The GM Documents, Part 2

2005-2007 Cobalt/Pursuit/G5 Front Airbag Non-Deployment 709,741 Vehicles Cost Estimate: $14.2M-$37.
7M
ETQ N-130454
Locations: US, CAN, MEX
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 drivers 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
Not applicable
20 +/-5 N-cm ACC - RUN RUN ACC
Torque to Rotate From Run to Accessory

20
Both ignition switches replaced 12/6/07, 12/27/07 All 3 ignition switches replaced 1/21/05, 1/21/09, 1/4/08
15
Torque (Ncm)
10
Cobalt HHR
5
0 2003
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.
2004 2005 2006 2007 2008 2009
Ion
G5
2010
It is unknown if any switches were replaced outside of warranty
Model Year
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 drivers knee
A B
One G5 incident, all others are Cobalt. 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

20
7/11/08
Both ignition switches replaced 12/6/07, 12/27/07

6/18/07
3/14/08 5/19/10 12/11/07 9/02/08 10/01/08 9/13/07 12/01/06 11/07/06 3/12/07 1/12/07 8/15/08 5/19/08 8/11/08
15
All 3 ignition switches replaced 1/21/05, 1/21/09, 1/4/08

4/22/04
1/19/07
Torque (Ncm)
3/14/05 9/27/05 11/09/05 8/23/05 7/14/05 1/23/06 10/24/05 12/22/05
10/20/09 5/05/08 10/04/05 3/02/07 8/08/06 9/15/06 6/19/06 9/05/06
10
9/16/04 9/08/04 1/19/05 10/14/03
8/25/05
2/24/06
Cobalt HHR
The date by each data point is the vehicle build date
Ion
G5

0 2003 2004 2005 2006 2007 2008 2009 2010
Model Year
Non-Deployment Allegations by Model Year Cobalt (22), G5 (1)

12 10 8 6 4 2 0 2005 MY 2006 MY 2007 MY 2008 MY 2009 MY 2010 MY
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.
2005-7 Cobalt/G5 Non Deploy Incidents & Population by MOB

30,000 2005 2006 25,000 2007 # Incident Vehicles 3
Population by Month of Build (MOB)
15,000
10,000
5,000
Build date not available for one 2005 vehicle
Month of Build As of 10/1/13
Incidents per MOB
20,000
2005-7 Cobalt / G5 Reports of Airbag Non-Deploy by Model Year & Incident Date
11
2/20/11 8/12/12
10 9 8 7 6 5 4 3
2005 2006 2007

2/6/07 12/29/06 10/1/06 3/14/06 2/10/06 11/17/05 8/6/07 3/5/07 9/26/07 4/5/08 5/29/08 5/21/08 9/13/08 12/6/08 12/31/10 12/31/10 2/13/11 10/16/07 5/20/13 12/13/09
Incident Count by Model Year
2
7/29/05
1 0
2005
2006
2007
2008
2009
Calendar Year
2010
2011
2012
2013
As of 10/1/13
Stalling VOQs by Model Year Potential Key Motion (Stall with No DTCs & Immediate Restart) Model COBALT HHR ION 2003 2004 2005 12 2006 13 11 8 2007 1 2 2008 1 1 2009 1 2010
2005-10 Cobalt TREAD Search - Elec, Eng, Strg Potential Knee-Key

2005 56 2006 43 2007 10 2008 1 2009 0 2010 0 Total 110
2005-2009 Cobalt VOQs for Potential Ignition off While Driving

14 13 12 11 10
Number of VOQs
9 8 7 6 5 4 3 2 1 0
2005 Cobalt 2006 Cobalt 2007 Cobalt 2008 Cobalt 2009 Cobalt
Incident Date
2003-9 Ion, HHR VOQs for Potential Ignition off While Driving
12 11
2003 Ion
10
2004 Ion 2006 HHR 2006 Ion 2007 HHR 2008 HHR
Number of VOQs per Model Year
9 8 7 6 5 4 3 2 1 0
Incident Date
2003-9 Ion, Cobalt, HHR, VOQs for Potential Ignition off While Driving
34 32 30 28 2003 Ion 2004 Ion 2005 Cobalt 2006 Cobalt, HHR, Ion 2007 Cobalt, HHR 2008 Cobalt, HHR 2009 Cobalt
26 24 22 20 18 16 14 12 10 8 6 4 2 0
Incident Date
14 13 12 11
2003 Ion 2004 Ion 2005 Cobalt 2006 Cobalt 2006 HHR 2006 Ion 2007 Cobalt
10 9 8 7 6 5 4 3 2 1 0
2007 HHR 2008 Cobalt 2008 HHR 2009 Cobalt
Incident Date
Issued Nov 2005 Reissued July 2011 to add the 2007 MY.
Key Slot vs. Hole Cobalt
2005MY-2009MY
2010 MY
Ignition switch with increased effort passed validation 4/26/06. Part number not changed. Implementation date is unknown.

20
15
Torque (Ncm)
10
Cobalt HHR
5
Ion
G5
0 2003
2004
2005
2006
2007
2008
2009
2010
Model Year

20
7/11/08

6/18/07
3/14/08 5/19/10 12/11/07 9/02/08 10/01/08 9/13/07 12/01/06 11/07/06 3/12/07 1/12/07 8/15/08 5/19/08 8/11/08
15

4/22/04
1/19/07
Torque (Ncm)
3/14/05 9/27/05 11/09/05 8/23/05 7/14/05 1/23/06 10/24/05 12/22/05
10/20/09 5/05/08 10/04/05 3/02/07 8/08/06 9/15/06 6/19/06 9/05/06
10
9/16/04 9/08/04 1/19/05 10/14/03
8/25/05
2/24/06
Cobalt HHR
Ion
G5

0 2003 2004 2005 2006 2007 2008 2009 2010
Model Year

15,000
10,000
5,000
Incidents per MOB
20,000
Non-deploys due to Ignition Switch Rotation 2005-7 Cobalt, G5, Pursuit, 2003-2007 Ion, 2006-2007 HHR
Incident Reports
2005-2007 Cobalt
2005 Cobalt 2006 Cobalt 2007 Cobalt
U.S. Population
618,014
140,646 229,231 248,137
IPHTV / Year Exposure

0.47
0.89 0.38 0.29
23
11 7 5
2006-2007 HHR 2003-2007 Ion

A Incidents
0 2A
214,072 478,986
0 0.04
can not be confirmed to be due to ignition switch rotation.
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 2000 GMT800 2000 S/T 2000 M/L 9 1 0
Population 572,108 455,500 96,328
IPHTV / Year Exposure 0.70 0.11 0
Cobalt Front Airbag Non-Deployment Incidents Per 100K Vehicles

2.5
2005 MY
2
2006 MY 2007 MY
1.5
IPHTV
1
2000 GMT800 @ 0.70
0.5
2000 S/T @ 0.11
0
1
2005
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
2006
2007
2008
2009
2010
2011
2012
2013
Calendar Year
Severity of Injuries: 2005-7 Cobalt / G5 Reports of Airbag Non-Deploy

11
Mild Moderate
10 9 8 7 6 5 4 3
2005 2006 2007

Severe Moderate Fatality Moderate Moderate Moderate Mild Mild Mild Fatality Moderate Mild Mild Mild Moderate Fatality Moderate Fatality Severe Moderate
2
Fatality
1 0
Severity Summary: - 7 mild - 9 moderate - 2 severe - 5 fatal
Incident Date As of 10/1/13
Injury Severity Comparison 2000 GMT800 Sensor Bounce: 9 Total (3 mild, 3 moderate, 2 severe, 1 fatal)
Fatal Skull & nose fracture, laceration right side of face & mouth. Whiplash. Lost consciousness. Wrist, knee, ankle, and foot injury. 6 days ICU Belted - Significant head and chest & lower leg injury. Fractured neck vertebrae Fractured neck vertebrae. Fractured shoulder Concussion, sore shoulder, and chest No treatment. Claimed chest injury Head trauma, bruises - treated at hospital Broken nose fatal Severe Severe moderate moderate moderate mild mild mild
2005-2007 Cobalt, G5, Pursuit: 23 Total (7 mild, 9 moderate, 2 severe, 5 fatal)

Fatality Fatal Fatality Fatal Driver & Front Passenger: Fatal Fatal (2) Fatality Fatal Fatality Fatal Traumatic Brain Injury Severe Quadriplegic Severe Bruising to left side of head, cuts to left knee and back P: Fractured ribs, shoulder blade, cuts, and bruises Moderate Unknown Injuries (D) P: Broken neck (w/o paralysis), fractured ribs, sternum, laceration to head, facial bruises Moderate Fractured ribs, nose, femur, and ankle Moderate Fractured vertebrae and severe ear laceration Moderate Kidney damage, left arm fracture, internal bleeding Moderate Lost teeth, several stiches in mouth, broken ankle, broken wrist Moderate Syncope, concussion, occipital laceration, multiple contusions, seizure disorder Moderate Fractured nose & scapula P:fractured leg Moderate Severe 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 Mild Bruised chest area, Bruises on head Mild Fractured front teeth and multiple contusions Mild Laceration to liver, cut nose, bruised chest, bumps all over, sore left knee Mild Laceration to head with scarring Mild Facial Laceration and dislocated hip Mild Broken nose , broken cheekbone, bruised lung, pain in right elbow Mild
Incidents Per 100k Vehicles /Year Exposure Cumulative 2005-2007 Cobalt

2005-2008 0.86
1.42 0.58 0.81
2009-2013 0.20
0.45 0.28 0.09
0.47
0.89 0.38 0.29
SDM Sensor Bounce Anomaly Decision June 2002 (approx. 2 yrs. Exposure) 2000 GMT800 - Safety Recall 2000 S/T - No field action.
Population 572,108 455,500 96,328
IPTV / Year Exposure 0.70 0.11 0
Cost Estimates (Includes Vehicle Attrition)
Replace Switch Production Year
Exchange: 2 slotted w/ 2 holes
Add Insert
Cobalt, G5, Pursuit* Ion HHR Total
2003 N/A 88,926 N/A 88,926
2004 N/A 113,028 N/A 113,028
2005 154,807 74,677 N/A 229,483
2006 261,924 100,436 113,003 475,364
2007 Total 293,010 709,741 101,919 478,986 101,069 214,072 495,998 1,402,799
Summary Points
A) Combined reports (FPA, VOQs, Tread) indicate that a distinct change occurred during 2007 MY:
2005 MY 2006 MY 2007 MY 2008 MY 2009 MY 2010 MY
79
63
16
B) The non-deployment incident rate for 2005 MY is over 2 times higher than 2006; approx. 3 times higher than 2007 MY. Incidents IPHTV/Yrs Exposure 2005 11 0.89 2006 7 0.39 2007 5 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 IPHTV/Yrs Exposure 8 1.42 4 0.58 3 0.28 4 0.81 1 0.09
2009-2013 3 IPHTV/Yrs Exposure 0.45 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.
March 17, 2006
2005-7 Cobalt, G5, Pursuit, 2003-2007 Ion, 2006-2007 HHR

Condition:
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 drivers 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 drivers 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 US Cobalt/G5# Pursuit Incidents IPTV/Yrs Exposure SOP 1/1/09 IPTV/Yrs Exposure 1/1/09-10/1/13 IPTV/Yrs Exposure 2005 140,464 11 0.0089 8 0.0142 3 0.0045 2006 229,231 7 0.0039 4 0.0058 3 0.0028 2007 248,137 5 0.0030 4 0.0081 1 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 2005-2007 Cobalt & G5

Vehicles Sold in US Cobalt/G5# Pursuit Incidents* IPTV/Yrs Exposure
(as of 10/1/13)
2005 140,464 11 0.0089
2006 229,231 7 0.0039
2007# 248,137 5 0.0030
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 Cobalt, G5 Ion
2003 N/A 0.04046
2004 N/A 0.02526
2005 0.05316 0.04346
2006 0.02886 0.01826
2007 0.00733 0.0
2008 ~0 N/A
2009 0 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 (61 driver)
11 10 9 8 7 6 5 4 3 2 1 0
3/14/06
8/12/12
2005 2006 2007
Key position per SDM: A = Accessory (13) O = Off (1) R = Run (8)
A
2/20/11
R
12/13/09
A
10/16/07
R
2/6/07
5/20/13
A
12/29/06 12/31/10
A R
12/31/10
R
10/1/06
A
9/13/08
O R*
4/5/08
2/13/11
A
2/10/06
12/6/08
A
11/17/05 8/6/07
A R
3/5/07
R A
5/29/08 5/21/08
R*
7/29/05
R
9/26/07
No Event
Incident Date
R* = Run but algorithm disabled
As of 10/1/13
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.
GMLAN
Batt
SDM
CM20324
AOS
IGN
Vehicle Scrap Rates

TRUCKS AGE 1 2 3 4 5 6 7 8 9 10 11 12
(Full Size Trucks and Vans)
CARS
(All others)
100% 99% 99% 98% 95% 94% 93% 92% 92% 91% 86% 79%
100% 99% 99% 97% 95% 93% 92% 91% 89% 85% 82% 76%
*data pulled by RL Polk in March 2012
2005-2007 Cobalt/Pursuit/G5 Ignition Switch 778,563 Vehicles Cost Estimate: $41.3M
ETQ N-130454
Locations: US, CAN, MEX
Condition: Front airbag non-deployment has been identified in certain crash events. In those events the 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. Service Bulletin: Bulletin #05-2-35-007 Inadvertent key turning issued Oct 2005. 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. Ignition Switch Change: Increased effort for RUN to ACCESSORY. 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
Slide 21 PPAP
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.
20
Salvage Yard Vehicle Measurements Torque to Rotate From Run Position

Spec. = 20 +/- 5 N-cm
15
Torque (Ncm)
10
Cobalt HHR
5
Ion G5
0 2003
2004
2005
2006
2007
2008
2009
2010
Model Year
Original Switches only.
Slide 21
20
Salvage Yard Vehicle Measurements Torque to Rotate From Run Position

Spec. = 20 +/- 5 N-cm
November 2006 Switch Change
15
Torque (Ncm)
10
Cobalt HHR
5

0 2003
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).
2004 2005 2006 2007 2008 2009
Ion G5
2010
Model Year
1. Forces required to rotate ignition from RUN to ACCESSORY/OFF
Static Key Ring Mass (lbs.) to Rotate Ignition Switch from Run Column Position
Switch Force
25 N-cm 20 N-cm 15 N-cm 10 N-cm
Low
5.20 4.16 3.12 2.08
Mid
4.97 3.97 2.98 1.99
High
4.49 3.59 2.70 1.80
Switch Specification = 20 +/- 5 N-cm Internal Cylinder Force (approx.) = 2 N-cm
Column High to Low

20
3.59 4.16 lbs.
Salvage Yard Vehicle Measurements Static System Torque to Rotate From Run
Spec. = 20 +/- 5 N-cm
15
2.70 3.12 lbs.
Torque (Ncm)
10
1.80 2.08 lbs.

Cobalt HHR
Ion G5
0 2003
2004
2005
2006
2007
2008
2009
2010
Model Year
Column High to Low

20
3.59 4.16 lbs.
Spec. = 20 +/- 5 N-cm
15
2.70 3.12 lbs.
Torque (Ncm)
10
1.80 2.08 lbs.
Measured Weights
5
Standard Fob Overmold Key Std Lockset Key
20 g 15 g 12 g 45 g 92 g
0.0441 lbs. 0.0331 lbs. 0.0264 lbs. 0.0992 lbs. 0.2028 lbs.
Gen I Flip Key Total

Model Year
Cadillac ATS Rough Road Testing Interior Accelerations @ SDM / MPG Evaluations Test Speed Z Accel. Max 550/629 Hop 550/629 Tramp Square Block Washboard #3 Pothole Chatter Bumps Massoit Bump Curb Impact Curb Drop-Off Belgian Blocks 30 MPH 30 MPH 30 MPH 40 MPH 25 MPH 60 MPH 45 MPH 5 MPH 20 MPH 35/40 MPH 7.25 G 4.87 G 5.42 G 5.06 G 13.10 G 1.32 G 1.87 G 1.88 G 2.83 G 1.92 G
2700
115
Max Pothole #3 1030
170
25mph Max Pothole #3
Column High to Low

20
3.59 4.16 lbs.
Spec. = 20 +/- 5 N-cm
15
2.70 3.12 lbs.
Torque (Ncm)
10
1.80 2.08 lbs.
Measured Weights Standard Fob Overmold Key 20 g 15 g 12 g 45 g 0.0441 lbs. 0.0331 lbs. 0.0264 lbs.
Model Year
@ 13.1 G 0.58 lbs. 1.01 lbs. 2.66 lbs.
Std Lockset Key Gen I Flip Key
0.0992 lbs.
Knee Clearance to Key Cylinder:

Model Lacrosse Malibu Cruze Verano Impala Traverse Camaro Program GMX353 GMX351 D1SC D1SB GMX352 GMT561 M2xx GMX521 D2LC D2SB GMX001 GMX350 M1xx GMT172 G1xx D1JCI A1LL E2SC GMT166 Knee to Cyl (MM) 55.8 56.4 58.9 58.9 67.7 70.7 73.4 73.9 76.2 76.2 91.1 91.7 92.4 106.7 149.2 Keyless Keyless Keyless Keyless
Cobalt
Cruze
Cobalt Regal Spark Equinox Sonic Volt CTS NG SRX
Spark
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. Photo
Camaro
Ignition Cylinder JDP Comparison

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
GM CONFIDENTIAL
11
Extend the time the SDM algorithm is active after the vehicle exits the RUN power mode:
GMLAN Batt
BCM
Batt
SDM
CM20324
AOS
IGN
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.
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
12 10 8 6 4 2 0 2005 MY Non-Deployment Allegations 2005 Total 248 Total Reports 2006 134 2007 22 2008 2 2009 1 2010 0
2006 MY
2007 MY
2008 MY
2009 MY
2010 MY
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 20052008. 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.
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 All
Cobalt
Saturn
Slide 11
Lower Column Shroud (Key Bump)
Traverse
Cobalt
Slide 11
Not applicable
20 +/-5 N-cm ACC - RUN RUN ACC

20
15
Torque (Ncm)
10
Cobalt HHR
5
0 2003
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.
2004 2005 2006 2007 2008 2009
Ion
G5
2010
Model Year
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 drivers knee
A B
One G5 incident, all others are Cobalt. 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

20
7/11/08

6/18/07
3/14/08 5/19/10 12/11/07 9/02/08 10/01/08 9/13/07 12/01/06 11/07/06 3/12/07 1/12/07 8/15/08 5/19/08 8/11/08
15

4/22/04
1/19/07
Torque (Ncm)
3/14/05 9/27/05 11/09/05 8/23/05 7/14/05 1/23/06 10/24/05 12/22/05
10/20/09 5/05/08 10/04/05 3/02/07 8/08/06 9/15/06 6/19/06 9/05/06
10
9/16/04 9/08/04 1/19/05 10/14/03
8/25/05
2/24/06
Cobalt HHR
Ion
G5

0 2003 2004 2005 2006 2007 2008 2009 2010
Model Year
Non-Deployment Allegations by Model Year Cobalt (22), G5 (1)

12 10 8 6 4 2 0 2005 MY 2006 MY 2007 MY 2008 MY 2009 MY 2010 MY
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.

15,000
10,000
5,000
Incidents per MOB
20,000
11
2/20/11 8/12/12
10 9 8 7 6 5 4 3
2005 2006 2007

2/6/07 12/29/06 10/1/06 3/14/06 2/10/06 11/17/05 8/6/07 3/5/07 9/26/07 4/5/08 5/29/08 5/21/08 9/13/08 12/6/08 12/31/10 12/31/10 2/13/11 10/16/07 5/20/13 12/13/09
2
7/29/05
1 0
2005
2006
2007
2008
2009
Calendar Year
2010
2011
2012
2013
As of 10/1/13

11
Mild Moderate
10 9 8 7 6 5 4 3
2005 2006 2007

2
Fatality
1 0
Reports - Potential Key Rotation Cobalt, G5 and Pursuit

2005 Airbag Non-Deploy Stalling VOQs TREAD Search Key Insert (Svc. Bulletin) Total 11 12 56 169 248 2006 7 13 43 71 134 2007 5 1 10 6 22 2 1 0 1 1 1 2008 2009 2010
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 2005 2006 2007 Total Reports 248 134 22 U.S. Population 140,646 229,231 248,137 Reports / 100k Vehicles / Years Exposure 19.6 7.4 1.3
2005-2009 Cobalt VOQs for Potential Ignition off While Driving

14 13 12 11 10
Number of VOQs
9 8 7 6 5 4 3 2 1 0
2005 Cobalt 2006 Cobalt 2007 Cobalt 2008 Cobalt 2009 Cobalt
Incident Date
2003-9 Ion, HHR VOQs for Potential Ignition off While Driving
12 11
2003 Ion
10
2004 Ion 2006 HHR 2006 Ion 2007 HHR 2008 HHR
9 8 7 6 5 4 3 2 1 0
Incident Date
34 32 30 28 2003 Ion 2004 Ion 2005 Cobalt 2006 Cobalt, HHR, Ion 2007 Cobalt, HHR 2008 Cobalt, HHR 2009 Cobalt
26 24 22 20 18 16 14 12 10 8 6 4 2 0
Incident Date
14 13 12 11
2003 Ion 2004 Ion 2005 Cobalt 2006 Cobalt 2006 HHR 2006 Ion 2007 Cobalt
10 9 8 7 6 5 4 3 2 1 0
2007 HHR 2008 Cobalt 2008 HHR 2009 Cobalt
Incident Date
Issued Nov 2005 Reissued July 2011 to add the 2007 MY.
Key Slot vs. Hole Cobalt
2005MY-2009MY
2010 MY
Ignition switch with increased effort passed validation 4/26/06. Part number not changed. Implementation date is unknown.

20
15
Torque (Ncm)
10
Cobalt HHR
5
Ion
G5
0 2003
2004
2005
2006
2007
2008
2009
2010
Model Year

20
7/11/08

6/18/07
3/14/08 5/19/10 12/11/07 9/02/08 10/01/08 9/13/07 12/01/06 11/07/06 3/12/07 1/12/07 8/15/08 5/19/08 8/11/08
15

4/22/04
1/19/07
Torque (Ncm)
3/14/05 9/27/05 11/09/05 8/23/05 7/14/05 1/23/06 10/24/05 12/22/05
10/20/09 5/05/08 10/04/05 3/02/07 8/08/06 9/15/06 6/19/06 9/05/06
10
9/16/04 9/08/04 1/19/05 10/14/03
8/25/05
2/24/06
Cobalt HHR
Ion
G5

0 2003 2004 2005 2006 2007 2008 2009 2010
Model Year

15,000
10,000
5,000
Incidents per MOB
20,000
Incident Reports
2005-2007 Cobalt
U.S. Population
618,014
140,646 229,231 248,137
IPHTV / Year Exposure

0.47
0.89 0.38 0.29
23
11 7 5
2006-2007 HHR 2003-2007 Ion

A Incidents
0 2A
214,072 478,986
0 0.04
can not be confirmed to be due to ignition switch rotation.
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)
Population 572,108 455,500 96,328
IPHTV / Year Exposure 0.70 0.11 0

11
Mild Moderate
10 9 8 7 6 5 4 3
2005 2006 2007

2
Fatality
1 0
Injury Severity Comparison 2000 GMT800 Sensor Bounce: 9 Total (3 mild, 3 moderate, 2 severe, 1 fatal)
Fatal Skull & nose fracture, laceration right side of face & mouth. Whiplash. Lost consciousness. Wrist, knee, ankle, and foot injury. 6 days ICU Belted - Significant head and chest & lower leg injury. Fractured neck vertebrae Fractured neck vertebrae. Fractured shoulder Concussion, sore shoulder, and chest No treatment. Claimed chest injury Head trauma, bruises - treated at hospital Broken nose fatal Severe Severe moderate moderate moderate mild mild mild
2005-2007 Cobalt, G5, Pursuit: 23 Total (7 mild, 9 moderate, 2 severe, 5 fatal)

Fatality Fatal Fatality Fatal Driver & Front Passenger: Fatal Fatal (2) Fatality Fatal Fatality Fatal Traumatic Brain Injury Severe Quadriplegic Severe Bruising to left side of head, cuts to left knee and back P: Fractured ribs, shoulder blade, cuts, and bruises Moderate Unknown Injuries (D) P: Broken neck (w/o paralysis), fractured ribs, sternum, laceration to head, facial bruises Moderate Fractured ribs, nose, femur, and ankle Moderate Fractured vertebrae and severe ear laceration Moderate Kidney damage, left arm fracture, internal bleeding Moderate Lost teeth, several stiches in mouth, broken ankle, broken wrist Moderate Syncope, concussion, occipital laceration, multiple contusions, seizure disorder Moderate Fractured nose & scapula P:fractured leg Moderate Severe 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 Mild Bruised chest area, Bruises on head Mild Fractured front teeth and multiple contusions Mild Laceration to liver, cut nose, bruised chest, bumps all over, sore left knee Mild Laceration to head with scarring Mild Facial Laceration and dislocated hip Mild Broken nose , broken cheekbone, bruised lung, pain in right elbow Mild
Incidents Per 100k Vehicles /Year Exposure Cumulative 2005-2007 Cobalt

2005-2008 0.86
1.42 0.58 0.81
2009-2013 0.20
0.45 0.28 0.09
0.47
0.89 0.38 0.29
SDM Sensor Bounce Anomaly Decision June 2002 (approx. 2 yrs. Exposure) 2000 GMT800 - Safety Recall 2000 S/T - No field action.
Population 572,108 455,500 96,328
IPTV / Year Exposure 0.70 0.11 0
Cost Estimates (w/o Vehicle Attrition)

2005-2007 Cobalt, G5, Pursuit
778,563 vehicles
Ignition Switch Replacement (Build Dates <11/1/06)

$41.3M
2 Key Inserts (all build dates)
Replace Switch
Add Insert
P/N 10392423
P/N 15842334
Vehicle scrap/survival rates are at approximately 91% for this population.
March 17, 2006
2005-7 Cobalt, G5, Pursuit, 2003-2007 Ion, 2006-2007 HHR

Condition:
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 drivers 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 drivers 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 US Cobalt/G5# Pursuit Incidents IPTV/Yrs Exposure SOP 1/1/09 IPTV/Yrs Exposure 1/1/09-10/1/13 IPTV/Yrs Exposure 2005 140,464 11 0.0089 8 0.0142 3 0.0045 2006 229,231 7 0.0039 4 0.0058 3 0.0028 2007 248,137 5 0.0030 4 0.0081 1 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 2005-2007 Cobalt & G5

Vehicles Sold in US Cobalt/G5# Pursuit Incidents* IPTV/Yrs Exposure
(as of 10/1/13)
2005 140,464 11 0.0089
2006 229,231 7 0.0039
2007# 248,137 5 0.0030
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
11 10 9 8 7 6 5 4 3 2 1 0
3/14/06
8/12/12
2005 2006 2007
Key position per SDM: A = Accessory (13) O = Off (1) R = Run (8)
A
2/20/11
R
12/13/09
A
10/16/07
R
2/6/07
5/20/13
A
12/29/06 12/31/10
A R
12/31/10
R
10/1/06
A
9/13/08
O R*
4/5/08
2/13/11
A
2/10/06
12/6/08
A
11/17/05 8/6/07
A R
3/5/07
R A
5/29/08 5/21/08
R*
7/29/05
R
9/26/07
No Event
Incident Date
R* = Run but algorithm disabled
As of 10/1/13
Ignition Cylinder Warranty (N100256)
Vehicle Scrap Rates

TRUCKS AGE 1 2 3 4 5 6 7 8 9 10 11 12
(Full Size Trucks and Vans)
CARS
(All others)
100% 99% 99% 98% 95% 94% 93% 92% 92% 91% 86% 79%
100% 99% 99% 97% 95% 93% 92% 91% 89% 85% 82% 76%
*data pulled by RL Polk in March 2012
Cobalt Front Airbag Non-Deployment Incidents Per 100K Vehicles Per Years Exposure
2.5
2005 MY 2006 MY
2007 MY
IPHTV
1.5
1
2000 GMT800 @ 0.70
0.5
2000 S/T @ 0.11
0
1
2005
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
2006
2007
2008
2009
2010
2011
2012
2013
Calendar Year
2003-2007 Ion, HHR, Solstice, Sky, Opel GT, G2X ETQ N-TBD Ignition Switch Unintended Rotation Vehicles 840,153 Cost Estimate: $34.3M (Switch Only) Locations: US, CAN, MEX Condition: Front airbag non-deployment has been identified in certain crash events. In those events the 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. Service Bulletin: Bulletin #05-2-35-007 Inadvertent key turning issued Oct 2005. 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). Ignition Switch Change: Increased effort for RUN to ACCESSORY. Potential Field Remedy: Replace ignition switch. Potential Field Action Category: Safety Recall
PPAP Chronology
Reports - Potential Unintended Key Rotation U.S. Only

Cobalt 05-07 Airbag Non-Deploy Incidents (# of vehicle reports) Fatalities Injuries Fatality - Insufficient Information* Injuries - Insufficient Information* Inconclusive** VOQs Key Insert (Svc. Bulletin) 28 246 0 4 G5 07 HHR 06-07 Ion (A) 03-07 Sol./Sky 06-07
Data Pull 2/20/14
23
8 16
2
0 2
2
0 2 0 0 0 5 37
4
5 0 0 2 2 3 182
0
0 0 0 0 0 0 5
Included Sources: GMs Legal Database (Team Connect) NHTSA VOQ Database
Total
Vehicle Counts IPTV
297
674,547 0.44
6
64,674 0.09
44
213,247 0.21
189
488,957 0.39
5
55,479 0.09
(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.
Engineering Problem Resolution (PRTS) Summary Ignition Switch Related

PRTS issued for the following programs: Chevrolet Cobalt/Pontiac G5 Chevrolet HHR Pontiac Solstice Saturn Sky Saturn Ion
3 0 0 0 8*
Source: Brian Thompson, Engineering Manager, Switches & Controls 2/23/2014 *Includes 3 Field Product Reports
Estimated Vehicles Remaining In Service:

Models Cobalt Produced Cobalt In Service G5 Produced G5 In Service Pursuit Produced Pursuit In Service Models Ion Produced Ion In Service HHR Produced HHR In Service Solstice Produced Solstice In Service Sky Produced Sky In Service Opel GT Daewoo G2X 2003 2004 2005 160,785 129,774 2006 260,724 222,324 2007 253,038 225,233 64,674 57,567
778,562 Prod 667,868 Remain In Service (86%)
2003 107,993 74,771
2004 132,330 99,733
12,665 10,222 2005 83,707 67,562
26,676 22,747 2006 110,215 93,982 124,006 105,742 21,273 18,140
2007 110,515 98,371 109,592 97,550 24,018 21,379 16,504 14,690 TBD
840,153 Prod. 691,921 Remain In Service (82%)
Page 1
1 of 1 DOCUMENT
Plain Dealer (Cleveland) June 26, 2005 Sunday Final 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 largest automaker 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 Chevrolet Cobalt (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 a generally favorable review of the Cobalt. In the sidebar story, free-lance writer Jeff Sabatini reported that a test 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, please excuse me, a knee slapper, suggesting that an engine that can be inadvertently turned off is not a safety problem. "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," it begins. "When this happens, the Cobalt is still controllable," the release says. "The engine can be restarted after shifting to neutral." Incidentally, in a telephone interview a GM spokesman said the steering does not lock when the engine stalls. So, if you're whisking along at 65 mph or trying to pull across an intersection and the engine stops, that's what you do. Only a gutless ninny would worry about such a problem. Real men are not afraid of temporary reductions 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 the driver's leg moves amid factors such as steering column position, seat height and placement. Depending on these 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 kind of 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 control their knees or with those haunted by stories of the Donner Party who have attached a five-pound salami to their key chain.
Page 2 Salamis, key rings and GM's ongoing sense of humor Plain Dealer (Cleveland) June 26, 2005 Sunday
Never mind that Sabatini, the troublemaker who started this, said the key chain being used was provided by GM and included such weighty items as a key fob and a tag identifying the vehicle as being part of Mother GM's brood. The release concludes with an explanation of the complexity of ignition systems, apparently an appeal to those 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 a running engine cut off by inadvertently bumping the ignition from the run to 'accessory' or 'off' position," it concluded. GM says it has no consumer complaints and, in fairness, I could only find one complaint filed with the National Highway Traffic Safety Administration that might match the ignition-switch situation; even that wasn't clear. 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 somebody pretend 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 general counsel Thomas Gottschalk in which he argued that windshield wiper failures on some 2002 and 2003 midsize 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 recalled and the agency scolded GM, accusing it of attempting to conceal a safety defect and suggesting this was not the first time the automaker could have been more forthcoming. Then it fined the world's largest automaker a record $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: cjensen@plaind.com, 216-999-4830 LOAD-DATE: June 28, 2005 LANGUAGE: ENGLISH PUBLICATION-TYPE: Newspaper
Copyright 2005 Plain Dealer Publishing Co.
3/31/2014
Making a Case for Ignitions That Don't Need Keys - New York Times
June 19, 2005
Making a Case for Ignitions That Don't Need Keys

By 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. General Motors 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 her words. 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."
Copyright 2005 The New York Times Company
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1/1
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 Benavides Director, Product Investigations General Motors LLC 30001 Van Dyke - Mail Code 480-210-2V Warren, MI 48090-9055 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 14V-047 NVS-215KS 14V-047
NHTSA Campaign Number:
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 kelly.schuler@dot.gov or through the office email at rmd.odi@dot.gov. We look forward to working with you.
Sincerely,
Jennifer Timian Chief, Recall Management Division Office of Defects Investigations Enforcement
By Recall Management Division at 1:37 pm, Feb 25, 2014
14V-047 (Amended) 3 Pages

The GM Documents, Part 2

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The GM Documents, Part 2

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2005-2007 Cobalt/Pursuit/G5 Front Airbag Non-Deployment 709,741 Vehicles Cost Estimate: $14.2M-$37.

Locations: US, CAN, MEX

20 +/-5 N-cm ACC - RUN RUN ACC

Torque to Rotate From Run to Accessory

It is unknown if any switches were replaced outside of warranty

Torque to Rotate From Run to Accessory

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

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

3/14/05 9/27/05 11/09/05 8/23/05 7/14/05 1/23/06 10/24/05 12/22/05

10/20/09 5/05/08 10/04/05 3/02/07 8/08/06 9/15/06 6/19/06 9/05/06

9/16/04 9/08/04 1/19/05 10/14/03

The date by each data point is the vehicle build date

It is unknown if any switches were replaced outside of warranty

Non-Deployment Allegations by Model Year Cobalt (22), G5 (1)

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

Population by Month of Build (MOB)

Build date not available for one 2005 vehicle

Month of Build As of 10/1/13

Incidents per MOB

2005 2006 2007

Incident Count by Model Year

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

2005-2009 Cobalt VOQs for Potential Ignition off While Driving

Number of VOQs per Model Year

Number of VOQs per Model Year

Number of VOQs per Model Year

2007 HHR 2008 Cobalt 2008 HHR 2009 Cobalt

Key Slot vs. Hole Cobalt

Torque to Rotate From Run to Accessory

It is unknown if any switches were replaced outside of warranty

Torque to Rotate From Run to Accessory

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

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

3/14/05 9/27/05 11/09/05 8/23/05 7/14/05 1/23/06 10/24/05 12/22/05

10/20/09 5/05/08 10/04/05 3/02/07 8/08/06 9/15/06 6/19/06 9/05/06

9/16/04 9/08/04 1/19/05 10/14/03

The date by each data point is the vehicle build date

It is unknown if any switches were replaced outside of warranty

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

Population by Month of Build (MOB)

Build date not available for one 2005 vehicle

Month of Build As of 10/1/13

Incidents per MOB

IPHTV / Year Exposure

2006-2007 HHR 2003-2007 Ion

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

Incident Reports 2000 GMT800 2000 S/T 2000 M/L 9 1 0

Population 572,108 455,500 96,328

IPHTV / Year Exposure 0.70 0.11 0

Cobalt Front Airbag Non-Deployment Incidents Per 100K Vehicles

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

2005 2006 2007

Incident Count by Model Year

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

Incident Date As of 10/1/13

2005-2007 Cobalt, G5, Pursuit: 23 Total (7 mild, 9 moderate, 2 severe, 5 fatal)

Incidents Per 100k Vehicles /Year Exposure Cumulative 2005-2007 Cobalt

Incident Reports 2000 GMT800 2000 S/T 2000 M/L 9 1 0

Population 572,108 455,500 96,328

IPTV / Year Exposure 0.70 0.11 0

Cost Estimates (Includes Vehicle Attrition)

Replace Switch Production Year

Exchange: 2 slotted w/ 2 holes

Cobalt, G5, Pursuit* Ion HHR Total