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December 14, 2022 NHTSA CAMPAIGN NUMBER: 22V923000
Front Impact Bar Not Welded Properly
An improperly welded front impact bar may result in the front crash sensors not performing correctly, increasing the risk of injury in a crash.
NHTSA Campaign Number: 22V923
Manufacturer General Motors, LLC
Components STRUCTURE
Potential Number of Units Affected 2,108
Summary
General Motors, LLC (GM) is recalling certain 2022-2023 Chevrolet Malibu vehicles. The front impact bar, a structural portion of the vehicle frame, may not be properly welded to the front frame rail.
Remedy
Dealers will inspect the right-hand and left-hand side of the vehicle’s motor rail for an incomplete weld. If the condition is found, the vehicle will be repurchased by GM. Owner notification letters were mailed January 20, 2023. Owners may contact Chevrolet customer service at 1-800-222-1020.
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.nhtsa.gov.
Check if your Vehicle has a Recall
Condition
General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2022-2023 model year Chevrolet Malibu vehicles. These vehicles may have a condition in which the front impact bar, a structural portion of the vehicle frame, may be improperly welded to the front frame rail. This defect may be present on the right-hand and/or left-hand side of the vehicle. If the front impact bar is improperly welded, front crash sensors may not perform as designed which may undermine occupant protection performance and increase the risk of injury in a frontal crash.
Correction
Dealers will inspect the right-hand and left-hand side of the vehicle’s motor rail for an incomplete weld. If the condition is found, the vehicle will be repurchased by GM.
Parts
No parts are required for this inspection procedure. It is estimated that a very small percentage of the involved vehicles will fail inspection. Approximately 1 VIN in 2,000 may fail.
Frequently Asked Questions (FAQs) for Safety Recall N222380601
Front Impact Bar Partially Welded
These questions and answers are being provided to help GM dealers respond to inquiries from involved vehicle owners about the Safety Recall identified above.
Q1) Which vehicles are involved?
General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2022-2023 model year Chevrolet Malibu vehicles.
Q2) What is the issue or condition?
These vehicles may have a condition in which the front impact bar, a structural portion of the vehicle frame, may be improperly welded to the front frame rail. This defect may be present on the right-hand and/or left-hand side of the vehicle.
Q3) What symptoms may be experienced? What warning signs may be associated with the issue or condition described?
None.
Q4) What is the remedy/repair?
Dealers will inspect the right-hand and left-hand side of the vehicle’s motor rail for an incomplete weld. If the condition is found, the vehicle will be repurchased by GM.
Q5) What is the safety risk? Is the vehicle safe to drive?
If the front impact bar is improperly welded, front crash sensors may not perform as designed which may undermine occupant protection performance and increase the risk of injury in a frontal crash.
Q6) Does the customer have to pay for this remedy/repair?
No, this inspection/repair will be done at no cost to the customer.
Q7) Is the remedy/repair available now?
Yes, please see the attached bulletin for details.
Q8) What should customers do until recall repairs can be completed? Are there any special instructions?
If special instructions are provided, they will be included in the notification letters to customers.
Q9) How can customers check to see if their vehicle is involved in this field action?
Customers who own a vehicle involved in the field action will be notified by mail by General Motors, but they may also check their Vehicle Identification Number (VIN) for field actions in GM Owner Center at https://my.gm.com/recalls or via NHTSA’s website at https://vinrcl.safercar.gov/vin/.
Q10) If customers are concerned, can they get a rental car or courtesy transportation?
Courtesy transportation is available for customers whose vehicles are involved in this recall and are within the warranty coverage period for the warranty which is associated with this recall. Please refer to Warranty Administration Bulletin #17-NA-073: Field Action Courtesy Transportation Policy for further information.
Chronology :
On August 3, 2022, a production operator discovered a section of the motor rail was missing while installing parts on a vehicle. Upon plant investigation, it was determined that the front rail outer panel was cut too short resulting in an incomplete weld condition to the front right-hand side of the front impact bar.
On August 11, 2022, a GM Quality Engineer submitted a report to GM’s Speak Up For Safety (SUFS) program regarding this issue. Immediately following, GM worked with the plant and supplier to identify and contain vehicles manufactured between July 27, 2022 and August 3, 2022. Of the 1,875 vehicles that GM contained and inspected, none had an incomplete weld. GM formally opened an investigation into the subject condition on September 20, 2022. GM’s investigation analyzed the potential effects of this condition on crash sensing and technical experts also provided their assessment of the effect of the incomplete weld on vehicle and occupant protection performance in a frontal crash. There are no known field incidents related to this condition.
GM’s Safety Field Action Decision Authority (SFADA) decided to conduct a safety recall on December 8, 2022.
2 Affected Products
Vehicle
MAKE | MODEL | YEAR |
CHEVROLET | MALIBU | 2022-2023 |
15 Associated Documents
Remedy Instructions and TSB
RCRIT-22V923-8525.pdf 210.55KB
Defect Notice 573 Report
RCLRPT-22V923-7626.PDF 214.463KB
Defect Notice 573 Report
RCLRPT-22V923-9616.PDF 214.463KB
Recall Acknowledgement
RCAK-22V923-9995.pdf 645.711KB
Miscellaneous Document – Frequently Asked Questions (FAQs) for Safety Recall N222380601 Front Impact Bar Partially Welded
RMISC-22V923-5513.pdf 99.206KB
Recall 573 Report – 12/19/22
RCLRPT-22V923-9690.PDF 214.571KB
Manufacturer Notices(to Dealers,etc) – Message re N222380601 – Safety Recall Front Impact Bar Partially Welded VINs Moved From Stop Delivery Reference N222380600
Manufacturer Notices to Dealers,etc) – Stop Message re Stop Delivery Order: GM Reference Number N222380600
Remedy Instructions and TSB
RCRIT-22V923-3252.pdf 227.594KB
Manufacturer Notices(to Dealers,etc) – Dealer Message re REVISION: N222380601-01 – Safety Recall Front Impact Bar Partially Welded Customer Letter Added
Miscellaneous Document – Frequently Asked Questions (FAQs) for Safety Recall N222380601 Front Impact Bar Partially Welded
RMISC-22V923-0678.pdf 99.206KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V923-9368.pdf 95.306KB
Recall Quarterly Report #1, 2023-1
RCLQRT-22V923-9804.PDF 211.126KB
Recall Quarterly Report #2, 2023-2
RCLQRT-22V923-2292.PDF 211.232KB
Recall Quarterly Report #3, 2023-3
RCLQRT-22V923-9506.PDF 211.456KB
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SEOCONTENT-START
Product Safety Recall N222380601 Front Impact Bar Partially Welded Copyright 2023 General Motors. All Rights Reserved. Page 1 of 7 Release Date: January 2023 Revision: 01 Revision Description: This bulletin is being revised to add the customer letter. Please discard all previous copies of N222380601. Attention: It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied. Vehicles involved in this recall were placed on stop delivery December 9, 2022. Once the service procedure contained in this bulletin has been performed on the vehicle, the vehicle is released from stop delivery and the vehicle can be delivered to the customer. All involved vehicles that are in dealer inventory must be held and not delivered to customers, dealer traded, or used for demonstration purposes until the repair contained in this bulletin has been performed on the vehicle. Make Model Model Year RPO Description From To Chevrolet Malibu 2022 2023 Involved vehicles are marked “Open” on the Investigate Vehicle History screen in GM Global Warranty Management system. This site should always be checked to confirm vehicle involvement prior to beginning any required inspections and/or repairs. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2022-2023 model year Chevrolet Malibu vehicles. These vehicles may have a condition in which the front impact bar, a structural portion of the vehicle frame, may be improperly welded to the front frame rail. This defect may be present on the right-hand and/or left-hand side of the vehicle. If the front impact bar is improperly welded, front crash sensors may not perform as designed which may undermine occupant protection performance and increase the risk of injury in a frontal crash. Correction Dealers will inspect the right-hand and left-hand side of the vehicle’s motor rail for an incomplete weld. If the condition is found, the vehicle will be repurchased by GM. Parts No parts are required for this inspection procedure. It is estimated that a very small percentage of the involved vehicles will fail inspection. Approximately 1 VIN in 2,000 may fail. Warranty Information Labor Operation Description Labor Time Trans. Type Net Item 9106570 Vehicle Passed Inspection (No Further Action Required) 1.1 ZFAT N/A 9106574* Failed Inspection, Vehicle Quarantined (FPR/PIR Passed by GM) 1.2 9106571* Failed Inspection, Vehicle Quarantined (FPR/PIR Failed by GM) 1.2 *For US Dealers, follow the US Product Report Submission Process. *For Canadian Dealers, follow the Canadian Product Report Submission Process. * Important: Vehicle must remain quarantined until a determination by GM has been made and further instructions have been provided. Service Procedure Note: It is not necessary to remove or transfer any of the front bumper trim or components. 1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement in SI. Product Safety Recall N222380601 Front Impact Bar Partially Welded Page 2 of 7 6215494 2. Locate the front section of the left and right lower front motor compartment frame rails where they bolt to the front bumper beam. 3. Carefully inspect the weld joint where the left and right bumper mounting brackets are welded to the frame rails on the outboard side. The brackets should be inserted into the end of the frame rails and secured with welds. 6215495 Example of Right Side That Passes Inspection Product Safety Recall N222380601 Front Impact Bar Partially Welded Page 3 of 7 6215496 Example of Left Side That Passes Inspection • If the bumper mounting bracket is properly inserted and the welds securing the bracket are complete, no further action is required. Reinstall the front bumper fascia. Refer to Front Bumper Fascia Replacement in SI. DO NOT FILE a Product Report (FPR/PIR). 6215497 Example of Failed Condition Showing Gap and Misplaced Weld • If there is a gap between the end of the frame rail and the bumper mounting bracket on either side of the vehicle, proceed to step 4. 4. If the left or right motor compartment frame rail to bumper bracket joint fails the inspection, quarantine the vehicle. Important: Vehicle must remain quarantined until a determination by GM has been made and further instructions have been provided. 5. Follow the Product Report (FPR/PIR) process below. Product Report Submission Process For US Dealers – Submit a Field Product Report (FPR) and pictures using the FPR section found in the Certified Service Mobile Toolbox app (CSMT) (reference TSB 02-00-89-002). For Canadian Dealers – Submit a Product Information Report (PIR) and pictures using the Certified Service Mobile Toolbox (CSMT) mobile application (reference TSB 10-00-89-006). In addition, Canadian dealers are required to call the Warranty Claim Centre at 1-888-222-5546 to request a case number. Be sure to include the following information: ▪ Dealer Name and Contact Information Product Safety Recall N222380601 Front Impact Bar Partially Welded Page 4 of 7 ▪ Enter VIN and Mileage ▪ For Condition enter: Front Impact Bar Failed Inspection ▪ For Cause enter: NA ▪ For Correction enter: Recall N222380601 ▪ Important: Include 2 Pictures – 1 Picture of the overall area showing the part and location of issue (suspect bumper bracket installation) and 1 picture showing more of a closeup of the gap between the motor compartment frame rail and bumper bracket. Please make sure the pictures are in focus and the issue can be clearly seen. ▪ Required for Canadian Dealers: Please call the Warranty Claim Centre at 1-888-222-5546 to request a case number. Please provide VIN, dealership name and a contact name at dealership. Dealer Responsibility – For USA & Export (USA States, Territories, and Possessions) It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied. The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Responsibility – All All new, used, GM Certified Used, courtesy transportation vehicles, dealer shuttle vehicles, etc. in dealers’ possession and subject to this recall must be held and inspected/repaired per the service procedure of this bulletin before customers take possession of these vehicles. Involved vehicles must be held and not delivered to customers, dealer-traded, released to auction, used for demonstration, or any other purpose. All GM Certified Used vehicles currently in the dealers’ inventory within the Certified Pre-Owned Inventory System (CPOIS) will be de-certified and must be held and remedied per the service procedure in this bulletin. Upon submitting an accepted/paid warranty transaction in the Global Warranty Management (GWM) system, the vehicle can be re-certified for sale within the CPOIS system, or once again be used in the CTP program. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this field action enters your vehicle inventory you must take the steps necessary to ensure the program correction has been made before selling the vehicle. In addition, for vehicles entering your facility for service, you are required to ensure the customer is aware of the open field action and make every reasonable effort to implement the program correction as set forth in this bulletin prior to releasing the vehicle. Dealer Reports – For USA & Export For dealers with involved vehicles, a listing has been prepared and will be available through GM GlobalConnect Maxis Field Action Reports or sent directly to export dealers. The Inventory tab of the dealer reports will contain VINs that apply to this recall. This information is intended to assist dealers with the PROMPT COMPLETION of these vehicles. The Customer In-Service tab will contain customer names and addresses from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall may be a violation of law in several states. Product Safety Recall N222380601 Front Impact Bar Partially Welded Page 5 of 7 Courtesy Transportation – For USA & Canada Courtesy transportation is available for customers whose vehicles are involved in a product program and still within the warranty coverage period. See General Motors Service Policies and Procedures Manual for courtesy transportation program details. Customer Notification USA & Canada – General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). GM bulletins are intended for use by professional technicians, NOT a “do-it-yourselfer”. They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the tools, equipment, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your dealer for information on whether your vehicle may benefit from the information. We Support Voluntary Technician Certification Product Safety Recall N222380601 Front Impact Bar Partially Welded Page 6 of 7 IMPORTANT SAFETY RECALL January 2023 This notice applies to your vehicle, VIN: _____________________________________ Dear General Motors Customer: This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2022 – 2023 model year Chevrolet Malibu vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. IMPORTANT • Your vehicle is involved in GM safety recall N222380601. • Schedule an appointment with your GM dealer. • This service will be performed for you at no charge. Why is your vehicle being recalled? These vehicles may have a condition in which the front impact bar, a structural portion of the vehicle frame, may be improperly welded to the front frame rail. This defect may be present on the right-hand and/or left-hand side of the vehicle. If the front impact bar is improperly welded, front crash sensors may not perform as designed which may undermine occupant protection performance and increase the risk of injury in a frontal crash. What will we do? Your GM dealer will inspect the right-hand and left-hand side of the vehicle’s motor rail for an incomplete weld, for free. If the condition is found, the vehicle will be repurchased by GM. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual inspection time of approximately 90 minutes. What should you do? You should contact your GM dealer to arrange a service appointment as soon as possible. Do you have questions? If you have any questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. For the hearing or speech impaired, please contact our Customer Assistance Center using the Telecommunication Relay Service by dialing 711 then providing the appropriate Customer Assistance Center number for your vehicle. Division Number Text Telephones (TTY) Chevrolet 1-800-222-1020 711 / 1-800-833-2438 Puerto Rico – English 1-866-467-9700 Puerto Rico – Español 1-866-467-9700 Virgin Islands 1-866-467-9700 If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.nhtsa.gov. The National Highway Traffic Safety Administration Campaign ID Number for this recall is 22V923. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Product Safety Recall N222380601 Front Impact Bar Partially Welded Page 7 of 7 Regina A. Carto Vice President Global Product Safety and Systems GM Recall: N222380601
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-923 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : General Motors, LLC Submission Date : DEC 14, 2022 NHTSA Recall No. : 22V-923 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : General Motors, LLC Address : 29427 Louis Chevrolet Road MAIL CODE 480-210-2V WARREN MI 48093 Company phone : 586-596-1733 Population : Number of potentially involved : 2,108 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2022-2023 Chevrolet Malibu Vehicle Type : Body Style : Power Train : NR Descriptive Information : Manufacturing records and supplier shipping records were used to determine the affected population. Vehicles produced with motor rail trim assembled outside the supplier’s suspect manufacturing window are not included in this recall. Production Dates : JUL 27, 2022 – AUG 03, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2022-2023 model year Chevrolet Malibu vehicles. These vehicles may have a condition in which the front impact bar, a structural portion of the vehicle frame, may be improperly welded to the front frame rail. This defect may be present on the right-hand and/or left-hand side of the vehicle. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If the front impact bar is improperly welded, front crash sensors may not perform as designed which may undermine occupant protection performance and increase the risk of injury in a frontal crash. Description of the Cause : The sheet metal blank for the front frame rail outer panel was improperly loaded into the die by the supplier, resulting in a front frame rail that was cut Part 573 Safety Recall Report 22V-923 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 10 millimeters short of its intended design. The shortened frame rail prevented proper welding of the front impact bar to the front frame rail. Identification of Any Warning that can Occur : NR Involved Components : Component Name 1 : RAIL ASM-F/CMPT SI Component Description : Front Motor Rail Component Part Number : 84791381 / 84791385 Supplier Identification : Component Manufacturer Name : Dieomatic INC (Magna) Address : 3251 Heartland Drive Libery Missouri 64068 Country : United States Chronology : On August 3, 2022, a production operator discovered a section of the motor rail was missing while installing parts on a vehicle. Upon plant investigation, it was determined that the front rail outer panel was cut too short resulting in an incomplete weld condition to the front right-hand side of the front impact bar. On August 11, 2022, a GM Quality Engineer submitted a report to GM’s Speak Up For Safety (SUFS) program regarding this issue. Immediately following, GM worked with the plant and supplier to identify and contain vehicles manufactured between July 27, 2022 and August 3, 2022. Of the 1,875 vehicles that GM contained and inspected, none had an incomplete weld. GM formally opened an investigation into the subject condition on September 20, 2022. GM’s investigation analyzed the potential effects of this condition on crash sensing and technical experts also provided their assessment of the effect of the incomplete weld on vehicle and occupant protection performance in a frontal crash. There are no known field incidents related to this condition. GM’s Safety Field Action Decision Authority (SFADA) decided to conduct a safety recall on December 8, 2022. Part 573 Safety Recall Report 22V-923 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : Dealers will inspect the right-hand and left-hand side of the vehicle’s motor rail for an incomplete weld. If the condition is found, the vehicle will be repurchased by GM. How Remedy Component Differs from Recalled Component : NR Identify How/When Recall Condition was Corrected in Production : GM’s assembly plant-initiated containment and inspection of vehicles manufactured in the suspect population on August 3, 2022, with no additional defects found. The supplier also began its containment efforts on August 3, 2022. Between August 3, 2022 and August 17, 2022, the supplier conducted inspections at both the beginning and end of the line to ensure the front frame rail was manufactured per design intent. The supplier repaired part presence sensors on tooling press for their inprocess station to prevent sheet metal blanks from being improperly loaded into the die on August 17, 2022. Recall Schedule : Description of Recall Schedule : Dealer will be notified on December 14, 2022. Owner notification is estimated to begin on February 6, 2023. Vehicles were placed on STOP Delivery on December 9, 2022. Planned Dealer Notification Date : DEC 14, 2022 – DEC 14, 2022 Planned Owner Notification Date : FEB 06, 2023 – FEB 06, 2023 * NR – Not Reported
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GLOBAL SAFETY FIELD INVESTIGATIONS DCS6362 URGENT – DISTRIBUTE IMMEDIATELY Date: December 9, 2022 Subject: Stop Delivery Order: GM Reference Number N222380600 Models: 2022 Chevrolet Malibu 2023 Chevrolet Malibu To: All General Motors Dealers STOP DELIVERY ORDER Effective immediately, stop the delivery of certain 2022-2023 model year Chevrolet Malibu vehicles which are in the attached VIN file and in new vehicle inventory. GM has made a safety recall decision that impacts these vehicles. The GM reference number is N222380600. GM will provide dealers with additional information in the coming days. The subject vehicles cannot be delivered or sold until further notice. Until further instructions are received, new vehicles subject to this stop delivery order must be held and not delivered to customers, dealer-traded, released to auction, used for demonstration purposes or any other dealer use. The Investigate Vehicle History (IVH) screen in the Global Warranty Management (GWM) system will be updated as “Stop Delivery – Await Communication” and Status as “Incomplete – Remedy Not Available” on December 9, 2022. This action has been taken to assist dealers with determining which vehicles are involved so they can properly respond to customer inquiries. This means the required repair is not yet available and dealers should not attempt to perform any repairs. A list of involved vehicles that have been identified as being in dealer new vehicle inventory is attached to this message. It is sorted by dealer Business Associate Code (BAC) for easy reference. Your dealership’s BAC will not be listed if none of the involved vehicles are currently in your new vehicle inventory. END OF MESSAGE GLOBAL SAFETY FIELD INVESTIGATIONS
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GLOBAL SAFETY FIELD INVESTIGATIONS DCS6375 URGENT – DISTRIBUTE IMMEDIATELY Date: December 14, 2022 Subject: N222380601 – Safety Recall Front Impact Bar Partially Welded VINs Moved From Stop Delivery Reference N222380600 Models: 2022 – 2023 Chevrolet Malibu To: All General Motors Dealers UPDATE ON STOP DELIVERY ORDER As previously communicated on December 9, 2022, via GlobalConnect message GCUS-3-2723, certain 2022-2023 model year Chevrolet Malibu vehicles in new or used vehicle inventory were placed on stop delivery. This communication is to inform dealers that GM has made a safety recall decision that impacts these vehicles. VINs previously included in Stop Delivery Reference N222380600 have been moved to new Safety Recall N222380601. General Motors is releasing Safety Recall N222380601 today. The total number of U.S. vehicles involved is approximately 2,108. Please see the attached bulletin for details. Question and Answer Document (Q&A) Attached to this message you will find a document that addresses the ten most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns. Global Warranty Management (GWM) The Required Field Action section on the Investigate Vehicle History (IVH) screen will be updated December 14, 2022. A list of involved vehicles in dealer new inventory is attached to this message. Please hold all warranty transactions until tomorrow, December 15, 2022. END OF MESSAGE GLOBAL SAFETY FIELD INVESTIGATIONS
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-923 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : General Motors, LLC Submission Date : DEC 19, 2022 NHTSA Recall No. : 22V-923 Manufacturer Recall No. : N222380601 Manufacturer Information : Manufacturer Name : General Motors, LLC Address : 29427 Louis Chevrolet Road MAIL CODE 480-210-2V WARREN MI 48093 Company phone : 586-596-1733 Population : Number of potentially involved : 2,108 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2022-2023 Chevrolet Malibu Vehicle Type : Body Style : Power Train : NR Descriptive Information : Manufacturing records and supplier shipping records were used to determine the affected population. Vehicles produced with motor rail trim assembled outside the supplier’s suspect manufacturing window are not included in this recall. Production Dates : JUL 27, 2022 – AUG 03, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2022-2023 model year Chevrolet Malibu vehicles. These vehicles may have a condition in which the front impact bar, a structural portion of the vehicle frame, may be improperly welded to the front frame rail. This defect may be present on the right-hand and/or left-hand side of the vehicle. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If the front impact bar is improperly welded, front crash sensors may not perform as designed which may undermine occupant protection performance and increase the risk of injury in a frontal crash. Description of the Cause : The sheet metal blank for the front frame rail outer panel was improperly loaded into the die by the supplier, resulting in a front frame rail that was cut Part 573 Safety Recall Report 22V-923 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 10 millimeters short of its intended design. The shortened frame rail prevented proper welding of the front impact bar to the front frame rail. Identification of Any Warning that can Occur : NR Involved Components : Component Name 1 : RAIL ASM-F/CMPT SI Component Description : Front Motor Rail Component Part Number : 84791381 / 84791385 Supplier Identification : Component Manufacturer Name : Dieomatic INC (Magna) Address : 3251 Heartland Drive Libery Missouri 64068 Country : United States Chronology : On August 3, 2022, a production operator discovered a section of the motor rail was missing while installing parts on a vehicle. Upon plant investigation, it was determined that the front rail outer panel was cut too short resulting in an incomplete weld condition to the front right-hand side of the front impact bar. On August 11, 2022, a GM Quality Engineer submitted a report to GM’s Speak Up For Safety (SUFS) program regarding this issue. Immediately following, GM worked with the plant and supplier to identify and contain vehicles manufactured between July 27, 2022 and August 3, 2022. Of the 1,875 vehicles that GM contained and inspected, none had an incomplete weld. GM formally opened an investigation into the subject condition on September 20, 2022. GM’s investigation analyzed the potential effects of this condition on crash sensing and technical experts also provided their assessment of the effect of the incomplete weld on vehicle and occupant protection performance in a frontal crash. There are no known field incidents related to this condition. GM’s Safety Field Action Decision Authority (SFADA) decided to conduct a safety recall on December 8, 2022. Part 573 Safety Recall Report 22V-923 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : Dealers will inspect the right-hand and left-hand side of the vehicle’s motor rail for an incomplete weld. If the condition is found, the vehicle will be repurchased by GM. Pursuant to 577.11, General Motors does not plan to provide notice about reimbursement to owners because owners would not have been aware of the issue prior to this recall. How Remedy Component Differs from Recalled Component : NR Identify How/When Recall Condition was Corrected in Production : GM’s assembly plant-initiated containment and inspection of vehicles manufactured in the suspect population on August 3, 2022, with no additional defects found. The supplier also began its containment efforts on August 3, 2022. Between August 3, 2022 and August 17, 2022, the supplier conducted inspections at both the beginning and end of the line to ensure the front frame rail was manufactured per design intent. The supplier repaired part presence sensors on tooling press for their inprocess station to prevent sheet metal blanks from being improperly loaded into the die on August 17, 2022. Recall Schedule : Description of Recall Schedule : Dealer will be notified on December 14, 2022. Owner notification is estimated to begin on February 6, 2023. Vehicles were placed on STOP Delivery on December 9, 2022. Planned Dealer Notification Date : DEC 14, 2022 – DEC 14, 2022 Planned Owner Notification Date : FEB 06, 2023 – FEB 06, 2023 * NR – Not Reported
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IMPORTANT SAFETY RECALL January 2023 This notice applies to your vehicle, VIN: _____________________________________ Dear General Motors Customer: This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2022 – 2023 model year Chevrolet Malibu vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. IMPORTANT • Your vehicle is involved in GM safety recall N222380601. • Schedule an appointment with your GM dealer. • This service will be performed for you at no charge. Why is your vehicle being recalled? These vehicles may have a condition in which the front impact bar, a structural portion of the vehicle frame, may be improperly welded to the front frame rail. This defect may be present on the right-hand and/or left-hand side of the vehicle. If the front impact bar is improperly welded, front crash sensors may not perform as designed which may undermine occupant protection performance and increase the risk of injury in a frontal crash. What will we do? Your GM dealer will inspect the right-hand and left-hand side of the vehicle’s motor rail for an incomplete weld, for free. If the condition is found, the vehicle will be repurchased by GM. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual inspection time of approximately 90 minutes. What should you do? You should contact your GM dealer to arrange a service appointment as soon as possible. Do you have questions? If you have any questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. For the hearing or speech impaired, please contact our Customer Assistance Center using the Telecommunication Relay Service by dialing 711 then providing the appropriate Customer Assistance Center number for your vehicle. Division Number Text Telephones (TTY) Chevrolet 1-800-222-1020 711 / 1-800-833-2438 Puerto Rico – English 1-866-467-9700 Puerto Rico – Español 1-866-467-9700 Virgin Islands 1-866-467-9700 If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.nhtsa.gov. The National Highway Traffic Safety Administration Campaign ID Number for this recall is 22V923. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Regina A. Carto Vice President Global Product Safety and Systems GM Recall: N222380601
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GLOBAL SAFETY FIELD INVESTIGATIONS DCS6404 URGENT – DISTRIBUTE IMMEDIATELY Date: January 11, 2023 Subject: REVISION: N222380601-01 – Safety Recall Front Impact Bar Partially Welded Customer Letter Added Models: 2022 – 2023 Chevrolet Malibu To: All General Motors Dealers Bulletin N222380601-01 has been revised to include a copy of the customer notification letter. Please discard all previous copies of bulletin N222380601. Customer Letter Mailing The customer letter mailing will begin on January 20, 2023. END OF MESSAGE GLOBAL SAFETY FIELD INVESTIGATIONS
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