New GM repair docs concerning roof problem
06-16-2006, 10:52 AM
#1
Instructor
Thread Starter
Member Since: May 2006
Posts: 126
Likes: 0
Received 0 Likes
on
0 Posts
New GM repair docs concerning roof problem
RECALLS - TO: ALL CHEVROLET DEALERS
ATTENTION: SERVICE MANAGER, PARTS MANAGER AND WARRANTY
ADMINISTRATOR
Subject: 05112C - Customer Satisfaction Program
Painted Roof Adhesive Separation
Service Procedure Revised
Message #: WIR20060307
SERVICE AND PARTS OPERATIONS
DCS1597
URGENT - DISTRIBUTE IMMEDIATELY
Date: June 7, 2006
Subject: 05112C – Customer Satisfaction Program
Painted Roof Adhesive Separation
Service Procedure Revised
Models: 2005-2006 Chevrolet Corvette with Painted Roof
To: All Chevrolet Dealers
Attention: Service Manager, Parts Manager and Warranty
Administrator
Customer Satisfaction Program Bulletin 05112B was released on May 11, 2006 via GM Administrative Message WIR20060302.
The service procedure in this bulletin has been revised. Specifically, the inspection portion has been changed and a new temporary roof panel repair procedure has been added due to part availability of the roof panel.
A copy of revised bulletin 05112C is attached below. Please review the new service procedure with all technicians immediately and discard all copies of bulletin 05112B.
The Service Information System (SI) version of this bulletin will reflect this change in the near future.Program Bulletin
Bulletin No.:
Date: 05112C June 2006
CUSTOMER SATISFACTION PROGRAM
SUBJECT: PAINTED ROOF ADHESIVE SEPARATION
MODELS: 2005-2006 CHEVROLET CORVETTE
WITH PAINTED ROOF
The inspection procedure in this bulletin has been revised and a new temporary roof
panel repair procedure has been added due to part availability of the roof panel. Labor
code T5641 has been added and should be submitted for the temporary roof panel repair.
This labor code will not close the program in GMVIS. Once a new roof panel is obtained
and installed on the vehicle, the claim should be submitted using the appropriate V labor
code, which will close the program in GMVIS. Labor code V1485 has also been added for
roof panels that arrive foam-filled. Please review the revised procedure with all
technicians immediately. Discard all copies of bulletin 05112B, issued May 2006.
**************************************** **************************************** ***************************
THIS PROGRAM IS IN EFFECT UNTIL MARCH 31, 2007.
CONDITION
On certain 2005-2006 Chevrolet Corvette vehicles, the painted roof panel may separate from its
frame in some areas if it is exposed to stresses along with high temperature and humidity. The
occupants of the vehicle may notice one or more of these symptoms: a snapping noise when
driving over bumps, wind noise, poor roof panel fit, roof panel movement/bounce when a door or
hatch is closed, or a water leak in the headliner.
CORRECTION
Dealers are to apply adhesive foam to ensure proper adhesion, or in a small number of
vehicles, replace the roof panel.
Page 2 June 2006 Bulletin No.: 05112C
VEHICLES INVOLVED
Involved are certain 2005-2006 Chevrolet Corvette vehicles with a painted roof, and built within
these VIN breakpoints:
YEAR DIVISION MODEL FROM THROUGH
2005 Chevrolet Corvette 55100002 55135053
2006 Chevrolet Corvette 65100001 65100046
IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry
System) prior to beginning program repairs. [Not all vehicles within the above
breakpoints may be involved.]
For US and Canada: For GM dealers, Canadian Saab, and Canadian Saturn retailers with
involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle
identification number, customer name and address data has been prepared and will be loaded
to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For US
Saturn retailers only, the involved vehicles are provided in a Facility VIN List file sent to you at
your current email address. Dealers/retailers will not have a report available if they have no
involved vehicles currently assigned.
For Export: For dealers with involved vehicles, a Campaign Initiation Detail Report containing
the complete vehicle identification number, customer name and address data has been
prepared, and is being furnished to involved dealers. Dealers will not receive a report with the
bulletin if they have no involved vehicles currently assigned.
The Campaign Initiation Detail Report 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 program is a violation of law in
several states/provinces/countries. Accordingly, you are urged to limit the use of this report to
the follow-up necessary to complete this program.
PARTS INFORMATION
Parts required to complete this program 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.
Part Number Description Quantity/Vehicle
88861400 Adhesive Kit-Foam 2
SPECIAL TOOL
Beginning the week of February 13, 2006, each dealer was shipped a Two-Part Adhesive
Applicator Gun, BO 48206, for use in this recall. This tool was furnished at no charge.
Additional tools, if required, may be purchased by contacting SPX Kent-Moore at
1-800-468-6657.
Page 3 June 2006 Bulletin No.: 05112C
SERVICE PROCEDURE
Tools Required
• BO 48206 Two-Part Applicator Gun
Inspection Procedure
1. Remove the roof panel from the vehicle.
Notice: Be sure to protect the painted surface of the panel from damage.
2. With the painted surface down, support the roof panel horizontally on a glass stand, bench,
or other suitable area.
3. Lift the edge of the headliner in the areas indicated for inspection in the next step.
1748402
4. Inspect for proper adhesion by inserting a 0.254 mm (.010 in) feeler gage between the
panel and the frame. Particular attention should be paid to the areas around the rear latch
and the front corners. If the feeler gage fits between the panel and the frame, and the
depth is 19.05 mm (.750 in) or greater, the roof panel has some degree of separation.
o If the feeler gage does not identify any area of the roof panel with separation, proceed
to Step 5.
o If less than 75 percent of the roof panel is separated from the frame, prepare the roof
panel for the foam adhesive injection procedure. Refer to the section titled, Roof Panel
Preparation for Roof Panels with Separation. This is a temporary repair that will
prevent the separation of the roof panel. Submit the claim using labor code T5641,
which will not close the program in GMVIS. When the roof panel is available, install the
new roof panel and submit the claim using the appropriate V labor code, which will
close the program in GMVIS.
Important: Inspect all roof panels, including new roof panels, to determine if the foam
fill procedure has been completed. Perform the foam adhesive injection procedure on
all new roof panels that have not been foam filled. Perform Steps 5-24 after removing
the original roof panel and following the SI procedures listed in the table below.
o If more than 75 percent of the roof panel is separated from the frame, replace the roof
panel. The SI procedures below may be used.
Page 4 June 2006 Bulletin No.: 05112C
Description SI Document #
Headliner Replacement - Roof Lift Off
Panel 1508849
Roof Lift Off Panel Rear Latch
Replacement 1582986
Roof Lift Off Panel Front Latch Handle
Replacement 1582355
Roof Lift Off Panel Molding
Replacement 656617
Roof Lift Off Panel Rear Locator Pin
Replacement 656610
Roof Lift Off Panel Adjustment 815143
Roof Panel Preparation for Roof Panels with Separation
1. Mark gaps or separation of the roof panel with tape.
1832863
2. Place a rubber-coated clamp (or equivalent) 102 mm (4 in) on either side of the separation.
Ensure a clamp is installed every 152 mm (6 in) along the gap or separation area. Refer to
the illustration for clamp position.
Important: If a bead of urethane is not applied to the gap or separation area, foam will
ooze out of the gap or separation area during the foam adhesive injection process.
3. Add a bead of urethane to the inner and outer edge of any area of the roof panel with a gap
or separation.
4. Proceed to Step 5.
Page 5 June 2006 Bulletin No.: 05112C
1748403
5. Remove the rear latch trim screws (1) and the trim (2).
1748406
6. Remove the rear latch attaching bolts (3) and the rear latch assembly (4).
Important: Perform Step 7 if no gap or separation was identified in Step 4. Proceed to
Step 8 if a gap or separation was identified in Step 4. If installing a new roof panel, proceed
to Step 8.
7. Inspect the area underneath the latch for foam.
o If foam is present, the foam adhesive injection process has been completed. No further
action is required.
o If foam is not present, proceed to Step 8.
8. Install the rear latch attaching bolts (3) to the frame.
Page 6 June 2006 Bulletin No.: 05112C
1748407
9. Remove the front corner brackets (5)
1748409
1748410
10. Tape off the rear latch and the front bracket areas.
Important: Cover the area completely with tape that has strong adhesion. It is difficult to
clean the foam off of visible surfaces.
11. Using a pen or small knife, cut holes in the tape to inject foam.
Page 7 June 2006 Bulletin No.: 05112C
6 Reducer
7 Two-Part Foam Cartridge
8 Nut
9 Mixer Nozzle
1748413
Important: This is a two-part foam product that expands and sets very quickly. Once the
mixing begins, the foam will be set in approximately 15 seconds. It is recommended that
technicians wear disposable gloves while working with foam.
12. Prepare a cartridge.
1748423
12.1 Remove a portion of the label.
12.2 Measure the length of the tubes containing the foam product. Divide the length and
mark the cartridge into four equal parts.
Page 8 June 2006 Bulletin No.: 05112C
1748414
12.3 Remove the top plug. Insert a screwdriver into the end and rock it back and forth.
1748416
12.4 Install a reducer into the cartridge.
1748417
12.5 Insert a mixer nozzle through a nut.
Page 9 June 2006 Bulletin No.: 05112C
1748419
12.6 Install the nozzle onto the cartridge.
1748420
12.7 Install the cartridge nozzle assembly to the BO 48206 applicator gun.
12.8 Prepare a piece of tape to cover the hole in each front cover after the foam is
injected.
Page 10 June 2006 Bulletin No.: 05112C
1832883
Important: The following steps must be performed within approximately 15 seconds from
start to finish.
13. Inject one half of the cartridge of foam into the right rear latch area (1) of the panel and the
other half of the cartridge into the left latch area (1) of the panel.
14. Tape over the holes to keep the foam from coming out.
15. Prepare a second cartridge.
1748423
15.1 Remove a portion of the label.
15.2 Measure the length of the tubes containing the foam product. Divide the length and
mark the cartridge into four equal parts.
15.3 Remove the top plug.
15.4 Install a reducer into the cartridge.
15.5 Insert a mixer nozzle through a nut.
15.6 Install the nozzle onto the cartridge.
15.7 Install the cartridge nozzle assembly to the BO 48206 applicator gun.
15.8 Prepare a piece of tape to cover the hole in each front corner after the foam is
injected.
Page 11 June 2006 Bulletin No.: 05112C
1748425
Important: The following steps must be performed within approximately 15 seconds from
start to finish.
16. Insert the cartridge approximately 25 mm (1 in) into the hole.
Important: Use one quarter of the cartridge in each of the next four steps.
16.1 While watching the cartridge, inject one quarter of the foam in one front corner,
pointing front to back.
1748426
16.2 In the same corner, turn the applicator and inject one quarter of the foam, pointing
the applicator from side to side.
16.3 Tape the hole closed.
16.4 Repeat for the other front corner.
17. Wait 60 seconds for the foam to set.
18. Remove all of the tape.
19. Look for any areas where the foam may have leaked out between the frame and the
composite panel. If required, clean the area where foam leaked out between the frame and
the composite panel. Apply a bead of urethane around the entire perimeter of the roof
panel to improve the appearance of the roof panel edge. Apply the bead of urethane
between the frame and composite panel.
Page 12 June 2006 Bulletin No.: 05112C
20. Install the front corner brackets. A sharp knife or small screwdriver may be needed to
remove just enough foam to install the brackets.
21. Remove the latch bolts.
22. Install the latch and bolts. A sharp knife or small screwdriver may be needed to remove just
enough foam to install the latch and latch trim cover.
23. Install the rear latch trim cover and screws.
24. Install a new headliner, if required.
25. Install the top to the vehicle.
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
Warranty. 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.
Page 13 June 2006 Bulletin No.: 05112C
CLAIM INFORMATION
Submit a Product Claim with the information indicated below:
REPAIR PERFORMED PART COUNT PART NO. PARTS ALLOW CC-FC LABOR OP LABOR HOURS NET ITEM
Inspect Roof Panel - No Further
Action Req'd. (Foam Adhesive Filled
Panel)
0 N/A N/A MA-96 V1485 0.2 N/A
Inspect & Inject Foam Adhesive
(panel had no adhesive separation) 2 --- * MA-96 V1442 0.4 **
Inspect & Inject Foam Adhesive
(panel had less than 75% adhesive
separation)
2 --- * T5641 0.7 **
Inspect & Replace Roof Panel &
Headliner (includes 1.5 hrs for paint
& mix time)
2 --- *** MA-96 V1482 1.8 ****
Add: Inject Foam Adhesive 2 * 0.4 **
Courtesy Transportation for vehicles
within the New Vehicle Limited
Warranty
(US & Canadian GM Dealers)
N/A N/A N/A MA-96 ***** N/A ******
* The "Parts Allowance" should be the sum total of the current GMSPO Dealer net price
plus applicable Mark-Up or Landed Cost Mark-Up (for Export) for the foam adhesive kits.
** The amount identified in the “Net Item” column should represent the actual sum total of
the current GMSPO Dealer net price plus applicable Mark-Up or Landed Cost Mark-Up
(for Export) for the tape if needed to perform the required repairs, not to exceed $0.50
USD, $0.58 CAD.
*** The "Parts Allowance" should be the sum total of the current GMSPO Dealer net price
plus applicable Mark-Up or Landed Cost Mark-Up (for Export) for the roof panel and
headliner needed to complete the repair.
**** The amount identified in the "Net Item" column should represent the actual sum total of
the current GMSPO Dealer net price plus applicable Mark-Up or Landed Cost Mark-Up
(for Export) for the paint allowance GI ($42.29 USD, $48.03 CAD).
***** Submit courtesy transportation using normal labor operations for courtesy transportation
as indicated in the GM Service Policies and Procedures Manual for vehicles within the
New Vehicle Limited Warranty.
****** The amount identified in the "Net Item" column should represent the actual dollar amount
for courtesy transportation.
CUSTOMER NOTIFICATION – For US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer
letter included with this bulletin).
Page 14 June 2006 Bulletin No.: 05112C
CUSTOMER NOTIFICATION – For Export
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 sample letter.
DEALER PROGRAM RESPONSIBILITY - All
All unsold new vehicles in dealers' possession and subject to this program must be held and
inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this program at no charge to customers, regardless
of mileage, age of vehicle, or ownership, through March 31, 2007.
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. Program 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 program enters your vehicle inventory, or is in
your dealership for service prior to March 31, 2007, you must take the steps necessary to be
sure the program correction has been made before selling or releasing the vehicle.
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
Page 15 June 2006 Bulletin No.: 05112C
February 2006
Dear General Motors Customer:
This notice is sent to inform you that Chevrolet is conducting a customer satisfaction program
that affects certain 2005 and 2006 model year vehicles that are equipped with a painted roof.
We have learned that the painted roof panel may separate from its frame in some areas if it is
exposed to stresses along with high temperature and humidity. The occupants of the vehicle
may notice one or more of these symptoms: a snapping noise when driving over bumps, wind
noise, poor roof panel fit, roof panel movement/bounce when a door or hatch is closed, or a
water leak in the headliner.
What We Will Do: To prevent this condition from occurring, your Chevrolet dealer will inspect
the roof panel for proper adhesion, and if necessary, inject adhesive foam to seal the panel. In
some cases, the roof panel may require replacement. This service will be performed for you at
no charge until March 31, 2007.
What You Should Do: To limit any possible inconvenience, we recommend that you contact
your dealer as soon as possible to schedule and appointment for this repair. By scheduling an
appointment, your dealer can ensure that the necessary parts will be available on your
scheduled appointment date.
Customer Reply Form: The enclosed customer reply form identifies your vehicle.
Presentation of this form 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
form and mailing it back to us.
If you have any questions or need any assistance, just contact your dealer or the appropriate
Customer Assistance Center at the number listed below. The Customer Assistance Center’s
hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.
Division Number Text Telephones (TTY)
Chevrolet 1-800-630-2438 1-800-833-2438
Guam 1-671-648-8650
Puerto Rico – English 1-800-496-9992
Puerto Rico – Español 1-800-496-9993
Virgin Islands 1-800-496-9994
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’s Manual and your
dealer for details on Courtesy Transportation.
We sincerely regret any inconvenience or concern that this situation may cause you. We want
you to know that we will do our best, throughout your ownership experience, to ensure that your
Chevrolet Corvette provides you many miles of enjoyable driving.
General Motors Corporation
Enclosure
05112
ATTENTION: SERVICE MANAGER, PARTS MANAGER AND WARRANTY
ADMINISTRATOR
Subject: 05112C - Customer Satisfaction Program
Painted Roof Adhesive Separation
Service Procedure Revised
Message #: WIR20060307
SERVICE AND PARTS OPERATIONS
DCS1597
URGENT - DISTRIBUTE IMMEDIATELY
Date: June 7, 2006
Subject: 05112C – Customer Satisfaction Program
Painted Roof Adhesive Separation
Service Procedure Revised
Models: 2005-2006 Chevrolet Corvette with Painted Roof
To: All Chevrolet Dealers
Attention: Service Manager, Parts Manager and Warranty
Administrator
Customer Satisfaction Program Bulletin 05112B was released on May 11, 2006 via GM Administrative Message WIR20060302.
The service procedure in this bulletin has been revised. Specifically, the inspection portion has been changed and a new temporary roof panel repair procedure has been added due to part availability of the roof panel.
A copy of revised bulletin 05112C is attached below. Please review the new service procedure with all technicians immediately and discard all copies of bulletin 05112B.
The Service Information System (SI) version of this bulletin will reflect this change in the near future.Program Bulletin
Bulletin No.:
Date: 05112C June 2006
CUSTOMER SATISFACTION PROGRAM
SUBJECT: PAINTED ROOF ADHESIVE SEPARATION
MODELS: 2005-2006 CHEVROLET CORVETTE
WITH PAINTED ROOF
The inspection procedure in this bulletin has been revised and a new temporary roof
panel repair procedure has been added due to part availability of the roof panel. Labor
code T5641 has been added and should be submitted for the temporary roof panel repair.
This labor code will not close the program in GMVIS. Once a new roof panel is obtained
and installed on the vehicle, the claim should be submitted using the appropriate V labor
code, which will close the program in GMVIS. Labor code V1485 has also been added for
roof panels that arrive foam-filled. Please review the revised procedure with all
technicians immediately. Discard all copies of bulletin 05112B, issued May 2006.
**************************************** **************************************** ***************************
THIS PROGRAM IS IN EFFECT UNTIL MARCH 31, 2007.
CONDITION
On certain 2005-2006 Chevrolet Corvette vehicles, the painted roof panel may separate from its
frame in some areas if it is exposed to stresses along with high temperature and humidity. The
occupants of the vehicle may notice one or more of these symptoms: a snapping noise when
driving over bumps, wind noise, poor roof panel fit, roof panel movement/bounce when a door or
hatch is closed, or a water leak in the headliner.
CORRECTION
Dealers are to apply adhesive foam to ensure proper adhesion, or in a small number of
vehicles, replace the roof panel.
Page 2 June 2006 Bulletin No.: 05112C
VEHICLES INVOLVED
Involved are certain 2005-2006 Chevrolet Corvette vehicles with a painted roof, and built within
these VIN breakpoints:
YEAR DIVISION MODEL FROM THROUGH
2005 Chevrolet Corvette 55100002 55135053
2006 Chevrolet Corvette 65100001 65100046
IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry
System) prior to beginning program repairs. [Not all vehicles within the above
breakpoints may be involved.]
For US and Canada: For GM dealers, Canadian Saab, and Canadian Saturn retailers with
involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle
identification number, customer name and address data has been prepared and will be loaded
to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For US
Saturn retailers only, the involved vehicles are provided in a Facility VIN List file sent to you at
your current email address. Dealers/retailers will not have a report available if they have no
involved vehicles currently assigned.
For Export: For dealers with involved vehicles, a Campaign Initiation Detail Report containing
the complete vehicle identification number, customer name and address data has been
prepared, and is being furnished to involved dealers. Dealers will not receive a report with the
bulletin if they have no involved vehicles currently assigned.
The Campaign Initiation Detail Report 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 program is a violation of law in
several states/provinces/countries. Accordingly, you are urged to limit the use of this report to
the follow-up necessary to complete this program.
PARTS INFORMATION
Parts required to complete this program 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.
Part Number Description Quantity/Vehicle
88861400 Adhesive Kit-Foam 2
SPECIAL TOOL
Beginning the week of February 13, 2006, each dealer was shipped a Two-Part Adhesive
Applicator Gun, BO 48206, for use in this recall. This tool was furnished at no charge.
Additional tools, if required, may be purchased by contacting SPX Kent-Moore at
1-800-468-6657.
Page 3 June 2006 Bulletin No.: 05112C
SERVICE PROCEDURE
Tools Required
• BO 48206 Two-Part Applicator Gun
Inspection Procedure
1. Remove the roof panel from the vehicle.
Notice: Be sure to protect the painted surface of the panel from damage.
2. With the painted surface down, support the roof panel horizontally on a glass stand, bench,
or other suitable area.
3. Lift the edge of the headliner in the areas indicated for inspection in the next step.
1748402
4. Inspect for proper adhesion by inserting a 0.254 mm (.010 in) feeler gage between the
panel and the frame. Particular attention should be paid to the areas around the rear latch
and the front corners. If the feeler gage fits between the panel and the frame, and the
depth is 19.05 mm (.750 in) or greater, the roof panel has some degree of separation.
o If the feeler gage does not identify any area of the roof panel with separation, proceed
to Step 5.
o If less than 75 percent of the roof panel is separated from the frame, prepare the roof
panel for the foam adhesive injection procedure. Refer to the section titled, Roof Panel
Preparation for Roof Panels with Separation. This is a temporary repair that will
prevent the separation of the roof panel. Submit the claim using labor code T5641,
which will not close the program in GMVIS. When the roof panel is available, install the
new roof panel and submit the claim using the appropriate V labor code, which will
close the program in GMVIS.
Important: Inspect all roof panels, including new roof panels, to determine if the foam
fill procedure has been completed. Perform the foam adhesive injection procedure on
all new roof panels that have not been foam filled. Perform Steps 5-24 after removing
the original roof panel and following the SI procedures listed in the table below.
o If more than 75 percent of the roof panel is separated from the frame, replace the roof
panel. The SI procedures below may be used.
Page 4 June 2006 Bulletin No.: 05112C
Description SI Document #
Headliner Replacement - Roof Lift Off
Panel 1508849
Roof Lift Off Panel Rear Latch
Replacement 1582986
Roof Lift Off Panel Front Latch Handle
Replacement 1582355
Roof Lift Off Panel Molding
Replacement 656617
Roof Lift Off Panel Rear Locator Pin
Replacement 656610
Roof Lift Off Panel Adjustment 815143
Roof Panel Preparation for Roof Panels with Separation
1. Mark gaps or separation of the roof panel with tape.
1832863
2. Place a rubber-coated clamp (or equivalent) 102 mm (4 in) on either side of the separation.
Ensure a clamp is installed every 152 mm (6 in) along the gap or separation area. Refer to
the illustration for clamp position.
Important: If a bead of urethane is not applied to the gap or separation area, foam will
ooze out of the gap or separation area during the foam adhesive injection process.
3. Add a bead of urethane to the inner and outer edge of any area of the roof panel with a gap
or separation.
4. Proceed to Step 5.
Page 5 June 2006 Bulletin No.: 05112C
1748403
5. Remove the rear latch trim screws (1) and the trim (2).
1748406
6. Remove the rear latch attaching bolts (3) and the rear latch assembly (4).
Important: Perform Step 7 if no gap or separation was identified in Step 4. Proceed to
Step 8 if a gap or separation was identified in Step 4. If installing a new roof panel, proceed
to Step 8.
7. Inspect the area underneath the latch for foam.
o If foam is present, the foam adhesive injection process has been completed. No further
action is required.
o If foam is not present, proceed to Step 8.
8. Install the rear latch attaching bolts (3) to the frame.
Page 6 June 2006 Bulletin No.: 05112C
1748407
9. Remove the front corner brackets (5)
1748409
1748410
10. Tape off the rear latch and the front bracket areas.
Important: Cover the area completely with tape that has strong adhesion. It is difficult to
clean the foam off of visible surfaces.
11. Using a pen or small knife, cut holes in the tape to inject foam.
Page 7 June 2006 Bulletin No.: 05112C
6 Reducer
7 Two-Part Foam Cartridge
8 Nut
9 Mixer Nozzle
1748413
Important: This is a two-part foam product that expands and sets very quickly. Once the
mixing begins, the foam will be set in approximately 15 seconds. It is recommended that
technicians wear disposable gloves while working with foam.
12. Prepare a cartridge.
1748423
12.1 Remove a portion of the label.
12.2 Measure the length of the tubes containing the foam product. Divide the length and
mark the cartridge into four equal parts.
Page 8 June 2006 Bulletin No.: 05112C
1748414
12.3 Remove the top plug. Insert a screwdriver into the end and rock it back and forth.
1748416
12.4 Install a reducer into the cartridge.
1748417
12.5 Insert a mixer nozzle through a nut.
Page 9 June 2006 Bulletin No.: 05112C
1748419
12.6 Install the nozzle onto the cartridge.
1748420
12.7 Install the cartridge nozzle assembly to the BO 48206 applicator gun.
12.8 Prepare a piece of tape to cover the hole in each front cover after the foam is
injected.
Page 10 June 2006 Bulletin No.: 05112C
1832883
Important: The following steps must be performed within approximately 15 seconds from
start to finish.
13. Inject one half of the cartridge of foam into the right rear latch area (1) of the panel and the
other half of the cartridge into the left latch area (1) of the panel.
14. Tape over the holes to keep the foam from coming out.
15. Prepare a second cartridge.
1748423
15.1 Remove a portion of the label.
15.2 Measure the length of the tubes containing the foam product. Divide the length and
mark the cartridge into four equal parts.
15.3 Remove the top plug.
15.4 Install a reducer into the cartridge.
15.5 Insert a mixer nozzle through a nut.
15.6 Install the nozzle onto the cartridge.
15.7 Install the cartridge nozzle assembly to the BO 48206 applicator gun.
15.8 Prepare a piece of tape to cover the hole in each front corner after the foam is
injected.
Page 11 June 2006 Bulletin No.: 05112C
1748425
Important: The following steps must be performed within approximately 15 seconds from
start to finish.
16. Insert the cartridge approximately 25 mm (1 in) into the hole.
Important: Use one quarter of the cartridge in each of the next four steps.
16.1 While watching the cartridge, inject one quarter of the foam in one front corner,
pointing front to back.
1748426
16.2 In the same corner, turn the applicator and inject one quarter of the foam, pointing
the applicator from side to side.
16.3 Tape the hole closed.
16.4 Repeat for the other front corner.
17. Wait 60 seconds for the foam to set.
18. Remove all of the tape.
19. Look for any areas where the foam may have leaked out between the frame and the
composite panel. If required, clean the area where foam leaked out between the frame and
the composite panel. Apply a bead of urethane around the entire perimeter of the roof
panel to improve the appearance of the roof panel edge. Apply the bead of urethane
between the frame and composite panel.
Page 12 June 2006 Bulletin No.: 05112C
20. Install the front corner brackets. A sharp knife or small screwdriver may be needed to
remove just enough foam to install the brackets.
21. Remove the latch bolts.
22. Install the latch and bolts. A sharp knife or small screwdriver may be needed to remove just
enough foam to install the latch and latch trim cover.
23. Install the rear latch trim cover and screws.
24. Install a new headliner, if required.
25. Install the top to the vehicle.
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
Warranty. 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.
Page 13 June 2006 Bulletin No.: 05112C
CLAIM INFORMATION
Submit a Product Claim with the information indicated below:
REPAIR PERFORMED PART COUNT PART NO. PARTS ALLOW CC-FC LABOR OP LABOR HOURS NET ITEM
Inspect Roof Panel - No Further
Action Req'd. (Foam Adhesive Filled
Panel)
0 N/A N/A MA-96 V1485 0.2 N/A
Inspect & Inject Foam Adhesive
(panel had no adhesive separation) 2 --- * MA-96 V1442 0.4 **
Inspect & Inject Foam Adhesive
(panel had less than 75% adhesive
separation)
2 --- * T5641 0.7 **
Inspect & Replace Roof Panel &
Headliner (includes 1.5 hrs for paint
& mix time)
2 --- *** MA-96 V1482 1.8 ****
Add: Inject Foam Adhesive 2 * 0.4 **
Courtesy Transportation for vehicles
within the New Vehicle Limited
Warranty
(US & Canadian GM Dealers)
N/A N/A N/A MA-96 ***** N/A ******
* The "Parts Allowance" should be the sum total of the current GMSPO Dealer net price
plus applicable Mark-Up or Landed Cost Mark-Up (for Export) for the foam adhesive kits.
** The amount identified in the “Net Item” column should represent the actual sum total of
the current GMSPO Dealer net price plus applicable Mark-Up or Landed Cost Mark-Up
(for Export) for the tape if needed to perform the required repairs, not to exceed $0.50
USD, $0.58 CAD.
*** The "Parts Allowance" should be the sum total of the current GMSPO Dealer net price
plus applicable Mark-Up or Landed Cost Mark-Up (for Export) for the roof panel and
headliner needed to complete the repair.
**** The amount identified in the "Net Item" column should represent the actual sum total of
the current GMSPO Dealer net price plus applicable Mark-Up or Landed Cost Mark-Up
(for Export) for the paint allowance GI ($42.29 USD, $48.03 CAD).
***** Submit courtesy transportation using normal labor operations for courtesy transportation
as indicated in the GM Service Policies and Procedures Manual for vehicles within the
New Vehicle Limited Warranty.
****** The amount identified in the "Net Item" column should represent the actual dollar amount
for courtesy transportation.
CUSTOMER NOTIFICATION – For US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer
letter included with this bulletin).
Page 14 June 2006 Bulletin No.: 05112C
CUSTOMER NOTIFICATION – For Export
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 sample letter.
DEALER PROGRAM RESPONSIBILITY - All
All unsold new vehicles in dealers' possession and subject to this program must be held and
inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this program at no charge to customers, regardless
of mileage, age of vehicle, or ownership, through March 31, 2007.
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. Program 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 program enters your vehicle inventory, or is in
your dealership for service prior to March 31, 2007, you must take the steps necessary to be
sure the program correction has been made before selling or releasing the vehicle.
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
Page 15 June 2006 Bulletin No.: 05112C
February 2006
Dear General Motors Customer:
This notice is sent to inform you that Chevrolet is conducting a customer satisfaction program
that affects certain 2005 and 2006 model year vehicles that are equipped with a painted roof.
We have learned that the painted roof panel may separate from its frame in some areas if it is
exposed to stresses along with high temperature and humidity. The occupants of the vehicle
may notice one or more of these symptoms: a snapping noise when driving over bumps, wind
noise, poor roof panel fit, roof panel movement/bounce when a door or hatch is closed, or a
water leak in the headliner.
What We Will Do: To prevent this condition from occurring, your Chevrolet dealer will inspect
the roof panel for proper adhesion, and if necessary, inject adhesive foam to seal the panel. In
some cases, the roof panel may require replacement. This service will be performed for you at
no charge until March 31, 2007.
What You Should Do: To limit any possible inconvenience, we recommend that you contact
your dealer as soon as possible to schedule and appointment for this repair. By scheduling an
appointment, your dealer can ensure that the necessary parts will be available on your
scheduled appointment date.
Customer Reply Form: The enclosed customer reply form identifies your vehicle.
Presentation of this form 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
form and mailing it back to us.
If you have any questions or need any assistance, just contact your dealer or the appropriate
Customer Assistance Center at the number listed below. The Customer Assistance Center’s
hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.
Division Number Text Telephones (TTY)
Chevrolet 1-800-630-2438 1-800-833-2438
Guam 1-671-648-8650
Puerto Rico – English 1-800-496-9992
Puerto Rico – Español 1-800-496-9993
Virgin Islands 1-800-496-9994
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’s Manual and your
dealer for details on Courtesy Transportation.
We sincerely regret any inconvenience or concern that this situation may cause you. We want
you to know that we will do our best, throughout your ownership experience, to ensure that your
Chevrolet Corvette provides you many miles of enjoyable driving.
General Motors Corporation
Enclosure
05112
Last edited by AtomicVette; 06-17-2006 at 12:50 PM.
06-16-2006, 11:03 AM
#2
Race Director
Are you asking how to make the pdf file readable?
If so, you need a PDF Reader program on your PC.
Go to www.adobe.com and download their free reader. It's right at the top of their home page on the left size.
Once the reader is on your PC, all you do is double click on your actual PDF file and it will open.
If so, you need a PDF Reader program on your PC.
Go to www.adobe.com and download their free reader. It's right at the top of their home page on the left size.
Once the reader is on your PC, all you do is double click on your actual PDF file and it will open.
06-16-2006, 11:36 AM
#5
Safety Car
Just put it somewhere and point a link to it. No different than pointing to animage. Just use "docname.pdf" instead of "picturename.jpg".
06-16-2006, 11:43 AM
#6
Le Mans Master
Member Since: Nov 2005
Location: Houston TX
Posts: 6,099
Likes: 0
Received 65 Likes
on
56 Posts
St. Jude Donor '09
Originally Posted by AtomicVette
its a PDF from my dealer - how do I attach it?
06-16-2006, 11:44 AM
#7
Le Mans Master
Member Since: Nov 2005
Location: Houston TX
Posts: 6,099
Likes: 0
Received 65 Likes
on
56 Posts
St. Jude Donor '09
Originally Posted by kvozel
Just put it somewhere and point a link to it. No different than pointing to animage. Just use "docname.pdf" instead of "picturename.jpg".
06-16-2006, 12:11 PM
#8
Burning Brakes
Originally Posted by AtomicVette
As it clearly says how do I ATTACH it so everyone can read it on the forum.
Converting the pdf to a jpeg may be best as stated. Send it to me I will convert it if you like. Plug the IMG name provided by photobucket into your message.
Or send me the pdf and I'll post it.
06-16-2006, 12:28 PM
#9
Burning Brakes
Member Since: Sep 2005
Location: Malibu California
Posts: 1,213
Likes: 0
Received 0 Likes
on
0 Posts
Originally Posted by AtomicVette
As it clearly says how do I ATTACH it so everyone can read it on the forum.
06-16-2006, 12:56 PM
#10
Burning Brakes
Originally Posted by AtomicVette
its a PDF from my dealer - how do I attach it?
If that doen't work for you then you only option might be to post a link to wherever you have the file parked on a server.
06-16-2006, 01:02 PM
#11
Moderator
Member Since: Dec 2002
Location: Lakewood Ranch, FL
Posts: 40,065
Received 3,578 Likes
on
1,619 Posts
This is from the Forum FAQ
The administrator may allow you to use the attachment feature of this forum, which gives you the ability to attach files of certain types to your posts. This could be an image, a text document, a zip file etc. There will be a limit to the file size of any attachments you make, as the forums should not be used as an extension of your hard disk!
To attach a file to a new post, simply click the [Browse] button at the bottom of the post composition page, and locate the file that you want to attach from your local hard drive.
Only certain types of files may be attached: these are the valid file extensions for files to be attached to this forum: bmp doc gif html jpe jpeg jpg mp3 pdf png psd txt wav wmv xls zip.
After posting, the attachment will show up in the body of your message. To view the contents of the attachment (if it is not already displayed) simply click the filename link that appears next to the attachment icon
To attach a file to a new post, simply click the [Browse] button at the bottom of the post composition page, and locate the file that you want to attach from your local hard drive.
Only certain types of files may be attached: these are the valid file extensions for files to be attached to this forum: bmp doc gif html jpe jpeg jpg mp3 pdf png psd txt wav wmv xls zip.
After posting, the attachment will show up in the body of your message. To view the contents of the attachment (if it is not already displayed) simply click the filename link that appears next to the attachment icon
06-16-2006, 02:58 PM
#13
Melting Slicks
Originally Posted by AtomicVette
its a PDF from my dealer - how do I attach it?
Don
06-16-2006, 04:31 PM
#14
Moderator
Member Since: Dec 2002
Location: Lakewood Ranch, FL
Posts: 40,065
Received 3,578 Likes
on
1,619 Posts
Originally Posted by AtomicVette
its a PDF from my dealer - how do I attach it?
You may post new threads
You may post replies
You may not post attachments
Supporting Members Only
You may edit your posts
This is on the left side of the screen in reply section
06-16-2006, 04:45 PM
#15
Team Owner
Originally Posted by AtomicVette
its a PDF from my dealer - how do I attach it?
