SB-10044380-2730

Recall Bulletin

Bulletin No.: 11290C
Date: May 2013

PRODUCT EMISSION RECALL
SUBJECT:

Degraded Connection between Ignition Coil Spark Plug Boots and Spark
Plugs

MODELS:

2009-2011 Chevrolet Aveo
2009-2010 Pontiac G3/Wave
Equipped with a 1.6L Gas Engine (LXV)

The Service Procedure section in this bulletin has been revised to include instruction on how
to remove the coil boot with compressed air. Please discard all copies of bulletin 11290B.
CONDITION
General Motors has decided to conduct a voluntary Emission Recall involving all 2009-2011
model year Chevrolet Aveo, and all 2009-2010 model year Pontiac G3/Wave vehicles
equipped with a 1.6L gas engine (LXV). A degraded connection between the spark plug boots
on the ignition coil assembly and the spark plugs may cause the illumination of the Check
Engine Soon light, rough engine operation, and lack of engine power.
CORRECTION
Dealers are to install new spark plug boots and spark plugs.
VEHICLES INVOLVED
All involved vehicles are identified by Vehicle Identification Number on the Investigate Vehicle
History screen in GM Global Warranty Management system. Dealership service personnel
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs. It is important to routinely use this tool to verify eligibility because
not all similar vehicles may be involved regardless of description or option content.
For dealers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared
and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will
not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle
Registration Records. The use of such motor vehicle registration data for any purpose other
than follow-up necessary to complete this recall is a violation of law in several
Copyright 2013 General Motors. All Rights Reserved.

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May 2013

Bulletin No.: 11290C

states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this recall.
PART INFORMATION
Parts required to complete this recall are to be obtained from General Motors Customer Care
and Aftersales (GMCC&A). Please refer to your “involved vehicles listing” before ordering
parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an
emergency situation, parts should be ordered on a CSO = Customer Special Order.
Part Number
19205426*

Description
SPARK PLUG KIT

Quantity/Vehicle
1

* Kit contains all parts required to repair one vehicle.
SERVICE PROCEDURE
Note: The spark plug kit contains new springs. Follow the instructions provided in the kit to
install the springs.
1. Remove the ignition coil assembly. Refer to Ignition Coil Replacement in SI.
2. Remove the spark plugs. Refer to Spark Plug Replacement in SI.
3. Install the four new spark plugs included in the spark plug kit.
Tighten
Tighten the spark plug to 25~30 N·m (18.4 ~ 22.1 lb-ft).

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4. Place the removed ignition coil on table.

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Bulletin No.: 11290C

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Caution: To avoid part damage, remove boots with coils in the horizontal position. Install new
springs and boots with coils pointing up to ensure the spring stays in the coil and is centered.
The new boot is fully seated when it is within 1 mm (0.040 inch) of metal shield.
5. Insert compressed air nozzle (1) into the boot. Ensure the air nozzle is inserted in the boot
enough to form a tight seal between the air nozzle and boot.

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6. Push the air nozzle button to inject compressed air into the boot. Inject compressed air
into the boot until the boot is removed from the metal shield. Perform steps 5 and 6 on the
remaining three boots BEFORE proceeding to step 7.
7. Insert the new boots onto the ignition coil towers partially.

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Bulletin No.: 11290C

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8. Insert the new boots onto the ignition coil towers fully. The new boot is fully seated when it
is within 1 mm (0.040 inch) of metal shield.
Note: Be careful of boot damage during installation because boot damage can cause a
weakened dielectric strength.
9. Install the ignition coil assembly into the engine. Refer to Ignition Coil Replacement in SI.
Tighten
Tighten the ignition coil mounting bolts to 8~12 N·m (70.8 ~ 106.2 lb-in).
10. Start the engine.
Warning: To avoid personal injury or vehicle damage, apply the parking brake lever, firmly
apply and hold the brake pedal, and only depress the acceleration pedal enough to put a safe
load on the engine.
11. Apply parking brake lever.
12. Press and hold brake pedal.
13. For vehicles equipped with an automatic transmission: press acceleration pedal for 3
seconds with gear position “Drive” and “Reverse”. Repeat this test three (3) times.
14. For vehicles equipped with a manual transmission: press acceleration pedal for 3 seconds
with gear position “Neutral”. Repeat this test three (3) times.
15. Using a scan tool, check trouble code(s) stored in freeze frame data.
16. If the problem does not occur, proceed to Step 17.
17. California, Connecticut, Maryland, Massachusetts, Maine, Oregon, Vermont, &
Washington vehicles only: Install a Recall Identification Label. Also, for California vehicles
complete a “Proof of Correction” certificate upon recall completion

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Bulletin No.: 11290C

RECALL IDENTIFICATION LABEL California/Connecticut/Maryland/Massachusetts/Maine/
Oregon/Vermont/Washington Vehicles Only
Place a Recall Identification Label on each vehicle corrected in accordance with the
instructions outlined in this Product Recall Bulletin. Each label provides a space to include the
recall number and the five-digit dealer code of the dealer performing the recall service. This
information may be inserted with a ballpoint pen.
Put the Recall Identification Label on a clean and dry surface of the
radiator core support in an area that will be visible to people servicing the
vehicle.
When installing the Recall Identification Label, be sure to pull the tab to
allow adhesion of the clear protective covering. Additional Recall
Identification Labels for US dealers can be obtained from Dealer Support
Materials
by
ordering
on
the
web
from
DWD
Store,
www.gmglobalconnect.com, and then click on the DWD Store link.
Request Item Number S-1015 when ordering.

GM
RECALL

11290

COMPLETED
DEALER CODE

ED
99-999

DO NOT REMOVE

CUSTOMER REIMBURSEMENT - For US
Customer requests for reimbursement of previously paid repairs for the recall condition are to
be submitted to the dealer by May 31, 2013, unless otherwise specified by state law. If this is
not convenient for the customer, they may mail the completed Customer Reimbursement
Request Form and all required documents to the GM Customer Assistance Center.
All reasonable and customary costs to correct the condition described in this bulletin
should be considered for reimbursement. Any questions or concerns should be
reviewed with your District Service Manager – Aftersales prior to processing the
request.
When a customer requests reimbursement, they must provide the following:




A completed Customer Reimbursement Request Form. This form is mailed to the
customer or can be obtained through GM GlobalConnect.
The name and address of the person who paid for the repair.
Paid receipt confirming the amount of the repair expense, a description of the repair,
and the person or entity performing the repair.

IMPORTANT: GM requires dealers to approve or deny a reimbursement request within 30
days of receipt. If a reimbursement request is approved, the dealer should immediately issue
a check to the customer and submit an appropriate warranty transaction for the incurred
expense. If a reimbursement request is denied, the dealer MUST provide the customer with a
clear and concise explanation, in writing, as to why the request was denied. The bottom
portion of the Customer Reimbursement Request Form may be used for this purpose. If the
denial was due to missing documents, the customer can resubmit the request when the
missing documents are obtained, as long as it is still within the allowed reimbursement period.
Warranty transactions for customer reimbursement of previously paid repairs are to be
submitted as required by GM Global Warranty Management. Additional information can also
be found in Warranty Administration Bulletin 11-00-89-004.

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Bulletin No.: 11290C

CUSTOMER REIMBURSEMENT - For Canada
Customer requests for reimbursement of previously paid repairs to correct the condition
described in this bulletin are to be submitted to the dealer prior to or by May 31, 2013.
When a customer requests reimbursement, they must provide the following:
-

Proof of ownership at time of repair.
Original paid receipt confirming the amount of unreimbursed repair expense(s)
(including Service Contract deductibles), a description of the repair, and the person or
entity performing the repair.

If the work was done by someone other than a GM dealership, the amount of reimbursement
will be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
COURTESY TRANSPORTATION
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within
the warranty coverage period and involved in a product program is very important in
maintaining customer satisfaction. Dealers are to ensure that these customers understand
that shuttle service or some other form of courtesy transportation is available and will be
provided at no charge. Dealers should refer to the General Motors Service Policies and
Procedures Manual for Courtesy Transportation guidelines.
WARRANTY TRANSACTION INFORMATION
Submit a transaction using the table below.
Labor
Code
V2531
V2596
V2597

Description
Replace Boot & Plug
Customer Reimbursement Approved
Customer Reimbursement Denied – For US dealer only

Labor
Time
0.5
0.2
0.1

Net
Item
N/A
*
N/A

* The amount identified in “Net Item” should represent the dollar amount reimbursed to the
customer. Note: this labor code is not to be used to reimburse for spark splugs that
were replaced under normal maintenance, which is every 25,000 miles (40,000 km).
CUSTOMER NOTIFICATION
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
included with this bulletin).
In order to ensure full protection under the emission warranty, and the right to participate in
future recalls, the customer notification letter recommends that customers have their vehicles
serviced as soon as possible. It also advises that failure to do so could legally be determined
to be lack of proper maintenance. The vehicle may fail a state or local emission inspection
test if the recall work is not completed.

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Bulletin No.: 11290C

DEALER RECALL RESPONSIBILITY
All unsold new vehicles in dealers' possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless
of mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for
which there is no customer information indicated on the dealer listing, are to be contacted by
the dealer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin
for your use in contacting customers. Recall follow-up cards should not be used for this
purpose, since the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in
your dealership for service in the future, you must take the steps necessary to be sure the
recall correction has been made before selling or releasing the vehicle.
***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA***
When a California emissions recall is completed by a GM dealer, the dealer must provide the
vehicle owner a “Proof of Correction Certificate” which the owner may need to present to the
California Department Of Motor Vehicles (DMV) when renewing their vehicle registration.
Without this correction certificate, the owner may be unable to renew their vehicle registration.
Additional Certificates can be obtained, at no charge, from Dealer Support Materials by
ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the
DWD Store link; request GM Item Number 1825 when ordering.

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,
equipment, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to
your vehicle, or that your vehicle will have that condition. See your dealer for information on whether your vehicle may benefit from the information.

We Support
Voluntary Technician
Certification

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May 2013

Bulletin No.: 11290C
May 2012

Dear General Motors Customer:
This notice is sent to inform you that General Motors is conducting a voluntary emission recall
that includes your vehicle.
Reason for This Recall: General Motors has decided to conduct a voluntary Emission Recall
involving all 2009-2011 model year Chevrolet Aveo, and 2009-2010 model year Pontiac
G3/Wave vehicles equipped with a 1.6L gas engine. A degraded connection between the
spark plug boots on the ignition coil assembly and the spark plugs may cause the illumination
of the Check Engine Soon light, rough engine operation, and lack of engine power.
What Will Be Done: Your GM dealer will install new spark plug boots and spark plugs. This
service will be performed for you at no charge.
What You Should Do: Please contact your GM dealer as soon as possible to arrange a
service date and to assure parts availability. Instructions for making this correction have been
sent to your dealer. Please ask your dealer if you wish to know how much time will be needed
to schedule, process, and repair your vehicle.
The new GM spark plug number and the new spark plug gap are listed below. Please update
your owner manual or place this letter in your owner manual for future reference.
New spark plug number:
New spark plug gap:

25186682
0.031-0.035 inch (0.8-0.9 mm)

As a reminder, the scheduled maintenance interval for spark plug replacement is every 25,000
miles (40,000 km).
If you have any questions or need any assistance, just contact your dealer or the appropriate
Customer Assistance Center at the number listed below.
Division

Number

Chevrolet
Pontiac
Guam
Puerto Rico – English
Puerto Rico – Español
Virgin Islands

1-800-222-1020
1-800-762-2737
65-6267-1752
1-800-496-9992
1-800-496-9993
1-800-496-9994

Text Telephones
(TTY)
1-800-833-2438
1-800-833-7668

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 Manual and
your dealer for details on Courtesy Transportation.
Emission Law Information: In order to ensure your full protection under the emission
warranty made applicable to your vehicle by state and federal law, and your right to participate
in future recalls, it is recommended that you have your vehicle serviced as soon as possible.
Failure to do so could legally be determined to be lack of proper maintenance of your vehicle.
Also, your vehicle may fail a state or local emission inspection if this recall is not
accomplished.

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Bulletin No.: 11290C

IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS
The California Air Resources Board (CARB) requires vehicle emission recalls be completed
prior to California registration renewal. Uncorrected emission recalls will result in the inability
to renew your California vehicle registration.
At the time of emission recall completion, your California dealer will issue a "Proof of
Correction Certificate". Keep this certificate and, if required, present it to the Department of
Motor Vehicles when renewing your California registration as proof of recall completion.
We are sorry to cause you this inconvenience; however, we have taken this action in the
interest of your continued satisfaction with our products.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
11290