle can be accelerated while the steering is locked 2 During quick cranks the ECL lock pin may not withdraw fully and in vehicles where there is abnormally low clearance to the lock plate there may be contact between the pin and lock plate This can cause a noise or ratcheting when the steering wheel is turned or if there is insufficient clearance the steering wheel cannot be turned If one of these conditions occurs a crash could occur without warning What Will Be Done Your GM dealer will remove the column lock on U S and Canadian vehicles equipped with an automatic transmission and U S vehicles equipped with a manual transmission After this service correction the steering column will no longer lock when the key is removed On Canadian vehicles equipped with a manual transmission and all export vehicles your dealer will 1 reprogram the PCM and 2 verify that there is adequate lock plate clearance and if necessary replace the lock plate After this service correction the steering column will continue to lock when the key is removed This service correction will be performed for you at no charge Until your Corvette is repaired you can easily verify that the column is unlocked by turning the steering wheel a full turn before shifting into gear If you hear a ratcheting noise while turning the wheel or experi
24. her tool including J 23653 D may result in the lock plate and retaining ring not being properly positioned on the steering column shaft Failure to properly position the retaining ring and lock plate on the steering column shaft may result in the ECL not functioning properly when tested later in this procedure Using J 23653 SIR 2 remove the retaining ring and the lock plate 1 and discard both Position the new lock plate and retaining ring on the steering column shaft Using J 23653 SIR and J 42137 included with J 23653 SIR install the new lock plate and new retaining ring Use J 42137 to slide the retaining ring into the groove on the shaft Make sure the retaining ring is completely seated in the groove all the way around the shaft Position the SIR coil on the steering column and install the snap ring Page 25 February 2006 Bulletin No 04006C 30 31 32 33 34 35 36 37 38 Install a NEW steering wheel set nut on the steering column shaft 40 41 42 43 44 45 46 47 Install the upper steering column cover and install the attaching screw Tighten Tighten the screw to 1 9 N m 17 Ib in Install the lower steering column and attaching screws Tighten the screws to 4 N m 35 Ib in If equipped connect the electrical connector to the inside air temperature sensor located on the knee bolster trim panel Install the knee bolster trim panel and press firmly to engage the locking t
25. nd all U S Manual Transmission Procedure 1A The following service procedure provides instructions for disconnecting the electric column lock ECL on vehicles equipped with an automatic transmission and on all U S manual transmissions DO NOT use this procedure on Canadian vehicles equipped with a manual transmission or on any export vehicles Tools Required e J 1859 A Steering Wheel Puller e J 42120 Steering Wheel Puller Legs e J 23653 SIR Steering Column Lock Plate Compressor e J 42137 Cam Orientation Plate Adaptor Important Disregard all instruction sheets that may be in the harness kit and follow the instructions provided in this service procedure 1 Turn the steering wheel so that the vehicle s front wheels are pointing straight ahead 2 Turn the ignition switch to the OFF position 3 Open the hood and disconnect the negative battery cable 71195 Disengage the upper latches on the front floor kick up panel on the passenger side Lift the kick up panel s lower edge out of the slots in the relay bracket Remove the SDM fuse from the IP fuse block located behind the kick up panel that was just removed OO Page 6 February 2006 Bulletin No 04006C 64671 7 Using a flat bladed tool carefully pry the IP courtesy lamp assembly from the driver s side lower closeout panel 95689 8 Remove the push on retaining nut from the steering column bracket stud 9 Release the driver s side lower closeout panel push
26. oth windows and turn off all accessories radio HVAC and lighting While listening carefully slowly turn the steering wheel to the full left and then back to the full right Then return the front tires wheels to the straight ahead position o If you heard any ratcheting ticking scraping or other type sounds coming from the steering column locate the source and correct before proceeding o If you did NOT hear any ratcheting ticking scraping or other type sounds continue to the next step Important The ignition key must be removed from the ignition switch in the next step Turn the ignition switch to the OFF position and REMOVE THE KEY Verify that the steering column LOCKED and that no ECL related messages are displayed on the Driver Information Center It may be necessary to turn the steering wheel slightly in order for the ECL to engage in one of the openings in the lock plate o If the column did not lock inspect for installation of a Cam Orientation Plate and the related wiring harness that are to be used only on Non Export vehicles with AUTOMATIC transmissions Inspect for installation of aftermarket wiring relay that override the operation of the steering column lock Repair the ECL system per Service Manual procedures before proceeding with this functional test Important On 1997 models and 1998 models built BEFORE 5 26 98 EL 47728 electronic column lock tester must be installed in the vehicle in the next st
27. r Reply Form The enclosed customer reply form identifies your vehicle Presentation of this form to your dealer will assist in making the necessary correction in the shortest possible time If you no longer own this vehicle please let us know by completing the form and mailing it back to us Customer Reimbursement The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition Courtesy Transportation If your vehicle is within the New Vehicle Limited Warranty your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair Please refer to your Owner s Manual and your dealer for details on Courtesy Transportation We are sorry to cause you this inconvenience however we have taken this action in the interest of your safety and continued satisfaction with our products General Motors Corporation Enclosure 04006
28. rs 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 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 equipment safety instructions and know how to do a job properly and safely If a condition is described DO NOT ass
29. ry 2006 Bulletin No 04006C Tech 2 Message Definitions Test Won t Start Battery voltage needs to be between 13 0 and 15 0 in order to run test e Connect the battery charger to the battery and operate the charger at a Low or Medium rate DO NOT operate the charger on High or Fast Charge Test Terminated Sequence 1 Make sure steering is not side loaded e The front tires are turned tightly left or right causing the steering column to be under load and the ECL pin to bind in lock plate To correct turn the steering wheel so that the tires are straight ahead and restart the test Test Terminated Sequence 2 Remove key from ignition switch e The test cannot run with the key in the ignition switch To correct remove the key and restart the test Test Terminated Sequence 3 Not applicable Depending on the condition different messages may be displayed in Sequence 4 Test Terminated Sequence 4 Test Terminated or Check for automatic transmission Non Export steering wheel theft deterrent lock shorting harness being installed e The harness is only for use on Non Export vehicles with automatic transmissions It is NOT for use on manual transmission vehicles or EXPORT automatic transmission vehicles If the harness has been installed it must be removed If the harness is not there replace the ECL Test Terminated Sequence 5 Test Terminated e Check for the automatic transmission Non Export steering wheel theft deterrent lo
30. termining the required repairs for the vehicle you are working on proceed to the appropriate service procedure PROCEDURE PROCEDURE PROCEDURE PROCEDURE 1A 1B 2 3 Functional Test Install Wire Install Wire Tech 2 Models Kit 89023816 Kit 88952428 Reprogram Tech 2 W SPX Tool 1997 2000 Automatic except export vehicles All X HH HHH TaQ aia 1997 2004 U S Manual All X T 1997 All Canadian Manual amp All Export All ee Senne a X Continued on next page Page 4 February 2006 Bulletin No 04006C PROCEDURE 1A PROCEDURE 1B PROCEDURE 2 PROCEDURE 3 Models 1998 All Canadian Manual amp All Export Built through 5 25 98 Built on or after 5 26 98 and CSC 01044 was performed V0743 Built on or after 5 26 98 and CSC 01044 was not performed V0743 1999 2000 All Canadian Manual amp All Export CSC 01044 or TSB 01 02 35 008 V0743 or N8505 was performed CSC 01044 or TSB 01 02 35 008 was not performed V0743 or N8505 2001 2004 All Canadian amp Export Manual amp All European Export Automatic All Install Wire Kit 89023816 Install Wire Kit 88952428 Reprogram Functional Test Tech 2 Tech 2 W SPX Tool Page 5 February 2006 Bulletin No 04006C 1997 2000 Corvettes Equipped With Automatic Transmission Excludes Export Vehicles a
31. to other wires in the harness using black electrical tape Connect the negative battery cable to the battery Page 16 February 2006 Bulletin No 04006C 26 Proceed to the section titled Service Reprogramming After reprogramming has been completed install the lower edge of the kick up panel in the slots in the relay bracket and engage the upper latches or hook and loop fasteners Service Reprogramming Procedure 2 Important In order to perform the following powertrain control module PCM reprogramming procedure your Tech 2 must be updated with software version 24 008 or later Please note that vehicles repaired previously using software version 24 008 or later do not need to be reprogrammed again If your Tech 2 does not have the necessary software you will need to update it before proceeding Also you must review Service Bulletin 02 06 04 022A Info PCM Reprogramming and Data Line Diagnosis Using J 42236 A before beginning to reprogram the PCM 1 Turn the ignition switch to the ON position 2 Connect the Tech 2 to the vehicle s diagnostic link connector DLC power it up and press ENTER 3 Select SERVICE PROGRAMMING for the PCM 4 Follow the on screen instructions and prompts If necessary refer to up to date Techline equipment user instructions Important If the vehicle is a 1997 or 1998 built before 5 26 98 do not reassemble the body control module BCM area of the vehicle until after the Functional Test of E
32. uary 2006 Bulletin No 04006C 19 20 21 Grasp the trim panel at the side edges and firmly pull rearward to release the locking 23 158135 Using a small flat bladed screwdriver pry the lower edge of the combination fog lamp trunk release switch to release the locking tab Disconnect the electrical connector from the switch Repeat this step on the inside air temperature grill located to the right side of the steering column loa 95692 Important When removing the driver s side knee bolster trim panel as described below care must be taken not to damage the console trim plate as the knee bolster trim panel tucks in behind the console trim plate Remove the driver s side knee bolster trim panel retaining screw located behind the area where the combination fog lamp trunk release switch is installed Repeat this step on the screw located in the inside air temperature cavity Remove the driver s side knee bolster trim panel lower retaining screws tabs and remove the panel If equipped disconnect the electrical connector from the inside air temperature sensor Page 10 February 2006 Bulletin No 04006C 73209 24 Remove the two screws that attach the lower steering column cover 3 to the upper 1 25 Remove the one screw that attaches the upper steering column cover to the column and remove the upper cover 26 Remove the snap ring and SIR coil from the steering column 1489425 Notice Tool J 236
33. ume that the bulletin applies to Voluntary your vehicle or that your vehicle will have that condition See your dealer retailer for information on whether your vehicle may benefit from the information Technician GM bulletins are intended for use by professional technicians NOT a do it yourselfer They are written to inform these technicians of conditions that may occur on some vehicles or to provide information that could assist in the proper service of a vehicle Properly trained technicians have the tools We Support Certification Page 29 February 2006 Bulletin No 04006C Dear General Motors Customer This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days Reason For This Recall General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1997 2004 model year Chevrolet Corvette vehicles When you remove the ignition key the electronic column lock ECL system prevents turning of the steering wheel When the vehicle is started it unlocks the steering system Two conditions can prevent steering while the vehicle is moving 1 Your vehicle is designed so that if the column fails to unlock when you start your vehicle the fuel supply will be shut off if you try to move your vehicle If volta
34. use bracket Close the panel and latches Connect the negative battery cable and close the hood Verify that the ECL and relay are synchronized Depending on the position of the relay and the ECL bolt when the key ignition switch is first turned to the ON position you may receive the message Pull Key and Wait 10 Sec o If you do NOT receive this message the ECL and relay ARE synchronized No further action is required o If you DO receive this warning message the ECL and relay are NOT synchronized To synchronize turn the ignition switch to the OFF position and REMOVE THE KEY from the switch lock cylinder Wait a MINIMUM of 10 seconds re insert the key and turn to the ON position From this point on the ECL and relay should be synchronized Start the engine and verify that the steering column in unlocked 1997 2004 Canadian amp Export Corvettes with manual transmissions and 1997 2000 EXPORT vehicles with automatic transmissions 2001 2004 EUROPEAN EXPORT vehicles with automatic transmissions The required repairs vary depending on the model year build date and what repairs Customer Satisfaction Campaign 01044 or Technical Service Bulletin 01 02 35 008 have been previously performed Refer to the chart at the beginning of the service procedure in this bulletin to determine the correct repairs for the vehicle you are working on If necessary check the Claim History in the Summary section in the GM Vehicle Inquir
35. y System GMVIS to determine whether Customer Satisfaction Campaign CSC 01044 or Technical Service Bulletin TSB 01 02 35 008 has been preformed on a vehicle DO NOT use the Required Field Action section to determine whether Customer Satisfaction Campaign 01044 has been performed All vehicles involved in that Campaign were listed as closed when the campaign was cancelled If either has been performed labor operation V0743 CSC 1044 or N8505 TSB 01 02 35 008 will be listed After determining the required repairs for the vehicle you are working on proceed to the appropriate Service Procedures in this bulletin for instructions Page 14 February 2006 Bulletin No 04006C Important If the vehicle requires the installation of a Wire Relay Kit that must be done first followed by the Reprogram followed by the Functional Test If the vehicle does not require the Wire Relay Kit then you should first perform the Reprogram followed by the Functional Test Remember you must complete all repairs listed for the vehicle being worked on in order to complete this recall Installing Wire And Relay Kit P N 88952428 Procedure 1B This procedure should ONLY be done if the vehicle you are working on has NOT had Customer Satisfaction Campaign CSC 01044 or Technical Service Bulletin TSB 01 02 35 008 performed See information above 1 Turn the steering wheel so that the vehicle s front wheels are pointing straight ahead 2
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