The GM Documents, Part 2

2005-2007 Cobalt/Pursuit/G5

Front Airbag Non-Deployment

709,741 Vehicles

Cost Estimate: $14.2M-$37.7M Locations: US, CAN, MEX

ETQ N-130454

Condition:

Front airbag non-deployment has been identified in certain crash events. In those events the

ignition switch was in ACCESSORY or OFF.

Root Cause:

• Field incidents involve vehicles going off the road or hitting smaller objects shortly before

a more significant impact.

• The driver’s knee may be interacting with the keys (ignition cylinder location).

• The mass of the keys may be causing the ignition switch to rotate and the torque to rotate

may be below specifications.

Effects: The airbags will not deploy if the ignition is not in RUN.

Number of Reports:

23 allegations of front airbag nondeployment. 28 VOQs for “Ignition Off” while driving.

Service Bulletin: Bulletin #05-2-35-007 – Inadvertent key turning – issued Oct 2005.

Ignition Switch Change: Increased effort for RUN to ACCESSORY.

Rate & Injury Comparison: GMT800 SDM Switch Contact Bounce.

Potential Field Remedy: Add key “inserts” - $14.2M. Replace ignition switch - $37.7M.

Potential Field Action Category: Safety Recall PPAP

Chronology:

10/29/04 PRTS N182276 issued. For ignition key low effort, may turn while driving.

Closed w/o action (Code 19 – part met requirements).

6/23/05 Investigation opened on 2005 Cobalt stall – Focus on key rotation.

6/28/05 Investigation closed: Plan for Bulletin adding insert and possibly changing key

from slot to hole.

11/28/05 Service Bulletin #05-2-35-007 issued to remedy inadvertent turning of key

cylinder (reduce content on key chain and add insert).

4/26/06 Ignition switch PPAP completed with new plunger and spring (effort increase).

No P/N change, production implementation date unknown.

8/1/09 Ignition key changed from slot to hole.

7/1/11 Service Bulletin #05-2-35-007 updated to add model years.

8/24/11 Investigator assigned for airbag nondeployment.

From Aug 2011 to Dec 2013

- Management updates

- Red X Study

- DFSS Project

- Outside consultant analysis

Backup

Cobalt

20 +/-5 N-cm • ACC - RUN• RUN – ACC

Not applicable

0

5

10

15

20

2003 2004 2005 2006 2007 2008 2009 2010

Torq

ue

(N

cm)

Model Year

Torque to Rotate From Run to Accessory

Cobalt

HHR

Ion

G5

It is unknown if any switches were replaced outside of warranty

All 3 ignition switches replaced1/21/05, 1/21/09, 1/4/08

Both ignition switches replaced12/6/07, 12/27/07

• Ion switch original for 2003 MY.

• For 2005 MY a capacity tooling increase was needed for Cobalt. The part number is the same, and it is not known which cavities were used for Ion and then for Cobalt/Pursuit.

• HHR added in 2006 MY, G5 in 2007 MY.

A One G5 incident, all others are Cobalt.B Ion uses Class 2 architecture which does not record in ACCESSORY. Cobalt, G5 & HHR use the GM LAN

which records to the SDM even with ignition in ACCESSORY

The Chevrolet Cobalt began production with the Saturn Ion ignition switch.All model years Cobalt, Pursuit, G5, Ion and HHR use same ignition switch part number.

Ignition Switch Position from SDM Download - Incident Vehicles

2005-2007 Cobalt, Pursuit (Canada only) & 2007 G5A

13 Accessory

1 Off

8 Run

1 No Event (not recorded)

2008 – 2010 Cobalt, Pursuit, G5

0

2003-2006 Ion

2 Not available from SDMB

2006-2008 HHR

0

Cobalt versus Ion (2 Potential Incidents) & HHR (No Reports)

• Review indicates 2 potential non-deploys for Ion, but are not confirmed to be the same cause.

• Ion has different column shroud which could affect potential for key interaction

• HHR has more clearance to the driver’s knee

0

5

10

15

20

2003 2004 2005 2006 2007 2008 2009 2010

Torq

ue

(N

cm)

Model Year


Cobalt

HHR

Ion

G5

The date by each data point is the vehicle build date



3/14/05

9/08/04

2/24/06

1/19/05

9/16/04

12/22/0510/24/05

1/23/06

7/14/058/23/05

8/25/05

10/04/0511/09/05

9/27/05

9/05/066/19/06

1/12/07

8/08/06

3/12/07

11/07/06

3/02/07

12/01/06

9/15/06

1/19/07

6/18/07

5/05/08

5/19/08

9/13/07

12/11/07

5/19/10

3/14/087/11/08

10/01/08

8/11/08

8/15/08

9/02/08

10/20/09

10/14/03

4/22/04


Non-Deployment Allegations by Model Year

Cobalt (22), G5 (1)

• The mechanical characteristics of the ignition switch were unchanged for all model years.

• A revision to the switch occurred during the 2007 MY to increase the torque to rotate.

-The part number was not changed and the breakpoint is unknown.

- Incidents within the 2007 MY are distributed throughout the build months.

0

2

4

6

8

10

12

2005 MY 2006 MY 2007 MY 2008 MY 2009 MY 2010 MY

Build date not available for one 2005 vehicle As of 10/1/13

0

1

2

3

0

5,000

10,000

15,000

20,000

25,000

30,000

Inci

de

nts

pe

r M

OB

Po

pu

lati

on

by

Mo

nth

of

Bu

ild (

MO

B)

Month of Build

2005-7 Cobalt/G5 Non Deploy Incidents & Population by MOB

2005

2006

2007

# Incident Vehicles

0

1

2

3

4

5

6

7

8

9

10

11

Inci

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Co

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el Y

ear

Calendar Year

2005-7 Cobalt / G5 Reports of Airbag Non-Deploy by Model Year & Incident Date

2005

2006

2007

7/29/05

11/17/05

8/12/12

10/16/07

2/10/06

3/14/06

10/1/06

12/29/06

2/6/07

2/20/11

12/13/09

9/13/08

4/5/08

8/6/07

3/5/07

12/31/10

12/31/10

5/20/13

2/13/11

5/29/08

5/21/08

9/26/07

12/6/08

As of 10/1/13

2005 2006 2007 2008 2009 2010 2011 2012 2013

2005-10 Cobalt TREAD Search - Elec, Eng, Strg Potential Knee-Key

2005 2006 2007 2008 2009 2010 Total

56 43 10 1 0 0 110

Stalling VOQs by Model Year

Potential Key Motion (Stall with No DTCs & Immediate Restart)

Model 2003 2004 2005 2006 2007 2008 2009 2010

COBALT 12 13 1 1 1

HHR 11 2 1

ION 1 2 8

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Nu

mb

er

of

VO

Qs

Incident Date

2005-2009 Cobalt VOQs for Potential Ignition off While Driving

2005 Cobalt

2006 Cobalt

2007 Cobalt

2008 Cobalt

2009 Cobalt

0

1

2

3

4

5

6

7

8

9

10

11

12

Nu

mb

er

of

VO

Qs

pe

r M

od

el Y

ear

Incident Date

2003-9 Ion, HHR VOQs for Potential Ignition off While Driving

2003 Ion

2004 Ion

2006 HHR

2006 Ion

2007 HHR

2008 HHR

0

2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

32

34

Nu

mb

er

of

VO

Qs

pe

r M

od

el Y

ear

Incident Date

2003-9 Ion, Cobalt, HHR, VOQs for Potential Ignition off While Driving

2003 Ion

2004 Ion

2005 Cobalt

2006 Cobalt, HHR, Ion

2007 Cobalt, HHR

2008 Cobalt, HHR

2009 Cobalt

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Nu

mb

er

of

VO

Qs

pe

r M

od

el Y

ear

Incident Date


2003 Ion

2004 Ion

2005 Cobalt

2006 Cobalt

2006 HHR

2006 Ion

2007 Cobalt

2007 HHR

2008 Cobalt

2008 HHR

2009 Cobalt

• Issued Nov 2005

• Reissued July 2011 to

add the 2007 MY.

2005MY-2009MY

2010 MY

Key

Slot vs. Hole

Cobalt

• Ignition switch with increased effort passed validation 4/26/06.

• Part number not changed.• Implementation date is

unknown.

0

5

10

15

20

2003 2004 2005 2006 2007 2008 2009 2010

Torq

ue

(N

cm)

Model Year


Cobalt

HHR

Ion

G5




0

5

10

15

20

2003 2004 2005 2006 2007 2008 2009 2010

Torq

ue

(N

cm)

Model Year


Cobalt

HHR

Ion

G5




3/14/05

9/08/04

2/24/06

1/19/05

9/16/04

12/22/0510/24/05

1/23/06

7/14/058/23/05

8/25/05

10/04/0511/09/05

9/27/05

9/05/066/19/06

1/12/07

8/08/06

3/12/07

11/07/06

3/02/07

12/01/06

9/15/06

1/19/07

6/18/07

5/05/08

5/19/08

9/13/07

12/11/07

5/19/10

3/14/087/11/08

10/01/08

8/11/08

8/15/08

9/02/08

10/20/09

10/14/03

4/22/04



0

1

2

3

0

5,000

10,000

15,000

20,000

25,000

30,000

Inci

de

nts

pe

r M

OB

Po

pu

lati

on

by

Mo

nth

of

Bu

ild (

MO

B)

Month of Build


2005

2006

2007

# Incident Vehicles

Incident Reports U.S. Population IPHTV /Year Exposure

2005-2007 Cobalt 23 618,014 0.47

2005 Cobalt 11 140,646 0.892006 Cobalt 7 229,231 0.382007 Cobalt 5 248,137 0.29

2006-2007 HHR 0 214,072 0

2003-2007 Ion 2A 478,986 0.04

SDM Sensor Bounce Anomaly – Safety Recall - Decision June 2002 (approx.. 2 yrs. Exposure)2000 GMT800 (Safety); 2000 S/T (No field action); 2000 M/L (No field action)

Incident Reports

Population IPHTV /Year Exposure

2000 GMT800 9 572,108 0.70

2000 S/T 1 455,500 0.11

2000 M/L 0 96,328 0

Non-deploys due to Ignition Switch Rotation2005-7 Cobalt, G5, Pursuit, 2003-2007 Ion, 2006-2007 HHR

A Incidents can not be confirmed to be due to ignition switch rotation.

0

0.5

1

1.5

2

2.5

1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 70 73 76 79 82 85 88 91 94 97 100

Cobalt – Front Airbag Non-Deployment Incidents Per 100K Vehicles

2005 MY

2006 MY

2007 MY

2005 2006 2007 2008 2009 2010 2011 2012 2013

Calendar Year

IPH

TV

2000 S/T @ 0.11

2000 GMT800 @ 0.70

0

1

2

3

4

5

6

7

8

9

10

11

Inci

de

nt

Co

un

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od

el Y

ear

Incident Date

Severity of Injuries: 2005-7 Cobalt / G5 Reports of Airbag Non-Deploy

2005

2006

2007

Fatality

Moderate

Moderate

Fatality

Moderate

Moderate

Fatality

Moderate

Severe

Mild

Moderate

Fatality

Moderate

Mild

Mild

Moderate

Fatality

Severe

Moderate

Mild

Mild

Mild

Mild

As of 10/1/13

Severity Summary:- 7 mild- 9 moderate- 2 severe- 5 fatal

Injury Severity Comparison

2000 GMT800 Sensor Bounce: 9 Total (3 mild, 3 moderate, 2 severe, 1 fatal)Fatal fatal

Skull & nose fracture, laceration right side of face & mouth. Whiplash. Lost consciousness. Wrist, knee, ankle, and foot injury. 6 days ICU

Severe

Belted - Significant head and chest & lower leg injury. Severe

Fractured neck vertebrae moderate

Fractured neck vertebrae. Fractured shoulder moderate

Concussion, sore shoulder, and chest moderate

No treatment. Claimed chest injury mild

Head trauma, bruises - treated at hospital mild

Broken nose mild

2005-2007 Cobalt, G5, Pursuit: 23 Total (7 mild, 9 moderate, 2 severe, 5 fatal) Fatality FatalFatality FatalDriver & Front Passenger: Fatal Fatal (2)Fatality FatalFatality FatalTraumatic Brain Injury SevereQuadriplegic SevereBruising to left side of head, cuts to left knee and back P: Fractured ribs, shoulder blade, cuts, and bruises ModerateUnknown Injuries (D) P: Broken neck (w/o paralysis), fractured ribs, sternum, laceration to head, facial bruises ModerateFractured ribs, nose, femur, and ankle ModerateFractured vertebrae and severe ear laceration ModerateKidney damage, left arm fracture, internal bleeding ModerateLost teeth, several stiches in mouth, broken ankle, broken wrist ModerateSyncope, concussion, occipital laceration, multiple contusions, seizure disorder ModerateFractured nose & scapula P:fractured leg ModerateSevere TBI, Basilar skull fracture, right hip fracture, right sacral fracture Moderate

Facial FX including: R. Orbital floor, R. Maxillary Sinus, and Bilateral Nasal Bone. Facial laceration & concussion MildBruised chest area, Bruises on head MildFractured front teeth and multiple contusions MildLaceration to liver, cut nose, bruised chest, bumps all over, sore left knee MildLaceration to head with scarring MildFacial Laceration and dislocated hip Mild

Broken nose , broken cheekbone, bruised lung, pain in right elbow Mild

Incidents Per 100k Vehicles /Year Exposure

Cumulative 2005-2008 2009-2013

2005-2007 Cobalt 0.47 0.86 0.20

2005 Cobalt 0.89 1.42 0.452006 Cobalt 0.38 0.58 0.28

2007 Cobalt 0.29 0.81 0.09

SDM Sensor Bounce Anomaly – Decision June 2002 (approx. 2 yrs. Exposure)2000 GMT800 - Safety Recall

2000 S/T - No field action.

Incident Reports

Population IPTV /Year Exposure

2000 GMT800 9 572,108 0.70

2000 S/T 1 455,500 0.11

2000 M/L 0 96,328 0


Exchange:

2 slotted w/

2 holes Add Insert

Replace Switch

Cost Estimates (Includes Vehicle Attrition)

2003 2004 2005 2006 2007 Total

Cobalt, G5, Pursuit* N/A N/A 154,807 261,924 293,010 709,741

Ion 88,926 113,028 74,677 100,436 101,919 478,986

HHR N/A N/A N/A 113,003 101,069 214,072

Total 88,926 113,028 229,483 475,364 495,998 1,402,799

Production Year

Summary Points

A) Combined reports (FPA, VOQs, Tread) indicate that a distinct change occurred during 2007 MY:

B) The non-deployment incident rate for 2005 MY is over 2 times higher than 2006; approx. 3 times higher than 2007 MY.

2005 2006 2007Incidents 11 7 5IPHTV/Yrs Exposure 0.89 0.39 0.30

(Combined IPTV/Yrs Exposure = 0.47 IPHTV)

C) 2005 MY incident rate is higher than the GMT800 (SDM Contact Bounce) field action which was at 0.77 IPHTV at the time of decision.

D) All Model Years show a decreasing trend. Reported non-deployment incidents within the last 5 years are significantly lower compared to the first 4 years of exposure.

2005 2006 2007

2005-2008 8 4 4IPHTV/Yrs Exposure 1.42 0.58 0.81

2009-2013 3 3 1IPHTV/Yrs Exposure 0.45 0.28 0.09

There have been 2 reports in the past 34 months.

E) The change to the ignition switch that was introduced during the 2007 Model Year (possibly Oct ‘06) is directionally correct. Four incidents have occurred on vehicles built after this date.

F) Changing the key from a slot to a hole is directionally correct.

2005 MY 2006 MY 2007 MY 2008 MY 2009 MY 2010 MY

79 63 16 2 1 0

March 17, 2006

2005-7 Cobalt, G5, Pursuit, 2003-2007 Ion, 2006-2007 HHRCondition:A review of selected Cobalt & G5 frontal crash events indicates some airbag non deploys have occurred where the ignition switch was in accessory or off. The condition appears to be limited to 2005-07 Cobalt & G5 vehicles. The noted field events involve vehicles going off the road and/or hitting smaller objects shortly before a more significant impact.

Questions:– Why no incidents on Ion or HHR

• Ion is Class 2 architecture vs GM LAN on Cobalt and HHR– Both disable SDM with key off, but Cobalt/HHR will store ignition state & crash record while Ion will not– NISM review indicates 2 potential non-deploys for Ion

• Ion has different column shroud which could affect potential for key interaction• Ion customers may be less likely to have the type of crash needed for the condition• Ion has different SDM and supplier than Cobalt• HHR has more clearance to the driver’s knee

– Why no incidents on 2008-10 Cobalt?• Ignition switch was revised to have longer plunger and spring to increase effort (confirmed

10/29/13)– Part number not changed, so implementation date is unknown (Validation complete 4/26/06). Salvage

yard samples included 2007 vehicles with longer plunger (unknown if any had been replaced in service).

Root Cause:– The hypothesis is that during the off road event the driver’s knee is interacting with

the keys and/or the mass of the keys is causing the ignition to rotate

Vehicle Population & Incident Rate 2005-2007

Vehicles Sold in US2005 2006 2007

Cobalt/G5# Pursuit 140,464 229,231 248,137

Incidents 11 7 5IPTV/Yrs Exposure 0.0089 0.0039 0.0030

SOP – 1/1/09 8 4 4IPTV/Yrs Exposure 0.0142 0.0058 0.0081

1/1/09-10/1/13 3 3 1IPTV/Yrs Exposure 0.0045 0.0028 0.00085

• 2000 GMT800 0.0070 IPTV/yr (approx 2 yrs exposure @ decision June 2002)• 2000 S/T truck 0.0011 IPTV/yr no field action

- SDM anomaly may result in no-deploy

Vehicle Population & Incident Rate 2005-2007Cobalt & G5

Vehicles Sold in US2005 2006 2007#

Cobalt/G5# Pursuit 140,464 229,231 248,137

Incidents* 11 7 5IPTV/Yrs Exposure 0.0089 0.0039 0.0030(as of 10/1/13)

Incident rate for 2005 is over 2 times higher than 2006 and about 3 times higher than 2007

Combined IPTV/Yrs Exposure 0.0053

*Except for 1 2007 G5, all reports are Cobalt. There is 1 incident reported on a 2008 vehicle. 2008 vehicle had front sensor fault that disabled system prior to crash. # G5 was 2007 start.

Test Set-up Using Torque Tool

Measure torque (Ncm) to rotate key from Run To Accessory

TREAD Search July 2012 (TAC & CAC)Stalling with No DTCs

IPTV/yr 2003 2004 2005 2006 2007 2008 2009

Cobalt, G5 N/A N/A 0.05316 0.02886 0.00733 ~0 0

Ion 0.04046 0.02526 0.04346 0.01826 0.0 N/A N/A

Cobalt, Ion & HHR Ignition Switch Measurement

• 5/22/12 44 vehicles in Davison salvage yard – Measured torque (Ncm) and force (N) to turn the ignition switch from

Run to Accessory.

• Five of the vehicles had a replacement key, or a key with a hole vs slot (force not measured)

Model Year

Model 2003 2004 2005 2006 2007 2008 2009 2010Grand Total

Cobalt 1 5 5 3 3 1 18

G5 1 1 2

HHR 4 3 2 1 1 11

Ion 2 5 3 1 2 13

Grand Total 2 5 4 10 11 5 5 2 44

Switch Background

• Ion switch original for 2003. For 2005 capacity tooling was needed for Cobalt. The part number is the same, so it is not known what cavities were used for Ion and then for Cobalt. HHR added in 2006– A change was initiated in 2006 to implement a new printed circuit

board (12861211 Rev 5) and a new detent plunger (741-79378). The taller plunger and spring with more coils completed validation testing 4/24/06. The switch p/n was not changed, so it is unknown when switches with the new content were put into production or service.*

*The change to the plunger and spring was not confirmed until Delphi provided details with that information on 10/29/13

2003 Ion vs 2007 Cobalt

HHR Knee Clearance to Ignition (6’1” driver)

0

1

2

3

4

5

6

7

8

9

10

11

Inci

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Incident Date


2005

2006

2007

7/29/05

11/17/05

8/12/12

10/16/07

2/10/06

3/14/06

10/1/06

12/29/06

2/6/07

2/20/11

12/13/09

9/13/08

4/5/08

8/6/07

3/5/07

12/31/10

12/31/10

5/20/13

2/13/11

5/29/08

5/21/08

9/26/07

12/6/08

As of 10/1/13

Key position per SDM:A = Accessory (13)O = Off (1)R = Run (8)

A

A

A

A

A

A

A

A

A

A

A

R*

R

R

R

R

R

R

R*

O

R

A

No Event

R* = Run but algorithm disabled

Ignition Cylinder Warranty (N100256)

Assessment SDM Change• Changing the SDM power down behavior is high risk. The power moding, fail

safe operation, and diagnostics portion of the SW would need to be modified. – The start up behavior, i.e. driver seat belt reminder would still need to be compliant –

even though there was no change to the “internal power mode” of the SDM on a quick IGN cycle.

– Diagnostics of the IGN line and AOS module (perhaps other U-Codes) would need to be modified

– Changes to the design of the SDM will need to be done by engineers who were not part of the original design team.

• Note that the AOS module is powered from IGN not battery – so it will power off when the key transitions from run. The FMVSS requirement is that the correct airbag state be displayed within 10 secs – so if the SDM shut off delay lasted longer than 10 seconds or if a transition of airbag state happened with 2-3 seconds of power mode change, there may be a violation of this requirement.

SDM AOSBatt

IGN

GMLAN

CM20324

Vehicle Scrap Rates

AGE

TRUCKS(Full Size

Trucks

and Vans)

CARS(All

others)

1 100% 100%

2 99% 99%

3 99% 99%

4 98% 97%

5 95% 95%

6 94% 93%

7 93% 92%

8 92% 91%

9 92% 89%

10 91% 85%

11 86% 82%

12 79% 76%

*data pulled by RL Polk in March 2012

2005-2007 Cobalt/Pursuit/G5

Ignition Switch

778,563 Vehicles

Cost Estimate: $41.3M Locations: US, CAN, MEX

ETQ N-130454

Condition:


ignition switch had moved from RUN to ACCESSORY or OFF.

Effects: The airbags will not deploy if the ignition has moved from RUN.

Root Cause: The ignition switch torque performance may be below specifications.


Number of Reports:

• 23 allegations of front airbag nondeployment.

Field incidents involve vehicles going off the road or hitting smaller objects

shortly before a more significant impact.

• 26 VOQs for “Ignition Off” while driving.

• 355 TREAD reports or application of Service Bulletin.


Rate & Injury Comparison: GMT800 SDM Switch Contact Bounce.

Potential Field Remedy: Add key inserts on all, replace ignition switch builds < Nov ‘06.

Potential Field Action Category: Safety Recall

PPAPSlide 21

Follow-up from December 17, 2013 FADC Review:

1. Forces required to rotate ignition from RUN to ACCESSORY/OFF

• Mass/number of keys

• Road inputs (rough road data – interior accelerations)

2. Knee Clearance to Key Cylinder

• GM Fleet vs. Cobalt

3. Power Mode Deactivation Delay

• Extend the time the SDM algorithm remains active after the vehicle

exits the RUN power mode.

0

5

10

15

20

2003 2004 2005 2006 2007 2008 2009 2010

Torq

ue

(N

cm)

Model Year

Salvage Yard Vehicle MeasurementsTorque to Rotate From Run Position

Cobalt

HHR

Ion

G5

Original Switches only.

Spec. = 20

+/- 5 N-cm

Slide 21

0

5

10

15

20

2003 2004 2005 2006 2007 2008 2009 2010

Torq

ue

(N

cm)

Model Year

Salvage Yard Vehicle MeasurementsTorque to Rotate From Run Position

Cobalt

HHR

Ion

G5

November 2006 Switch Change


Spec. = 20

+/- 5 N-cm

• With 99% confidence, these two populations are unique.

• Using a t-test, the difference between the two means

lies between (0.8826 to 10.74).

1. Forces required to rotate ignition from RUN to ACCESSORY/OFF

Column Position

Switch Force Low Mid High

25 N-cm 5.20 4.97 4.49

20 N-cm 4.16 3.97 3.59

15 N-cm 3.12 2.98 2.70

10 N-cm 2.08 1.99 1.80

Static Key Ring Mass (lbs.) to Rotate Ignition Switch from Run

Switch Specification = 20 +/- 5 N-cm

Internal Cylinder Force (approx.) = 2 N-cm

0

5

10

15

20

2003 2004 2005 2006 2007 2008 2009 2010

Torq

ue

(N

cm)

Model Year

Salvage Yard Vehicle MeasurementsStatic System Torque to Rotate From Run

Cobalt

HHR

Ion

G5


2.70 – 3.12 lbs.

1.80 – 2.08 lbs.

3.59 – 4.16 lbs.

Column High to Low

Spec. = 20

+/- 5 N-cm

0

5

10

15

20

Torq

ue

(N

cm)

Model Year



2.70 – 3.12 lbs.

1.80 – 2.08 lbs.

3.59 – 4.16 lbs.

Column High to Low

Spec. = 20

+/- 5 N-cm

Measured Weights

Standard Fob 20 g 0.0441 lbs.

Overmold Key 15 g 0.0331 lbs.

Std Lockset Key 12 g 0.0264 lbs.

Gen I Flip Key 45 g 0.0992 lbs.

Total 92 g 0.2028 lbs.

Cadillac ATS Rough Road Testing – Interior Accelerations @ SDM/ MPG Evaluations

Test Speed Z Accel. Max

550/629 Hop 30 MPH 7.25 G

550/629 Tramp 30 MPH 4.87 G

Square Block 30 MPH 5.42 G

Washboard 40 MPH 5.06 G

#3 Pothole 25 MPH 13.10 G

Chatter Bumps 60 MPH 1.32 G

Massoit Bump 45 MPH 1.87 G

Curb Impact 5 MPH 1.88 G

Curb Drop-Off 20 MPH 2.83 G

Belgian Blocks 35/40 MPH 1.92 G

25mph Max Pothole #3

2700

170

115

1030

Max Pothole #3

0

5

10

15

20

Torq

ue

(N

cm)

Model Year


2.70 – 3.12 lbs.

1.80 – 2.08 lbs.

3.59 – 4.16 lbs.

Column High to Low

Spec. = 20

+/- 5 N-cm

Measured Weights @ 13.1 G

Standard Fob 20 g 0.0441 lbs. 0.58 lbs.1.01 lbs.

2.66 lbs.

Overmold Key 15 g 0.0331 lbs.

Std Lockset Key

12 g 0.0264 lbs.

Gen I Flip Key 45 g 0.0992 lbs.

Model Program Knee to Cyl (MM)

Lacrosse GMX353 55.8

Malibu GMX351 56.4

Cruze D1SC 58.9

Verano D1SB 58.9

Impala GMX352 67.7

Traverse GMT561 70.7

M2xx 73.4

Camaro GMX521 73.9

D2LC 76.2

D2SB 76.2

Cobalt GMX001 91.1

Regal GMX350 91.7

Spark M1xx 92.4

Equinox GMT172 106.7

Sonic G1xx 149.2

Volt D1JCI Keyless

CTS A1LL Keyless

NG E2SC Keyless

SRX GMT166 Keyless

RAMSIS Assumptions:

• 95th US male.

• H-pt located within seat travel box, mid travel (up/down).

• Posture prediction algorithm used .

• Distance calculated from right inner leg to center of key

Cylinder face.

• Driver right ball of foot placed on center of brake pedal

pad surface at unapplied position.

Knee Clearance to Key Cylinder:

Spark

Cruze

Cobalt

Camaro

Photo

GM CONFIDENTIAL 11

High mount executions show lowest

pph – low mount highest.

Colorado/Canyon

– low mount and

awkward key

insertion

Equinox - mid

mount –

increases shroud

width

Tahoe - high

mount –

eliminates ability

to have RH wiper

stalk

Ignition Cylinder

JDP Comparison

Extend the time the SDM algorithm is active after the vehicle exits the RUN power mode:

SDM: Software for power moding, fail safe operation, and diagnostics would require modification.

– Must address driver seat belt reminder (MVSS) on a quick ignition cycle.

– Requires modification to the diagnostics of the IGN line and AOS module (and other U-Codes).

– Software design changes would be done by Conti engineers who were not part of the original design team (originally Siemens).

– AOS: The occupant sensor module is powered from IGN and will power off when the key transitions from run. MVSS requirements for airbag state display would be violated if a transition of airbag state occurred within 2-3 seconds of power mode change.

– Not designed to be programmable. Approximately 25% would require replacement.

– Replacing with a newer (2011 MY) unit requires replacement of all crash sensors and crash testing to develop calibrations.

– Possible introduction of other issues or non-conformances that would be typically discovered in a full IVER.

SDM AOSBatt

IGN

GMLAN

CM20324BCM

Batt

Chronology:

10/29/04 PRTS N182276 issued. For ignition key low effort, may turn while driving. Closed w/o

action (Code 19 – part met requirements).

6/23/05 Investigation opened on 2005 Cobalt stall – Focus on key rotation.

6/28/05 Investigation closed: Plan for Bulletin adding insert and possibly changing key from slot to

hole.

11/28/05 Service Bulletin #05-2-35-007 issued to remedy inadvertent turning of key cylinder (reduce

content on key chain and add insert).

4/26/06 Ignition switch PPAP completed with new plunger and spring (effort increase). No P/N

change, production implementation date unknown.

8/1/09 Ignition key changed from slot to hole.

7/1/11 Service Bulletin #05-2-35-007 updated to add model years.

8/24/11 Investigator assigned for airbag nondeployment.

From Aug 2011 to Dec 2013

- Management updates

- Red X Study (2)

- DFSS Project

- Outside consultant analysis

10/29/13 Delphi confirms spring and plunger change made to switch. Validation completed 4/26/06.

No part number change. Implementation date unknown.

12/17/13 FADC review.

12/19/13 FPET review.

TBD FADC review.

Backup

Summary Points

1. The rate of reported stall or non-deployment incidents has decreased significantly from ‘05 to ‘06 without any known changes.

2. The rate of reported stall or non-deployment incidents from ‘06 to ‘07 has decreased significantly. 80% of the ‘07 MY reports are after the switch change (believed to have occurred Nov ’06).

3. The 2008 and later models do not have any non-deployment allegations. There are no known differences between ‘07 MY (produced after Nov ’06) and these vehicles.

4. The same switch is used on Ion and HHR which have a total of 2 unconfirmed reports.

5. Two thirds (16) of the non-deployment allegations occurred in the 4 calendar years from 2005-2008. Only one third (7) have occurred in the 5 calendar years from 2009-2013.

6. There have been only two non-deployment events in the last 3 calendar years. Random off road crashes should be continuous, not decreasing (91% of the vehicles are still in use).

7. Of the 12 VOQs for 2005MY, all occurred prior to Dec 2007.

8. The 2006MY VOQs (13) are consistent with the most recent Aug 2013.

0

2

4

6

8

10

12

2005MY

2006MY

2007MY

2008MY

2009MY

2010MY

2005 2006 2007 2008 2009 2010

Total 248 134 22 2 1 0

Total ReportsNon-Deployment Allegations

December 8, 2006• Evaluation of rotational effort of key locking/parklock cable system prior to lock cylinder durability.• 2008 Prototype GMT-900 steering column assemblies tested per DTP.5014.1.44.

Cobalt

Cobalt

Cobalt

Saturn

All

Slide 11

Lower Column Shroud (Key Bump)

Traverse

Cobalt

Slide 11

20 +/-5 N-cm • ACC - RUN• RUN – ACC

Not applicable

0

5

10

15

20

2003 2004 2005 2006 2007 2008 2009 2010

Torq

ue

(N

cm)

Model Year


Cobalt

HHR

Ion

G5




• Ion switch original for 2003 MY.

• For 2005 MY a capacity tooling increase was needed for Cobalt. The part number is the same, and it is not known which cavities were used for Ion and then for Cobalt/Pursuit.

• HHR added in 2006 MY, G5 in 2007 MY.

A One G5 incident, all others are Cobalt.B Ion uses Class 2 architecture which does not record in ACCESSORY. Cobalt, G5 & HHR use the GM LAN

which records to the SDM even with ignition in ACCESSORY

The Chevrolet Cobalt began production with the Saturn Ion ignition switch.All model years Cobalt, Pursuit, G5, Ion and HHR have the same mechanical properties for the ignition switch.

Ignition Switch Position from SDM Download - Airbag Non-Deployment Incidents

2005-2007 Cobalt, Pursuit (Canada only) & 2007 G5A

13 Accessory

1 Off

8 Run

1 No Event (not recorded)

2008 – 2010 Cobalt, Pursuit, G5

0

2003-2006 Ion

2 Not available from SDMB

2006-2008 HHR

0

Cobalt versus Ion (2 Potential Incidents) & HHR (No Reports)

• Review indicates 2 potential non-deploys for Ion, but are not confirmed to be the same cause.

• Ion has different column shroud which could affect potential for key interaction

• HHR has more clearance to the driver’s knee

0

5

10

15

20

2003 2004 2005 2006 2007 2008 2009 2010

Torq

ue

(N

cm)

Model Year


Cobalt

HHR

Ion

G5




3/14/05

9/08/04

2/24/06

1/19/05

9/16/04

12/22/0510/24/05

1/23/06

7/14/058/23/05

8/25/05

10/04/0511/09/05

9/27/05

9/05/066/19/06

1/12/07

8/08/06

3/12/07

11/07/06

3/02/07

12/01/06

9/15/06

1/19/07

6/18/07

5/05/08

5/19/08

9/13/07

12/11/07

5/19/10

3/14/087/11/08

10/01/08

8/11/08

8/15/08

9/02/08

10/20/09

10/14/03

4/22/04


Non-Deployment Allegations by Model Year

Cobalt (22), G5 (1)

A revision to the switch occurred during the 2007 MY to increase the torque to rotate.

- The part number was not changed and the breakpoint is unconfirmed, but is believed to

be in early November 2006.

- 4 of the allegations within the 2007 MY are after November 2006.

0

2

4

6

8

10

12

2005 MY 2006 MY 2007 MY 2008 MY 2009 MY 2010 MY


0

1

2

3

0

5,000

10,000

15,000

20,000

25,000

30,000

Inci

de

nts

pe

r M

OB

Po

pu

lati

on

by

Mo

nth

of

Bu

ild (

MO

B)

Month of Build


2005

2006

2007

# Incident Vehicles

0

1

2

3

4

5

6

7

8

9

10

11

Inci

de

nt

Co

un

t b

y M

od

el Y

ear

Calendar Year


2005

2006

2007

7/29/05

11/17/05

8/12/12

10/16/07

2/10/06

3/14/06

10/1/06

12/29/06

2/6/07

2/20/11

12/13/09

9/13/08

4/5/08

8/6/07

3/5/07

12/31/10

12/31/10

5/20/13

2/13/11

5/29/08

5/21/08

9/26/07

12/6/08

As of 10/1/13

2005 2006 2007 2008 2009 2010 2011 2012 2013

0

1

2

3

4

5

6

7

8

9

10

11

Inci

de

nt

Co

un

t b

y M

od

el Y

ear

Incident Date


2005

2006

2007

Fatality

Moderate

Moderate

Fatality

Moderate

Moderate

Fatality

Moderate

Severe

Mild

Moderate

Fatality

Moderate

Mild

Mild

Moderate

Fatality

Severe

Moderate

Mild

Mild

Mild

Mild

As of 10/1/13


2005 2006 2007 2008 2009 2010

Airbag Non-Deploy 11 7 5

Stalling VOQs 12 13 1 1 1

TREAD Search 56 43 10 1

Key Insert (Svc. Bulletin) 169 71 6

Total 248 134 22 2 1 0

Reports - Potential Key Rotation – Cobalt, G5 and Pursuit

• 24 of the 407 total reports are G5 or Pursuit. All others are Cobalt.

• All airbag Non-Deployment reports included vehicles that had left the road surface.

Normalized Report Rate

Model Year

TotalReports

U.S.Population

Reports /100k Vehicles /Years Exposure

2005 248 140,646 19.6

2006 134 229,231 7.4

2007 22 248,137 1.3

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Nu

mb

er

of

VO

Qs

Incident Date

2005-2009 Cobalt VOQs for Potential Ignition off While Driving

2005 Cobalt

2006 Cobalt

2007 Cobalt

2008 Cobalt

2009 Cobalt

0

1

2

3

4

5

6

7

8

9

10

11

12

Nu

mb

er

of

VO

Qs

pe

r M

od

el Y

ear

Incident Date

2003-9 Ion, HHR VOQs for Potential Ignition off While Driving

2003 Ion

2004 Ion

2006 HHR

2006 Ion

2007 HHR

2008 HHR

0

2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

32

34

Nu

mb

er

of

VO

Qs

pe

r M

od

el Y

ear

Incident Date


2003 Ion

2004 Ion

2005 Cobalt

2006 Cobalt, HHR, Ion

2007 Cobalt, HHR

2008 Cobalt, HHR

2009 Cobalt

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Nu

mb

er

of

VO

Qs

pe

r M

od

el Y

ear

Incident Date


2003 Ion

2004 Ion

2005 Cobalt

2006 Cobalt

2006 HHR

2006 Ion

2007 Cobalt

2007 HHR

2008 Cobalt

2008 HHR

2009 Cobalt

• Issued Nov 2005

• Reissued July 2011 to

add the 2007 MY.

2005MY-2009MY

2010 MY

Key

Slot vs. Hole

Cobalt

• Ignition switch with increased effort passed validation 4/26/06.

• Part number not changed.• Implementation date is

unknown.

0

5

10

15

20

2003 2004 2005 2006 2007 2008 2009 2010

Torq

ue

(N

cm)

Model Year


Cobalt

HHR

Ion

G5




0

5

10

15

20

2003 2004 2005 2006 2007 2008 2009 2010

Torq

ue

(N

cm)

Model Year


Cobalt

HHR

Ion

G5




3/14/05

9/08/04

2/24/06

1/19/05

9/16/04

12/22/0510/24/05

1/23/06

7/14/058/23/05

8/25/05

10/04/0511/09/05

9/27/05

9/05/066/19/06

1/12/07

8/08/06

3/12/07

11/07/06

3/02/07

12/01/06

9/15/06

1/19/07

6/18/07

5/05/08

5/19/08

9/13/07

12/11/07

5/19/10

3/14/087/11/08

10/01/08

8/11/08

8/15/08

9/02/08

10/20/09

10/14/03

4/22/04



0

1

2

3

0

5,000

10,000

15,000

20,000

25,000

30,000

Inci

de

nts

pe

r M

OB

Po

pu

lati

on

by

Mo

nth

of

Bu

ild (

MO

B)

Month of Build


2005

2006

2007

# Incident Vehicles

Incident Reports U.S. Population IPHTV /Year Exposure

2005-2007 Cobalt 23 618,014 0.47

2005 Cobalt 11 140,646 0.892006 Cobalt 7 229,231 0.382007 Cobalt 5 248,137 0.29

2006-2007 HHR 0 214,072 0

2003-2007 Ion 2A 478,986 0.04

SDM Sensor Bounce Anomaly – Safety Recall - Decision June 2002 (approx.. 2 yrs. Exposure)2000 GMT800 (Safety); 2000 S/T (No field action); 2000 M/L (No field action)

Incident Reports

Population IPHTV /Year Exposure

2000 GMT800 9 572,108 0.70

2000 S/T 1 455,500 0.11

2000 M/L 0 96,328 0


A Incidents can not be confirmed to be due to ignition switch rotation.

0

1

2

3

4

5

6

7

8

9

10

11

Inci

de

nt

Co

un

t b

y M

od

el Y

ear

Incident Date


2005

2006

2007

Fatality

Moderate

Moderate

Fatality

Moderate

Moderate

Fatality

Moderate

Severe

Mild

Moderate

Fatality

Moderate

Mild

Mild

Moderate

Fatality

Severe

Moderate

Mild

Mild

Mild

Mild

As of 10/1/13


Injury Severity Comparison

2000 GMT800 Sensor Bounce: 9 Total (3 mild, 3 moderate, 2 severe, 1 fatal)Fatal fatal

Skull & nose fracture, laceration right side of face & mouth. Whiplash. Lost consciousness. Wrist, knee, ankle, and foot injury. 6 days ICU

Severe

Belted - Significant head and chest & lower leg injury. Severe

Fractured neck vertebrae moderate

Fractured neck vertebrae. Fractured shoulder moderate

Concussion, sore shoulder, and chest moderate

No treatment. Claimed chest injury mild

Head trauma, bruises - treated at hospital mild

Broken nose mild

2005-2007 Cobalt, G5, Pursuit: 23 Total (7 mild, 9 moderate, 2 severe, 5 fatal) Fatality FatalFatality FatalDriver & Front Passenger: Fatal Fatal (2)Fatality FatalFatality FatalTraumatic Brain Injury SevereQuadriplegic SevereBruising to left side of head, cuts to left knee and back P: Fractured ribs, shoulder blade, cuts, and bruises ModerateUnknown Injuries (D) P: Broken neck (w/o paralysis), fractured ribs, sternum, laceration to head, facial bruises ModerateFractured ribs, nose, femur, and ankle ModerateFractured vertebrae and severe ear laceration ModerateKidney damage, left arm fracture, internal bleeding ModerateLost teeth, several stiches in mouth, broken ankle, broken wrist ModerateSyncope, concussion, occipital laceration, multiple contusions, seizure disorder ModerateFractured nose & scapula P:fractured leg ModerateSevere TBI, Basilar skull fracture, right hip fracture, right sacral fracture Moderate

Facial FX including: R. Orbital floor, R. Maxillary Sinus, and Bilateral Nasal Bone. Facial laceration & concussion MildBruised chest area, Bruises on head MildFractured front teeth and multiple contusions MildLaceration to liver, cut nose, bruised chest, bumps all over, sore left knee MildLaceration to head with scarring MildFacial Laceration and dislocated hip Mild

Broken nose , broken cheekbone, bruised lung, pain in right elbow Mild

Incidents Per 100k Vehicles /Year Exposure

Cumulative 2005-2008 2009-2013

2005-2007 Cobalt 0.47 0.86 0.20

2005 Cobalt 0.89 1.42 0.452006 Cobalt 0.38 0.58 0.28

2007 Cobalt 0.29 0.81 0.09

SDM Sensor Bounce Anomaly – Decision June 2002 (approx. 2 yrs. Exposure)2000 GMT800 - Safety Recall

2000 S/T - No field action.

Incident Reports

Population IPTV /Year Exposure

2000 GMT800 9 572,108 0.70

2000 S/T 1 455,500 0.11

2000 M/L 0 96,328 0


Add InsertReplace Switch

Cost Estimates (w/o Vehicle Attrition)

P/N 10392423

2005-2007 Cobalt, G5,

Pursuit

Ignition Switch Replacement

(Build Dates <11/1/06)

2 Key Inserts

(all build dates)

778,563 vehicles $41.3M

Vehicle scrap/survival rates are at approximately 91% for this population.

P/N 15842334

March 17, 2006

2005-7 Cobalt, G5, Pursuit, 2003-2007 Ion, 2006-2007 HHRCondition:A review of selected Cobalt & G5 frontal crash events indicates some airbag non deploys have occurred where the ignition switch was in accessory or off. The condition appears to be limited to 2005-07 Cobalt & G5 vehicles. The noted field events involve vehicles going off the road and/or hitting smaller objects shortly before a more significant impact.

Questions:– Why no incidents on Ion or HHR

• Ion is Class 2 architecture vs GM LAN on Cobalt and HHR– Both disable SDM with key off, but Cobalt/HHR will store ignition state & crash record while Ion will not– NISM review indicates 2 potential non-deploys for Ion

• Ion has different column shroud which could affect potential for key interaction• Ion customers may be less likely to have the type of crash needed for the condition• Ion has different SDM and supplier than Cobalt• HHR has more clearance to the driver’s knee

– Why no incidents on 2008-10 Cobalt?• Ignition switch was revised to have longer plunger and spring to increase effort (confirmed

10/29/13)– Part number not changed, so implementation date is unknown (Validation complete 4/26/06). Salvage

yard samples included 2007 vehicles with longer plunger (unknown if any had been replaced in service).

Root Cause:– The hypothesis is that during the off road event the driver’s knee is interacting with

the keys and/or the mass of the keys is causing the ignition to rotate

Vehicle Population & Incident Rate 2005-2007

Vehicles Sold in US2005 2006 2007

Cobalt/G5# Pursuit 140,464 229,231 248,137

Incidents 11 7 5IPTV/Yrs Exposure 0.0089 0.0039 0.0030

SOP – 1/1/09 8 4 4IPTV/Yrs Exposure 0.0142 0.0058 0.0081

1/1/09-10/1/13 3 3 1IPTV/Yrs Exposure 0.0045 0.0028 0.00085

• 2000 GMT800 0.0070 IPTV/yr (approx 2 yrs exposure @ decision June 2002)• 2000 S/T truck 0.0011 IPTV/yr no field action

- SDM anomaly may result in no-deploy

Vehicle Population & Incident Rate 2005-2007Cobalt & G5

Vehicles Sold in US2005 2006 2007#

Cobalt/G5# Pursuit 140,464 229,231 248,137

Incidents* 11 7 5IPTV/Yrs Exposure 0.0089 0.0039 0.0030(as of 10/1/13)

Incident rate for 2005 is over 2 times higher than 2006 and about 3 times higher than 2007

Combined IPTV/Yrs Exposure 0.0053

*Except for 1 2007 G5, all reports are Cobalt. There is 1 incident reported on a 2008 vehicle. 2008 vehicle had front sensor fault that disabled system prior to crash. # G5 was 2007 start.

Cobalt, Ion & HHR Ignition Switch Measurement

• 5/22/12 44 vehicles in Davison salvage yard – Measured torque (Ncm) and force (N) to turn the ignition switch from

Run to Accessory.

• Five of the vehicles had a replacement key, or a key with a hole vs slot (force not measured)

Model Year

Model 2003 2004 2005 2006 2007 2008 2009 2010Grand Total

Cobalt 1 5 5 3 3 1 18

G5 1 1 2

HHR 4 3 2 1 1 11

Ion 2 5 3 1 2 13

Grand Total 2 5 4 10 11 5 5 2 44

Switch Background

• Ion switch original for 2003. For 2005 capacity tooling was needed for Cobalt. The part number is the same, so it is not known what cavities were used for Ion and then for Cobalt. HHR added in 2006– A change was initiated in 2006 to implement a new printed circuit

board (12861211 Rev 5) and a new detent plunger (741-79378). The taller plunger and spring with more coils completed validation testing 4/24/06. The switch p/n was not changed, so it is unknown when switches with the new content were put into production or service.*

*The change to the plunger and spring was not confirmed until Delphi provided details with that information on 10/29/13

0

1

2

3

4

5

6

7

8

9

10

11

Inci

de

nt

Co

un

t b

y M

od

el Y

ear

Incident Date


2005

2006

2007

7/29/05

11/17/05

8/12/12

10/16/07

2/10/06

3/14/06

10/1/06

12/29/06

2/6/07

2/20/11

12/13/09

9/13/08

4/5/08

8/6/07

3/5/07

12/31/10

12/31/10

5/20/13

2/13/11

5/29/08

5/21/08

9/26/07

12/6/08

As of 10/1/13

Key position per SDM:A = Accessory (13)O = Off (1)R = Run (8)

A

A

A

A

A

A

A

A

A

A

A

R*

R

R

R

R

R

R

R*

O

R

A

No Event

R* = Run but algorithm disabled

Ignition Cylinder Warranty (N100256)

Vehicle Scrap Rates

AGE

TRUCKS(Full Size

Trucks

and Vans)

CARS(All

others)

1 100% 100%

2 99% 99%

3 99% 99%

4 98% 97%

5 95% 95%

6 94% 93%

7 93% 92%

8 92% 91%

9 92% 89%

10 91% 85%

11 86% 82%

12 79% 76%

*data pulled by RL Polk in March 2012

0

0.5

1

1.5

2

2.5

1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 70 73 76 79 82 85 88 91 94 97 100

Cobalt – Front Airbag Non-Deployment Incidents Per 100K Vehicles

Per Years Exposure2005 MY

2006 MY

2007 MY

2005 2006 2007 2008 2009 2010 2011 2012 2013

Calendar Year

IPH

TV

2000 S/T @ 0.11

2000 GMT800 @ 0.70

2003-2007 Ion, HHR, Solstice, Sky, Opel GT, G2X

Ignition Switch – Unintended Rotation

Vehicles 840,153

Cost Estimate: $34.3M (Switch Only) Locations: US, CAN, MEX

ETQ N-TBD

Condition:


ignition switch had moved from RUN to ACCESSORY or OFF.

Effects: The airbags will not deploy if the ignition has moved from RUN.

Root Cause: The ignition switch torque performance may be below specifications.


Number of Reports:

• 6 allegations of front airbag nondeployment.

Field incidents involve vehicles going off the road or hitting smaller objects

shortly before a more significant impact.

• 9 VOQs for “Ignition Off” while driving.

• 224 application of Service Bulletin (the key insert).


Potential Field Remedy: Replace ignition switch.

Potential Field Action Category: Safety Recall

PPAPChronology

Cobalt

‘05-’07

G5

‘07

HHR

‘06-’07

Ion (A)

‘03-’07

Sol./Sky

‘06-’07

Airbag Non-Deploy Incidents

(# of vehicle reports)23 2 2 4 0

Fatalities 8 0 0 5 0

Injuries 16 2 2 0 0

Fatality - Insufficient Information* 0 0 0

Injuries - Insufficient Information* 0 2 0

Inconclusive** 0 2 0

VOQs 28 0 5 3 0

Key Insert (Svc. Bulletin) 246 4 37 182 5

Total 297 6 44 189 5

Vehicle Counts 674,547 64,674 213,247 488,957 55,479

IPTV 0.44 0.09 0.21 0.39 0.09

Reports - Potential Unintended Key Rotation – U.S. Only

(A) Ion uses Class 2 architecture which does not record in ACCESSORY.

* “Insufficient Information” indicates that additional information is being pursued.

** “Inconclusive” indicates that no additional information can be obtained and the incident can

not be included or ruled out.

Note: The above counts represent the best judgment based on available data.

Data Pull 2/20/14

Included Sources:

GM’s Legal

Database (Team

Connect)

NHTSA VOQ

Database

Engineering Problem Resolution (PRTS) SummaryIgnition Switch Related

• PRTS issued for the following programs:

– Chevrolet Cobalt/Pontiac G5 3

– Chevrolet HHR 0

– Pontiac Solstice 0

– Saturn Sky 0

– Saturn Ion 8 *

Source: Brian Thompson, Engineering Manager, Switches & Controls 2/23/2014*Includes 3 Field Product Reports

Models 2003 2004 2005 2006 2007

Cobalt Produced 160,785 260,724 253,038

Cobalt In Service 129,774 222,324 225,233

G5 Produced 64,674

G5 In Service 57,567

Pursuit Produced 12,665 26,676

Pursuit In Service 10,222 22,747

Models 2003 2004 2005 2006 2007

Ion Produced 107,993 132,330 83,707 110,215 110,515

Ion In Service 74,771 99,733 67,562 93,982 98,371

HHR Produced 124,006 109,592

HHR In Service 105,742 97,550

Solstice Produced 21,273 24,018

Solstice In Service 18,140 21,379

Sky Produced 16,504

Sky In Service 14,690

Opel GTDaewoo G2X

TBD

Estimated Vehicles Remaining In Service:

778,562 Prod

667,868

Remain In

Service (86%)

840,153 Prod.

691,921

Remain In

Service (82%)

1 of 1 DOCUMENT

Plain Dealer (Cleveland)

June 26, 2005 SundayFinal Edition; All Editions

Salamis, key rings and GM's ongoing sense of humor

BYLINE: CHRISTOPHER JENSEN, Plain Dealer Auto Editor

SECTION: DRIVING; Pg. F1

LENGTH: 696 words

Just when things look so glum for General Motors, what a relief that somebody at the world's largestautomaker still has a sense of humor.

In this case it comes from a GM news release about the possibility that the engine on its 2005 ChevroletCobalt (built by God-fearing and corn-fed Buckeyes in Lordstown) might inadvertently shut off.

The release was issued in response to a short piece in last Sunday's New York Times that accompanied agenerally favorable review of the Cobalt. In the sidebar story, free-lance writer Jeff Sabatini reported that atest Cobalt driven by his wife stalled, apparently after her knee bumped the steering column.

Intrigued, I asked GM in Detroit if there was an official statement. Sure enough there was and it is, pleaseexcuse me, a knee slapper, suggesting that an engine that can be inadvertently turned off is not a safetyproblem.

"In rare cases when a combination of factors is present, a Chevrolet Cobalt driver can cut power to theengine by inadvertently bumping the ignition key to the accessory or off position while the car is running," itbegins.

"When this happens, the Cobalt is still controllable," the release says. "The engine can be restarted aftershifting to neutral." Incidentally, in a telephone interview a GM spokesman said the steering does not lockwhen the engine stalls.

So, if you're whisking along at 65 mph or trying to pull across an intersection and the engine stops, that'swhat you do. Only a gutless ninny would worry about such a problem. Real men are not afraid of temporaryreductions in forward momentum.

The chuckles are not over yet.

"GM has analyzed this condition and believes it may occur when a driver overloads a key ring, or when thedriver's leg moves amid factors such as steering column position, seat height and placement. Depending onthese factors, a driver can unintentionally turn the vehicle off."

The release goes on to say that service advisers are telling customers they "can virtually eliminate" this kindof unintended deceleration by "removing non-essential materials from their key rings."

So this is not an engineering or manufacturing problem, but a problem with clumsy drivers who can't controltheir knees or with those haunted by stories of the Donner Party who have attached a five-pound salami totheir key chain.

Page 1

Never mind that Sabatini, the troublemaker who started this, said the key chain being used was provided byGM and included such weighty items as a key fob and a tag identifying the vehicle as being part of MotherGM's brood.

The release concludes with an explanation of the complexity of ignition systems, apparently an appeal tothose with an appreciation for an in-depth, technical dive.

"Ignition systems are designed to have 'on' and 'off' positions and practically any vehicle can have power to arunning engine cut off by inadvertently bumping the ignition from the run to 'accessory' or 'off' position," itconcluded.

GM says it has no consumer complaints and, in fairness, I could only find one complaint filed with theNational Highway Traffic Safety Administration that might match the ignition-switch situation; even that wasn'tclear.

But a GM spokesman said two GM employees driving Cobalts have experienced the problem.

There is no evidence it is a widespread problem, but you have to admit it is pretty funny to hear somebodypretend that turning off the engine by mistake isn't a safety issue.

But the record for GM automotive belly laughs belongs to correspondence sent to NHTSA by GM's generalcounsel Thomas Gottschalk in which he argued that windshield wiper failures on some 2002 and 2003midsize sport utilities such as the Chevrolet TrailBlazer weren't a safety problem.

Unfortunately, NHTSA apparently does not have a sense of humor: Almost 600,000 vehicles were recalledand the agency scolded GM, accusing it of attempting to conceal a safety defect and suggesting this was notthe first time the automaker could have been more forthcoming. Then it fined the world's largest automaker arecord $1 million.

GM said the automaker chose to simply pay the fine to avoid the expense and hassle of a long court case.

Ha.

To reach this Plain Dealer reporter: [email protected], 216-999-4830

LOAD-DATE: June 28, 2005

LANGUAGE: ENGLISH

PUBLICATION-TYPE: Newspaper

Copyright 2005 Plain Dealer Publishing Co.

Page 2Salamis, key rings and GM's ongoing sense of humor Plain Dealer (Cleveland) June 26, 2005 Sunday

3/31/2014 Making a Case for Ignitions That Don't Need Keys - New York Times

http://www.nytimes.com/2005/06/19/automobiles/19KEYS.html?pagewanted=print&action=click&module=Search&region=searchResults%230&am… 1/1

June 19, 2005

Making a Case for Ignitions That Don't Need KeysBy JEFF SABATINI

CHEVROLET dealers are telling Cobalt owners to lighten their key rings to prevent intermittent stalling and the loss of electrical power in their cars. GeneralMotors issued a service bulletin to dealers suggesting this fix.

"In rare cases when a combination of factors is present, a Chevrolet Cobalt driver can cut power to the engine by inadvertently bumping the ignition key to

the accessory or off position while the car is running," Alan Adler, a manager for safety communications, said. "Service advisers are telling customers they

can virtually eliminate this possibility by taking several steps, including removing nonessential material from their key rings."

During my time with the Cobalt, I encountered the problem once, or rather, my wife did. She was driving on a freeway when the car "just went dead," in herwords. She recalled bumping her knee against the steering column just before the car shut off. She was able to coast to the shoulder of the road, where,

once parked, the car started and behaved normally.

The only things on the ring, other than the key, were the fob for the remote locking system and a tag identifying the car as G.M.'s - just as the key ring was

given to me.

Though my wife was able to continue to her destination, I wanted a dealer service department to look at the car. Young Chevrolet Oldsmobile Cadillac, in

Owosso, Mich., found nothing wrong, but did share the service bulletin.

Curious whether this experience was indeed rare, I searched the Internet for others who had encountered the same problem. I found a newspaper review

describing the writer's experience with a Cobalt that unintentionally shut off.

"Unplanned engine shutdowns happened four times during a hard-driving test week," Gary Heller wrote in The Daily Item of Sunbury, Pa., on May 26. "I

never encountered anything like this in 37 years of driving. I hope I never do again."

Mr. Adler said that G.M. did not currently consider this situation a safety issue. "When this happens, the Cobalt is still controllable," he said. "The engine can

be restarted after shifting to neutral. Ignition systems are designed to have on and off positions, and practically any vehicle can have power to a running

engine cut off by inadvertently bumping the ignition from the run to accessory or off position."

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Case3:14-cv-01339-JSW Document1 Filed03/24/14 Page1 of 72

1200 New Jersey Avenue SE Washington, DC 20590

February 14, 2014

Ms. Carmen BenavidesDirector, Product InvestigationsGeneral Motors LLC30001 Van Dyke - Mail Code 480-210-2VWarren, MI 48090-9055

NVS-215KS14V-047

Subject: Ignition Switch may Turn Off

Dear Ms. Benavides:

This letter serves to acknowledge General Motors LLC's notification to the National Highway Traffic Safety Administration (NHTSA) of a safety recall which will be conducted pursuant to Federal law for the product(s) listed below. Please review the following information to ensure that it conforms to your records as this information is being made available to the public. If the information does not agree with your records, please contact us immediately to discuss your concerns.

Makes/Models/Model Years: CHEVROLET/COBALT/2005-2007 PONTIAC/G5/2007

Mfr's Report Date: February 7, 2014

NHTSA Campaign Number: 14V-047

Components: ELECTRICAL SYSTEM:IGNITION:SWITCH

Potential Number of Units Affected: 619,122

Problem Description:General Motors LLC (GM) is recalling certain model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. In the affected vehicles, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine.

Consequence:If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.

Remedy:GM will notify owners, and dealers will replace the ignition switch, free of charge. The manufacturer has not yet provided a notification schedule. Owners may contact Chevrolet at 1-800-222-1020 or Pontiac at 1-800-762-2737. GM's number for this recall is 13454.

Notes:Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

As required in Part 573.6(c)(6), in the case of a defect, please provide a chronology of all principal events that were the basis for the determination that the defect related to motor vehicle safety, including a summary of all warranty claims, field or service reports, and other information, with their dates of receipt. Please provide this information as soon as possible. Please be reminded of the following requirements: You are required to submit a draft owner notification letter to this office no less than five days prior to mailing it to the customers. Also, copies of all notices, bulletins, dealer notifications, and other communications that relate to this recall, including a copy of the final owner notification letter and any subsequent owner follow-up notification letter(s), are required to be submitted to this office no later than 5 days after they are originally sent (if they are sent to more than one manufacturer, distributor, dealer, or purchaser/owner). You are required to provide an estimated date including month, day, and year, when you will send notifications to owners, dealers, and distributors as soon as it becomes available. Please be reminded that it is expected owners will be notified of a safety defect in their vehicles within 60 days of a manufacturer's notification to NHTSA of a safety defect in those vehicles. As stated in Part 573.7, submission of the first of six consecutive quarterly status reports is required within one month after the close of the calendar quarter in which notification to purchasers occurs. Therefore, the first quarterly report will be due on, or before, 30 days after the close of the calendar quarter. On August 20, 2013, NHTSA announced new changes to the requirements governing safety recalls. Some of these requirements are already in effect. Please ensure your company will be in compliance with each requirement on, or before, its respective effective date. For a summary of the requirements and their effective dates please click on the "New!" link at http://www.safercar.gov/Vehicle+Manufacturers.

Your contact for this recall will be Kelly Schuler who may be reached by phone at (202) 366-5227, or by email at [email protected] or through the office email at [email protected]. We look forward to working with you. Sincerely,

Jennifer Timian Chief, Recall Management Division Office of Defects Investigations Enforcement

14V-047 (Amended) 3 Pages

joshua.neff

Received

The GM Documents, Part 2

Documents

Transcript of The GM Documents, Part 2