F/CMVSS Noncompliance - Headlamp Photometrics

General Motors has decided that certain 2002 Chevrolet Malibu model vehicles equipped fail to conform to Federal/Canada Motor Vehicle Safety Standard (FMVSS) 108, Lamps, Reflective Devices, and Associated Equipment, (CMVSS) 108 Lighting System and Retroflective Devices, because the left low-beam headlamp does not meet certain photometric performance requirements. Light intensities below the minimum requirements cause some reduction in visibility down the road for the driver of the vehicle, and intensities above the maximum requirements cause some increase in glare for drivers ahead of or approaching the vehicle.

Dealers are to inspect and left low-beam headlamps and replace those that do not meet the requirements.

Involved are certain 2002 Chevrolet Malibu model vehicles built within these VIN breakpoints:

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

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned.

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

Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

For additional information, refer to the Lighting subsection of the Body and Accessories section of the Service Manual.

1. Open the hood.



2. Hold the left headlamp (2) in place while pulling upward on the two release tabs (1).
3. Remove the left headlamp (2) by pulling it straight forward from the body.



4. Turn the left headlamp upside down and inspect the date code (1) located in the lower right corner of the label.

•	If the date code on the label is NOT equal to, or is NOT between 1/14/02 and 1/30/02, the headlamp does NOT need to be replaced. Proceed to Step 8 of this procedure.

•	If the date code on the label IS equal to, or is between 1/14/02 and 1/30/02, the headlamp assembly must be replaced. Proceed to the next step of this procedure.




5. Disconnect the electrical connectors from the low and high beam bulbs and remove the park lamp/turn signal bulb socket form the lamp assembly.
6. Remove the protective paper cover over the opening for the park lamp/turn signal bulb in the NEW headlamp assembly.
7. Connect the electrical connectors to the low and high beam bulbs and install the park lamp/turn signal bulb socket.
8. Install the headlamp assembly to the body.
9. Hold the headlamp in place while pushing downward on the release tabs.
10. If a NEW headlamp assembly was installed, check and adjust the headlamp aim as necessary. If the headlamp was NOT replaced, it is NOT necessary to check the aim.
11. Install the GM Recall Identification Label.
12. Close the hood.

FOR US AND IPC

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

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

FOR CANADA

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

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

The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other 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.

Submit a Product Recall Claim with the information indicated below:

Refer to the General Motors WINS Claim Processing Manual for details on Product Recall Claim Submission.

FOR US AND CANADA

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

FOR IPC

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached suggested dealer letter.

FOR US AND IPC (US States, Territories, and Possessions)

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale.

ALL

All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear Chevrolet Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

General Motors has decided that certain 2002 Chevrolet Malibu model vehicles equipped fail to conform to Federal/Canada Motor Vehicle Safety Standard (FMVSS) 108, Lamps, Reflective Devices, and Associated Equipment, (CMVSS) 108 Lighting System and Retroflective Devices, because the left low-beam headlamp does not meet certain photometric performance requirements. Light intensities below the minimum requirements cause some reduction in visibility down the road for the driver of the vehicle, and intensities above the maximum requirements cause some increase in glare for drivers ahead of or approaching the vehicle.

Your dealer will inspect the left low-beam headlamp and replace it if it does not meet the requirements. This service will be performed for you at no charge .

The length of time required to perform this inspection and service correction is approximately 15 to 30 minutes. Additional time may be required to schedule and process your vehicle. If you dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed schedule, process, and repair your vehicle.

Please contact your dealer as soon as possible to arrange a service date. Parts are available and instructions for making this correction have been sent to your dealer.

Your dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the number listed below:

If, after contacting the appropriate customer assistance center, you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street SW, Washington, DC 20590 or call 1-888-327-4236.

The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the attached and mailing it in the postage paid envelope.

If your vehicle is within the New Vehicle Limited Warranty, your dealer will provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products.

General Motors Corporation

Enclosure