Bulletin No.: 15642
Date: December 2015

Service Bulletin
SPECIAL COVERAGE
SUBJECT:

Special Coverage Adjustment - Side Impact Airbag Connectors

MODELS:

2011 Chevrolet Volt

CONDITION
On some 2011 model year Chevrolet Volt vehicles, the airbag indicator may illuminate. This may
be caused by the sensing and diagnostic module (SDM) monitoring an increase in the resistance
of the driver or passenger side-impact airbag deployment loop circuits. This increased resistance
may be caused by loose terminal crimps in either the driver or passenger seat mounted side-impact
airbag wiring harness connectors.
SPECIAL COVERAGE ADJUSTMENT
This special coverage covers the condition described above for a period of 10 years or 120,000
miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service,
regardless of ownership.
Dealers are to inspect for the presence of specific Diagnostic Trouble Codes (DTCs) and, if
necessary, bypass the harness connectors and repair wiring in the driver and/or passenger front
side-impact airbag deployment loop circuits. The repairs will be made at no charge to the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after
December 18, 2015, are covered by this special coverage and must be submitted using the labor
operation codes provided with this bulletin. Claims with repair orders prior to December 18, 2015,
must be submitted to the Service Contract provider.
VEHICLES INVOLVED
All involved vehicles are identified by Vehicle Identification Number on the Applicable Warranties
section 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.

Copyright 2015 General Motors. All Rights Reserved.

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Bulletin No.: 15642

PART INFORMATION
For U.S., Canada, and Export: 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
05297428
12355010

Description
Clip, Wrg Harn Splice (Pack of 10)
Tubing, Shrink (1/8" Black) (Pack of 10)

*1089482
(Preferred)

Woven Polyester Electrical Tape (PET)

*90235
(Preferred)

Yellow Electrical Tape

Obtain Locally

Wire, Jumper (0.8 mm / 18 gauge)

Quantity/Vehicle
4 Per Seat
1 Per Seat
As Required,
(Submit in Net
Item)
As Required,
(Submit in Net
Item)
As Required,
(Submit in Net
Item)

* To obtain the PET and Yellow tape, contact Kent Automotive at 1-888-937-5368 or www.kentautomotive.com. Do not order from GMCCA.
SERVICE PROCEDURE
Verify that DTC B0014 04 Driver Side Air Bag Deployment Loop Open, or DTC B0014 0D Driver
Side Air Bag Deployment Loop High Resistance and/or B0021 04 Passenger Side Air Bag
Deployment Loop Open, or DTC B0021 0D Passenger Side Air Bag Deployment Loop High
Resistance are set as Current or in History. Refer to the appropriate diagnostic information in SI.


If the above listed DTCs are not set as Current or in History, no further action is required. Inform
the customer that any additional diagnosis and repairs are not covered under this special
coverage.



Using the above DTC information, determine which seat needs to be serviced using the repair
procedure below.

REPAIR PROCEDURE
Use the following steps to remove existing yellow seat cushion to seat back mated connector pair
and splice the remaining wires together using splice clips, jumper wire, solder and heat shrink.
Warning: When performing service on or near the SIR components or the SIR wiring, the SIR
system must be disabled. Failure to observe the correct procedure could cause deployment of the
SIR components. Serious injury can occur. Failure to observe the correct procedure could also
result in unnecessary SIR system repairs.
1. Disable the Supplemental Inflatable Restraints (SIR) system. Refer to SIR Disabling and
Enabling in SI.
2. Remove the affected seat. Refer to Driver or Passenger Seat Removal and Installation in SI.
3. Place the seat on a clean, covered work surface. Position the seat so you can access the yellow
Side Impact Airbag (SIAB) harness connectors on the underside of the seat cushion.

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December 2015

4325289

4. Remove the protective fabric as necessary.

4325291

5. Locate the yellow Side Impact Airbag (SIAB) harness connector.

4325293

6. Remove the connector from the seat spring by releasing the metal clip.

Bulletin No.: 15642

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December 2015

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4325294

7. Using side cutters, cut the connectors from both sides of the seat harness as close to the
connector as possible.
8. Strip off approximately 13 mm (1/2 in) of insulation from the wiring ends. Fold the wires.
9. Add one approximate 38 mm (1.5 in) section of heat shrink tube to each of the four wires.

4325295

10. Prepare two approximate 75 mm (3.0 in) length jumper wires. Use locally sourced 0.8 sq mm
(18 gauge) wire for the jumper wires. Strip off approximately 13 mm (1/2 in) of insulation from
the wiring ends. Fold the wires as shown.
11. Insert the two jumper wires between the four harness wires. Ensure the correct wire colors are
aligned.

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December 2015

Bulletin No.: 15642

4325296

Note: Keep the heat shrink tube below the splice when soldering the splice to ensure that the heat
shrink is not prematurely shrunk and closed down over the wire or splice area due to the heat
from the soldering iron.
12. Crimp a splice clip over the joined wires using Special Tool J-38125-8, nest F. Verify the crimp
quality. Repeat this crimp process on all four wire connections.
Warning: DO NOT use soldering equipment that is battery or electric powered. These types of
soldering irons can induce voltage into the circuit, which may cause inflator module deployment
and/or damage to electrical components. Use only the J-38125-5A Ultra Torch or another butane
fueled soldering iron when working on SIR circuits.

4325297

13. Solder all four crimp and splice clips using the Ultratorch, part number J-38125-5, or another
butane fueled soldering iron.

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December 2015

Bulletin No.: 15642

4325298

14. Center the heat shrink tube over all four splices and shrink/seal the heat shrink tube securely
over the splice crimp and insulated wires.
15. Wrap woven polyester electrical tape (PET) or equivalent anti-abrasion tape around the spliced
section of both wires.
Warning: Ensure yellow tape is wrapped around the splice section of the seat wire harness to
properly identify supplemental inflatable restraint (SIR) wiring. Failure to properly identify SIR
wiring could cause deployment of the SIR components, personal injury, or unnecessary SIR
system repairs.
16. Wrap yellow electrical tape over the polyester electrical tape.
17. Reinstall the protective fabric as necessary.
18. Reinstall the seat. Refer to Driver or Passenger Seat Removal and Installation in SI.
19. Enable the Supplemental Inflatable Restraints (SIR) system. Refer to SIR Disabling and
Enabling in SI.
20. Clear any sensing and diagnostic module (SDM) DTCs using a scan tool. Verify that the airbag
indicator is NOT displayed on the instrument panel cluster (IPC). If DTCs appear after clearing
the SDM, refer to the appropriate diagnostic information in SI.
CUSTOMER REIMBURSEMENT - For US
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer by December 31, 2016, unless otherwise specified
by state law. If this is not convenient for the customer, the customer may mail the completed
Customer Reimbursement Request Form and all required documents to the GM Customer
Assistance Center. Repairs must have occurred within the 10 years of the date the vehicle was
originally placed in service, or 120,000 miles, whichever occurs first.
All reasonable and customary costs to correct the condition described in this bulletin should
be considered for reimbursement. Any questions or concerns should be reviewed with your
GM representative prior to processing the request.
When a customer requests reimbursement, they must provide the following:

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December 2015

Bulletin No.: 15642



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.
CUSTOMER REIMBURSEMENT - For Export
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 December 31, 2016. Repairs must
have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000
kilometers, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
-

Proof of ownership at time of repair.

-

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

All reasonable and customary costs to correct the condition described in this bulletin should be
considered for reimbursement. Any questions or concerns should be reviewed with your GM
representative prior to processing the request.
COURTESY TRANSPORTATION – For US
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.

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December 2015

Bulletin No.: 15642

WARRANTY TRANSACTION INFORMATION
Submit a transaction using the table below. All transactions should be submitted as a ZREG
transaction type, unless noted otherwise.

Vehicles Still Covered Under Applicable New Vehicle Limited Warranties
Labor
Code
6459939
6480268

Description
Electronics/Airbags - Customer Concern Not Duplicated
(CCND)
Driver or Passenger Seat SIAB Connector Removal
ADD: For Second Seat

Labor
Time
0.1-0.3

Net
Item
N/A

0.7
0.6

*

Note: For reimbursements on vehicles covered under warranty, refer to the Policies and Procedures
Manual.
Vehicles No Longer Covered Under Applicable New Vehicle Limited Warranties
Labor
Code
9900284
9900285
9900286
9900287

Description
Electronics/Airbags - Customer Concern Not Duplicated
(CCND)
Driver or Passenger Seat SIAB Connector Removal
ADD: For Second Seat
Customer Reimbursement Approved
Customer Reimbursement Denied - For US dealers only

Labor
Time
0.1-0.3

Net
Item
N/A

0.7
0.6
0.2
0.1

*
**
N/A

Note: To avoid having to "H" route the customer reimbursement transaction for approval, it must
be submitted prior to the repair transaction.
*

The amount identified in “Net Item” should represent the actual cost of the woven polyester
electrical tape (PET), jumper wire, and yellow tape needed to perform the required repairs, not
to exceed $0.85 USD.

**

The amount identified in “Net Item” should represent the dollar amount reimbursed to the
customer.

CUSTOMER NOTIFICATION
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter included with this bulletin - actual divisional letter may vary slightly).

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/retailer for information on
whether your vehicle may benefit from the information.

We Support
Voluntary Technician
Certification

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December 2015

Bulletin No.: 15642
January 2016

This notice applies to your vehicle, VIN: _____________________________________
Dear General Motors Customer:
As the owner of a 2011 model year Volt, your satisfaction with our product is very important to us.
This letter is intended to make you aware that some 2011 Volt vehicles, may have a condition
where the airbag indicator may illuminate. This may be caused by the sensing and diagnostic
module (SDM) monitoring an increase in the resistance of the driver or passenger side-impact
airbag deployment loop circuits. This increased resistance may be caused by loose terminal
crimps in either the driver or passenger seat mounted side-impact airbag wiring harness
connectors.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that
your vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the
condition described above. If this condition occurs on your 2011 model year Volt within 10 years
of the date your vehicle was originally placed in service or 120,000 miles (193,000 km), whichever
occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions
other than the condition described above is not covered under this special coverage program.
What You Should Do: If you believe that your vehicle has the condition described above, repairs
and adjustments qualifying under this special coverage must be performed by a General Motors
dealer. You may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will
also allow your dealer to order parts if they are not already in stock. Keep this letter with your
other important glove box literature for future reference.
Reimbursement: If you have paid for repairs for the condition described in this letter, please
complete the enclosed reimbursement form and present it to your dealer with all required
documents. Working with your dealer will expedite your request, however, if this is not
convenient, you may mail the completed reimbursement form and all required documents to
Reimbursement Department, PO Box 33170, Detroit, MI 48232-5170. The completed form and
required documents must be presented to your dealer or received by the Reimbursement
Department by December 31, 2016, unless state law specifies a longer reimbursement period.
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
Puerto Rico – English
Puerto Rico – Español
Virgin Islands

1-800-222-1020
1-800-496-9992
1-800-496-9993
1-800-496-9994

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

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December 2015

Bulletin No.: 15642

We are sorry for any inconvenience you may experience; however, we have taken this action in
the interest of your continued satisfaction with our products.
Terry M. Inch
Executive Director
Global Connected Customer Experience
Enclosure
15642

Headline Details

Page 1 of 1

15642 - Special Coverage - Side Impact Airbag Connectors
Updated Date: Dec 18, 2015 9:10 ET
GM CUSTOMER CARE AND AFTERSALES
DCS3880
URGENT - DISTRIBUTE IMMEDIATELY

Date:

December 18, 2015

Subject:

15642 – Special Coverage Adjustment
Side Impact Airbag Connector

Models:

2011 Chevrolet Volt

To:

All Chevrolet Dealers

Attention: General Manager, Service Advisor, Service Manager, Parts and
Service Director, Parts Manager, Used Vehicle Sales Manager,
and Warranty Administrator

General Motors is releasing Special Coverage Adjustment 15642 today. The total number of U.S. vehicles involved is 4,369. Please see the attached bulletin for details.

Customer Letter Mailing
The customer letter mailing will begin in mid-January, 2016.

Global Connect (GWM)
The "Investigate Vehicle History" (IVH) screen will be updated December 18, 2015.

Campaign Initiation Detail Report (CIDR)
The CIDR is not available for Special Coverage Adjustments.

GM CUSTOMER CARE AND AFTERSALES
15642 Bulletin.pdf

About this Article
Reference Number: GCUS-9-1393
Published to: Service
Version: 1.0
Original Published Date: Dec 18, 2015 9:10 ET
Expires: Feb 29, 2016 0:00 ET
Contact: [email protected]

https://dealer.autopartners.net/portal/uscontent/headlines/Pages/GCUS-9-1393.aspx

12/18/2015