View Full Version : Official TSB and Recall Thread


ChevyMgr
03-04-2008, 05:02 PM
Re-posting all TSB on this thread. If you have a question or need a TSB not shown here please post those questions in this thread: http://www.chevyhhr.net/forums/showthread.php?t=1919 or create a new thread if you like.

Some advice on presenting a TSB to your dealership:

Most dealer service departments have been numbed to customers presenting TSBs from forums. Most of the TSBs that people bring with them don't even pertain to either their vehicle, their model or their year of vehicle. EVERYONE seems to be on some type of forum and dealers don't really care to hear what the customer has read on the internet.

That being said, if you want to copy and paste a TSB from this thread to show your dealer, I would suggest you just say you found it on the internet. Make sure it is relevant to your vehicle, model and year.

FYI: GM issued this TSB concerning adding both XM Radio and PAL to an HHR.

SERVICE - ALL CHEVROLET AND PONTIAC DEALERS


Subject: Cobalt/G5/HHR Accessories XM Radio Kit + PAL: Usage Restriction
Message #: VSS20081401

Cobalt / G5 / HHR Accessories XM Radio Kit + PAL: Usage Restriction


Installation issues have been identified when attempting to install a GM Accessories XM Radio Kit (P/N 17800594) and Personal Audio Link, or PAL (P/N 19171028) on a Cobalt, G5, or HHR. Specifically, both products share the same vehicle harness connector and, on some vehicles, both products share the same packaging (installed) location.

Therefore, usage restrictions will soon be in place for both products on each of these vehicle lines – advising not to install both products onto the same vehicle.

NOTE: This issue does NOT pertain to vehicles equipped with factory-installed (RPO) XM Radio. Those vehicles can still have a PAL installed.

ChevyMgr
03-19-2008, 06:29 PM
#08-05-22-001: Pedal Noise/Buzz, Extra Effort Needed to Depress Brake Pedal After Vehicle Has Not Been Driven for Extended Period of Time (Reprogram Electronic Brake Control Mdoule (EBCM)) - (Mar 18, 2008)


Subject: Pedal Noise/Buzz, Extra Effort Needed to Depress Brake Pedal After Vehicle Has Not Been Driven for Extended Period of Time (Reprogram Electronic Brake Control Module (EBCM))


Models: 2008 Chevrolet HHR SS




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Condition
Some customers may comment that after their vehicle has not been operated for an extended period of time, there may be a noise or buzz coming from the brake pedal or extra effort may be needed to depress the brake pedal.

Correction
Important: The following Optimized Hydraulic Brake (OHB) characteristics are considered to be normal and no mechanical parts should be replaced in an effort to change the operation of the system:

• Ratchet sound coming from the brake system during OHB activation.

• Brake pedal movement or pulsation when the OHB is active.

• Increased brake pedal effort under low brake booster vacuum.

• Change in brake pedal effort when OHB is active.

• Frequent brake stops may result in OHB activation.

• High altitude driving may result in OHB activation.

Refer to Corporate Bulletin Number 07-05-22-002 for further information on Optimized Hydraulic Boost Brake System Characteristics.

DO NOT replace the brake vacuum booster, brake vacuum sensor, EBCM or ABS module for this condition.

An Electronic Brake Control Module (EBCM) calibration was released that may reduce the effort the customer feels when depressing the brake pedal on a car that has not been operated for an extended period of time. Reprogram the EBCM with updated calibration files using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2® is updated with the latest software version.

night31
04-11-2008, 08:50 PM
Here is the bulletin about brake pulsation and the splash shields as promised in another post....will also post it there..

#08-05-23-003: Front Brake Noise, Brake Pulsation, Front Brake Inner Pad Wear (Replace Front Brake Pads and Add Splash Shields) - (Mar 20, 2008)


Subject: Front Brake Noise, Brake Pulsation, Front Brake Inner Pad Wear (Replace Front Brake Pads and Add Splash Shields)


Models: 2006-2008 Chevrolet HHR




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Condition
Some customers may comment on a brake noise and/or pulsation on brake apply. This condition can be more frequent if the customer resides or travels on dirt/gravel roads and usually occurs within 11,300 km (7,000 mi) to 16,000 km (10,000 mi) intervals.

Upon investigation, the technician may find that there is considerable difference between the front brake outer and inner pad thickness.

Cause
This condition may be due dust, dirt, and debris intruding between the inner brake pad and rotor.

Correction
Road test the vehicle and confirm that the brake noise and/or pulsation is coming from the front brakes. If it is determined that the noise is coming from the front brakes and there is a measurable difference between the outer and inner pad thickness, remove the front wheel bearing/hub assembly following published SI procedures, remove the bearing/hub-to-steering knuckle spacer and replace the spacer with a splash shield on each side.

Replace the front brake pads and follow the procedures outlined in Service Bulletin 00-05-22-002J for servicing the disc brake rotors.

Parts Information
Part Number
Description
Qty

25884778
Shield, Front Brake (Right)
1

25884779
Shield, Front Brake (Left)
1

night31
04-11-2008, 08:59 PM
Here is another about stones hitting the a/c condensor..... It is missing the picture showing where to place the shield, it goes in the lower opening


#08-06-02-001: No A/C, Engine Coolant Leak, Engine Overheating (Install Plastic Shield to Stop Stone/Debris Impingement) - (Feb 13, 2008)


Subject: No A/C, Engine Coolant Leak, Engine Overheating (Install Plastic Shield to Stop Stone/Debris Impingement)


Models: 2006-2007 Chevrolet HHR, LS, LT and Panel Van

Built Prior to August 27, 2007
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Condition
Some customers may comment on the engine overheating, a coolant leak, or that the A/C is inoperative.

Cause
This may be due to the very large opening in the front fascia. Stones/debris can impact the A/C condenser and/or the radiator and pierce the horizontal cooling tubes. This in turn causes loss of A/C refrigerant, loss of engine coolant and/or engine overheating.

Correction

Important:: Verify that the customer concern was caused by condenser/radiator impingement.

Important:: Prior to installing the shield, inspect the condenser and the radiator for stone impingement.

Dealer technicians are to install a plastic shield that snaps onto the condenser vertical tubes that protects the horizontal radiator and condenser cooling tubes.

Parts Information
Part Number
Description
Qty

25829960
Screen, Radiator Grille
1

ChevyMgr
07-24-2008, 11:38 AM
#08-06-01-017: EI08224 - 2.0L LNF, 2.2L L61, 2.4L LE5 Engine Oil Leak (Engineering Information) - (Jul 18, 2008)


Subject: EI08224 - 2.0L LNF, 2.2L L61, 2.4L LE5 Engine Oil Leak (Engineering Information)


Models: 2008 Chevrolet Cobalt, HHR

2008 Pontiac G5, G6

2008 Saturn VUE

with 2.0L, 2.2L or 2.4L Engine (VINs X, D, B - RPOs LNF, L61, LE5)



Attention: Dealers in U.S. and Canada Only -- Proceed with this bulletin ONLY if the customer has commented about this concern AND the EI number is listed in GMVIS. If the customer has not commented about this condition or the EI does not show in GMVIS, disregard the bulletin and proceed with diagnostics found in published service information. THIS IS NOT A RECALL -- refer to TSB 04-00-89-053B for more details on the use of Engineering Information bulletins.



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Condition
Some customers may comment about an engine oil leak.

Cause
Engineering suspects an oil leak may be developing in the area of the A/C compressor bracket and would like to get further information. If a vehicle comes in to your dealership with an engine oil leak, complete the following steps:

Clean the side of the engine where the oil appears to be leaking from.
Install engine oil dye and run the engine or test drive the vehicle until you are able to identify the source of the oil leak.

----------------------------------------------------------------------------
My Comments:
There won't be many HHR owners with this problem, but if it leaks in that area the fix is to replace the engine. It appears they may have drilled a bolt hole too deep.

ChevyMgr
07-24-2008, 11:49 AM
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#PIC4317D: Noise From rear Of Vehicle During Cold Start - Potential Noise Characteristic - keywords BQMI - (Jul 16, 2008)


Subject: Noise From Rear of Vehicle During Cold Start


Models: 2004-2008 Chevrolet Aveo

2006-2008 Chevrolet Cobalt, HHR

2007-2008 Pontiac G5

2005-2006 Pontiac Pursuit (Canada Only)

2005-2008 Pontiac Wave (Canada Only)

2006-2007 Saturn ION
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This PI was superseded to update models. Please discard PIC4317C.


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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Shortly after cold starting the engine, 3-5 brief knock noises may be heard from the rear of vehicle that sounds like someone tapping on the rear window or quarter panel. This may be the result of the EVAP vent valve going through a normal diagnostic cleaning cycle.

Recommendation/Instructions:
If this concern is experienced and the noise is isolated to the EVAP vent valve, inspect the vent valve pipe to ensure that it is routed properly and not grounding out. If the pipe is routed properly, this noise should be considered a normal characteristic and no repairs should be performed.

ChevyMgr
07-24-2008, 12:01 PM
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#PIP4437: Noise From Transmission Area In Park Or Neutral - keywords 4T45 4T45E drive driven MN5 moving no noise not range sprocket support transmission whine - (Jul 22, 2008)


Subject: Noise from transmission area in Park or Neutral


Models: 2009 Chevrolet Cobalt, Malibu, HHR

2009 Pontiac G5, G6

2009 Saturn Aura, Vue

built between 16 June 08 and 04 July 08 with automatic transmission RPO MN5, 4T45E.




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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
The vehicle may have a concern of a noise from transmission area in Park or Neutral, but goes away in Drive range and not moving. The noise may be noticed if vehicle is moving in gear. The noise may be coming from the Driven Sprocket Support.

Recommendation/Instructions:
If vehicle build date is between June 16th and July 4th of 2008, and the transmission Julian build date is between 8165 and 8178. The Julian date is stamped on the ID tag located on the transmission. See eSI for location information.

IF THE TRANSMISSION BUILD DATE IS OUTSIDE THIS RANGE (8165-8178) THEN DO NOT REPLACE THE DRIVEN SPROCKET SUPPORT. PROCEED WITH NORMAL DIAGNOSTIC PROCEDURES.
Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.

ChevyMgr
07-24-2008, 12:05 PM
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#PIP3932A: Transmission Fluid Leak Slipping Clutch Or Broken Axle Shaft - keywords crack housing shift slip - (Jul 21, 2008)


Subject: Transmission Fluid Leak, Slipping Clutch or Broken Axle Shaft


Models: 2005-2008 Chevrolet Cobalt SS

2008 Chevrolet HHR SS

2004-2007 Saturn Ion Redline

Equipped with a 5-Speed Manual Transmission (RPO MU3)




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This PI was superseded to update models and model years. Please discard PIP3932.


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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers have commented about transmission oil in the clutch housing, slipping clutches or broken axle shafts on this model. An analysis of several of these failures has revealed that the problem is due to excessive front wheel hop during WOT acceleration events.

Excessive wheel hop transmits a torsional shock load into the transmission case. This causes the case to crack and transmission fluid to leak into the clutch housing. See photos below.

3411

3412

3413


Recommendation/Instructions:
Stiffer axle shafts and hardware will change the system harmonics and help prevent wheel hop. These planned changes will not be available until the 2008 model year.

Note: Be advised that failures of this nature are abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by the dealer and Area Vehicle Manager. A product report should be submitted on each.

ChevyMgr
10-01-2008, 02:51 PM
#PIC4974: Supplement To Bulletin (08-05-22-001) - keywords activation BQMI brake buzz cold control depress driven EBCM effort electronic extended extra OHB module noise pedal period program ratchet reprogram - (Sep 18, 2008)


Subject: Supplement to Bulletin (08-05-22-001)


Models: 2008 -2009 Chevrolet HHR SS
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may complain that they "still" do not like the normal operational characteristics of the OHB brake system AFTER the EBCM has been reprogrammed. This reprogram does enhance the feel of the OHB system significantly.

Recommendation/Instructions:
As described in TSB 08-05-22-001 the following Optimized Hydraulic Brake (OHB) characteristics are considered to be normal and no mechanical parts should be replaced in an effort to change the operation of the system:

• Ratchet sound coming from the brake system during OHB activation.

• Brake pedal movement or pulsation when the OHB is active.

• Increased brake pedal effort under low brake booster vacuum.

• Change in brake pedal effort when OHB is active.

• Frequent brake stops may result in OHB activation.

• High altitude driving may result in OHB activation.

Refer to Corporate Bulletin Number 07-05-22-002 for further information on Optimized Hydraulic Boost Brake System Characteristics.

DO NOT replace the brake vacuum booster, brake vacuum sensor, EBCM or ABS module for this condition.

GM Engineering is working on developing an additional service repair for vehicles that the customers feel do not provide adequate brake assist after the calibration has been performed per TSB 08-05-22-001. This repair procedure is not yet available and no other repairs should be attempted. Further information will be provided when any additional repair is available.

ChevyMgr
10-15-2008, 08:46 AM
#PIP4349A: Moan Groan Noise From Manual Transaxle - keywords apply differential howl slip - (Oct 10, 2008)


Subject: Moan Groan Noise From Manual Transaxle


Models: 2005-2009 Chevrolet Cobalt SS

2008-2009 Chevrolet HHR SS

2005-2007 Saturn Redline

Equipped With RPO MU3 Manual Transmission and RPO G85 Limited Slip Differential.

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This PI was superseded to update model years. Please discard PIP4349.
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may comment about a moan or groan noise coming from the transaxle under specific conditions.

Recommendation/Instructions:
The noise can be easily reproduced by placing the two front tires on surfaces with different traction capabilities and lightly accelerating or during hard cornering when accelerating. As the front wheels and tires begin to spin at different speeds, the noise will occur. This noise occurs when the limited slip differential is directing the torque from one front wheel to the other front wheel.

This moan/groan noise is a normal event, and the vehicle requires no repair by the dealer. The technicians should test drive the vehicle to verify the noise does not occur when accelerating on pavement without spinning the tires. If there is no noise without Tire spin then advise the customer that this is an operating characteristic of the limited slip differential.

ChevyMgr
10-21-2008, 09:47 AM
#PIT4787C: Approximate 150 To 200 mA Draw From The Power Steering Control Module - keywords battery electric motor PSCM - (Feb 18, 2009)


Subject: Approximate 150 to 200 ma Draw From The Power Steering Control Module


Models: 2007-2009 Chevrolet Cobalt, Equinox and HHR

2007-2009 Pontiac Torrent

2008-2009 Saturn VUE
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This PI was superseded to update models and Condition/Concern. Please discard PIT4787B.


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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
The vehicles listed above may have a 150 to 200 ma battery draw from the power steering control module. If the mega fuse for the power steering control module is removed, the draw may drop to around 20 - 25 ma. This can be due to the power steering control module staying awake for approximately 45 minutes. This may be a normal draw.

On the following vehicles: Equinox, Torrent, VUE and HHR SS only the power steering control module will stay awake for 45 minutes and then shut down.

On the Cobalt and HHR base model, the power steering control module may stay awake for up to 45 minutes. On these vehicles the PSCM module may stay awake based on the power steering motor temperature. The hotter the motor, the longer the module will stay awake (up to 45 minutes).

Recommendation/Instructions:
When diagnosing a battery draw, if the draw drops after removing the mega fuse for the power steering control module, do the following: Reinstall the mega fuse for the power steering control module and make sure to plug everything back in, then turn the ignition key on and then back off. Let the vehicle sit for up to 45 minutes and then re-check the battery draw readings. If the draw drops to around 20 - 25 ma, after 45 minutes, this is normal operation of the vehicle.

ChevyMgr
10-21-2008, 09:54 AM
#PIP4511: Unable To Reset The Engine Oil Life System Using The Accelerator Pedal - keywords DIC ECM EOL engine inop inoperative intermittent life lof lnf maintenance message monitor oil OLM pedal performance - (Oct 16, 2008)

Subject: Unable to Reset the Engine Oil Life System Using the Accelerator Pedal


Models: 2008-2009 Chevrolet HHR SS With Engine RPO LNF ONLY
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A technician may report that the Engine Oil Life (EOL) will not reset.

Recommendation/Instructions:
Engineering has determined that the ECM for the 2008-09 HHR SS does not support the use of the accelerator pedal for the Engine Oil Life System reset procedure. This is listed incorrectly in eSI and the Owners Manuals of this vehicle; and is in the process of being changed.

Technicians should be advised to use the DIC procedure or Tech2 to perform the EOL reset.

ChevyMgr
11-05-2008, 02:34 PM
#PIP4520: Low Boost / Power And/Or DTC P0299 Or P0101 - keywords actuator boost CAC charge control cooler driveability DTC ECM engine gas lnf low maf MIL reduced reducedpwmde SES wastegate - (Nov 4, 2008)


Subject: Low Boost/Power and/or DTC P0299 or P0101


Models: 2008-2009 Chevrolet Cobalt SS Only

2008-2009 Chevrolet HHR SS Only

2007-2009 Pontiac Solstice GXP

2007-2009 Saturn Sky Redline

With Engine RPO LNF Only
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A technician may encounter a vehicle with a low boost/power condition and/or DTC P0299 and or P0101 setting. This may be the result of a cracked or broken fitting at the turbocharger assembly.

Recommendation/Instructions:
It has been determined that the nipple for the turbocharger wastegate actuator may be damaged causing this condition. If this concern is noted please inspect the area on the underside of the turbo compressor housing for the wastegate actuator solenoid valve. The nipple (see CALLOUT #1) may have been damaged causing a loss of boost pressure. It may be necessary to remove the charge air duct for a closer inspection. See eSI "Turbocharger Wastegate Actuator Replacement" for solenoid replacement procedure.


3979


This solenoid is available separate from the turbocharger and should be replaced as a sub assembly. Do not replace the turbocharger assembly.

ChevyMgr
11-05-2008, 03:16 PM
#PIP3673E: P0833 And/Or Cruise Control Inop - keywords 5sp 6sp clutch code control cruise cylinder false grind hard inoperative low pedal shift slip switch transmission - (Oct 28, 2008)


Subject: P0833 and/or Cruise Control Inop


Models: 2004-2007 Cadillac CTS-V

2004-2007 Chevrolet Cobalt

2004-2006 Chevrolet Corvette, Silverado and SSR

2006-2007 Chevrolet HHR

2004-2006 Pontiac GTO

2005-2006 Pontiac Pursuit (Canada)

2006-2007 Pontiac Solstice

2007-2007 Pontiac G5

2007-2007 Saturn SKY

2006-2007 Saturn Ion

2004-2006 GMC Sierra

Equipped with Manual Transmission
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This PI was superseded to combine data from AIC3407A and to remove the 08 MY from list as these vehicles do not set the P0833 DTC. Please discard PIP3673D.
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may comment that the cruise control is inoperative and/or the MIL is on with DTC P0833 stored. The condition may not be duplicated by the dealer; however, the customer may have a repeat concern.

Recommendation/Instructions:
Check the "Top of Travel" or CCP switch for adjustment if your application is adjustable. Also check for possible intermittent connections in the clutch switch circuit.

It has been discovered in some applications that using a Tech II during circuit testing of the clutch and cruise switches may lead to false readings and improper diagnosis of the CCP switch. The Tech II may read APPLIED/RELEASE upon initial toggling of the switch, however repeated toggling may then lead the Tech II to indicate a steady APPLIED or RELEASED state.

Use a DVOM to check the clutch and cruise switches.

If no circuit concerns are found, verify that the customer's driving habits are not inducing the concern. This code can set (and the cruise control disabled) if the driver rests their foot on the clutch continuously and therefore prevents the pedal from reaching the top switch. This will keep the ECM from seeing transitions while they drive above and then below the vehicle speeds listed for setting the DTC. This can cause a false P0833 to set. An example of this occurring would be in slow moving stop and go traffic such as a construction zone or heavy traffic.

Important: Please make the customer aware of this scenario and advise to make an effort to refrain from resting their foot on the clutch pedal in these situations to avoid disabling the cruise control and/or setting DTC P0833.

Note: FOR THE FOLLOWING VEHICLES ONLY

2005-2007 Chevrolet Cobalt

2006-2007 Chevrolet HHR

2005-2006 Pontiac Pursuit

2007 Pontiac G5

2006-2007 Saturn ION

If the technician has followed the SI procedure for adjustment/replacement of the clutch pedal position sensor this may make the switch too sensitive for some driver's habits. The PPS should be adjusted to reduce the sensitivity. This can be accomplished by watching the PPS change states with a Tech2 and adjusting the PPS so that the pedal must travel farther before engaging switch. (I.e. from 1/4 inch travel to 1/2 inch of travel when changing states.)

ChevyMgr
11-19-2008, 09:21 AM
#PIC4125B: Reduced Power Message Or Long Crank No Start On The First Key Crank - keywords 2.2 2.2L 2.4 2.4L battery cooling crankshaft dead DTC drain draw engine extended fan hard harness key lamp L61 LE5 light - (Nov 17, 2008)


Subject: Reduced Power Message or Long Crank, No Start On The First Key Crank


Models: 2006 - 2007 Chevrolet HHR

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This PI was superseded to combine information from AIC3193 due to both concerns coming from same harness issue. Please discard PIC4125A.


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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A customer may bring the vehicle in with a Reduce Engine Power message on the DIC. Any of the following codes may set:

P2120: Accelerator Pedal Position (APP) Sensor 1 Circuit

P2122: Accelerator Pedal Position (APP) Sensor 1 Circuit Low Voltage

P2123: Accelerator Pedal Position (APP) Sensor 1 Circuit High Voltage

P2125: Accelerator Pedal Position (APP) Sensor 2 Circuit

P2127: Accelerator Pedal Position (APP) Sensor 2 Circuit Low Voltage

P2128: Accelerator Pedal Position (APP) Sensor 2 Circuit High Voltage

P2138: Accelerator Pedal Position (APP) Sensor 1-2 Correlation

In addition, on vehicles with the 2.4L LE5 Engine (VIN Code P) only, the following codes could also occur:

P0651: 5 Volts Reference 2 Circuit

C0561: System Disabled Information Stored

P0326: Knock Sensor (KS) Performance

P2135: Throttle Position (TP) Sensor 1-2 Correlation

P0335: Crankshaft Position (CKP) Sensor Circuit)

It has also been reported that the cooling fans may run constantly due to this condition.

Recommendation/Instructions:
It has been identified that the engine harness may contact the purge solenoid bracket, causing harness damage and exposing the wires.


4164


Inspect the harness and repair any necessary wires and secure the harness away from the bracket to prevent harness from grounding on the bracket.

ChevyMgr
11-25-2008, 04:24 PM
#PIC5038: RVS Inoperative / Horn Chirp When RVS Function Is Performed - keywords beep button chirp fob function horn inop intermittent key keyless locate no pressed performed remote start - (Nov 20, 2008)


Subject: RVS Inoperative/Horn Chirp When RVS Function is Performed


Models: 2006-2009 Chevrolet Cobalt

2006-2009 Chevrolet HHR

2007-2009 Pontiac G5
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A customer may comment the Remote Start is inoperative. When attempting an RVS event the customer will hear three horn chirps and park lights flash.

Recommendation/Instructions:
The three horn chirps should be used as a key indicator for what is causing the RVS not to work properly.

While monitoring the key fob data list, technicians should perform a RVS function, When you press the RVS button on the keyfob, the data list will show "locate" instead of "Start/RVS/Engine".

This issue has been identified as an internal concern with the keyfob. Keyfob replacement should resolve this issue.

ChevyMgr
12-05-2008, 12:36 PM
#08-08-67-018: Wind/Air Deflector Bracket on Sunroof Module Broken (Replace Bracket) - (Dec 2, 2008)


Subject: Wind/Air Deflector Bracket on Sunroof Module Broken (Replace Bracket)


Models: 2006-2009 Chevrolet HHR




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Condition
Some customers may comment that the sunroof will not close because the wind deflector won't fold down properly when the sunroof glass closes.

Cause

4236


The end on the wind deflector retaining bracket may have broken off, which causes the wind deflector to function improperly.

Correction
Remove the headliner following SI procedures.
Open the sunroof and protect the interior.
Clean the sunroof tracks around the broken bracket.
Tape off the area around the bracket to contain the drill shavings in the next step.

4237

Using a 1/4 inch drill bit, drill off the head of the two rivets.
Vacuum the drill shavings.
Using a small drift, pound out the rest of the rivet in the sunroof module.

4238

Attach the wind deflector to the new bracket and clamp the bracket in place.
Using the holes as a guide in the sunroof module, drill 1/8 inch holes through the bottom of the new brackets.

4239

Install two 1/8 x 3/8 inch long rivets (obtained locally) through the BOTTOM of the sunroof module to the new bracket.
Apply weatherstrip adhesive to the top of the rivet head.
Replace the bracket on the other side following steps 3 through 10.
Important: Make sure the tracks are clean and no metal shavings are present.

Cycle the sunroof several times to make sure the sunroof functions properly.
Reinstall the Headliner following SI procedures.
Parts Information
Part Number
Description

20794829
Bracket-Sun RF Frm SI LH

20794830
Bracket-Sun RF Frm Si RH

ChevyMgr
12-15-2008, 08:51 AM
#PIC5055: Rear Hatch Will NOT Lock - keywords door fuse gate latch lift liftgate lock pad release RKE touch UBEC unlock - (Dec 11, 2008)


Subject: Rear Hatch Will NOT Lock


Models: 2006-2009 Chevrolet HHR

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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
The customer will notice that at anytime by using the touch pad on the rear lift gate the lift gate will open WITHOUT unlocking the vehicle.

Recommendation/Instructions:
If this condition exists, check for a fuse in position #11 in the Underhood Buss Electrical Center. If there is a fuse in that position, remove it, as it is not supposed to be there.

Note: A fuse in that position will cause the release relay (coil side) to stay powered up at all times and will only need a ground (touch pad) to activate the relay.

If no fuse is present then check for voltage on circuit #1221 (WH/BK) and proceed with diagnostics.

ChevyMgr
12-18-2008, 11:14 AM
2006 HHRs in Emission Testing States


Document ID: 2219832
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#PIP4547: No Communication With Emission Test Equipment - Reprogram ECM - keywords 240 controls facility failed inspection I/M IM no state - (Dec 17, 2008)


Subject: No Communication With Emission Test Equipment- Reprogram ECM


Models: 2006 Chevrolet Cobalt

2006 Chevrolet HHR

2006 Saturn ION

With 2.2L Engine - (RPO-L61)

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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some emission test equipment may not communicate with the ECM but normal communication is noted with a Tech 2.

Recommendation/Instructions:
If this is encountered, reprogram the ECM with the latest calibrations and re-evaluate the concern.

Important: With the ignition is OFF, apply the parking brake to disable the daytime running lights (DRL) prior to starting the reprogramming procedures. On models equipped with an "Auto Headlamp Feature", the headlamps must be turned off prior to reprogramming.

Important: Select the "Reprogram" option in order to reprogram the ECM.

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.

ChevyMgr
01-07-2009, 08:37 AM
#09-08-64-001: Rear Side Cargo Door Not Opening With Button Activation (Add Washers to Check Link) - (Jan 5, 2009)


Subject: Rear Side Cargo Door Not Opening With Button Activation (Add Washers to Check Link)


Models: 2008-2009 Chevrolet HHR Panel Van

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Condition
Some customers may comment that the rear side cargo door(s) intermittently will not release open upon first activation of the instrument panel (IP) buttons, or by using the key fob.

Cause
Assembly variation may be causing the door latch mechanism to stick or only release intermittently.

Correction
Note: Ensure that the door latch does react to the IP and key fob buttons, and that there is no drag between the latch and striker.


4411


Remove the bolt (1) holding the rear side cargo door check link bracket to the "B" pillar.

4412

Add a 2 mm thick washer (1), P/N 11609679, or equivalent, to the bolt. Slide the washer onward to rest against the outer surface of the bracket.



Position the check link bracket to the B pillar and reinstall the bolt.
Tighten
Tighten the bolt to 20 N·m (15 lb ft).

Verify that the door is releasing open upon first activation of the IP or key fob buttons. If the door is releasing properly, repair is complete. If the condition has NOT been corrected, continue on to step 5.
Remove the rear side cargo door interior trim panel. Refer to Rear Side Door Trim Panel Replacement in SI.
Pull the top front edge of the water deflector downward to gain access to the check link.

4413

Remove the "B" pillar bolt (1) and the nuts (2) retaining the check link to the door.



Remove the check link through the inside of the door.

4414

Add a 2 mm thick washer (1) , P/N 11609679, or equivalent, to each bolt on the check link (two total). Slide them onward to rest against the body of the check link.



Reinstall the check link through the inside of the door, and position the check link to the inner door frame.



Install the nuts (2) that retain the check link to the door.
Tighten
Tighten the nuts to 10 N·m (89 lb in).

Position the check link bracket to the "B" pillar and reinstall the bolt (1) with washer.
Tighten
Tighten the bolt to 20 N·m (15 lb ft).

Verify that the door is releasing open upon first activation of the IP or key fob buttons.
Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement in SI.
Parts Information
Part Number Description Qty

11609679 Washer (2 mm thick) 10 per package

ChevyMgr
01-07-2009, 08:42 AM
#09-08-67-001: Sunroof Frame Tox Rivet Rattle (Install Flocking Tape) - (Jan 6, 2009)


Subject: Sunroof Frame Tox Rivet Rattle (Install Flocking Tape)


Models: 2006-2009 Buick Lucerne

2003-2007 Cadillac CTS

2005-2009 Cadillac STS

2006-2009 Cadillac DTS

2005-2009 Chevrolet Cobalt, Equinox

2006-2009 Chevrolet HHR

2006-2009 Pontiac Torrent

2007-2009 Pontiac G5

2004-2007 Saturn VUE




--------------------------------------------------------------------------------

Condition
Some customers may comment of a rattling noise coming from the sunroof or roof area.

Cause
This condition may be caused by the inboard tox rivets, which retain the sunroof center support beam to the side rails, pulling through the side rail track on one or both sides. This may cause the support beam to rattle against the side rail track.

Correction
Important: Once the sunroof module is bolted into the roof ring of the vehicle, the support provided by the center beam is no longer necessary. DO NOT replace the sunroof frame when the above condition is noted.

Install flocking tape between the sunroof center support beam and the side rail track.

4415



Following SI, lower the front portion of the headliner enough to gain access to the sunroof module center support beam through the opening in the headliner.

4416

Check both sides of the center support beam for loose rivets (2) by inserting a trim stick (1) between the center support and the side rail track

4417

Look for separation of the center support beam and the side rail track.
Cut a piece of Kent-Automotive ™ 30 mm wide BRS Flocking tape, or equivalent, approximately 152 mm (6 in) in length.

4418

install the flocking tape (1) underneath the center support beam using the trim stick (2) to separate the center support beam and the side rail track.

4419

Ensure that the flocking tape is positioned underneath the complete width of the center support beam.
Reinstall the headliner.
Parts Information
BRS Flocking tape is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automitive.com.

Part Number Description

KT 13486 BRS Tape (Flocking Tape)

ChevyMgr
01-07-2009, 09:39 AM
#09-08-58-001: Outside Rearview Mirror Wind Noise (Install Flocking Tape and Shim Stock) - (Jan 6, 2009)


Subject: Outside Rearview Mirror Wind Noise (Install Flocking Tape and Shim Stock)


Models: 2006-2009 HHR
--------------------------------------------------------------------------------

Condition
Some customers may comment about a more than desirable amount of wind noise coming from the outside rearview mirror(s).

Cause
Air intrusion may be occurring between the outside rearview mirror cover and the mirror housing, which may create a noise when the air passes over the holes in the mirror housing.

Correction
Install flocking tape and adhesive back shim stock to the outside rearview mirror housing. The pattern is noted in the steps below:

http://www.chevyhhr.net/gallery/files/4/8/6/5/mirrora.gif



Using a trim stick, or suitable tool, carefully remove the outside rearview mirror cover.

http://www.chevyhhr.net/gallery/files/4/8/6/5/mirrorb.gif

Important: The mirror cover has retaining tabs and features that must be positioned into the hole locations noted above. Do NOT cover any of these holes with the tape or shim stock.

http://www.chevyhhr.net/gallery/files/4/8/6/5/mirrorc.gif


Install a 1/2 width piece of 5/8" x 1/8" Kent Automotive™ Adhesive Back Shim Stock (1), or equivalent, around the outside of the larger rectangular hole in the mirror housing.
Install 1/2 width pieces of Kent Automotive ™ 30 mm wide BRS Flocking tape, or equivalent, around the perimeter and underside of the mirror housing.

http://www.chevyhhr.net/gallery/files/4/8/6/5/mirrord.gif

3.1. Install pieces of flocking tape to the top, sides, and bottom of the back rounded surface of the mirror housing.

Tip
Install the tape just inside the outer edge of the back rounded surface.

http://www.chevyhhr.net/gallery/files/4/8/6/5/mirrore.gif

3.2. Install another piece of flocking tape between the shim stock and the side tape, being sure to avoid the retainer hole locations.

http://www.chevyhhr.net/gallery/files/4/8/6/5/mirrorf.gif


3.3. Install pieces of flocking tape starting at the shim stock, and wrapping around to the underside of the mirror housing. Ensure the tape is inboard of the retainer hole locations.

http://www.chevyhhr.net/gallery/files/4/8/6/5/mirrorg.gif


Carefully position the outside rearview mirror cover to the mirror housing and push to engage the retaining tabs. Ensure all the retainers are fully seated.
Parts Information
Flocking Tape and Shim Stock is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com.

Part Number Description

KT 13486 BRS Tape (Flocking Tape)

P40100 Adhesive Back Shim Stock

ChevyMgr
01-07-2009, 09:46 AM
#08-07-29-001C: EI08046-Manual Transmission Grinds in Either Third or Fourth Gear When Clutch is Fully Disengaged (Replace 3rd and 4th Gear Blocker Rings) - (Jan 5, 2009)


Subject: EI08046 - Manual Transmission Grinds in Either Third or Fourth Gear When Clutch is Fully Disengaged (Replace 3rd and 4th Gear Blocker Rings)


Models: 2008 Chevrolet Cobalt, HHR

2008 Pontiac G5

Equipped with Manual Transmission (RPO M86)

Prior to the Serial Numbers Shown Below
--------------------------------------------------------------------------------

This bulletin is being revised to include a Transmission Serial Number breakpoint. Please discard Corporate Bulletin Number 08-07-29-001B (Section 07- Transmissions)


--------------------------------------------------------------------------------
Models
Transmission P/N Transmission Serial Number

Cobalt XFE 24248018 61 YEH 08058387

Cobalt, G5 (STD) 24241747 61 YED 08083169

HHR 24241746 61 YEC 08062188

Condition
Some customers may comment on a grinding noise in third or fourth gear when the clutch is fully disengaged.

Cause
Based on feedback provided by dealer technicians, engineering was able to determine the manual transmission grinding in 3rd or 4th gear. It is possible to correct the condition by replacing the 3rd and 4th gear blocker rings.

Correction

4420

4421

Check the Transmission Serial Number label to determine if the transmission is built prior to the chart above. The Transmission Serial Number label is located on the back side of the transmission between the halfshafts. If the transmission is built prior to the chart above, then replace the 3rd and 4th gear ring blocker, GM P/N 192076072.

Parts Information**Parts Description**Quantity

19207672**Ring, Blocker**2

ChevyMgr
01-07-2009, 09:48 AM
Document ID: 2220636
--------------------------------------------------------------------------------

#PIC5064: iTouch Issues On Panasonic Radios - (Jan 6, 2009)


Subject: iTouch issue on Panasonic radios


Models: 2009 Chevrolet HHR, Malibu

2009 Pontiac Solstice, Solstice Coupe

2009 Opel GT

2009 Saturn Aura, Sky
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may comment that their Apple iPhone or iTouch device may not work as desired. If the customer has an Apple iPhone or iTouch with firmware version 2.1 the device may experience the following operating condition when it is plugged into the USB port on the radio. The device will connect and operate initially. After a short period of time the radio may display no USB device. The customer may disconnect and reconnect the device and the radio does not recognize the device. This condition may not go away with cycling the ignition or rebooting the device.

Recommendation/Instructions:
A software anomaly exists between the radio and the connected device resulting in the described operating condition when using software version 2.1 on the device.

The customer should upgrade the Apple iPhone or iTouch with firmware version 2.2. to resolve this condition.

ChevyMgr
01-07-2009, 09:50 AM
Bluetooth and Apple iPhone

#PIC5002A: Bluetooth Issues With Apple iPhone V2.1 - keywords audio call drop onstar UPF - (Jan 5, 2009)


Subject: Bluetooth® issues with Apple iPhone V2.1


Models: 2008 - 2009 Cadillac CTS, CTS-V

2009 Buick Enclave, Lacrosse, Lucerne

2009 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT, SRX, STS, XLR

2009 Chevrolet Cobalt, Corvette, Equinox, HHR, Impala, Malibu, Silverado, Suburban, Tahoe, Trailblazer, Traverse

2009 GMC Acadia, Envoy, Sierra, Yukon, Yukon XL

2009 Hummer H2. H3

2009 Pontiac G5, G6, Solstice, Torrent

2009 SAAB 9-3, 9-7x

2009 Saturn Aura, Outlook, Sky, Vue
--------------------------------------------------------------------------------

This PI was superseded to update repair information due to release of V2.2 software. Please discard PIC5002.


--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Customers may report various issues when trying to use an Apple iPhone with the embedded Bluetooth® system that is part of the GEN8 OnStar system. They may state that the system had been working properly and recently developed the issue.

Recommendation/Instructions:
DO NOT replace the radio or OnStar VCIM for this condition.

An issue has been identified with the Apple iPhone software version 2.1 released September 12, 2008. The customer would have received this software update upon connecting to iTunes and saying yes to the update after 9/12/08. This may cause such issues as inability to hear incoming/outgoing calls, or dropped calls while using the Bluetooth®.

Apple iPhone software version 2.2 was released on 11/21/08 and does resolve this issue. Customers should connect to Apple via their phone and update the software then retest the operation.

ChevyMgr
01-07-2009, 09:53 AM
#PIP4548C: Repeat DTC P0016 And P0017 - keywords cam camshaft correlation crankshaft CKP CMP code exhaust intake L61 LAP LAT LE5 LE8 MIL position SES solenoid timing unwanted - (Feb 8, 2011)


Subject: Repeat DTC P0016 and P0017


Models: 2008-2009 Chevrolet Cobalt SS

2006-2009 Chevrolet Cobalt

2006-2009 Chevrolet HHR

2008-2009 Chevrolet HHR SS

2008-2009 Chevrolet Malibu

2007-2009 Pontiac G5

2008-2009 Pontiac G6

2006-2009 Pontiac Pursuit (Canada Only)

2007-2009 Saturn Aura

2006-2007 Saturn Ion

2006-2009 Saturn Vue

OR

Equipped with the following engines

2007-2010 2.0L (RPO LNF)

2007-2011 2.2L (RPO L61/LAP/LE8)

2006-2011 2.4L (RPO LE5/LE9/LAT/LAF)
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
These DTCs may be caused by a camshaft reluctor that has moved on the cam.

Recommendation/Instructions:
This condition is more prevalent if the engine has been overheated. The camshaft reluctor may have moved on the cam causing this DTC. The CMP phaser and or the actuator solenoid may have been replaced with no change after following SI diagnostic for this code. Additionally the tech may state that the engine is timed correctly and all timing indicators line up correctly.

Note: Each of the procedures below may not detect a small movement in the reluctor, it may be necessary to compare to another like vehicle. Also note that the rocker cover gasket surface does not line up with the same face or slot on the intake and exhaust reluctor.

To check the Exhaust Cam reluctor position:
With the exhaust camshaft positioned so that the valves for #4 cylinder are at maximum lift (fully opened valves), the reluctor should be flush/parallel to the rocker cover gasket surface as shown in the attached pictures. After comparing the camshaft reluctor position to the illustration and the reluctor does not line up correctly the camshaft must be replaced. The reluctor is press fit and is not indexed/keyed to the camshaft, it is an interference type fit. An overheat condition may contribute to the concern, causing the reluctor to spin on the camshaft when hot.

4422

To check the Intake Cam reluctor position:
With the Intake camshaft positioned so that the valves for #1 cylinder are at maximum lift (fully opened valves), the reluctor should be flush/parallel to the rocker cover gasket surface as shown in the attached pictures. After comparing the camshaft reluctor position to the illustration and the reluctor does not line up correctly the camshaft must be replaced. The reluctor is press fit and is not indexed/keyed to the camshaft, it is an interference type fit. An overheat condition may contribute to the concern, causing the reluctor to spin on the camshaft when hot.

4423

ChevyMgr
01-07-2009, 09:55 AM
#PIP4549A: Various Intermittent DTCs Or Electrical / Communication Concerns - keywords bare battery bracket CEL chaff circuit class2 connection controls crank data DTC ECM engine ground harness high intermittent - (Jan 5, 2009)


Subject: Various Intermittent DTC's or Electrical/Communication Concerns


Models: 2005-2009 Chevrolet Cobalt SS

2005-2009 Chevrolet Cobalt

2006-2009 Chevrolet HHR

2008-2009 Chevrolet HHR SS

2008-2009 Chevrolet Malibu

2007-2009 Pontiac G5

2008-2009 Pontiac G6

2005-2009 Pontiac Pursuit (Canada Only)

2007-2009 Saturn Aura

2005-2007 Saturn Ion

2004-2007 Saturn Ion Redline

2002-2009 Saturn Vue

With any of the following ECOTEC engines:

2.0L Engine (RPO LSJ/LNF)

2.2L Engine (RPO L61/LAP)

2.4L Engine (RPO LE5/LE9/LAT)
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A technician may comment of intermittent CEL, DTC's or No communication with various modules. This may be caused by a short to ground of the vehicle wiring in the engine harness.


Recommendation/Instructions:
The harness may chaff in the area of the Canister Purge Solenoid attachment bracket, causing an intermittent shorting to ground. The harness routing forces the harness into the edge of the bracket. This bracket is present with any Ecotec engine. The Purge Solenoid bracket may have a sharp edge from the manufacturing/shearing operation. If any DTCs are setting consistently, perform the eSI diagnostics and repair as necessary. If the eSI diagnostics do not isolate the concern, inspect the engine harness for potential shorts to ground at the EVAP purge valve bracket on the side of the cylinder head. Then repair and reposition the circuits/harness as necessary.

Note: To prevent future chaffing remove the sharp edge from the purge solenoid bracket and add conduit to the engine harness at the ECM and Purge Solenoid harness breakout.

4424

This PI applies to all DTCs Listed below:

P0326 P0335 P060E P0561 P0651 P2120 P2122 P2123 P2125 P2127 P2128 P2135 P2138 U1863 U1886 U1899 U2105 U2106 U2107 U2143

ChevyMgr
01-08-2009, 08:57 AM
#PIP4551: Installation Tips Stage 1 Turbo Upgrade - keywords accessory air boost CAC cal calibration cel charge control cooler driveability DTC ECM engine gas leak inf low MAF MAP MIL P0642 P0193 performance - (Jan 7, 2009)


Subject: Installation Tips Stage 1 Turbo Upgrade


Models: 2008-2009 Chevrolet HHR SS
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A technician may comment that DTC's (P0642 / P0193) may set after installing the Performance Parts accessory upgrade Stage I Turbo kit. They may report the vehicles will crank but not start and they have rechecked their installation with no problems found.

Recommendation/Instructions:
Due to differences in the new sensors and wiring harness colors between vehicle models some confusion may occur when installing the new TMAP sensors. The following may help.

The technician may mistake the intake manifold TMAP sensor with the Charge air pipe TMAP sensor which is located on the charge air pipe from the turbocharger. This may lead to the technician rewiring the sensor for the wrong location.
The technician may be confused at steps #4 and #10 where they are to rewire the new sensors. Due to production differences the wire colors do not correspond to those found on the vehicle. In addition eSI documents for the 2008-09 HHR may not be correct for these circuits. (eSI change request has been submitted) This may cause the technician to install the pigtail incorrectly. To remedy this concern match the production terminal to the provided terminal. (Pin to pin) Follow these charts below from the installation instructions for reference. (Production wire colors omitted)

INTAKE MANIFOLD TMAP SENSOR WIRING
Production Terminal Location
New Wire Color
New Terminal Location

A/1 White 3

B/2 White 1

C/3 White 4


Pin # 2 is not used; cover and tape back the white wire.

CHARGE AIR PIPE TMAP SENSOR WIRING
Production Terminal Location
New Wire Color New Terminal Location

A White 1

B White 2

C White 3

D White 4


Note: When installing the TMAP sensor on the Charge air pipe the technician may notice interference between the pipe and the new sensor. This has been addressed in PIC5062, which details removing a boss from the sensor to allow proper alignment.

ChevyMgr
01-12-2009, 09:06 AM
#PIC4108G: Battery Draw From The BCM 2 Fuse - (May 11, 2009)


Subject: Battery Draw From The BCM 2 Fuse


Models: 2005-2009 Chevrolet Cobalt

2006-2009 Chevrolet HHR

2007-2009 Pontiac G5
--------------------------------------------------------------------------------

This PI was superseded to correct module reference. Please discard PIC4108F.
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Customers may report a battery drain on their vehicle. Upon inspection technicians may see a battery draw of 100-170 mA on the battery. Typically when the BCM 2 fuse in the UBEC is pulled, the draw goes away. When looking at the wiring schematics you will NOT see the microprocessor (inside the BCM) that is powered by this fuse. This Microprocessor is sending small amounts of voltage out on the door lock input circuit #682 (White, BCM X1 pin 7) and the dome lamp output circuit #149 (D-BU/WHT, BCM X3 pin A3), Either of these circuits could be pulled low and will cause this condition.

Recommendation/Instructions:
Install the Tech-2/Candi module and look at the door lock switch status in the BCM data section. Status should be reading "Idle". If it reads Unlock or Lock, then check for a possible short to ground in circuit #682 (White) or a possible door lock switch concern. If those check out OK then remove circuit #149 from the BCM and wait to see if your draw times out in 20 minutes. If it does then check for a STG in circuit #149 (D-BU/WHT).

ChevyMgr
01-14-2009, 11:41 AM
#PIP4559: DTC P2227 After Turbo Upgrade Kit Installation - keywords accessory air boost cal calibration cel charge control cooler driveability DTC ECM engine gas leak inf low MAF MAP MIL PCM performance power - (Jan 13, 2009)


Subject: DTC P2227 After Turbo Upgrade Kit Installation


Models: 2008-2009 Chevrolet HHR SS

2008-2009 Chevrolet Cobalt SS

2007-2009 Pontiac Solstice GXP

2007-2009 Saturn Sky Redline

With 2.0L RPO LNF
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A technician may comment that DTC P2227: Barometric Pressure (BARO) Sensor Performance has set after installation of the Accessory/Performance Parts Turbo Upgrade kit for the 2.0L RPO LNF Turbocharged engine.

Recommendation/Instructions:
The DTC P2227: Barometric Pressure (BARO) Sensor Performance will only set if the calibration was not completed correctly or was not installed. This is a Type-B DTC and will only set upon a second drive cycle after the diagnostic runs and fails. This calibration installation can be verified by checking the calibration/SW part numbers using the Tech2 after the new cal is flashed. Those can then be checked against what should be flashed to confirm the correct calibration was actually installed.

Note: Anytime an ECM/PCM is replaced, has DTCs cleared, an updated cal installed or is SPS programmed, the technician should drive the vehicle at least 2 drive cycles to verify the service/repair.

ChevyMgr
01-26-2009, 09:03 AM
TSB too long to post all information:


#09-05-22-001: Hard Brake Pedal, Extra Effort Needed to Depress Brake Pedal on Cold Start-Up (Add Auxiliary Vacuum Pump) - (Jan 22, 2009)


Subject: Hard Brake Pedal, Extra Effort Needed to Depress Brake Pedal on Cold Start-up (Add Auxiliary Vacuum Pump)


Models: 2008-2009 Chevrolet HHR SS

Built Prior to January 2009 and Equipped with Automatic Transmission



Attention: Proceed with this bulletin ONLY if a customer has brought their vehicle in for this concern. For vehicles in inventory or in the service department for an unrelated customer concern, review Bulletin # 08-05-22-001A to reprogram EBCM built prior to and including VIN Breakpoint 8S653008.



--------------------------------------------------------------------------------

Condition
Some customers may comment that extra effort may be needed to depress the brake pedal on cold start-up.

Correction
Add an auxiliary vacuum booster pump to the brake system using the procedure listed below.

ChevyMgr
02-27-2009, 10:42 AM
#PIC5106A: Turbo Boost Gauge Flicker - (Mar 18, 2009)


Subject: Turbo Boost Gauge Flicker


Models: 2008 Chevrolet Cobalt-SS or HHR-SS
--------------------------------------------------------------------------------

This PI was superseded to advise dealers to contact TCSC for VCI number. Please discard PIC5106.
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers with a 2008 Cobalt-SS or HHR-SS may comment that their turbo boost gauge backlighting will flicker intermittently.

Recommendation/Instructions:
Calibrations will not be found in TIS 2 Web SPS. Dealers should contact Techline Customer Support (TCSC) for a VCI

Note: Vehicles built after the following dates already have the updated software installed to address this condition.

• HHR build date: 5/12/08

• Cobalt build date: 5/4/08

ChevyMgr
03-03-2009, 07:56 AM
#09-06-04-009: Information on Stage Kit TMAP Sensor Modification - (Mar 2, 2009)


Subject: Information on Stage Kit TMAP Sensor Modification


Models: 2008-2009 HHR SS

Equipped with 2.0L Engine (VIN X - RPO LNF)
--------------------------------------------------------------------------------

When installing the GM Performance Parts accessory upgrade Stage I Turbo kit # 19212670 on a 2008-09 HHR SS, the intake air pressure temperature (TMAP) sensor interferes with the charge air cooler (CAC) pipe. The TMAP sensor is located on the charge air duct between the intercooler and the engine. The sensor requires modification before assembly or leaks may occur. Following these steps will prevent any concerns when mounting the TMAP to the duct pipe.

Inspect/Removal of Tap

4724


Inspect the TMAP sensor when mounted on the charge air duct. Note how the TMAP sensor is not mounted flush on the duct (1).


4725


Carefully remove the boss (1) until the TMAP will mount flush on the duct. The boss interferes with the anti-rotation bar on the duct.


4726


The TMAP sensor after the boss was removed (1).


4727


The TMAP sensor mounted flush onto the duct (1).

ChevyMgr
03-03-2009, 08:03 AM
#PIT4738A: iPod Compatability With GM PAL - keywords accessories apple audio band compatible connect connector electrical entertainment link nano personal radio touch - (Feb 27, 2009)


Subject: iPod Compatibility With GM PAL


Models: 2008 Buick Enclave

2006-2008 Chevrolet HHR

2007-2008 Chevrolet Cobalt

2008 Chevrolet Avalanche, Malibu, Silverado, Suburban, Tahoe

2008 GMC Acadia, Sierra, Yukon, Yukon XL

2008 Hummer H2

2006-2008 Pontiac Solstice

2007-2008 Pontiac G5

2007-2008 Saturn Sky

2008 Saturn Aura, Outlook
--------------------------------------------------------------------------------
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
The following Apple iPod models have been tested and proven to be compatible with the GM Personal Audio Link (PAL) accessory system.

iPod Touch (2nd gen.)

iPod Touch

iPod Classic (120GB)

iPod Classic

iPod (5th gen.) (Late 2006) (60/80GB)

iPod w/ Video (5th gen) (20/60GB)

iPod Color (20 GB, 30 GB, and 60 GB)

iPod Photo (40 GB, 60 GB)

iPod with Click Wheel (20 GB, 40 GB including U2 Special Edition)

iPod with Dock Connector (10 GB, 15 GB, 20 GB, 30 GB, 40 GB)

iPod Nano (4th gen.)

iPod Nano (3rd gen.)

iPod Nano (2nd gen.)

iPod Nano

iPod Mini (2nd gen.)

iPod Mini

Remaining models are not compatible or have not yet been tested. Visit http://www.apple.com/support/ipod/ to help identify your iPod model.

ChevyMgr
03-03-2009, 01:10 PM
#09-00-89-004: 2010 Model Year Powertrain Warranty Coverage - (Jan 22, 2009)
Subject:
Warranty Administration -- 2010 Model Year Powertrain Warranty Coverage
Models: 2010 GM Passenger Cars and Light Duty Trucks (Including Saturn)
2010 HUMMER H2, H3
Attention: This bulletin does NOT apply to Medium Duty trucks, Saab vehicles and export/NAIPC dealers.
________________________________________
Effective January 1, 2009, several changes have been made to the 2010 powertrain warranty coverage. We have the "best coverage in North America" when you combine the warranty with roadside assistance and courtesy transportation programs* and coverage remains 5 years or 100,000 miles/160,000 kilometers and is transferable.

The following is the new powertrain warranty coverage with the inclusions and exclusions highlighted for convenience.

Engine Coverage includes:
All internally lubricated parts, engine oil cooling hoses, lines and radiators. Also included are all actuators and electrical components internal to the engine (i.e.: Active Fuel Management Valve Lifter Oil Manifold, etc.), cylinder head, block, timing gears, timing chain, timing cover, oil pump/oil pump housing, OHC carriers, valve covers, oil pan, seals, gaskets, manifolds, flywheel, water pump, harmonic balancer, engine mount, starter motor, turbocharger and supercharger. Timing belts are covered until the first scheduled maintenance interval.
Exclusions:
Excluded from the powertrain coverage are sensors, wiring, connectors, engine radiator, coolant hoses, coolant and heater core. Coverage on the engine cooling system begins at the inlet to the water pump and ends with the thermostat housing and/or outlet that attaches to the return hose. Also excluded is the entire pressurized fuel system (in-tank fuel pump, pressure lines, fuel rail(s), regulator, injectors and return line) as well as the Engine/Powertrain Control Module and/or module programming.

Transmission/Transaxle Coverage includes:
All internally lubricated parts, case, torque converter, mounts, seals and gaskets as well as any electrical components internal to the transmission/transaxle. Also covered are any actuators directly connected to the transmission (slave cylinder, etc.).

Exclusions:
Excluded from the powertrain coverage are transmission cooling lines, hoses, radiator, sensors, wiring, electrical connectors. Also excluded are clutch and pressure plate as well as any Transmission Control Module and/or module programming .

Transfer Case Coverage includes:
All internally lubricated parts, case, mounts, seals and gaskets as well as any electrical components internal to the transfer case. Also covered are any actuators directly connected to the transfer case as well as encoder motor.

Exclusions:
Excluded from the powertrain coverage are transfer case cooling lines, hoses, radiator, sensors, wiring, electrical connectors as well as the transfer case control module and/or module programming.

Drive Systems Coverage includes:
All internally lubricated parts, final drive housings, axle shafts and bearings, constant velocity joints, propeller shafts and universal joints. All mounts, supports, seals, gaskets as well as any electrical components internal to the drive axle. Also covered are any actuators directly connected to the drive axle (i.e. front differential actuator, etc.).

Exclusions:
Excluded from the powertrain coverage are all wheel bearings, drive wheel front and rear hub bearings, locking hubs , drive system cooling, lines, hoses, radiator, sensors, wiring and electrical connectors related to drive systems as well as any drive system control module and/or module programming .

* Courtesy Transportation is not part of or included in the coverage provided by the New Vehicle Limited Warranty. General Motors and General Motors of Canada Limited reserve the right to make any changes or discontinue the Courtesy Transportation program at any time without notification.

ChevyMgr
03-10-2009, 10:51 AM
#09041: F/CMVSS Noncompliance - Shift Lever Indicator May Not Display Correct Gear - (Mar 9, 2009)


Subject: 09041 -- Shift Lever Indicator May Not Display Correct Gear


Models: 2009 Buick Enclave

2009 Chevrolet Cobalt, HHR, Malibu, Traverse

2009 GMC Acadia

2009 Pontiac G5, G6

2009 Saturn AURA, OUTLOOK
--------------------------------------------------------------------------------

Condition
General Motors has decided that certain 2009 model year Buick Enclave; Chevrolet Cobalt, HHR, Malibu, Traverse; GMC Acadia; Pontiac G5, G6; and Saturn AURA and OUTLOOK vehicles fail to conform to Federal/Canada Motor Vehicle Safety Standard 102 , "Transmission Shift Position Sequence, Starter Interlock, and Transmission Braking Effect", and Standard 114, "Theft Protection and Rollaway Prevention". On some of these vehicles, the transmission shift cable adjustment clip may not be fully engaged. If the clip is not fully engaged, the shift lever and the actual position of the transmission gear may not match. With this condition, the driver could move the shifter to PARK and remove the ignition key, but the transmission gear may not be in PARK. The driver may not be able to restart the vehicle and the vehicle could roll away after the driver has exited the vehicle, resulting in a possible crash without prior warning.

Correction
Dealers are to inspect and ensure that the shift cable adjustment clip is fully engaged. In the event that the clip does not engage, the shift cable must be replaced.

Vehicles Involved
Involved are certain 2009 model year Buick Enclave; Chevrolet Cobalt, HHR, Malibu, Traverse; GMC Acadia; Pontiac G5, G6; and Saturn AURA and OUTLOOK vehicles built within these VIN breakpoints:

2009 Chevrolet HHR 9S500003-9S614420

Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.

Parts Information
No parts are needed for this recall. In the rare event that a shift cable is required, please order the appropriate cable and H-route the claim for wholesale approval.

Service Procedure
Park the vehicle on a flat secure surface with the shifter in the PARK position.
Disengage the shift cable adjuster lock.
Turn the transmission side manual shaft lever counterclockwise and then release the lever to ensure that the transmission manual shaft is in the PARK position fully.
Push the shift cable adjuster lock down to fully engage the adjuster lock.

4770

Warning: In the extremely rare event that the adjuster lock becomes disengaged, replace the shift cable. Refer to Floor Shift Control Cable Replacement (Cobalt, G5, HHR, Malibu) or Range Selector Lever Replacement (Acadia, Aura, Enclave, G6, Outlook, Traverse) in SI.

Apply a LIGHT vertical (upward) force with 2 fingers to the sides of the adjuster locking clip engagement legs. Refer to illustration. Push the shift cable adjuster lock down fully one more time to ensure complete lock engagement.
Move the shifter back and forth from PARK to N or L 3 times.
Verify that the vehicle shift system operates correctly.

Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject.

ChevyMgr
03-10-2009, 02:11 PM
#PIC4733C: Chime Volume Adjustment (US8/US9 Radio) - keywords int intermittent level loud normal preset radio soft three - (Dec 23, 2008)


Subject: Chime Volume Adjustment (US8/US9 radio)


Models: 2006-2009 Chevrolet Cobalt

2006-2009 Chevrolet HHR

2008-2009 Chevrolet Malibu (New body style)

2007-2009 Pontiac G5

2006-2009 Pontiac Solstice

2007-2009 Saturn Aura

2007-2009 Saturn Sky
--------------------------------------------------------------------------------
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A customer might comment that the audible chimes (headlight,door,key) are too loud and they wish to have the chime volume lowered. Currently there is no procedure in SI-2000 to adjust the volume of the Chime.

Recommendation/Instructions:
Important: There was a radio supplier change at the beginning of the 2009 model year FOR ALL VEHICLES LISTED ABOVE, and we lost the ability to adjust the chime volume.

Here are the programs that have the chime volume adjustment feature:

Years and Models* Radio

2006 to 2008 Chevy Cobalt and Pontiac G5* (US8 and US9)

2006 to 2008 HHR* (US8 and US9)

2009 forward HHR* (UUI)

2008 Malibu* (US8 and US9)

2009 forward Malibu* (US9 and UUI)

2007 and 2008 Aura* (US8 and US9)

2009 forward Aura* (US9 and UUI)

2006 to 2008 Solstice* (US8 and US9)

2009 forward Solstice* (US9 and UUI)

2007 and 2008 Saturn Sky* (US8 and US9)

2009 forward Saturn Sky* (US9 and UUI)


Chime Level Adjustment:
The radio is used to adjust the vehicle's chime level. To change the volume level of the chime, press and hold push-button 6 with the ignition on and the radio power off.

The volume level will change from the normal level to loud, and LOUD will appear on the radio display. To change back to the default or normal setting, press and hold push-button 6 again. The volume level will change from the loud level to normal, and NORMAL will appear on the radio display.

Notice: Each time the chime volume is changed, three chimes will sound to indicate the new volume selected.

Here are the programs that do NOT have the chime volume adjustment feature.

Years and Models* Radio RPO's

2009 forward Chevy Cobalt and Pontiac G5* (US8 and UUI)

2009 forward HHR* (US8 )

2009 forward Malibu* (US8 )

2009 forward Aura* (US8 )

2009 forward Solstice* (US8 )

2009 forward Saturn SKY8 (US8 )

ChevyMgr
03-16-2009, 10:46 AM
Document ID: 2246377
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#: Information on Unblocking Front Passenger Seat Belt Retractor When Webbing Is Seized/Will Not Release - (Mar 12, 2009)


Subject: Information on Unblocking Front Passenger Seat Belt Retractor When Webbing Is Seized/Won't Release


Models: 2008-2009 Chevrolet HHR

Built Between April 1, 2008 and December 8, 2008

--------------------------------------------------------------------------------

The seat belt automatic locking retractor (ALR) is activated when the seat belt webbing is fully extracted. If this occurs in combination with the shoulder belt height adjuster being placed at the uppermost position, the retractor may become blocked. The customer will be able to return the seat belt webbing to its original position but will not be able to pull the webbing out again.

If this blocked condition is found, DO NOT replace the seat belt assembly.

4781


In order to unblock the retractor, push down on the release button (1) and slide the shoulder belt height adjuster towards its lowest position, until the ALR is unblocked. Pull out the webbing to verify that the retractor is releasing and working properly.

The customer should be instructed on the proper operation of the seat belts and how to unblock the retractor. You may wish to give the customer a copy of this bulletin for future reference.

ChevyMgr
03-16-2009, 10:54 AM
#08-08-44-024: Voice Recognition System Will Not Recognize Bluetooth Command - (Jun 27, 2008)


Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command


Models: 2009 Buick Enclave

2009 Cadillac CTS, SRX

2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse

2009 GMC Acadia, Sierra, Yukon

2009 Pontiac G5, Solstice, Torrent

2009 Saturn OUTLOOK, SKY, VUE

with UE1 (OnStar) but Without UPF (Bluetooth)


2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio)

--------------------------------------------------------------------------------

On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth:" is an option.

Description
Proper Operation
In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play.

If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS).

Typical Customer Experience
Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue:

• System Response: "Ready"


• Customer says, "Bluetooth"


• System Response: "Pardon"


• Customer says, "Bluetooth"


• System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye".


• Customer says, "Bluetooth"


• System Response: "Pardon"


• Customer says, "Bluetooth"


• System Response: "Thank you. Goodbye" and the session is ended.


Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command.

Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option.

ChevyMgr
03-19-2009, 09:13 AM
Document ID: 2247048
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#09-08-44-005: EI09063 - Radio Inoperative or No Display (Engineering Information) - (Mar 16, 2009)

Subject: EI09063 -- Radio Inoperative or No Display (Engineering Information)

Models: 2009 Chevrolet Cobalt, HHR, Malibu
2009 Pontiac G5, G6, Solstice
2009 Saturn AURA, SKY

All Equipped with Radio (RPO UUI or US8)



Attention: Proceed with this bulletin ONLY if the customer has commented about this concern AND the EI number is listed in GMVIS. If the customer has not commented about this condition or the EI does not show in GMVIS, disregard the bulletin and proceed with diagnostics found in published service information. THIS IS NOT A RECALL - refer to Service Bulletin 04-00-89-053B for more details on the use of Engineering Information bulletins.
--------------------------------------------------------------------------------

Condition
Some customers may comment that the radio does not turn on/is inoperative or that the display does not illuminate when the radio is turned on and the audio is operating properly.

Cause
GM Engineering is attempting to determine the root cause of the above condition. Radios which have been replaced for being inoperative or having no display have not exhibited either condition during the root cause analysis. There is a possibility that removing the radio from the vehicle and disconnecting the power will reset the radio.

Correction
Important: DO NOT attempt to diagnose or repair the radio. Avoid clearing codes or disconnecting the radio. If the radio is currently exhibiting this condition, it is very important that the radio is not disturbed.

Prior to attempting diagnosis or repair of a radio with this condition, contact one of the GM engineers listed below with the details.

ChevyMgr
03-19-2009, 09:22 AM
-------------------------------------------------------------------------------
Date: 03/19/2009 Ref. number: Service / Service Operations / G_0000024352
Subject: Rear Console Cup Holder Liner Removed 2009 Chevrolet HHR

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GM SERVICE AND PARTS OPERATIONS

GMSO19

URGENT - DISTRIBUTE IMMEDIATELY



Date: March18, 2009
Subject: Rear Console cup holder liner removed

Models: 2009 Chevrolet HHR



To: Chevrolet Dealers in U.S.A

Attention: Sales & Service Managers

ANNOUNCEMENT:

General Motors is announcing that the rear of console cup holder liner has been removed on all Chevrolet HHR’s built after March16, 2009. Please share this information with all sales staff and service technicians.

ChevyMgr
03-24-2009, 07:38 AM
#PIP4609: Coolant Leak From Water Pump O-Ring - (Mar 23, 2009)


Subject: Coolant Leak From Water Pump O-ring


Models: 2009 Chevrolet Cobalt SS

2009 Chevrolet HHR SS

2009 Saturn Sky Redline

2009 Pontiac Solstice GXP

With 2.0L RPO LNF

2009 Chevrolet Cobalt (Including XFE)

2009 Pontiac G5 (Including XFE)

With 2.2L RPO LAP

2009 Chevrolet Malibu BAS Hybrid

2009 Saturn Vue BAS Hybrid

With 2.4L RPO LAT

2009 Chevrolet HHR

2009 Chevrolet Malibu

2009 Pontiac G6

2009 Pontiac Solstice

2009 Saturn Sky

2009 Saturn Aura

2009 Saturn Vue

With 2.4L RPO LE5

2009 Chevrolet HHR

With 2.2L RPO LE8

2009 Chevrolet HHR

With 2.4L RPO LE9
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A technician may comment of coolant loss in the water pump area, usually at PDI. The leak may be more prevalent with cold ambient temperatures.

Recommendation/Instructions:
Confirm coolant leak at water pump to block interface.
Run vehicle to operating temperature and let cool; repeat this procedure 2 times. Inspect area for leakage.
• a. If the suspected leak has stopped no further action is needed. Return vehicle to service.

• b. If the concern is still present continue to step #3.


Caution: HOT COOLANT COULD SPRAY IF CAP IS FULLY REMOVED.


Carefully Loosen coolant cap to relieve pressure, tighten cap after pressure relief.
Loosen the four bolts (two on front of engine, two on rear of pump) on the water pump (approx 360°) but do not fully remove.

4789

Torque the bolts to 25nm +/- 4nm (18.5 FT/LB +/- 3 ft. lbs) in the following sequence.
• 1. Top bolt on front of engine.

• 2. Lower bolt on rear of water pump.

• 3. Lower bolt on front of engine.

• 4. Upper bolt on rear of water pump.


Note: A crows foot may be used (where required) to ensure the torque value is met.


Top coolant in surge tank to cold full mark.
Clean and ensure all residual evidence of leaks is removed from top and lower section of water pump.
Pressure check and run vehicle to operating temperature to check for coolant leak at water pump to block joint. Let vehicle cool and heat cycle 2 additional times.
• a. If the suspected leak has stopped no further action is needed. Return vehicle to service.

• b. If a leak is still present from the o-ring area after the re-torque of the water pump, the water pump o-ring will need to be replaced. Make sure to follow the sequential torque procedure listed above when replacing the o-ring.

ChevyMgr
03-25-2009, 07:53 AM
#09-08-50-007: Toe Kick Panel of Front Seat Cushion Cover Loose or Hanging Unsecured (Reattach with Tie Straps) - (Mar 24, 2009)


Subject: Toe Kick Panel of Front Seat Cushion Cover Loose or Hanging Unsecured (Reattach with Tie Straps)


Models: 2006-2009 Chevrolet HHR

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Condition
Some customers may comment that the toe kick panel of the driver or passenger front seat cushion cover is loose or hanging unsecured.

Cause
This condition may be caused by the J-channel clips, which retain the toe kick panel to the seat cushion frame, releasing from the frame. The retention strength of the clip may not be sufficient enough to keep it securely retained.

Correction

http://www.chevyhhr.net/gallery/files/4/8/6/5/s1.gif


Important: The toe kick panel of the front seat cushion cover may be one of two designs. Visually verify which design the seat cover has. If the toe kick panel is the "strap and hook" design (shown above), and exhibits damage, the seat cushion cover would have to be replaced. The following repair is specific to toe kick panels with the J-channel design.

Important: If the above condition is noted on a front seat cushion cover with J-channels, repair following the steps below. DO NOT replace the front seat cushion cover.

Drill holes through the toe kick panel J-channels (one each side) and re-secure the panel with tie straps using the following steps:

Slide the seat fully forward.

http://www.chevyhhr.net/gallery/files/4/8/6/5/s2.gif

Disengage the toe kick cover panel from the seat cushion frame, and flip the panel over to expose the J-channels (1).

http://www.chevyhhr.net/gallery/files/4/8/6/5/s3.gif

Drill a 6.35 mm (1/4 in) diameter hole through the J-channel and fabric on each side. Ensure that the hole is centered in the J-channel as shown above.

http://www.chevyhhr.net/gallery/files/4/8/6/5/s4.gif

Tip
Once installed and trimmed, the tie strap length is much shorter than the starting 355 mm (14 in) length. A shorter tie strap can be used, however the longer tie strap may be easier to get in position while working under the seat.

Insert a tie strap, obtained locally, into each hole in the toe kick panel. Approximate size of the tie strap should be 4.75 mm (0.187 in) width and 355 mm (14 in) length.

http://www.chevyhhr.net/gallery/files/4/8/6/5/s5.gif

Reposition the toe kick panel and secure the two tie straps to the underside of the seat cushion.

http://www.chevyhhr.net/gallery/files/4/8/6/5/s6.gif

Important: The seat cushion above has been removed for illustration purposes.


5.1. Slide each tie strap under the suspension wire of the seat cushion as shown above. Tighten the tie straps, ensuring that the toe kick panel fabric is straight and taut.

http://www.chevyhhr.net/gallery/files/4/8/6/5/s7.gif



5.2. Clip off the excess strap with wire snips.

ChevyMgr
03-27-2009, 09:30 AM
#08-07-29-001D: EI08046 - Manual Transmission Grinds in Either Third or Fourth Gear When Clutch is Fully Disengaged (Replace 3rd and 4th Gear Sleeve Hub Assembly, Speed Gear Assemblies and Shift Fork) - (Mar 26, 2009)


Subject: EI08046 - Manual Transmission Grinds in Either Third or Fourth Gear When Clutch is Fully Disengaged (Replace 3rd and 4th Gear Sleeve Hub Assembly, Speed Gear Assemblies, and Shift Fork)


Models: 2008 Chevrolet Cobalt, HHR

2008 Pontiac G5

Equipped with Manual Transmission (RPO M86)

Prior to the Serial Numbers Shown Below
--------------------------------------------------------------------------------

This bulletin is being revised to update service procedure and include additional service parts. Please discard Corporate Bulletin Number 08-07-29-001C (Section 07- Transmissions)


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Models
Transmission P/N Transmission Serial Number

Cobalt XFE 24248018 61 YEH 08058387

Cobalt, G5 (STD) 24241747 61 YED 08083169

HHR 24241746 61 YEC 08062188


Condition
Some customers may comment on a grinding noise in third or fourth gear when the clutch is fully disengaged.

Cause
Based on feedback provided by dealer technicians, engineering was able to determine the manual transmission grinding in 3rd or 4th gear. It is possible to correct the condition by replacing the 3rd and 4th Gear Sleeve Hub Assembly, Speed Gear Assemblies, and Shift Fork

Correction

http://www.chevyhhr.net/gallery/files/4/8/6/5/t1.gif

http://www.chevyhhr.net/gallery/files/4/8/6/5/t2.gif

Check the Transmission Serial Number label to determine if the transmission is built prior to the chart above. The Transmission Serial Number label is located on the back side of the transmission between the halfshafts. If the transmission is built prior to the chart above, then replace the 3rd and 4th Gear Sleeve Hub Assembly, Speed Gear Assemblies, and Shift Fork.

Parts Information
Part Number Description

89060051 HUB ASM, 3RD & 4TH GR SYN

93321261 GEAR ASM, 3RD

93321267 GEAR ASM, 4TH

93368559 FORK ASM, 3RD & 4TH SHFT

19207672 RING, BLOCKER (Qty 2)

ChevyMgr
03-27-2009, 09:38 AM
#PIP4611: Misfire Smoking And/Or No Heat With Loss Of Coolant - (Mar 25, 2009)


Subject: Misfire, Smoking and/or No Heat With Loss of Coolant


Models: 2009 Chevrolet Malibu and HHR

2009 Pontiac G6 and Solstice

2009 Saturn Aura and Sky

Equipped With 4 Cylinder Ecotec Engine RPO's LE5 and LE9
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
On rare occasions, a low coolant light may be experienced due to a low coolant level. However, no visible leaks will be present upon inspection. A brief engine misfire and DTC P0300 or P0304 may also be experienced immediately after the engine is started. If the coolant level is low enough, a loss of heat from the HVAC may be experienced and DTCs P0117 or P0128 may be stored.

Recommendation/Instructions:
If this concern is experienced with no sign of an external leak, perform each step of the SI diagnostics for "Loss of Coolant" and repair as necessary. If there is no problem found after following the diagnostics, pressurize the cooling system again and allow the engine to hot soak for up to 2 hours. If the pressure decays, remove the #4 spark plug and use a bore scope to inspect the top of the piston for any sign of coolant. If a bore scope is not available, place the piston at bottom dead center and inspect the visible area of the piston top through the spark plug hole using a pen light. If there is any sign of coolant on the top of the piston, remove the cylinder head and inspect the face for damage in the area around the #4 cylinder fire ring. If damage is found replace the cylinder head. See illustration callout #1 below for location/example of damage.
http://www.chevyhhr.net/gallery/files/4/8/6/5/H1.gif

ChevyMgr
04-01-2009, 01:34 PM
#08-09-41-006B: SIR/Airbag Light Illuminated, DTC B0081 (Passenger Presence System (PPS) Code) Stored (Inspect PPS System Connectors) - (Mar 27, 2009)


Subject: SIR/Airbag Light Illuminated, DTC B0081 (Passenger Presence System (PPS) Code) Stored (Inspect PPS System Connectors)


Models: 2006-2009 Chevrolet Cobalt, HHR

2006 Pontiac Pursuit (Canada Only)

2007-2009 Pontiac G5
--------------------------------------------------------------------------------

This bulletin is being updated to correct the component location. Please discard Corporate Bulletin Number 08-09-41-006A (Section 09 - Restraints).


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Condition
Some customers may comment that the SIR light is illuminated.

Upon investigation, the technician may find the following Passenger Presence System codes stored:

• DTC B0081 3A: Passenger Presence System Incorrect Component Installed

• DTC B0081 39: Passenger Presence System Internal Electronic Failure

• DTC B0081 71: Passenger Presence System Invalid Serial Data Received

With Passenger Presence System (PPS) Flash Code of DTC 023

Note: You will only find DTC 023 by going through the (PPS) menu

Correction
Technicians are to inspect the electrical connections to all the PPS components.

Inspect the PPS module connector, the pressure sensor connector and the seat connector (all located under the front passenger seat).
Inspect the connector of the belt tension sensor (BTS) that is part of the retractor assembly (Located under the trim near the bottom of the center pillar on the passenger side of vehicle).
Clear the codes.
Verify that the DTC does not reset.

ChevyMgr
04-01-2009, 01:37 PM
#09-08-44-009A: Radio Will Not Display Accurate XM Station/Song/Artist Information (Replace Radio) - (Apr 16, 2009)


Subject: Radio Will Not Display Accurate XM Station/Song/Artist Information (Replace Radio)


Models: 2009 Chevrolet HHR

Equipped with Radio (RPO UUI)

Please Refer to GMVIS



Attention: This condition only affects the following radio part numbers: 25964501 or 25964502. If the radio does not have either of these part numbers, this bulletin is not applicable.
--------------------------------------------------------------------------------

This bulletin is being revised to add an Attention statement. Please discard Corporate Bulletin Number 09-08-44-009 (Section 08 -- Body and Accessories).
--------------------------------------------------------------------------------

Condition
Some customers may comment that when the radio is in XM mode, the station name, artist and song display information is intermittent or not available.

They may also comment that when they select a different station, the information displayed does not change.

Cause
This condition may be caused by an internal software anomaly that prevents the radio from receiving the information from the XM module.

Correction
A radio with revised software has been released to address this condition. Technicians are to remove and replace the radio if this condition is present. Refer to Radio Replacement in SI.

Parts Information
DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center to obtain the radio. Refer to Corporate Bulletin Number 08-08-44-029A - Updated Warranty and Goodwill Exchange Program for Electronic Products.

Part Number Description

20788673 Radio, AM/FM Stereo & Clk & MP3 Player & Aux In & USB (2nd Des) (incls 5-8) (Ebony)

20788674 Radio, AM/FM Stereo & Clk & MP3 Player & Aux In & USB (2nd Des) (incls 5-8) (Gray)

ChevyMgr
04-02-2009, 03:45 PM
#09-06-01-004: Clicking/Ticking Sound/Noise Heard from Rear of Engine (Install Sound Isolation Cover Over High Pressure Fuel Pump) - (Apr 1, 2009)


Subject: Clicking/Ticking Sound/Noise Heard From Rear of Engine (Install Sound Isolation Cover Over High Pressure Fuel Pump)


Models: 2008-2009 Chevrolet Cobalt, Cobalt SS, HHR, HHR SS

2007-2009 Pontiac Solstice GXP

2007-2009 Saturn SKY Redline

2007-2009 Opel GT

2007-2009 Daewoo G2X

Equipped with 2.0L Engine (VIN X -- RPO LNF)
--------------------------------------------------------------------------------

Condition
Some customers may comment on a ticking sound from the rear of the engine. Upon investigation, the technician may find the sound coming from the high pressure fuel pump and/or the injectors.

Cause
The 2.0L turbo engine (VIN X - RPO LNF) uses a direct injection fuel system that operates at very high fuel pressures. A direct injection fuel system produces a rapid, clicking/ticking sound that can be heard from the engine compartment. The sound is more evident when outside around the vehicle or when the hood is open. The sound is more noticeable during idle, and is more frequent during a cold start but lessens once the engine is warm. The rapid ticking noise on cold start up is the fuel pump (located on the rear of the cylinder head) building up high fuel pressure. When the engine warm-up is completed, the high pressure fuel pump will continue to tick at a lower rate of approximately one tick per second during idle. The clicking sound is the fuel injectors pulsing on and off under higher fuel pressures. These sounds are the results of a normal direct injection fuel system operating properly.

Correction
Install a sound isolation cover over the high pressure fuel pump following the procedure below. This will make the sound coming from the high pressure fuel pump less noticeable, but it will not completely eliminate it.

Important: DO NOT attempt to replace any parts for this kind of clicking or ticking concern.

Verify the noise is coming from the high pressure fuel pump.
Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement in SI.
Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
Remove the engine wiring harness from the high pressure fuel pump cover bracket.

4824

Remove the high pressure fuel pump cover bolts (1).
Remove the high pressure fuel pump cover bracket.

4825

Remove the old design cover and install the new high pressure fuel pump insulator, GM P/N 12628069.
Position the high pressure fuel pump cover bracket. Install the high pressure fuel pump cover bolts.
Tighten
Tighten the bolts to 10 N·m (89 lb in).

Connect the engine wiring harness electrical connector to the high pressure fuel pump.
Attach the engine wiring harness to the fuel pump cover bracket using a zip tie.
Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement in SI.
Parts Information
Part Number Description Qty

12628069 Insulator/PMP 1

ChevyMgr
04-09-2009, 08:04 AM
#07-07-30-005C: 4T45 Transmission, MIL/SES On, DTC P1818, Power Door Locks, Cruise Control, Shift Interlock or Retractable Hardtop Inoperative, Engine Speed Revs Limited, Hybrids-Autostop Regen or Boost Inoperative - (Apr 8, 2009)


Subject: 4T45 Transmission, MIL/SES On, DTC P1818, Power Door Locks, Cruise Control, Shift Interlock or Retractable Hardtop Inoperative, Engine Speed Revs Limited, Hybrids-Autostop, Regen or Boost Inoperative (Reprogram TCM)


Models: 2006-2007 Chevrolet Cobalt, HHR

2007 Chevrolet Malibu

2006 Pontiac Pursuit (Canada)

2006-2007 Pontiac G6

2007 Pontiac G5

2007 Saturn AURA, ION, VUE, VUE Hybrid

with 4T45 Automatic Transmission (RPOs MN5, ME7)




--------------------------------------------------------------------------------

This bulletin is being revised to add the 2006 model year for Cobalt, Pursuit, G6, and HHR. Please discard Corporate Bulletin Number 07-07-30-005B (Section 07-Transmission/Transaxle).


--------------------------------------------------------------------------------

Condition
Some customers may comment on the illumination of the Malfunction Indicator Lamp (MIL) or the Service Engine Soon (SES) light, the power door locks, cruise control, shift interlock, retractable hardtop being inoperative and engine speed revs limited to 4,000 RPM in first gear after a cold start or cold soak with temperatures between 0° to 10°C (32°F to 50°F).

Customers with hybrid vehicles may also comment on the following conditions:

-- Hybrid Autostop, regen or boost inoperative

Cause
These conditions may be caused by the TCM setting a false DTC P1818 (Transmission Fluid Pressure (TFP) Valve Position Switch Indicates Drive without Drive Ratio).

Correction
Verify the conditions and reprogram the transmission control module (TCM) with the new updated calibration using the procedure below.

Check for DTCs.
Clear DTC P1818.
Start the engine.
Apply the brake pedal.
Place the transmission in reverse.
With a Tech 2®, monitor the transmission fluid pressure (TFP) switch parameter.
• If the TFP parameter indicates Reverse, reprogram the TCM with the updated calibration.

• If the TFP parameter indicates Park/Neutral, refer to DTC P1818 in SI for further diagnosis.

Important: Confirm the newest calibration includes the "false P1818 fix".

An updated TCM calibration is now available to address this concern. This calibration, or any that follow, is designed to address this concern. Reprogram the TCM with the software now available in the TIS2WEB using the Service Programming System (SPS).

If you cannot access the calibration, call the Techline Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be provided. As always, make sure your Tech 2® Diagnostic Scan Tool is updated with the latest software version.

Clear any codes and verify the condition has been fixed.

ChevyMgr
04-09-2009, 08:05 AM
#09-07-30-009: EI09082 - Transmission Will Not Move, No Reverse or Slips (Engineering Information) - (Apr 7, 2009)


Subject: EI09082 -- Transmission Will Not Move, No Reverse or Slips (Engineering Information)


Models: 2008-2009 Chevrolet Cobalt, HHR, Malibu

2008-2009 Pontiac G5, G6

2008-2009 Saturn AURA, VUE

All Equipped with 4T45-E Automatic Transmission (RPO MN5 or ME7)



Attention: Proceed with this bulletin ONLY if the customer has commented about this concern AND the EI number is listed in GMVIS. If the customer has not commented about this condition or the EI does not show in GMVIS, disregard the bulletin and proceed with diagnostics found in published service information. THIS IS NOT A RECALL -- refer to Service Bulletin 04-00-89-053B for more details on the use of Engineering Information bulletins.



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Condition
Important: If the customer did not bring their vehicle in for this concern, DO NOT proceed with this bulletin.

Some customers may comment on an automatic transmission concern of no movement, no reverse or slipping.

These concerns may be due to an issue with the direct clutch.

Cause
GM Engineering is attempting to determine the root cause of the transmission direct clutch concerns. Engineering has a need to gather information on vehicles, PRIOR to repair, that may exhibit these conditions. As a result, this information will be used to "root cause" the customer's concern and develop/validate a field fix.

Instructions
If a vehicle is encountered with a transmission condition of no movement, no reverse, or slipping, verify the concern. Prior to any vehicle disassembly, please contact the engineering listed below for additional instructions related to diagnosis and repair. After the repair, engineering may request parts back. Parts will be requested back using the WPC return process. Do ship until a request form has been received from WPC.

The engineer may also want to visit dealerships that are located near Detroit, Michigan.

Contact Information
Chris Preston @
If the engineer is unable to take your call, please leave the following information in a message:

• Technician Name


• Dealer Name, City, State and Phone Number


• Complete VIN and Repair Order Number


If you do not receive a response from engineering within two hours, proceed to repair the vehicle according to SI.

© 2009 General Motors Corporation. All rights reserved.

ChevyMgr
04-09-2009, 08:06 AM
#PIC5139A: Buzz Noise During Call When Using Bluetooth - (Apr 2, 2010)


Subject: Buzz noise during call when using Bluetooth®


Models: 2008 - 2009 Cadillac CTS, CTS-V

2009 Buick Enclave, Lacrosse, Lucerne

2009 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT, SRX, XLR

2009 Cadillac STS with RPO YQ1 or YQ2

2009 Chevrolet Cobalt, Corvette, Equinox, HHR, Impala, Malibu, Silverado, Suburban, Tahoe, Trailblazer, Traverse

2009 GMC Acadia, Envoy, Sierra, Yukon, Yukon XL

2009 Hummer H2. H3

2009 Pontiac G5, G6, Solstice, Torrent

2009 SAAB 9-7x

2009 Saturn Aura, Outlook, Sky, Vue

2010 Chevrolet Camaro
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
On any vehicle equipped with OnStar® (UE1) & Bluetooth® (UPF), an EMC buzz can be heard from the land-line side only of the phone during a Bluetooth® phone call made with an older model GSM phone. The buzz is only heard with older model GSM phones and is dependent on the distance of the phone from the microphone. The newer 3G GSM phones or other cellular phones (CDMA, TDMA, etc) have not shown this concern.

Recommendation/Instructions:
A new microphone has been developed to address to the EMC buzz from GSM phones. Replace the microphone with p/n 20951265

A service bulletin for this concern will be released in the near future.

ChevyMgr
04-09-2009, 12:29 PM
#PIT3173A: Information On Testing Centers For Fluid Contamination Analysis - keywords axle brake coolant differential engine facility fuel gas gasoline gear hydraulic oil power R12 R134 R134A refrigerant spec - (Nov 11, 2008)


Subject: Information On Testing Centers For Fluid Contamination Analysis


Models: All GM Passenger Cars and Light Duty Trucks

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Inquiries on fluid contamination may be directed to one of the following testing centers according to the category of fluid being tested.

Recommendation/Instructions:
For the testing of Oil, Fuel, and Coolant Contamination:



Cleveland Technical Center

18419 Euclid Ave.

Cleveland, OH 44112-1016

1-800-726-540

For the testing of Oil, Coolant, Fuels, Transmission, and All hydraulic Fluids including Power Steering.

Southwest Research Institute

6220 Culebra Rd.

P.O Drawer 28510

San Antonio, Texas 78238-5166

Contact: Janet Barker 210-522-6924 or Mike Birke 210-522-5310


For the testing of Oil, Coolant, Fuels, Transmission, and All hydraulic Fluids including Power Steering, Brake Fluid, and Refrigerants.

Analyst, Inc.

2450 Hassell

Hoffman Estates, Ill 60195

1-708-884-7877

1-800-222-0071

ChevyMgr
04-10-2009, 10:45 AM
#07-06-04-019A: Intermittent MIL/SES, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) - (Nov 6, 2008)


Subject: Intermittent MIL/SES, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)


Models: 2005-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn)

2005-2008 HUMMER H2

2006-2008 HUMMER H3

2005-2008 Saab 9-7X
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Condition
Some customers may comment on an intermittent MIL/SES light Illuminated with a message center or an indicator that displays Reduced Engine Power. DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation may be set. The voltage difference between APP sensor 1 and APP sensor 2 exceeds a predetermined value for more than a brief period. Refer to DTC P2138 in SI for further diagnostics.

Cause
On some vehicles, the IP to body harness connector, which carries the APP signal to the ECM/PCM, is located in the left hand kick panel area or inside the IP. Water intrusion into these areas could cause an electrical short in the APP circuits setting a P2138 code.

Correction
Note: Make sure that no add-on/aftermarket equipment is electrically connected to the APP signals or to the other ECM/PCM five volt reference or return lines. These can generate false P2138 and/or other ETC System DTCs. If there are other engine DTCs besides P2138, such as MAP sensor faults (i.e. P0107, P0108), resolve these first before attempting to diagnose P2138 DTCs.

Important: Refer to DTC P2138 in SI to confirm that the ETC pedal is operating correctly.

Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Check to see if there is a water leak into the area and repair as necessary. Use a water hose to determine the source of a water leak and effectiveness of repair. Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if so equipped) and windshield/cowl sealing. Finally, repair or replace the IP to body harness connector, making sure no corrosion or debris is left on or between the terminals.

ChevyMgr
04-10-2009, 11:37 AM
#08-09-41-007B: Passenger Presence System (PPS) May Command Passenger Airbag Indicator and Seat Belt Reminder On When Electronic Devices (Computers, MP3 Players, Cell Phones, Tech 2, etc.) are Placed on Front Seat - (Jun 2, 2009)


Subject: Passenger Presence System (PPS) May Command Passenger Airbag Indicator and Seat Belt Reminder On When Electronic Devices (Computers, MP3 Players, Cell Phones, Tech 2®, etc.) Are Placed on Front Passenger Seat, DTCs 5045, B0074 0F, B101D or B0081 Set


Models: 2009-2010 Buick Enclave

2009-2010 Cadillac CTS

2009-2010 Chevrolet Cobalt (except SS model), HHR (except SS model), Impala, Traverse

2010 Chevrolet Equinox

2009-2010 GMC Acadia

2009-2010 Saturn OUTLOOK

2010 Saturn VUE
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This bulletin is being revised to add Tech 2® and DTCs to the subject line, update the model years and add Warranty Information. Please discard Corporate Bulletin Number 08-09-41-007A (Section 09 -- Restraints).


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Dealers should be aware that when certain electronic devices (computers, MP3 players, cell phones, Tech 2®, etc.) are placed on the front passenger seat, the front passenger airbag indicator may illuminate. The seat belt reminder light/chime may also be activated. This is due to the fact that some electronic devices placed on the front passenger seat may interfere with the electric field generated by the PPS system, causing it to enable (turn ON) the passenger airbag and turn on the safety belt reminder light and chime - even though the seat is not occupied. The electronic device does not necessarily need to be turned on to cause this condition. DTCs 5045, B0081 0F, B0074 0F or B101D may set depending on the vehicle. If you remove the electronic device from the front passenger seat, the DTC will go into history. If this happens, clear all SDM and PPS DTCs. If the DTC is still current, follow the service procedure in SI for that DTC. If the DTCs do not return, no repair is needed (do not replace any parts for this condition).

Note: Never rest the Tech 2® on the passenger front seat or touch the passenger front seat while the Tech 2® is in contact with your body. This will cause the SIR lamp to illuminate while holding the Tech 2® because your body can transfer the electronic "noise" from the Tech 2® to the sensor mat in the passenger front seat.

Please advise the customer to avoid placing the electronic device in the front passenger seat in the future.

ChevyMgr
04-13-2009, 06:33 PM
#08-03-16-001B: Key Fobs Inoperative, TPM System Not Reading Correctly - Dashes on Al Four Tire Readings, DTCs C0775, C0569, B3105 Set, Unable to Program TPM Sensors (Reprogram RCDLR) - (Jul 31, 2008)


Subject: Key Fobs Inoperative, TPM System Not Reading Correctly - Dashes On All Four Tire Readings, DTCs C0775, C0569, B3105 Set, Unable to Program TPM Sensors (Reprogram RCDLR)


Models: 2008 Chevrolet Cobalt, HHR, Malibu

2008 Pontiac G5, G6, Solstice

2008 Saturn AURA, SKY

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This bulletin is being revised to update the Important statement to reflect the new direction to no longer contact TCSC. Please discard Corporate Bulletin Number 08-03-16-001A (Section 03 - Suspension).


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Condition
Some customers may comment that the key fobs are inoperative or that the TPM system is showing dashes as the reading for all four tires.

Technicians may find DTCs C0775, C0569 and B3105 set simultaneously in the RCDLR module.

In addition, the technicians may find Tire Pressure Monitoring sensors are unable to be programmed to the vehicle by adding or releasing pressure to the tire while the vehicles in the TPM learn mode.

Cause
These conditions may be caused by the following:

• The RCDLR may lose its transmitter and tire pressure monitoring data from its memory if a low voltage condition occurs on the vehicle.

• The ability for TPM learning by adding or releasing pressure to the tire has been disabled in the RCDLR.

Correction
Reprogram the RCDLR with an updated software calibration to address both issues listed above. This new service calibration is available on TIS2WEB using Service Programming System (SPS). As always, make sure your Tech 2® is updated with the latest software.

Important: If the Tech 2® could not establish communication with the RCDLR AND the programming event ended with error, attempt to reprogram in Service Programming System (SPS) by selecting "Remote Control Door Lock Receiver (TSB 08-03-16-001) with E4399 error -- Pass Thru Only".

Once the RCDLR module has been reflashed with the latest software and calibrations, the following may also be necessary:

• Relearn all keyless entry transmitters.

• Reconfigure the tire pressure placards and the tire type.

• Relearn the tire pressure sensors.

Refer to SI for the procedures to relearn transmitters, placard and tire type configuration and tire pressure sensor learn.

ChevyMgr
04-17-2009, 11:57 AM
#09-00-89-016: Warranty Administration - Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications - (Mar 31, 2009)


Subject: Warranty Admin - Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications


Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab)

2010 and Prior HUMMER H2, H3

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The purpose of this warranty administration bulletin is to provide retail and wholesale service personnel with the policies/procedures and the warranty claims submission procedures that support the suspicion of tampering to a vehicle's electrical, chassis/body or propulsion system.

Labor Operation Z1111 - Suspected Tampering
Effective January 1, 2009 a new labor operation Z1111, Documentation of Vehicle Tampering or Non-GM Vehicle Modifications can be used to reimburse the dealership for the time used to identify and document customer concerns that the dealership has determined are the result of tampering or non-GM vehicle modifications to a vehicle.

Tampering is defined as causing intentional damage to a vehicle and is not covered under the terms of the GM New Vehicle Limited Warranty.

Tampering can include, but is not limited to:

• inducing an electrical components and/or system failures

• disconnecting wires or connectors

• intentional contamination of fluids

Non-GM vehicle modifications include, but are not limited to:

• installation of non-GM accessories

• installation of suspension lowering or lift kits

• installation of aftermarket tires and/or wheels

• installation of "power-up chip" and/or non-GM control module calibrations.

The new Z1111 labor operation is to be used to reimburse the dealership for identifying and documenting tampering or non-GM vehicle modifications. If tampering and/or non-GM vehicle modifications are suspected as the root cause for a customer's concerns, please follow the guidelines below:

• When the Z1111 labor operation is used, thoroughly document the repair order to support the use of the Z1111 labor operation. All straight time must be documented and verified.

• The Z1111 labor operation can be used independently.

• The repair order must be accurately documented with the facts supporting the condition, including photographs or other documentation as appropriate.

• Notify the District Service Manager (DVM) of the situation.

If the dealership management decides, in the interest of customer satisfaction, to perform repairs related to tampering or non-GM vehicle modifications, the repair order must clearly document that the work performed is not being done to correct a warrantable defect in material or workmanship.

Claims should be submitted using the appropriate labor operation and the dealer must use failure code 98 (Customer Satisfaction) or the Customer Satisfaction box in Global Warranty Management.

If additional time and/or parts are to be charged to GM, use the appropriate labor operation as if it were a defect in material or workmanship. When submitting such a claim, failure code 98 (Customer Satisfaction) must be used. All documentation must clearly indicate that these are not repairs performed under the terms of the New Vehicle Warranty.

Service management must be involved in any situation that would justify the use of labor operation Z1111 and all claims will have to be "H" routed to the District Service Manager for approval.

With the proper documentation, and with the assistance of your Zone Team members, it may be appropriate to initiate the Warranty Block procedures outlined in the GM Service Policy & Procedures Manual, section 1.4.14 (Voided Warranties and Branded Titles).

ChevyMgr
04-17-2009, 12:11 PM
#09-08-44-008A: Radio Will Not Communicate with Generation 2 iTouch Device (Replace Radio) - (Apr 16, 2009)


Subject: Radio Will Not Communicate with Generation 2 iTouch Device (Replace Radio)


Models: 2009 Chevrolet HHR

Equipped with Radio (RPO UUI)

Built Between June 2008 and December 2008 Only

Please Refer to GMVIS

Attention: This condition only affects the following radio part numbers: 25964501 or 25964502. If the radio does not have either of these part numbers, then this bulletin is not applicable.
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This bulletin is being revised to add an Attention statement. Please discard Corporate Bulletin Number 09-08-44-008 (Section 08 -- Body and Accessories).
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Condition
Some customers may comment that when they connect their Generation 2 iTouch device to the vehicle radio, they will not communicate.

Cause
This condition may be caused by a change in the communication protocol between the radio and the device.

Correction
Important: If the customer is experiencing this concern with a Generation 1 iTouch device, then the device needs the latest firmware installed. Instruct the customer to upgrade their device at the iTunes website.

Confirm that the customer has the Generation 2 iTouch device by verifying the model number of the device before replacing the radio.
A radio with revised software has been released to address this condition. Technicians are to remove and replace the radio if this condition is present. Refer to Radio Replacement in SI.
Parts Information
DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center to obtain the radio. Refer to Corporate Bulletin Number 08-08-44-029A - Updated Warranty and Goodwill Exchange Program for Electronic Products.

Part Number Description

20788673 Radio, AM/FM Stereo & Clk & MP3 Player & Aux In & USB (2nd Des) (incls 5-8) (Ebony)

20788674 Radio, AM/FM Stereo & Clk & MP3 Player & Aux In & USB (2nd Des) (incls 5-8) (Gray)

ChevyMgr
04-20-2009, 12:49 PM
#PIC4578E: EPS/STR Wheel Control Fuse (19) Open - (Oct 20, 2009)


Subject: EPS/STR Wheel Control Fuse (#19) Open


Models: 2005-2009 Chevrolet Cobalt

2006-2009 Chevrolet HHR

2005-2006 Pontiac Pursuit (Canada Only)

2007-2009 Pontiac G5
--------------------------------------------------------------------------------

This PI was superseded to remove Admin Details requiring contact with BQM on issue. Please discard PIC4578D.


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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A customer might complain that their power steering system is in "Default mode" and/or their Steering Wheel Radio Controls are inoperative. A condition has been identified through TAC cases where a common area for a wiring Short To Ground (STG) exists that could cause the EPS/STR Wheel control fuse to open.

Recommendation/Instructions:
There are two known locations where a short to ground is possible

First check for a short to ground in circuit # 1539 (PNK) wire behind the radio. This circuit has reportedly been shorted on the radio mounting bracket, and just below the radio bracket almost to the BCM mounting location.

Note: For ease of locating this possible short remove the radio, HVAC control head, and the upper console trim panels and inspect for wiring/brace contact.

Second check for a short to ground in circuit # 339 (PNK) wire behind the driver's side air bag.

ChevyMgr
04-21-2009, 09:03 AM
#08-08-49-017B: Instrument Panel Cluster (IPC) Gages Inoperative, Erratic/Inaccurate Gauge Readings (Reprogram IPC) - (Apr 20, 2009)


Subject: Instrument Panel Cluster (IPC) Gages Inoperative, Erratic/Inaccurate Gauge Readings (Reprogram IPC)


Models: 2008 Buick Enclave

2008 Chevrolet Equinox, HHR, Malibu (excluding Malibu Classic)

2008 GMC Acadia

2008 Pontiac Torrent

2008 Saturn AURA, OUTLOOK
--------------------------------------------------------------------------------

This bulletin is being revised to include the HHR models. Please discard Corporate Bulletin Number 08-08-49-017A (Section 08 - Body and Accessories).
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Condition
Some customers may comment that the instrument gages appear to be erratic/inaccurate or are inoperative.

This condition may be intermittent and occur over one or multiple ignition cycles, eventually resetting itself.

Cause
A software anomaly within the IPC allows the microprocessor to lose communication with the gage temporarily.

Correction
Do This
Reprogram the instrument panel cluster (IPC).

Don't Do This
Do not replace the instrument panel cluster (IPC).


A revised calibration has been developed to correct this condition. Technicians are to reprogram the instrument panel cluster (IPC) using SPS with the latest software available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI. As always make sure your Tech 2® is updated with the latest software version.

ChevyMgr
04-23-2009, 10:41 AM
#08-06-04-001B: Check Engine Light On, DTCs P0171, P0300, P1174 Set (Perform Injector Test, Replace Injectors and Reprogram ECM, If Necessary) - (Apr 21, 2009)


Subject: Check Engine Light On, DTCs P0171, P0300, P1174 Set (Perform Injector Test, Replace Injectors and Reprogram ECM, if Necessary)


Models: 2006-2007 Chevrolet Cobalt, HHR

2006 Pontiac Pursuit (Canada)

2007 Pontiac G5, G6

2006-2007 Saturn ION

with 2.4L Engine (VIN B, P - RPO LE5)

Condition
Some customers may comment on the check engine light being illuminated.

A scan tool may reveal DTC P0171, P0300 or P1174 set as current or in history.

Cause
This condition may be caused by the plugging of one or more of the injector director plate orifices which results in a lean condition.

Correction
Important: This condition cannot be corrected by cleaning the injector(s).

Important: For Chevrolet and Pontiac vehicles, reprogramming must be done using the remote method.

For Saturn vehicles, reprogramming must be done using the pass-through method.


Follow the published diagnostics in SI for any DTC recorded.

Perform an injector balance test using the Active Fuel Injector Tester (AFIT), CH-47976. Refer to the Fuel Injector Diagnosis (w/CH47976) procedure in SI. If any injector is identified as having a lean condition, replace all four injectors with the revised injectors. After installing the new injectors, reprogram the ECM with updated calibration files using the TIS2WEB Service Programming System (SPS) application. There are two calibration part numbers that are valid for "Engine Operation". Select the part number with the description that reads for vehicles with second design injector. The injector has a dark blue overmold color for this repair.

Important: The fuel injectors must be replaced and the new calibration files must be installed to ensure a complete repair. Failure to perform both repairs will result in the customer returning with the same condition.

If a vehicle returns with the same condition after having this repair performed, the technician should first verify that the complete repair was performed before continuing with SI diagnostics.

Parts Information
Part Number Description Qty

12625029 Injector, Fuel 4

ChevyMgr
04-23-2009, 11:29 AM
#PIP4631: P0172 Setting After Engine Replacement - (Apr 21, 2009)


Subject: P0172 Setting After Engine Replacement


Models: 2007-2009 Chevrolet HHR

2007-2009 Chevrolet Malibu

2007-2009 Pontiac G6

2007-2009 Pontiac Solstice

2007-2009 Saturn Aura

2007-2009 Saturn Sky

2007-2009 Saturn Vue

With 2.4L RPO LE5
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A technician may find DTC P0172 setting after engine replacement. Additionally since Saturn warranty history is not listed in VIS, some retailers may not be aware the engine was replaced.

Recommendation/Instructions:
Some service replacement engines such as the 2.4L RPO (LE5) available in 2007-2009 MY vehicles come equipped with fuel injectors and rail attached that may NOT be applicable for the vehicle. Service engines have injectors installed for a SPECIFIC calibration which may NOT be applicable for every vehicle combination. This is specifically called out on the engine tag from SPO; however the technician may have not seen the instructions. When the injectors are not swapped as described, dtc P0172 may set. To remedy this concern swap the original injectors (or equivalent) onto the replacement engine. Please refer to the engine tag for directions when replacing an engine.

An example of the LE5 tag information is printed below.

PART NO. 19181849

TITLE: Engine Installation for LE5 without SAI

This service engine is based on the 2009 LE9 with out SAI Engine for Chevrolet HHR vehicle (with automatic transmission).

For use in other LE5 and LAT applications, the following components must be transferred from the existing engine:

• Dipstick tube and dipstick for Saturn Sky, Pontiac Solstice, and Hybrid Saturn Aura, Vue, Chevrolet Malibu vehicles

• Fuel rail assembly and fuel injectors for all 2007 - 2009 vehicles and all rear wheel drive applications

• Flywheel for all manual transmission applications

• Crankshaft balancer for all rear wheel drive and LAT BAS hybrid applications

• Front engine lift bracket for all applications, except Chevrolet HHR vehicles

• Vehicles with hydraulic power steering pump, transfer the belt tensioner and balancer/dampner.

Reference parts catalog if new replacement parts are required.

ChevyMgr
04-27-2009, 09:20 AM
#PIP4632: Engine Noise With Low Oil Pressure - keywords adjuster bearing cam camshaft cap change damage filter hot idle indicator lamp lash lifter light LOF mechanical no P0011 P0014 P0016 P0017 rattle tick - (Apr 23, 2009)


Subject: Engine Noise with Low Oil Pressure


Models: 2009 Chevrolet HHR

2009 Chevrolet Malibu

2009 Pontiac G6

2009 Pontiac Solstice

2009 Saturn Sky

2009 Saturn Aura

2009 Saturn Vue

With 2.4L RPO LE5

2009 Chevrolet HHR

With 2.4L RPO LE9




--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
On rare occasions, a technician may comment of engine noise (such as lifter noise, rattle etc.) or cam phaser/solenoid DTC accompanied by low oil pressure.

Recommendation/Instructions:
Engineering has determined that a machining concern with the oil pan pick up tube sealing surface may cause a low oil pressure condition. If upon checking the oil pressure (per eSI Oil Pressure Diagnosis and Testing) and the minimum spec of 50-80 psi @ 1000 rpm is not achieved (provided all mechanical causes have been eliminated) the oil pan may need to be replaced. Suspect engines were installed in vehicles within the following build dates (11/1/2008 to 12/31/2008).


4935


(1) Suspect Area

Note: It may not be possible to identify the concern visually (the ID of the oil pan pick up tube sealing surface is too large). However if all mechanical causes have been eliminated and the vehicle was built within the dates above, replace the oil pan.

ChevyMgr
05-04-2009, 11:14 AM
#PIT4693B: Power Window Inoperative After Start Up - (Sep 13, 2010)


Subject: Power Window Inoperative After Start Up

Models: 2008-2011 Chevrolet HHR

2007-2011 Chevrolet Silverado without DL3 and/or AN3

2009-2011 Chevrolet Traverse without AXC or AXE

2007-2011 GMC Acadia without AXC or AXE

2007-2011 GMC Sierra without DL3 and/or AN3

2007-2010 Saturn Outlook without AXC or AXE


--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some owners may comment if they push down on the driver's power window switch, shortly before cranking the engine, the drivers power window may be inoperative for a short time after the engine starts. The driver’s power window switch has [Prime ]stuck switch software[Prime ] built into the switch, which disables the switch in the event of a switch sticking in a position other than neutral. If the power window switch is pressed shortly before cranking the engine, the software may recognize it as a stuck switch and disable the switch. The power window switch will reset itself automatically once the switch is in the neutral position (released) for 2 seconds. Notice: If the switch is released and reapplied before the 2 seconds has elapsed, it will remain inoperative until the switch is released for a full 2 seconds.

Recommendation/Instructions:
This is a normal characteristic and no repairs should be made.

ChevyMgr
05-06-2009, 10:39 AM
#PIT4864: Adding Bluetooth Option RPO UPF - keywords accessories accessory add battery blue blue-tooth body cal calibration factory gen7 gen8 generation heat nav navigation non nonapproved oem onstar options - (May 5, 2009)


Subject: Adding Bluetooth Option RPO UPF

Models: 2007-2010 All Passenger Car and Trucks
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Technical assistance has received several calls from dealers requesting assistance to upfit their vehicle to include the Bluetooth feature RPO UPF.

Recommendation/Instructions:
There are no provisions to up-fit vehicles with this option. This feature is ONLY available on vehicles built with option UPF or offered within an equipment option group (i.e LTZ or SLE type package). Please do not call Technical Assistance, PARTECH or Techline Customer Support Centers with questions on how to add this feature.

ChevyMgr
05-07-2009, 08:59 AM
#PIP4638: Dificult To Shift Or Unable To Select All Gears - keywords shifter - (May 6, 2009)


Subject: Difficult To Shift Or Unable To Select All Gears


Models: 2008-2010 Chevrolet Cobalt SS, HHR SS

Equipped With RPO MU3 Manual Transmission
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Customers may comment that the transmission is difficult to shift and or it cannot be shifted into all gears. This condition may be caused by a locator pin left in place (see photo below) that was meant to be removed at the assembly plant or a shift cable out of position.

Recommendation/Instructions:
Inspect the transmission and shift linkage if the locator pin is still in place remove the pin and discard, retest transmission operation. If the pin is not found in position inspect the shift cables for being properly seated in the cable bracket, if the cables are out of the bracket reseat the cable or cables and test operation. If neither of the above conditions are found follow SI to properly diagnose the transmission shifting concern. Also reference the latest version of PIC4992 to aid in hard to shift concerns.

ChevyMgr
05-11-2009, 09:38 AM
#PIP3404D: Machining Debris On The Oil Filter Element - Replace Engine Oil And Filter - keywords aluminum change chips contamination metal shaving - (May 7, 2009)


Subject: Machining Debris on the Oil Filter Element - Replace Engine Oil and Filter


Models: 2005 Chevrolet Cavalier

2005-2009 Chevrolet Cobalt, Cobalt SS

2006-2009 Chevrolet HHR

2005-2009 Chevrolet Malibu

2005 Chevrolet Malibu Classic

2007-2009 Pontiac G5

2006-2009 Pontiac G6

2005 Pontiac Grand Am, Sunfire

2005-2006 Pontiac Pursuit (Canada Only)

2006-2009 Pontiac Solstice

2007-2009 Pontiac Solstice GXP

2007-2009 Saturn Aura, Aura Hybrid

2005-2007 Saturn Ion

2005-2007 Saturn Ion Redline

2005 Saturn L Series

2007-2009 Saturn Sky, Sky Redline

2005-2009 Saturn Vue

2007-2009 Saturn Vue Hybrid

With any of the following engines:

2.0L Engine (LSJ)

2.0L Engine (LNF)

2.2L Engine (L61)

2.2L Engine (LAP)

2.2L Engine (LE8)

2.4L Engine (LE5)

2.4L Engine (LAT)

2.4L Engine (LE9)
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
On rare occasions, machining debris (aluminum) may be found on the oil filter element during the vehicle's first oil change. This debris consists of small boring chips and milling burrs from the oil passage that is between the oil pump and oil filter.

Recommendation/Instructions:
If this condition is encountered, replace the engine oil and filter. No additional repairs should be attempted since this debris does not affect the reliability or durability of the engine.

ChevyMgr
05-14-2009, 08:56 AM
#PIC5149: Check Engine Light With P258B DTC - (May 13, 2009)


Subject: "Check Engine" light with P258B DTC


Models: 2008 - 2009 Chevrolet HHR-SS
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some dealers have reported that after installation of the OHB Brake kit per TSB 09-05-22-001A, a CHECK ENGINE light will be on and DTC P258B will be set. Following eSI diagnostics may lead dealers to try reprogramming the ECM or EBCM and also replace the Vacuum pump.

Recommendation/Instructions:
Dealers should check the vacuum line from the vacuum pump to the inline "T" on the main vacuum line to the booster. There is a check valve built into this line near the pump. If the technician can blow through the line in both directions, replace this section of vacuum line. If airflow is blocked in one direction then continue with diagnosis. If the hose is replaced, prior to installation, confirm that airflow is blocked in one direction on the new hose.

ChevyMgr
05-14-2009, 09:06 AM
#PIP4469E: DTC P0011 P0014 P0016 P0017 Setting Or Hesitation / Stall Engine RPO LAF LAP LAT LNF LE5 LE8 LE9 - (Jul 31, 2009)


Subject: DTC P0011, P0014, P0016, P0017 Setting or Hesitation/Stall Engine RPO LAF LAP LAT LNF LE5 LE8 LE9


Models: 2009 Chevrolet Cobalt

With RPO LAP 2.2L, LNF 2.0L

AND

2009 Chevrolet HHR

With RPO LNF 2.0L, LE8 2.2L, LE9 2.4L

AND

2009 Pontiac G5

With RPO LAP 2.2L

AND

2009 Chevrolet Malibu

2009 Pontiac G6

2009 Pontiac Solstice

2009 Saturn Sky

2009 Saturn Aura

2009 Saturn Vue

With RPO LE5 2.4L

AND

2009 Saturn AURA Hybrid

2009 Saturn VUE Hybrid

2009-2010 Chevrolet Malibu Hybrid

With RPO LAT 2.4L

AND

2010 Chevrolet Equinox

2010 GMC Terrain

With RPO LAF 2.4L SIDI




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This PI was superseded to add the 2009 2.4L LAT and the 2010 2.4L LAF/LAP also to add DTCs P0016/P0017 and hesitation/stall as keywords. Please discard PIP4469D.


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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
In rare instances a technician may comment that they find DTC's for cam phaser operation and or have noticed a hesitation/stumble typically on a PDI or with very low mileage. They may have followed eSI diagnostics and the dtc/condition has returned. They may have replaced the ECM with no change and/or they may find one or more of the DTCs listed below.

P0011-Intake Camshaft Position (CMP) System Performance

P0014-Exhaust Camshaft Position (CMP) System Performance

P0016-Crankshaft Position - Intake Camshaft Position Not Plausible

P0017-Crankshaft Position - Exhaust Camshaft Position Not Plausible

Recommendation/Instructions:
Engineering has determined that casting sand and or non-ferrous (aluminum) machining debris in the camshaft phasers/solenoid valves can cause a hesitation/stumble and or these DTCs to set intermittently. This condition/DTCs typically will set very early in the vehicle's life or at PDI. When the technician follows the eSI diagnostic chart for these codes they may be led to ECM replacement; however additional diagnostics should be made before replacement of any parts. After inspection of the solenoid valve and wiring per eSI confirms correct electrical operation, check for debris. The technician should inspect each CMP actuator solenoid valve assembly for torn screens or debris on the screens, then clean and replace as necessary. If the dtc continues to reset after thorough inspection and cleaning of the solenoid valves, replace the affected camshaft actuator(s) depending upon the dtc(s) that set.

Note: When debris is found change the oil and filter before returning to service, in some instances it may be necessary to change the oil/filter multiple times. The filter can be inspected afterwards to ensure no additional debris is present.

ChevyMgr
05-14-2009, 04:18 PM
Service Information 2008 Chevrolet HHR | HHR (VIN A) Service Manual | Document ID: 2272292
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#09-03-16-002: Dealership Service Consultant Procedure as Vehicle Comes Into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (May 4, 2009)


Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information


Models: 2006-2010 Cars and Light Duty Trucks (Including Saturn and Saab)

Attention: The information found in this bulletin is to be used as a dealership service consultant procedure for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner’s Maintenance item and is not covered under warranty.
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Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps:

Procedure
Turn the key to ON, without starting the engine.

• If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer:

- The system is working properly.

- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door).

- More detailed information can be found in the Owner Manual.

- Service is not covered under warranty - this maintenance is the responsibility of the owner.

- Give the customer a copy of the attached "GM Customer TPMS Information".

• If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC):

- A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service.

- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle’s TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2®).

- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures.

• If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer:

- The system is working properly.

- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door).

- More detailed information can be found in the Owner Manual.

- Service is not covered under warranty - this maintenance is the responsibility of the owner.

- Give the customer a copy of the attached "GM Customer TPMS Information".

For more detailed information, refer to Corporate Bulletin Number 07-03-16-004 and TPMS Training Course 13044.12T2.

Tire Pressure Light
At key on, without starting the vehicle:

Steady Solid Glowing TPM Indicator

5045


If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition.

Blinking TPM Indicator

5046


If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed.

The Effect of Outside Temperature on Tire Pressures
Important: As a rule of thumb, tire pressure will change about 7 kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.

Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver’s door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on:

• Use an accurate, high quality tire pressure gauge.

• Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature.

• Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation.

• When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures.

• After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary).

• Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2® to initiate the relearn whenever possible to avoid invalid sensor I.D. learns.

Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. For example, on colder days (20°F/-7°C), if setting the tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more than the placard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placard range.

Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020B.

Important: All Models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or module), always use the Tech 2® to initiate the J 46079 relearn process. Tech 2®-initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2® prior to and following relearn to verify they are the same can prevent invalid I.D. learns.

Customer TPMS Information
Dear GM Customer:

Customer care is at the top of our priority list at GM. We value our customers and want to make certain of a great ownership experience. To assist you in better understanding your vehicle, please make note of the following information relative to tire air pressure and the vehicle system that monitors air pressure performance.



Tire air pressure is a maintenance item in which the owner is responsible. Your vehicle is equipped with a Tire Pressure Monitoring System (TPMS) designed to provide you with adequate information to maintain proper tire air pressure. Proper tire air pressure is important to optimize safety, fuel economy, vehicle performance, and tire wear.



Changes in weather, including warm or cold outdoor temperatures, can cause air in your tires to expand or contract. Should this occur, your vehicle’s TPMS may give you a low tire signal/alert along with the following message: Check Tire Pressure/Low Tire Pressure/Add Air To Tire.


Your GM Dealer has determined that the TPMS on your vehicle is working properly. The light will turn off upon adding the proper amount of air to the tires (per the Tire & Loading Information label in the driver’s door opening) followed by driving the vehicle a short distance. The low tire light is similar to the low fuel indicator and adding fuel or air to the vehicle will turn off the light.

For more information, refer to the Owner Manual or go to www.CheckMyTires.org.

ChevyMgr
05-15-2009, 10:05 AM
Some advice on presenting a TSB to your dealership:

Most dealer service departments have been numbed to customers presenting TSBs from forums. Most of the TSBs that people bring with them don't even pertain to either their vehicle, their model or their year of vehicle. EVERYONE seems to be on some type of forum and dealers don't really care to hear what the customer has read on the internet.

That being said, if you want to copy and paste a TSB from this thread to show your dealer, I would suggest you just say you found it on the internet. Make sure it is relevant to your vehicle, model and year.

ChevyMgr
05-20-2009, 02:12 PM
#09-08-44-013B: Information on USB Command and Control Multimedia Player Interface/List of Supported Devices - (Mar 11, 2010)


Subject: Information on USB Command and Control Multimedia Player Interface/List of Supported Devices


Models: 2010 Buick Enclave, LaCrosse

2008-2010 Cadillac CTS

2010 Cadillac Escalades, SRX

2009-2010 Chevrolet Cobalt, HHR, Malibu

2010 Chevrolet Avalanche, Camaro, Equinox, Silverado, Suburban, Tahoe, Traverse

2010 GMC Acadia, Sierra, Terrain, Yukons

2009-2010 Pontiac G5, G6, Solstice, Solstice Coupe

2009-2010 Saturn AURA, SKY

2010 Saturn OUTLOOK

All Equipped with Convenience and Connectivity Package - RPOs KTA, KTB, SRJ, U4H, UUI, UUJ, UUM, UUN, U2S, U2X, U2Y, UAV, UYZ, UY5

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This bulletin is being revised to add the RPO U4H. Please discard Corporate Bulletin Number 09-08-44-013A (Section 08 - Body and Accessories).
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USB Radio and MP3 Functionality
The USB (Universal Serial Bus) will be a USB 2.0 port on the radio faceplate, on the IP or in the center console. This interface will give the customer the additional functionality of iPod/MP3 command and control. Customers now have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The customer will also have playback capability with a USB memory stick (only MP3 and WMA files).

Note: Not all memory sticks are supported.

Customers have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The iPod will be charging while connected to the radio.

Note: Video from the iPod is NOT capable of being transferred to a Navigation radio display.

For the Chevrolet Cobalt, HHR and Malibu; Pontiac G5, G6, Solstice; and Saturn AURA, SKY, the USB port is on the faceplate of the radio. For all other models, it is located in the center console or IP.

For the Cadillac CTS only, a special iPod cable (USB and AUX cable) is needed. This special cable comes delivered with the vehicle. In all cases, the iPod will be charging while connected to the radio through the USB port when the vehicle is running or the RPA is active.

Problems with iPod Not Connecting
If the infotainment system does not operate properly when using a device connected through the USB port, this may be due to an incompatible media device.

Important: DO NOT replace the radio or multimedia interface module due to a customer device incompatibility issue.

Verify the customer's media device is validated for this system using the list below. If the customer's device is a validated device for this system, follow the SI diagnostic procedure to isolate the fault. If the customer's device is not on the validated device list, explain to the customer that their particular unit is not compatible with the system.

Troubleshooting Tips for iPod Devices
Check the version of the iPod/MP3 to confirm that it is supported.
Unplug and Re-insert the iPod to verify the customer complaint.
Verify the battery charge of the iPod. A low battery condition on the iPod may not allow it to connect to the radio. The iPod may need to be charged before it can be controlled by the radio.
If the customer receives a "Device Not Supported" message on their radio or is having general iPod/MP3 connection issues (and they have a supported device), they may need to reset their iPod. To reset the iPod:
• For the iPod Nanos and Classic , Toggle the Hold switch on and off. (Slide it to Hold, then turn it off again. Press and hold the Menu and Center (Select) buttons simultaneously until the Apple logo appears, about 6 to 8 seconds. You may need to repeat this step.

• For the iPod Touch and iPhone: Press and hold the Sleep/Wake button for a few seconds until the red slider appears, then slide the slider.

Have the customer check their cable for quality.
• Aftermarket cables can wear from use. The customer may need to purchase a new USB cable.

• Verify that cable extensions are not present. The extra capacitance may cause too large a signal drop for the iPod to communicate with the radio.

If the customer receives a "Device Not Supported" message on their radio with an iPod connected (and they have a supported device), the customer may need to download the latest firmware from the Apple website (Please visit www.apple.com for more information).
Validated Apple Device - Both Charge/Support Digital Audio (For All RPOs)
For further information on identifying iPod models, please visit http://support.apple.com/kb/HT1353




Brand Name/Description Number

Apple iPod Classic 5 & 5.5 Gen 1

Apple iPod Nano 1Gen 2

Apple iPod Nano 2Gen 3

Apple iPod Nano 3 4

Apple iPod Classic 5

Apple iPod Touch 1Gen & 2Gen 6

Apple iPhone (User must switch to "airplane mode") 7

Apple iPod Nano 4 GEN 8


Other Validated Device-- Both Charge/Support Digital Audio for Buick LaCrosse, Chevrolet Camaro, Equinox Only (RPO KTA or KTB)

6498

Important: : Must be set to MTP (Mass Transfer Protocol) in the MP3 Player device setting.

Brand Name/Description

SanDisk Sansa e280

Toshiba Gigabeat

Philips Philips GoGear

Sony Sony NWZ-A828

Sony Sony NWZ-S616F

Insignia Insignia

Iriver Iriver Clix

Iriver H10

Samsung S5J AB/XAA(4GB)

Samsung T10

Samsung Yepp S5

Microsoft Zune (Gen 1 & 2)


Important: These devices (and additional MP3 players) may be capable of connecting to the other USB options by internally setting the MP3 device to MSC (Mass Storage Class) mode. In this mode, the USB port will see the device as a flash drive. Please have the customer refer to their MP3 device manual on how to set the device to MSC. If the device is not able to be set to MSC, the customer must use the AUX jack.

Note: MTP mode must be used in order to transfer ANY Digital Rights Managment (DRM) protected content.

Non-Validated Apple Device
Important: The following devices are NOT supported by USB interface. Apple does not support digital media transfer from these devices through the USB port. The customer can still listen to their older iPod on vehicle by connecting it to the Auxiliary Input Jack using a standard 3.5mm (1/8 in) stereo cable.

6499


Brand Description Number

Apple iPod Shuffle Gen1 1

Apple iPod Shuffle Gen2 2

Apple iPod mini Gen1&2 3

Apple iPod Photo 4

Apple iPod G4 5

Apple iPod Gen3 6

Apple iPod Gen2 7

Apple iPod Gen1 8

Apple iPod Shuffle Gen 3 9

ChevyMgr
05-28-2009, 03:27 PM
#08-06-04-033C: Identifying Aftermarket Engine and Transmission Calibrations 2.0L, 2.2L, 2.4L, 2.8L, 2.9L, 3.0L, 3.1L, 3.2L, 3.4L 3.5L, 3.6L, 3.8L, 3.9L, 4.2L, 4.3L, 4.4L, 4.6L, 5.0L, 5.3L, 5.7L 6.0L, 6.2L 7.0L, 7.4L - (Dec 18, 2008)


Subject: Identifying Aftermarket Engine and Transmission Calibrations 2.0L, 2.2L, 2.4L, 2.8L, 2.9L, 3.0L, 3.1L, 3.2L, 3.4L, 3.5L, 3.6L, 3.8L, 3.9L, 4.2L, 4.3L, 4.4L, 4.6L, 4.8L, 5.0L, 5.3L, 5.7L, 6.0L, 6.2L, 7.0L, 7.4L, 8.1L Gas Powered Engines Only and 6T40/45 (MH8), 6T70/75 (MH2, MH4, MH6, MY9), 6L50 (MYB) 6L80 (MYC) or 6L90 (MYD) Automatic Transmission


Models: 2006-2009 GM Passenger Cars and Light Duty Trucks

2006-2009 HUMMER H2, H3

2006-2009 Saturn Models

2006-2009 Opel GT

2007-2008 Daewoo G2X

EXCLUDING Chevrolet Aveo, Pontiac Vibe, Wave, G3, Saab Models, Saturn ASTRA
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This bulletin is being revised to remove Saturn (except Astra) from the list of excluded vehicles. Please discard Corporate Bulletin Number 08-06-04-033B (Section 06 -- Engine/Propulsion System).
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Important: This bulletin applies to Gas Powered Engines ONLY. For Diesel Powered Engines, refer to Service Bulletin #08-06-04-006C.

If a suspicious hard part failure is observed in the engine, transmission, transfer case or driveline, perform the calibration verification described to determine if a non-GM issued engine calibration is installed. Non-GM issued engine calibrations subject driveline components to stresses different from the calibrations that these components were validated to. Repairs to engine, transmission, transfer case and/or other driveline components where a non-GM engine calibration has been verified are not covered under the terms of the New Vehicle Warranty.

Instructions for Confirming Calibration Verification Number (CVN):
Go to TIS2WEB
Select "Calibration Information (SPS Info)"
Enter VIN
Select "Get Cal ID"
Select "ECM Engine Control Module" or "TCM Transmission Control Module"
Select "Next"
Select "Complete History"
Print
Take the printout to the vehicle along with the Tech 2®
Plug in the Tech 2®
Go to diagnostics and build the vehicle
Select "Powertrain"
Select "Engine"
*Select "Engine Control Module" or "PCM" or "TCM"
*Select "Module ID Information" or "I/M Information System" if module ID information selection is not available.
*If "I/M information System" was selected in step 15, it may be necessary to select "Vehicle Information" in order to display the calibration information.
Compare the calibration ID and Calibration Verification Numbers (CVN) to the Calibration Verification Numbers (CVN) on the printout.
* Steps may vary by controller.

Although the part numbers will be the same for each, it's the CVN that will determine if the calibration is GM issued. If ALL of the CVN's are EXACTLY the same, the calibration is GM issued.

If the part numbers match and ANY CVN's DO NOT match the printout, it is likely that a non-GM certified calibration has been installed.

If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information.

If a non-GM calibration is found to be in the ECM or TCM (CVN's on the Tech 2® do not match TIS printout) - In order to document the case -- a CLEAR digital picture should be taken of the Tech 2® screen showing the VIN and the CVNs that do not match the TIS2WEB printout. The picture, VIN and reason the vehicle is currently in for service should be emailed to xxxxxx for verification. Please copy your GM District Service Manager (DVM) on the e-mail. In Canada, please copy your GM Warranty Manager. GM will verify if the CVNs are not GM issued and respond via e-mail within 72 hours.

ChevyMgr
05-29-2009, 03:38 PM
#09-06-93-002: Turbocharger Housing Inlet Flange Cracks in Partition Wall - (May 27, 2009)


Subject: Turbocharger Housing Inlet Flange Cracks in Partition Wall


Models: 2008-2009 Chevrolet Cobalt SS, HHR SS

2007-2009 Pontiac Solstice GXP

2007-2009 Saturn SKY Redline

2007-2009 Opel GT

2007-2009 Daewoo G2X

All Equipped with Engine RPO LNF

Please Refer to GMVIS

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Important: DO NOT replace the turbocharger assembly for this concern.

The purpose of this bulletin is to address concerns with turbocharger housing cracks in the inlet flange partition wall. Vehicles diagnosed with various driveability concerns or turbocharger DTCs P0299 or P0234 after inspection, are revealing cracks in the inlet flange partition wall of the turbocharger housing. Turbocharger assemblies are being replaced based on the discovery of these cracks.

The pictures below illustrate typical cracks found in the turbocharger housing.

5108

This illustration shows the location of the cracks in the partition wall of the turbocharger inlet flange on the left (1) and on the right (2).

5109

This illustration shows a close-up of the crack on the left side of the partition wall (1).

5110

This illustration shows a close-up of the crack on the right side of the partition wall (2).

These cracks are not uncommon and are considered a normal condition and should NOT be a reason for replacing the turbocharger assembly. The cracks will not affect performance. If the vehicle exhibits driveability concerns or turbocharger DTCs P0299 or P0234 are set, refer to SI and follow the established diagnostics for correction of the customer concern.

ChevyMgr
05-29-2009, 03:51 PM
#07-02-32-007B: Diagnostic Tips for Power Steering Inoperative/Steering Wheel Hard to Turn, Power Steering Message Displayed on DIC, DTCs C0176, C0475, C0476, C0550, U2105, U2107 Set - (Aug 6, 2009)


Subject: Diagnostic Tips for Power Steering Inoperative/Steering Wheel Hard to Turn, Power Steering Message Displayed on DIC, DTCs C0176, C0475, C0476, C0550, U2105, U2107 Set


Models: 2005-2010 Chevrolet Cobalt

2006-2010 Chevrolet HHR

2005-2006 Pontiac Pursuit (Canada Only)

2007-2009 Pontiac G5

2003-2007 Saturn ION

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This bulletin is being revised to update the information for DTC C0475. Please discard Corporate Bulletin Number 07-02-32-007A (Section 02 -- Steering).

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The following diagnostics might be helpful if the vehicle exhibits the condition(s) described above. Use the appropriate recommendation based on what symptom has occurred.

No DTCs
Review Corporate Bulletin Number 05-02-32-002D to assure you do not have a blown 60 amp steering fuse. The fuse can be blown during improper jump starting of the vehicle on the HHR and ION. Check for this particularly for tow in conditions. DO NOT replace the steering column unless an internal short has been identified in the column that is causing fuse to blow.

Power Steering Warning Message on DIC with DTCs C0176 and C0476
This condition is often the result of excessive lock-to-lock turns of the steering wheel, causing the thermal protection in the power steering control module (PSCM) to take the steering motor temporarily off line. This is a normal operating characteristic of the system. DO NOT replace the steering column for this condition. Refer to Corporate Bulletin Number 06-02-32-002C for additional information.

Power Steering Warning Message on DIC with DTC C0550 in the PSCM
Inspect the motor harness connection to the PSCM. If no connector problems are found, replace the steering column ONLY as this is an internal controller issue.

Power Steering Warning Message on DIC with DTC C0475 in the PSCM
Check the connection between the EPS motor and the power steering control module (PSCM) by ensuring the harness connector is properly seated. If the connection is normal, replace ONLY the EPS motor.

Note: If the DTC resets immediately following motor replacement, replace the steering column.

Power Steering Warning Message on DIC with DTC U2105 and/or U2107 in the PSCM with any other U codes
Although the code(s) appear in the PSCM, these are communication codes and are not the result of a problem with the column operation or the control module. If the codes are in history, clear the codes and re-key the vehicle a few times to see if they come back. If they reappear, look for a communication issue from the BCM U2107 or ECM U2105 (wiring, connector, etc.) as the root cause. If the codes do not reappear after a test drive, return the vehicle back to the customer. DO NOT replace the steering column.

ChevyMgr
06-01-2009, 09:31 AM
#05-02-32-002D: Power Steering Inoperative/Steering Wheel Hard to Turn, PWR STR Message Displayed on DIC After Jump Starting Vehicle (Replace Fuse and Instruct Owner How to Jump Start Vehicle) - (May 29, 2009)


Subject: Power Steering Inoperative/Steering Wheel Hard to Turn, "PWR STR" Message Displayed on Driver Information Center (DIC) After Jump Starting Vehicle (Replace Fuse and Instruct Owner How to Jump Start Vehicle)


Models: 2006-2009 Chevrolet HHR

2003-2007 Saturn ION




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This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 05-02-32-002C (Section 02 -- Steering.)


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Condition
Some customers may comment that the steering wheel is hard to turn and that a message of "PWR STR" is displayed on the Driver Information Center (DIC) of the instrument panel (I/P) cluster. They may also comment that this condition occurred after they had to have the vehicle jump started.

Cause
Improper "jump starting" of the vehicle has been determined as a cause for the power steering fuses to open (blow). Customers may mistakenly believe that the Underhood Junction Block (UHJB) is actually the battery; therefore, they believe there is both a positive and negative post in the UHJB. After only seeing one post, they may remove the cover and discover there is another small post on the passenger side of the UHJB. The small post on the passenger side of the UHJB is the B+ post for the electric power steering . When the jumper cables are attached to both of these posts and the cable is connected to another vehicle, the power steering fuses will blow.

Correction
Replace the blown fuses and verify that concern is eliminated.

Important: If the fuse continues to blow, refer to the appropriate diagnostic procedure below:

• For 2003-04 Saturn IONs, refer to Diagnostic System Check - Power Steering in SI or the 2003 or 2004 Saturn ION Service Manual.

• For 2005-07 Saturn IONs, refer to Diagnostic Starting Point - Power Steering System in SI or the 2005, 2006 or 2007 Saturn ION Service Manual.

• For 2006-09 Chevrolet HHRs, refer to Diagnostic Starting Point - Power Steering System in SI.


On 2003-2005 Saturn ION vehicles only, open the fuse box cover, then remove and discard the small plastic cover that has the words "REMOVE AND DISCARD THIS COVER FOR FUSE OR RELAY SERVICING" listed on the top. This cover is used only to protect the fuses upon initial factory installation.

Provide the owner with a copy of the following procedure and refer owners to Step 9 for the correct negative cable attachment point.

Jump Starting Procedure
If your vehicle's battery has run down, you may want to use another vehicle and some jumper cables to start your vehicle. Be sure to use the following steps to do it safely.

Caution: Batteries can hurt you. They can be dangerous because:

• They contain acid that can burn you.

• They contain gas that can explode or ignite.

• They contain enough electricity to burn you.

If you do not follow these steps exactly, some or all of these things can hurt you.

Notice: Ignoring these steps could result in costly damage to your vehicle that would not be covered by your warranty. Trying to start your vehicle by pushing or pulling it will not work, and it could damage your vehicle.

Check the other vehicle. It must have a 12-volt battery with a negative ground system.
Notice: If the other vehicle's system is not a 12-volt system with a negative ground, both vehicles can be damaged. Only use vehicles with 12-volt systems with negative grounds to jump start your vehicle.

Get the two vehicles close enough so the jumper cables can reach, but be sure the vehicles are not touching each other. If they are, it could cause a ground connection you do not want. You would not be able to start your vehicle, and the bad grounding could damage the electrical systems. To avoid the possibility of the vehicles rolling, set the parking brake firmly on both vehicles involved in the jump start procedure. Put an automatic transaxle in PARK (P) or a manual transaxle in NEUTRAL (N) before setting the parking brake.
Notice: If you leave your radio or other accessories on during the jump starting procedure, they could be damaged. The repairs would not be covered by your warranty. Always turn off your radio and other accessories when jump starting your vehicle.

Turn off the ignition on both vehicles. Unplug unnecessary accessories plugged into the cigarette lighter or the accessory power outlet. Turn off the radio and all lamps that are not needed. This will avoid sparks and help protect both batteries and radios.
Saturn ION




Chevrolet HHR




Open the hoods and locate the positive (+) and negative (-) terminal locations on each vehicle. You will not need to access your battery for jump starting. Your vehicle has a remote positive (+) jump starting terminal. The remote positive (+) terminal is located on the engine compartment fuse block, under a red cap. Do not remove the black fuse box cover.
Caution: An electric fan can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan.

Caution: Using a match near a battery can cause battery gas to explode. People have been hurt doing this, and some have been blinded. Use a flashlight if you need more light. Be sure the battery has enough water. You do not need to add water to the battery installed in your new vehicle. But if a battery has filler caps, be sure the right amount of fluid is there. If it is low, add water to take care of that first. If you do not, explosive gas could be present. Battery fluid contains acid that can burn you. Do not get it on you. If you accidentally get it in your eyes or on your skin, flush the place with water and get medical help immediately.

Caution: Fans or other moving engine parts can injure you badly. Keep your hands away from moving parts once the engine is running.

Check that the jumper cables do not have loose or missing insulation. If they do, you could get a shock. The vehicles could be damaged too. Before you connect the cables, here are some basic things you should know:
• Positive (+) will go to positive (+) or to a remote positive (+) terminal if the vehicle has one.

• Negative (-) will go to a heavy, unpainted metal engine part or to a remote negative (-) terminal if the vehicle has one.

• Do not connect positive (+) to negative (-) or you will get a short that would damage the battery and maybe other parts too.

• Do not connect the negative (-) cable to the negative (-) terminal on the vehicle with dead battery because this can cause sparks.

Remove the red terminal cover and connect the red positive (+) cable to the positive (+) terminal of the dead battery. Use a remote positive (+) terminal if the vehicle has one.
Do not let the other end touch metal. Connect it to the positive (+) terminal of the good battery. Use a remote positive (+) terminal if the vehicle has one.
Now connect the black negative (-) cable to the negative (-) terminal of the good battery. Use a remote negative (-) terminal if the vehicle has one. Do not let the other end touch anything until the next step.
Connect the other end of the negative (-) cable at least 18 inches (45 cm) away from the dead battery, but not near engine parts that move. The electrical connection is just as good there, and the chance of sparks getting back to the battery is much less. Refer to appropriate model year below for correct negative location.



• For 2003 and 2004 model year IONs, attach the black negative (-) cable to the engine lift hook of the dead battery vehicle, about 18 inches (45 cm) away from the remote positive (+) terminal, but not near engine parts that move.





• For 2005 and 2006 model year IONs, attach the black negative (-) cable to the remote negative terminal. The remote terminal is located under the GND (-) sticker on the driver side of the radiator support bar (near hood prop rod).





• For 2006 HHRs, attach the black negative (-) cable to the remote negative terminal. The remote terminal is located on the driver's side shock tower and is marked with a GND (-) sticker.

Now start the vehicle with the good battery and run the engine for a while.
Press the unlock button on the remote keyless entry transmitter to disarm your security system, if equipped.
Try to start the vehicle that had the dead battery. If it will not start after a few tries, it probably needs service.
Notice: If the jumper cables are connected or removed in the wrong order, electrical shorting may occur and damage the vehicle. The repairs would not be covered by your warranty. Always connect and remove the jumper cables in the correct order, making sure that the cables do not touch each other or other metal.

Disconnect jumper cables.
13.1. Disconnect the black negative (-) cable from the vehicle that had the dead battery.

13.2. Disconnect the black negative (-) cable from the vehicle with the good battery.

13.3. Disconnect the red positive (+) cable from the vehicle with the good battery.

13.4. Disconnect the red positive (+) cable from the other vehicle.

13.5. Return the red protector cap to its original position.

ChevyMgr
06-05-2009, 10:53 AM
#PIP4651: Soft Shifts Erratic Shifts DTC P1811 - keywords 4T45 4T45E actual body code control desired line MIL MN5 ME7 pc pcs pressure SES solenoid valve - (Jun 3, 2009)


Subject: Soft Shifts, Erratic Shifts, DTC P1811


Models: 2007 - 2009 Chevrolet Cobalt, HHR, Malibu

2007 - 2009 Pontiac G5, G6

2007 Saturn Ion

2007 - 2008 Saturn Aura

2007 - 2009 Saturn Vue

with 4T45 Automatic Transmission (RPO MN5 or ME7)
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some owners of the above vehicles with a Hydra-Matic 4T45 transaxle may comment on soft shifts or shifts erratically. These conditions may appear intermittently or set a DTC P1811. During diagnosis, a low or high line pressure (actual versus desired) may be observed. This condition may be due to sediment or debris inside the pressure control (PC) solenoid valve, causing the PC solenoid valve to mechanically bind, which may affect line pressure output.

Recommendation/Instructions:
Perform the Line Pressure Check as described in SI Document ID: 2126463. If the actual versus desired pressures are not within the values specified, inspect the PC solenoid valve for sludge or debris buildup. Replace the PC solenoid valve, and if necessary clean the valve body. Install two 29535617 magnets in the oil pan, per bulletin 08-07-30-040B.

ChevyMgr
06-10-2009, 09:37 AM
#09-00-89-025: GM Accessories: 2-Way Advanced Remote Start Systems Part Information - (Jun 9, 2009)


Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information


Models: 2007-2010 Buick Lucerne

2008-2010 Buick Enclave

2007-2010 Cadillac Escalade ESV, EXT

2008-2010 Cadillac DTS

2007-2009 Chevrolet Equinox, HHR

2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe

2008-2010 Chevrolet Impala, Malibu

2009-2010 Chevrolet Traverse

2007-2010 GMC Acadia, Sierra, Yukon

2008-2010 HUMMER H2

2007-2009 Pontiac Torrent

2007-2010 Pontiac G5, G6

2008-2010 Pontiac G8

2010 Pontiac Solstice

2007-2010 Saturn AURA, OUTLOOK

2009-2010 Saturn VUE

2010 Saturn SKY



Attention: This bulletin does not apply to GMODC dealers.
--------------------------------------------------------------------------------

This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems.

Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work.

Parts Information
Service parts common to all 2-Way Advanced Remote Start Systems:

Part Number Description

12493150 Transmitter Battery

19172336 Antenna

19131612 2-Way Transmitter

19131603 2-Way Transmitter

19131613 2-Way Transmitter

19131602 2-Way RCDLR

19131628 2-Way RCDLR

ChevyMgr
06-10-2009, 09:56 AM
#PIC5078B: SIR Light On With Codes B0083 Or B0084 - keywords battery B0083SYM71 B0084SYM71 code dead DTC lamp low voltage - (Jun 5, 2009)


Subject: Sir Light On With Codes B0083 Or B0084


Models: 2008-2009 Chevrolet Cobalt, HHR, Malibu

2008-2009 Pontiac G5, G6, Solstice

2008-2009 Cadillac STS

2008-2009 Saturn Aura, Sky

2008-2009 Opel GT
--------------------------------------------------------------------------------

This PI was superseded to update Title and talk about sensors and not point to both. Please discard PIC5078A.
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A low battery condition on any of the above listed vehicles, could potentially cause the SIR light to come. The SDM under low power situations could set codes B0083 or B0084.

Recommendation/Instructions:
If you have EITHER of these SIR codes setting and no other symptoms with the vehicle please follow the steps below.

Fully charge the battery and make sure it will successfully pass the Midtronics tester.
Clear the codes and try to duplicate the condition by performing random restarts of the engine.
If code(s) do come back after you are positive that the battery is in good condition, look for a possible loose connection at the SDM.

ChevyMgr
06-15-2009, 08:30 AM
#07-08-46-002C: Audio Whine Noise from Radio Speakers When Using OnStar (Install Noise Suppression Filter) - (Jun 11, 2009)


Subject: Audio Whine Noise from Radio Speakers When Using OnStar® (Install Noise Suppression Filter)


Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn)

2007-2010 HUMMER H2, H3

2007-2009 Saab 9-7X

Equipped with OnStar® (RPO UE1)
--------------------------------------------------------------------------------

Condition
Some customers may comment on an audio whine coming from the radio speakers when using the OnStar® system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed.

Cause
This condition may be caused by electrical noise on the OnStar® Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.

Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar® battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.

Important: The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead.

Parts Information Part Number Description--Qty

1224205 Filter, Universal Alternator Whine-- 1

ChevyMgr
06-15-2009, 08:59 AM
#99-01-39-004C: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) - (Jun 12, 2009)


Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating)


Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn)

2010 and Prior HUMMER H2, H3

All Equipped with Air Conditioning

--------------------------------------------------------------------------------
Condition
Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions.

Cause
This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment.

There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection.

The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module.

Correction
Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment.

Important: If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876).

Important: When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas.

To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure:

Vehicle and Applicator Tool Preparation
The evaporator core must be dry . This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time.
Note: Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces.

Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle.
Place a protective cover over the carpet below the evaporator core.
Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer.
If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE .
Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi).
Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube.
Note: The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle.

Use one of the following three methods to apply the Cooling Coil Coating.
Important: If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)).

Application Through Blower Motor Control Module Opening
• Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI.

• Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface.

• Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening.

• Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces.

• When the application is complete, install the blower motor blower motor control module (blower motor control module).

Application Through Blower Motor Opening
• Remove the blower motor. Refer to the applicable blower motor removal procedure in SI.

• Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface.

• Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening.

• Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces.

• When the application is complete, install the blower motor.

Application Through a Hole in the HVAC Module
• If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module.

• Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan.

• With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core.

• Use a GM approved RTV sealant to plug the hole in the HVAC module.

After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface.
While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool.
Shut off the engine and enable the compressor again.
Verify proper HVAC system operation.
Remove the protective cover from inside the vehicle.
Remove the drain pan from underneath the vehicle.
Reinstall the cabin air filter if necessary.
Parts Information
Important: The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth.

Part Description GM Part Number SPX Kent-Moore Part Number

Cooling Coil Coating (CCC) Kit (with flexible applicator tool and 1 bottle of Cooling Coil Coating) 12346391 J-43810-A

Cooling Coil Coating Flexible Applicator Tool only N/A J-43810-20A

Refill for Cooling Coil Coating Applicator Kit (2 x 120 ml (4 oz) Bottles of CCC) 12346390

(N/A in Canada, use SPX Kent-Moore J-43810-4) J-43810-4

Refill for Cooling Coil Coating Applicator Kit (1 x 120 ml (4 oz) Bottle of CCC)
N/A J-43810-30

Cooling Coil Coating (1 x 180 ml (6 oz) Aerosol Can of CCC) 12377951 (In Canada use 10953503) N/A

Electronic Evaporator Dryer Module Kit (one per vehicle) 12497910 (AC Delco 15-5876) N/A

ChevyMgr
06-15-2009, 09:12 AM
#09-07-29-003: Transmission Fluid Leak, Slipping Clutch or Broken Axle Shaft (Replace Trans Assembly/Front/Rear Mounts and Both Axle Shafts-Contact District Svc Mgr (Warranty Mgr in Canada) for Repair Approval) - (Jun 12, 2009)


Subject: Transmission Fluid Leak Due to Clutch Housing Fatigue, Slipping Clutch or Broken Axle Shaft (Contact District Service Manager/Warranty Manager (in Canada) for Repair Approval)


Models: 2005-2009 Chevrolet Cobalt SS

2008-2009 Chevrolet HHR SS

2004-2007 Saturn ION Redline

Equipped with 5-Speed Manual Transmission (RPO MU3)

Built Prior to February 12, 2009 (Lordstown) or February 26, 2009 (Ramos)

Attention: Be advised that failures of this nature are generally caused by customer abuse. They are NOT defects in materials or workmanship for which General Motors would be responsible for and should not be covered under the terms of the new vehicle warranty. Vehicles with this complaint should be inspected by your service manager and District Service Manager (Warranty Manager in Canada). A field product report should be submitted on each case. Also, if aftermarket kits are added that may effect the driveline loads, the transmission would not be warranted.

--------------------------------------------------------------------------------

Condition
Some customers may comment about a slipping clutch. Upon further investigation, the technician will find transmission oil in the clutch housing.

Cause
This condition may be caused by excessive front wheel hop during wide open throttle (WOT) acceleration events. Excessive wheel hop transmits a torsional shock load into the transmission case. This may cause the transmission case to fracture (as shown in graphic below) and transmission fluid to leak into the clutch housing.

5176

5177

5178

Correction
Important: Prior to any work being performed, contact your District Service Manager/Warranty Manager for repair approval.

For 2005-2007 Chevrolet Cobalt SS and 2004-2007 Saturn ION Redline
If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, replace the front (GM P/N 20814994) and rear (GM P/N 20814995) powertrain mounts. Refer to SI for the procedures on replacing the transmission front and rear mounts.

For 2008-2009 Chevrolet Cobalt SS and 2008-2009 Chevrolet HHR SS
If this repair is approved by the District Service Manager/Warranty Manager, replace the transmission assembly. During removal of the transmission, inspect the following parts and replace if necessary (excluding tires):

• Tire wear (excessive or uneven) front vs. rear or rubber debris in the front wheel house liner area.

• Inspect the upper right side mount for fluid leaks or (rubber) structural failure.

• Front and rear powertrain mounts, if necessary (refer to SI for the procedure on replacing the transmission front and rear mounts).

Important: Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J 2534 MDI will reprogram the modules in less time than the Tech 2® scan tool.

Reprogram the ABS with a updated service calibration using the TIS2WEB Service Programming System (SPS) application. Make sure your Tech 2® is updated with the latest software version. The ABS calibration is available to dealerships in TIS2WEB (website version of TIS). Refer to Electronic Brake and/or Traction Control Module Reprogramming with SPS procedure in SI.

Install Clutch Actuator Pipe Elbow Assembly (P/N 24252286)
Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
Remove the cover from the underhood electrical center.

5179

Remove the underhood electrical center bracket from the vehicle and reposition the electrical center (1) to access the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement.

5180

Note: Rotate the hose to stop brake fluid from running out of it.

Disconnect the hydraulic clutch hose (3) from the clutch actuator cylinder (2) and the clutch master cylinder (1).
Install the clutch actuator pipe elbow assembly, GM P/N 24252286.
Connect the hydraulic clutch hose (3) to the clutch actuator cylinder (2).
Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding.
Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement.
Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.

Parts Information
Part Number Description Qty

24252286 Elbow Asm - Clu Actr Cyl Pipe 1

20814994 (Front) Transmission Mount 1

20814995 (Rear) Transmission Mount 1

ChevyMgr
06-15-2009, 09:20 AM
#PIC5190: Diagnosing Driver Door Latch / Lock Inoperative Or Binding - (Jun 11, 2009)


Subject: Diagnosing Driver Door Latch/Lock Inoperative or Binding


Models: 2009 Chevrolet HHR
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may comment that the driver door lock rod/latch is inoperative or binding.

Recommendation/Instructions:
If this condition is verified, use this side door lock quick check procedure to verify root cause and prevent un-necessary repairs to the latch.

SIDE DOOR LOCK QUICK CHECK PROCEDURE
Approach Vehicle
Obtain RKE Fob
Lower Window Glass
Close Door
Actuate Power LOCK with RKE Fob
Pull O/S Door Handle to Verify Door Locked
Push down on Lock Knob to Verify Full Travel--Note if knob travels further continue to step 10, then see procedure below *
Actuate Power UNLOCK with RKE Fob
Pull O/S Door Handle to Verify Door Unlocked
Pull Up on Lock Knob to Verify Full Travel--Note if knob travels further--see procedure below *
*If rod travel is restricted, remove trim panel and repeat procedure beginning at step 4.

Note: Repeating this procedure is to verify the door latch is fully functional. If latch is functioning properly per this procedure, DO NOT REPLACE latch.

ChevyMgr
06-15-2009, 09:25 AM
#PIP3144C: Poor Acceleration From A Stop Or Detonation In Gear At A Stop - keywords DTC low MIL ping - (Jun 12, 2009)


Subject: Poor Acceleration from a Stop or Detonation in Gear at a Stop


Models: 1996-2009 All General Motors Passenger Cars and Light Duty Trucks

--------------------------------------------------------------------------------
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Customer concern of poor acceleration, detonation or "ping" at idle in drive or reverse, and/or possible DTC P0101, P0106 and/or P0121 set in the PCM. The vehicle will perform properly after attaining a speed of about 30 - 40 mph. The condition may also be described by the customer or the dealer as a hesitation, stall when putting into gear, surge on acceleration (similar to hitting fuel cut off or rev limiter). The ultimate cause may be a non-holding torque converter stator or damaged stator support shaft within the automatic transmission.

Recommendation/Instructions:
Important Note: Do not follow the below diagnostics until published SI diagnostics have been followed COMPLETELY. If all published SI diagnostics have been exhausted the following information may help in isolating a possible torque converter concern.

The following checks should be performed in the event that normal engine driveability checks have not resolved the detonation or "ping" at idle in drive or reverse, lack of power from a stop, stall, and surge on acceleration and or hesitation complaint.

The IAC counts throttle angle and/or MAP voltage and KPA should be compared to a like vehicle in park and in gear after reaching operating temperature. If the counts and map are high or throttle angle is open excessively in comparison this may be a result of high engine load and a torque converter and or stator support shaft related concern.

If the above information does not lead to resolution, follow torque converter diagnostics listed below:

The transmission oil cooler outlet line (line to the cooler) should be checked for excessive heat. The Tech II scan tool may be helpful on vehicles equipped with the transmission fluid temperature sensor in the cooler line (mainly front wheel drive). On vehicles that do not have the temperature sensor in the cooler line a temperature probe should be used to check the temperature. The temperature readings should be compared to a like vehicle with the same powertrain option content.

A stall test (brake torque) may point to a damaged torque converter; the stall rpm speed will be lower than a like vehicle. However, poor engine performance will also produce a lower stall speed rpm.

If the torque converter stator or stator support is suspect, the transmission should be removed and THE STATOR SUPPORT SHOULD BE INSPECTED FOR SPLINE DAMAGE. If the stator support splines are damaged the transmission should be repaired and new torque converter installed. If damage is not present on the stator support the concern is either internal to the torque converter stator or an engine performance concern.

ChevyMgr
06-19-2009, 08:21 AM
#PIC5014B: Odor In Vehicle After Water Leak - Supplement to Bulletin 07-08-57-001 - (Jun 18, 2009)


Subject: Odor in vehicle after water leak - Supplement to Bulletin 07-08-57-001


Models: 2006-2009 Chevrolet HHR
--------------------------------------------------------------------------------

This PI was superseded to provide technical direction in lieu of contacting BQM. Please discard PIC5014A.


--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may notice an odor in the vehicle following a water leak concern.

Recommendation/Instructions:
The common cause for odor is the water leaks. Dealers should thoroughly review that all steps in the current version of TSB 07-08-57-001 have been followed. Even if one possible leak has been identified and resolved it is not uncommon to find additional leaks.

Once all leaks have been corrected it is important to ensure that all affected areas are completely dried and cleaned. Not following this important step can lead to odor due to mold and mildew.

Important: DO NOT REPLACE carpets, seats, insulation, etc unless all attempts to clean with approved deodorizer have failed. A thorough cleaning normally will remove the odor.

In some cases following a water leak the seam sealer may have an undesirable odor due to the chemical reaction of the sealer and the water. In the event this has occurred then care must be taken to completely remove the seam sealer from the areas shown below and replace the sealer with a latex base seam sealer.

5186

5187

5188

ChevyMgr
06-25-2009, 05:42 PM
#07-08-45-003A: Intermittent No Start/Long Crank, Start then Stall, Check Engine Light On, Airbag Light On, Reduced Power Steering Assist, Intermittently Functioning or Inop Electrical Systems, DTC P0442 or P0449 Set - (Jun 22, 2009)


Subject: Intermittent No Start/Long Crank, Start Then Stall, Check Engine Light On, Airbag Light On, Reduced Power Steering Assist, Intermittently Functioning or Inoperative Electrical Systems, DTC P0442 or P0449 Set (Inspect UBEC and Replace Connectors, As Necessary)


Models: 2006-2009 Chevrolet HHR

2006-2009 Pontiac Solstice

2007-2009 Saturn SKY

2007-2009 Opel GT

2007-2008 Daewoo G2X


Condition
Some customers may comment about one or more of the following conditions:

• Intermittent no start

• Intermittent extended crank

• Intermittent start then stall

• Intermittent check engine light illuminated

• Intermittent reduced power steering assist

• Intermittent airbag light illuminated

• Intermittently functioning or inoperative electrical systems

Upon investigation, the technician may find DTC P0442 or P0449 set as current or in history. These DTCs may also be accompanied by other DTCs.

Cause

5209

5210

These conditions may be caused by poor electrical contact between the underhood fuse block (UBEC) and its connectors. This poor contact may be due a bent or twisted male terminal (as shown above) on the UBEC side. During assembly when the UBEC is bolted to the connectors, the male terminal contacts the edge of the mating female terminal and pushes the terminal (1) out of the cavity. When this occurs, the terminal lock on the connector breaks and the terminal will no longer lock into the connector.

Correction
Remove the UBEC from the connectors. Visually inspect the suspect connector to see if the terminal has been pushed out of its cavity. If the terminal has been pushed out of its cavity, the terminal lock is damaged and connector replacement is required. Also, inspect the terminal for damage and replace if necessary. Straighten the UBEC male terminal (use a business card as a straight edge). If the terminal is twisted, attempt to straighten it using needle nose pliers.

Parts Information
Part Number Description

88988759 Connector, Engine Wiring (C1 or X1)

88988756 Connector, Engine Wiring (C2 or X2)

19115601 Connector, Engine Wiring (C3 or X3)

19115600 Connector, Engine Wiring (C4 or X4)

ChevyMgr
06-25-2009, 05:46 PM
#: Instrument Panel Cluster (IPC) Air Bag Indicator Illuminated (Install Protective Material) - (Jun 23, 2009)


Subject: Instrument Panel Cluster (IPC) Air Bag Indicator Illuminated (Install Protective Material)


Models: 2007-2009 Chevrolet Cobalt

2008-2009 Chevrolet HHR SS

2006-2009 Pontiac Solstice

2007-2009 Pontiac G5

2007-2009 Saturn SKY

2007-2009 Opel GT

2007-2008 Daewoo G2X

Built Prior to 02-02-09
--------------------------------------------------------------------------------

Condition
Some customers may comment that the air bag indicator lamp, located in the instrument panel cluster, is illuminated.

Upon performing a DTC check, the technician may find a B0012-02, B0012-0E, B0013-02 or B0013-0E code stored in the supplemental inflatable restraints (SIR) system.

Cause

5211

This condition may be caused by a short to ground in the yellow SIR wiring harness. This wiring harness is located within the steering wheel assembly and connects the steering wheel inflatable restraint module to the steering wheel inflatable restraint module coil. A sharp edge on the steering wheel stamped steel horn plate may rub through the yellow SIR wiring harness insulation, allowing the harness to ground to the horn plate.

Correction
Remove the steering wheel inflatable restraint module. Refer to Steering Wheel Inflatable Restraint Module Replacement in SI.

5212

Inspect the yellow SIR wiring harness that connects the steering wheel inflatable restraint module to the steering wheel inflatable restraint module coil. Look for any chafing, cracks or areas where the wiring, insulation or protective wire sleeve has been damaged.
If the inspection of the wiring harness reveals a condition that may allow the wiring to short to ground, replace the steering wheel inflatable restraint module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement in SI for replacement procedures.
With the steering wheel inflatable restraint removed, use the following steps to install a piece of adhesive-backed flocking material to the stamped steel horn plate in order to prevent future damage to the SIR wiring harness.
4.1. Prepare a 15 mm (19/32 in) X 70 mm (2-3/4 in) piece of adhesive-backed flocking material (such as Kent Industries Part KY13487* or the equivalent).

5213

4.2. Install the flocking material to the stamped steel horn plate as shown. Center the length of the flocking material on the horizontal edge of the opening in the horn plate. Ensure that 5-7 mm (1/4 in) of the flocking material overlaps the front and back of the horn plate. The flocking material must cover the complete length of the horizontal opening. Press (pinch) along the length of the flocking material to ensure adhesion to the horn plate.

Install the steering wheel inflatable restraint module. Refer to Steering Wheel Inflatable Restraint Module Replacement in SI.
* We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources.

Parts Information
This product is currently available from Kent Industries (1-888-YES-KENT).

Part Number Description Quantity

KT13487 BRS Adhesive-Backed Flocked Material 15 mm (19/32 in) X 70 mm (2-3/4 in)

ChevyMgr
07-08-2009, 01:36 PM
#PIP4669A: Intermittent DTC P2261 Setting - (Aug 10, 2009)


Subject: Intermittent DTC P2261 Setting


Models: 2008-2010 Chevrolet Cobalt SS

2008-2010 Chevrolet HHR SS
--------------------------------------------------------------------------------

This PI was superseded to update model years. Please discard PIP4669.


--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A technician may find DTC P2261: Turbocharger Bypass Valve Stuck Closed set with no problem found. It may be intermittent in nature or they may find the dtc will set after a hard acceleration, usually in third gear. DTC P2261 is a type B dtc and will not set on the first drive cycle the dtc sets, therefore multiple test drives should be performed to confirm repair.

Recommendation/Instructions:
SI diagnostics for this DTC states that the ECM compares the measured MAF reading to the modeled MAF and has detected a series of pulsations in the induction system that exceed a calibrated threshold. A snapshot of "Induction Data" will show the fault, however the tech may need to compare the snapshot data to another vehicle if they are unfamiliar with the readings. They should note a fluctuation and or a difference in the desired versus requested boost level. When diagnosing this dtc pay close attention to Circuit/System testing step #1. This step has you inspecting for any vacuum leaks, damage, restrictions, improper routing or connecting of the vacuum hoses on the charge air bypass valve solenoid, the charge air bypass valve, and the charge air bypass valve vacuum tank.

We have found leaking vacuum tanks causing this dtc. When testing the vacuum tank, care must be used or the results may not be valid. The vacuum tank has an integral check valve not noted in SI. To check the Vacuum Tank operation, disconnect the hose that runs from the tank to the Bypass Valve Solenoid at the solenoid and apply vacuum to the tank. The tank should be able to maintain vacuum with no decay. Note: If you remove the vacuum hose from the intake manifold and plug it and the decay stops the check valve is leaking, if the decay continues the tank itself is leaking.

Note: Front wheel drive platforms using the 2.0 Liter RPO (LNF) incorporate a charge air bypass valve supplemental vacuum tank. The purpose of the tank is to provide an instant source of vacuum to the bypass valve via the bypass solenoid (when it is commanded open by the ECM). This results in less pressure buildup under closed throttle conditions, thereby reducing compressor noise, surge and spool time.

ChevyMgr
07-22-2009, 10:18 AM
#09126: Service Update for Inventory and Customer Vehicles-Charge Air Cooler Inlet Duct Detachment - (Jul 21, 2009)


Subject: 09126 -- Service Update for Inventory and Customer Vehicles - Charge Air Cooler Inlet Duct Detachment - Expires with Base Warranty


Models: 2008-2009 Chevrolet Cobalt SS, HHR SS

Equipped with a Manual Transmission
--------------------------------------------------------------------------------

THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN TO THE DEALERSHIP FOR ANY REASON. IT WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD.

Purpose
This bulletin provides a service procedure to install a new stud and retainer on certain 2008-2009 model year Chevrolet Cobalt SS and HHR SS vehicles equipped with a manual transmission. On these vehicles, the charge air cooler inlet duct may become detached and contact the high pressure fuel pump connector. This contact could eventually cause damage to the connector, causing the fuel pump to become inoperative. If this were to happen, the Engine Power Reduced message would illuminate in the DIC and the maximum vehicle speed would be reduced to 20 mph (32 km/h).

This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period.

Vehicles Involved
A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in GM GlobalConnect (US) or attached to the Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below.

Year Division Model From Through

2008 Chevrolet Cobalt SS 87229258 8735153

2009 Chevrolet Cobalt SS 97100001 97254608

2008 Chevrolet HHR SS 8S581592 8S722574

2009 Chevrolet HHR SS 9S500006 9S621588


Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved.

Parts Information
Parts required to complete this service update are to be obtained from General Motors Service and 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 Qty/ Vehicle

11570937 Stud, Chrg Air Clr Brkt Plt 1

90278102 Retainer, Chrg Air Clr 1


Service Procedure

http://www.chevyhhr.net/gallery/files/4/8/6/5/09126A.gif


(1) First Design Stud
(2) Second Design Stud
(3) Retainer Clip

Open the hood.

http://www.chevyhhr.net/gallery/files/4/8/6/5/09126B.gif

Locate the charge air cooler (CAC) duct (4).

http://www.chevyhhr.net/gallery/files/4/8/6/5/09126C.gif

Remove the CAC duct (4) off of the first design mounting stud (1).

http://www.chevyhhr.net/gallery/files/4/8/6/5/09126D.gif

Remove and discard the first design mounting stud (1).

http://www.chevyhhr.net/gallery/files/4/8/6/5/09126E.gif

Install the second design mounting stud (2).

http://www.chevyhhr.net/gallery/files/4/8/6/5/09126F.gif

Secure the CAC duct (4) onto the second design mounting stud.

http://www.chevyhhr.net/gallery/files/4/8/6/5/09126G.gif

Install the retainer clip (3) to the second design mounting stud. Ensure that the retainer clip is installed properly.

Close the hood.

ChevyMgr
07-22-2009, 10:45 AM
#09-06-93-004: Intermittent MIL/Check Engine Light On, DTC P0299 or P0234 Set (Adjust Turbocharger Wastegate Actuator) - (Jul 21, 2009)


Subject: Intermittent MIL/Check Engine Light On, DTC P0299 or P0234 Set (Adjust Turbocharger Wastegate Actuator)


Models: 2008-2009 Chevrolet Cobalt, HHR

2008-2009 Pontiac Solstice GXP

2008-2009 Saturn SKY Redline

2008-2009 Opel GT

2008 Daewoo G2X

with Engine RPO LNF and LDK (Europe)

Please Refer to GMVIS
--------------------------------------------------------------------------------

Condition
Some customers may comment that the SES light is on. Upon inspection, you may find DTC P0299 (Turbocharger Engine Underboost) or P0234 (Turbocharger Engine Overboost) set.

Cause
This condition may be caused by a mis-adjusted wastegate.

Correction
Note: The wastegate adjustment is sometimes a very fine process. When adjusting the wastegate, only small adjustments should be made. Loosen one nut at a time and only adjust the nut one turn at a time; then tighten the other nut against the shaft and test drive to verify. This may have to be performed several times to achieve the desired boost level. To ensure proper adjustment, the vehicle should be at full operating temperature when testing. The vehicle will be very hot and may need to cool between adjustments. Too large of an adjustment can cause repeat DTCs.

Adjust the turbocharger wastegate. Refer to Turbocharger Wastegate Actuator Adjustment in SI.

Troubleshooting Tips for DTC P0299 - Turbocharger Engine Underboost
To increase boost, adjust the nuts (in) towards the actuator; in essence making the shaft shorter.

Troubleshooting Tips for DTC P0234 - Turbocharger Engine Overboost
To reduce boost, adjust the nuts (out) towards the end of the shaft; in essence making the shaft longer.

ChevyMgr
07-22-2009, 10:54 AM
#09-07-29-004: Information on Revised Getrag 5-Speed Manual Transmission (RPO M86) Fluid Usage - (Jul 14, 2009)


Subject: Information on Revised Getrag 5-Speed Manual Transmission (RPO M86) Fluid Usage


Models: 2008 Chevrolet HHR

Equipped with Manual Transmission (RPO M86)
--------------------------------------------------------------------------------

For 2008, the transmission fluid for the manual transmission (2.2L and 2.4L L4 engines) in the Owner Manual lists manual transmission fluid P/N 88861801. This fluid part number is incorrect.

Use DEXRON-VI® P/N 88861003 (U.S.) (in Canada, P/N 88861004) when replacing manual transmission fluid. DEXRON-VI® usage begins in 2008-2010. Please make this correction to the Owner Manual to reflect the correct part number.

Parts Information Part Number Description

88861003 (US)

88861004 (Canada) DEXRON-VI®

ChevyMgr
07-22-2009, 10:57 AM
#09-08-67-011: Squeaking Noise Upon Operation of Sunroof (Trim Roof Panel Sound Deadener Foil) - (Jul 9, 2009)


Subject: Squeaking Noise Upon Operation of Sunroof (Trim Roof Panel Sound Deadener Foil)


Models: 2008-2009 Chevrolet HHR

with Sunroof (RPO CF5)

--------------------------------------------------------------------------------

Condition
Some customers may comment on hearing a squeaking noise when opening/closing the sunroof glass.

Cause
This condition may be caused by an area of the roof panel sound deadener foil losing retention, hanging down and contacting the sunroof glass.

Correction
Verify the condition and trim the roof sound deadener foil following the steps below:

Fully close the sunroof glass and sunshade.
In order to access the underside of the roof panel, lower the headliner. Refer to Headlining Trim Panel Replacement in SI.

5353

Inspect the roof sound deadener foil for any areas that are loose and hanging down (1).

5354

Using a utility knife, or similar tool, trim away the loose foil.
Important: Before completely installing the headliner, operate the sunroof to ensure the noise is gone.

Reinstall the headliner. Refer to Headlining Trim Panel Replacement in SI.

ChevyMgr
07-22-2009, 11:07 AM
#PIE0003: EI09140 - Engine Oil Leak From Crankshaft Front Oil Seal (Engineering Information) - (Jul 17, 2009)


Subject: EI09140 -- Engine Oil Leak From Crankshaft Front Oil Seal (Engineering Information)


Models: 2009 Chevrolet Cobalt, Cobalt SS, HHR, HHR SS, Malibu

2009 Pontiac G5, G6, Solstice, Solstice GXP

2009 Saturn Aura, Sky, Sky Redline

Equipped with Engine RPO LAP, LE5, LE8, LE9 or LNF



Attention: Proceed with this bulletin ONLY if the customer has commented about this concern AND the EI number is listed in GMVIS. If the customer has not commented about this condition or the EI does not show in GMVIS, disregard the bulletin and proceed with diagnostics found in published service information. THIS IS NOT A RECALL -- refer to Service Bulletin 04-00-89-053B for more detail on the use of Engineering Information bulletins.

--------------------------------------------------------------------------------

Condition
Important: If the customer did not bring their vehicle in for this concern, DO NOT proceed with this bulletin.

Some customers may comment on an oil leak under the vehicle.

Further inspection will reveal the leak to be engine oil and show the leak is coming from the crankshaft front oil seal.

Cause
GM Engineering is attempting to determine the cause of the engine oil leak. General Motors has a need to gather information first-hand from the dealer technician DURING diagnosis and BEFORE repair. As a result, this information will be used by engineeering to help "root cause" the customer's concern and develop/validate a field fix.

Instructions
Important: GM Engineering is only interested in vehicles that have 16,093 km (10,000 mi) or less mileage.

First, verify the leak is engine oil using a leak detection lamp and dye. If the leak is engine oil and it is determined to be coming from the crankshaft front oil seal, please contact the engineer listed below for additional instructions. If the vehicle has mileage higher than 16,093 km (10,000 mi), proceed with diagnosing and repairing the vehicle based on information found in SI. Submit a Field Product Report with the repair information.

ChevyMgr
07-22-2009, 11:14 AM
#PIP4674: Blocked Shift Gear Hop Out 1st 3rd 5th Gear Or Dificulty Shifting - (Jul 21, 2009)


Subject: Blocked Shift, Gear Hop Out, 1st, 3rd, 5th Gear Or Difficulty Shifting


Models: 2005-2010 Chevrolet Cobalt

2006-2010 Chevrolet HHR

2005-2009 Pontiac G5, Pursuit

2003-2007 Saturn Ion

2004-2007 Saturn VUE

Equipped With A Getrag Manual Transmission RPO M86 Or MG3
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may comment about hop-out or blocked shift of 1st, 3rd and 5th gears or difficulty shifting the above listed manual transmissions. The shift lever roll pin can back out and contact the shift cover during a shift event. This can cause an incomplete, blocked shift or difficulty shifting the transmission. See photos, the first two are of a dislodged roll pin and the last two are of a correctly installed roll pin.

Recommendation/Instructions:
Prior to any internal transmission repairs inspect the shift cover and lever to see if the roll pin has backed out and is dragging on or contacting the housing. If roll pin contact is evident then the shifting difficulty may NOT be an internal transmission concern.

If the shift cover shows witness marks from contact with the roll pin, dealers should replace the complete shift cover assembly, item #1 as shown in SI document #881811.

Important: Do not replace the transmission for this concern.

If the roll pin is not dislodged follow published SI diagnostics.

5355

5356

5357

5358

ChevyMgr
08-06-2009, 08:03 AM
#PIC4992: Hard Or Difficult Shifts With Manual Transaxle - keywords 5sp adjustment block cable first fifth fourth gear MU3 reverse second shift shifter third transmission - (Oct 3, 2008)

Subject: Hard or Difficult Shifts with Manual Transaxle


Models: 2008-2009 Chevrolet Cobalt SS, HHR SS

Equipped With RPO MU3 Manual Transmission
--------------------------------------------------------------------------------
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may comment about hard or difficult shifts to any gear in the Chevrolet Cobalt SS and HHR SS equipped with RPO MU3 manual transmission.

Recommendation/Instructions:
The technician should verify that it is hard or difficult to shift to any gear. As described in the owner's manual, a second attempt at shifting to FIRST (1) may be necessary if the car is not moving. When shifting to REVERSE (R), the lift ring below the shift knob must be used. A second attempt at shifting to REVERSE (R) may be necessary. Once the technician has verified that it is hard or difficult to shift to any gear, he/she should check for the following conditions prior to any repairs:

Shift and select cable ends are correctly installed on shift and select levers on transmission.
Shift and select cables are correctly routed in vehicle.
Shift and select cable housings are fully seated into bracket on transmission.
Shift and select cable housings are fully seated into shifter support/housing assembly.
Shift and select cables are correctly adjusted (see Shift Cable Adjustment in SI)
Note: If the shift cables and levers are properly connected, adjusted and routed please follow SI document 1731557 for hard to shift related concerns.

ChevyMgr
08-06-2009, 08:51 AM
#PIC4738B: iPod Compatibility With GM PAL - keywords accessories accessory apple audio band compatible connect connector electrical entertainment link nano personal PIC4738A radio touch - (Aug 17, 2009)


Subject: iPod Compatibility With GM PAL


Models: 2008-2009 Buick Enclave

2006-2009 Chevrolet HHR

2007-2009 Chevrolet Cobalt

2008-2009 Chevrolet Avalanche, Malibu, Silverado, Suburban, Tahoe, Traverse

2008-2009 GMC Acadia, Sierra, Yukon, Yukon XL

2008-2009 Hummer H2

2006-2009 Pontiac Solstice

2007-2009 Pontiac G5

2007-2009 Saturn Sky

2008-2009 Saturn Aura, Outlook

--------------------------------------------------------------------------------

This PI was superseded to add 2009 models and Note about certain IPod. Please discard PIC4738A.

--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
The following Apple iPod models have been tested and proven to be compatible with the GM Personal Audio Link (PAL) accessory system.

• iPod Touch 2nd gen. (See Note 1 Below)


• iPod Touch


• iPod Classic 120GB (See Note 1 Below)


• iPod Classic


• iPod 5th gen. (Late 2006) (60/80GB)


• iPod w/ Video 5th gen (20/60GB)


• iPod Color (20 GB, 30 GB, and 60 GB)


• iPod Photo (40 GB, 60 GB)


• iPod with Click Wheel (20 GB, 40 GB including U2 Special Edition)


• iPod with Dock Connector (10 GB, 15 GB, 20 GB, 30 GB, 40 GB)


• iPod Nano 4th gen. (See Note 1 Below)


• iPod Nano 3rd gen.


• iPod Nano 2nd gen.


• iPod Nano


• iPod Mini 2nd gen.


• iPod Mini


Remaining models are not compatible or have not yet been tested.

Notie: Some iPod models may have minor functionality concerns example: the ABC search, while in the Album category, may not work properly. Before replacing any components try other iPod models.

Note 1: Currently, the GM PAL system does not support USB charging. The iPod's listed above referring to this NOTE only have USB charging and therefore will not charge when connected to the vehicle. They will function properly without charging.

Recommendation/Instructions:
Visit http://www.apple.com/support/ipod/ to help identify your iPod model.

ChevyMgr
08-07-2009, 12:23 PM
#09-08-64-029: Drivers Front Side Door Power Lock Intermittent Operation, Binding, Sticking (Revise Front Side Door Trim Panel) - (Aug 6, 2009)


Subject: Drivers Front Side Door Power Lock Intermittent Operation, Binding, Sticking (Revise Front Side Door Trim Panel)


Models: 2009 Chevrolet HHR Built Before 08-17-2009
--------------------------------------------------------------------------------

Condition
Some customers may comment that the driver's front side door power lock may not function when using the key FOB or the interior mounted power lock control switch. This may be an intermittent condition and only applies to the driver's side front door. The door can be locked and unlocked using the door mounted manual lock control knob.

Cause
This condition may be caused by excessive trim panel material in the front side door lock manual control knob hole. This excess material may cause the manual lock control knob to bind and prevent power actuation of the lock.

Correction
Important: Do not replace the front side door trim panel to correct this condition.

Use the following procedure to trim the excess material from the front side door lock manual control knob hole.

5449


Examine the lock knob hole in the front side door trim panel. Excess material should be visible on the inboard side of the hole as shown.
Remove the front side door trim panel. Refer to Front Side Door Trim Panel Replacement in SI.

5450

Use a small round file to trim the excess material, approximately 1.0 mm (3/64 in) as shown (the trim panel in the graphic has been cut away to show the area that needs to be trimmed). Use care to not remove any material from the grained exterior surface of the trim panel.

5451

Ensure that the lock control knob can move freely in the hole as shown.
Finish any rough edges with a fine file or fine sandpaper.
Reinstall the front side door trim panel. Ensure that the top retention fin on the trim panel is engaged in all four clips on the door. Refer to Front Side Door Trim Panel Replacement in SI.
Cycle the power lock function to verify the condition has been corrected.

ChevyMgr
08-11-2009, 09:28 AM
#09-02-35-005B: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder) - (Feb 4, 2010)


Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition Cylinder)


Models: 2008-2009 Cadillac CTS (Built Prior to VIN Breakpoint 90163371)

2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009)

2006-2010 Chevrolet HHR (Built Prior to February 1, 2010)

2007-2009 Chevrolet Equinox (Built Prior to July 2008)

2005-2006 Pontiac Pursuit (Canada Only)

2006-2009 Pontiac Solstice (Built Prior to April 14, 2009)

2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008)

2006-2009 Saturn SKY (Built Prior to April 24, 2009)

Attention: This bulletin only applies to vehicle equipped with automatic transmission.
--------------------------------------------------------------------------------

This bulletin is being revised to update the build date and add the 2010 HHR. Please discard Corporate Bulletin Number 09-02-35-005A (Section 02 -- Steering).
--------------------------------------------------------------------------------

Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder.

Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder assembly and coding, use the instructions provided with the new cylinder.

Important: To properly seat the new ignition lock cylinder into the housing, the key must be inserted and turned to the RUN position.

Parts Information
Part Number Description

20869121 Cylinder, Ignition Lock (Uncoded)

ChevyMgr
08-11-2009, 09:30 AM
#PIP3535A: Whine Noise From Timing Chain Area - (Aug 10, 2009)


Subject: Whine Noise From Timing Chain Area


Models: 2002-2005 Chevrolet Cavalier

2004-2010 Chevrolet Cobalt (Including Cobalt SS)

2010 Chevrolet Equinox

2006-2010 Chevrolet HHR (Including HHR SS)

2004-2010 Chevrolet Malibu (Including Hybrid)

2004-2005 Chevrolet Malibu Classic

2010 GMC Terrain

2002-2004 Oldsmobile Alero

2007-2010 Pontiac G5

2006-2010 Pontiac G6

2002-2005 Pontiac Grand Am, Sunfire

2005-2006 Pontiac Pursuit (Canada Only)

2006-2009 Pontiac Solstice (Including GXP)

2007-2010 Saturn Aura (Including Hybrid)

2003-2007 Saturn Ion (Including Redline)

2001-2005 Saturn L Series

2007-2009 Saturn Sky, (Including Redline)

2002-2010 Saturn Vue (Including Hybrid)

2003-2010 Saab 9-3

With any of the following engines:

2.0L Engine (LSJ)

2.0L Engine (LNF)

2.2L Engine (LAP)

2.2L Engine (L61)

2.4L Engine (LE5)

2.2L Engine (LE8)

2.4L Engine (LE9)

2.4L Engine (LAF)

2.4L Engine (LAT)

2.0L Engine (B207)
--------------------------------------------------------------------------------

This PI was superseded to update model years and engines involved. Please discard PIP3535.


--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A whine noise from the front of the engine may be experienced if the balance shaft tensioner has ratcheted out, causing the balance shaft chain to be too tight. In rare instances the balance shaft tensioner will ratchet out during service of the cylinder head, timing chain or if the water pump is replaced without using the water pump sprocket holding tool (J43651). This will cause the balance shaft chain to be too tight, which can cause a whine noise from the front of the engine.

Recommendation/Instructions:
Before attempting repairs, ensure that the noise is definitely abnormal by comparing the noise to other known good vehicles. If the noise is abnormal and the noise was not present previously, the balance shaft chain tensioner may need to be reset or replaced. Follow eSI repair procedures and reset/replace the balance shaft chain tensioner as needed.

ChevyMgr
08-13-2009, 08:15 AM
#09-08-50-013: Information on Front Passenger Heated Seat Insufficient Heat - (Aug 12, 2009)


Subject: Information on Front Passenger Heated Seat Insufficient Heat


Models: 2009-2010 Chevrolet HHR (Excluding SS Model)

--------------------------------------------------------------------------------

The passenger seat, by design, has a smaller heating surface area than the driver seat. The driver seat has a heating element on the insert and front thigh area of the cushion. The passenger seat has a heating element on the insert of the cushion only; therefore, the passenger seat heat may not feel as warm as the driver seat heat.

In addition, the time to heat will be longer on the passenger seat than driver seat due to the passenger presence sensor (PPS) mat assembled on top of the heater element.

Important: Do not replace the heater element for this concern.

Advise the customer that the passenger and driver heated seats are working as designed. If additional symptoms are diagnosed, refer to Seat Heating and Cooling in SI.

Passenger Seat

5494


(1) Passenger Presence Sensor Mat (assembled on top of the heater element - the heater element is located on the insert of the cushion only)

Driver Seat

5495


(1) Heater Element (located on the insert and the front thigh area of the cushion)

ChevyMgr
09-08-2009, 02:50 PM
#PIC5236: Difficulty Installing New Ignition Lock Cylinder (Supplement To TSB 09-02-35-005A) - (Sep 4, 2009)


Subject: Difficulty installing new ignition lock cylinder (supplement to TSB 09-02-35-005A)


Models: 2008-2009 Cadillac CTS (Built Prior to VIN Breakpoint 90163371)

2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009)

2006-2009 Chevrolet HHR (Built Prior to April 14, 2009)

2007-2009 Chevrolet Equinox (Built Prior to July 2008)

2005-2006 Pontiac Pursuit (Canada Only)

2006-2009 Pontiac Solstice (Built Prior to April 14, 2009)

2007-2009 Pontiac G5 (Built Prior to April 14, 2009), Torrent (Built Prior to July 2008)

2006-2009 Saturn SKY (Built Prior to April 24, 2009)

With Automatic Transmission Only
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some dealers may report difficulty installing the new style ignition lock cylinder.

Recommendation/Instructions:
Before installing the new cylinder it is important to carefully inspect the housing for debris or damage from the old lock cylinder. No tools are required for installing the new lock cylinder. When installing into the housing, ensure that the lock cylinder is fully seated to ensure it latches into position.

DO NOT use the old style lock cylinder that is still used on the manual transmission vehicle on an automatic transmission car. The original binding condition will likely return.

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.

ChevyMgr
09-09-2009, 08:09 AM
Bulletin No.:09014
Date:September 2009
Special Coverage


SPECIAL COVERAGE
SUBJECT: SPECIAL COVERAGE ADJUSTMENT – ENGINE CONTROL MODULE -
EMISSION RELATED REPROGRAMMING
MODELS: 2006 CHEVROLET COBALT, HHR
2006 PONTIAC PURSUIT (CANADA ONLY)
2006 SATURN ION
WITH 2.2L (L61) ENGINE

CONDITION

Engine control modules on certain 2006 model year Chevrolet Cobalt, HHR; Pontiac Pursuit; and Saturn ION vehicles, equipped with a 2.2L engine (RPO L61), may randomly fail to respond to single information requests made by an On-Board Diagnostic (OBD) emission test device, generic scan tool, or other aftermarket devices that plug into the vehicle's Data Link Connector (DLC).
GM Tech 2® scan tools are not affected by this condition. It is possible that the lack of a single ECM response to an emission test tool could result in
missing or inaccurate OBD emission test data (for example no or partial electronic VIN display) resulting in a customer's vehicle failing or being rejected from a state/province mandated OBD emission test (Inspection and Maintenance (I/M) Test or Smog Check).

SPECIAL COVERAGE ADJUSTMENT
This special coverage covers ECM reprogramming for the condition described above for a period of 15 years or 150,000 miles (240,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. ECM reprogramming will be performed at no
charge to the customer. This special coverage does not apply to vehicles that have previously been reprogrammed with the updated software (November 15, 2006, or later) or for repairs that are not related to this
condition. Repairs to address issues such as malfunction indicator light (MIL) illumination, stored diagnostic trouble codes, unset readiness monitors, component/circuit repair or replacement, etc., do not apply to this special coverage. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 8, 2009, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 8, 2009, must be submitted to the Service Contract provider.

VEHICLES INVOLVED
Involved are certain 2006 model year Chevrolet Cobalt, HHR; Pontiac Pursuit; and Saturn ION vehicles, equipped with a 2.2L (RPO L61) 4-cylinder engine and built within the following VIN breakpoints:

YEAR DIVISION MODEL FROM THROUGH
2006 Chevrolet Cobalt 67600003 67887446
2006 Chevrolet HHR 6S500043 6S679770
2006 Pontiac Pursuit 67600110 67887269
2006 Saturn ION 6Z100015 6Z211250

Important: Dealer/retailers using the Global Warranty Management (GWM) system are to confirm vehicle eligibility prior to beginning repairs by using the "Investigate Vehicle History" link on the GWM application within Global Connect. Special coverages are displayed in the Applicable Warranties section.

PARTS INFORMATION
No parts are required for this special coverage.

SERVICE PROCEDURE
1. Determine if the ECM has been programmed on or after 11/15/06 using GMVIS.
• If the ECM was reprogrammed on or after 11/15/06, programming of the ECM is NOT required. The ECM has been programmed with the most recent OBD information and does not have the condition described in this special coverage. Diagnose and repair vehicle based on standard warranty coverage policies, if applicable.
• If the ECM was not programmed on or after 11/15/06, programming of the ECM is required.

ChevyMgr
09-30-2009, 02:09 PM
#09-08-49-016: Accelerator Pedal is Out of Place or Has Unusual Movement (Replace IP Module Plate) - (Sep 22, 2009)


Subject: Accelerator Pedal is Out of Place or Has Unusual Movement (Replace IP Module Plate)


Models: 2009 Chevrolet HHR

Equipped with Automatic Transmission (RPO MN5)

Built Prior to VIN Breakpoint 9S639466

--------------------------------------------------------------------------------

Condition
Note: This condition does not affect the function of the accelerator pedal.

Some customers may experience an accelerator pedal that is out of place or has unusual movement when depressing the pedal. Upon further diagnosis, the technician may find broken or loose mounting studs for the pedal.

Correction
Replace the Instrument Panel (IP) module plate following the procedure listed below.

Recover the A/C refrigerant and drain the coolant.
Remove the console. Refer To Front Floor Console Extension Replacement Center.
Remove the IP center support bracket. Refer to Instrument Center Support Bracket Replacement.
Remove the passenger side air bag. Refer to Inflatable Restraint Instrument Panel Module Replacement.
Remove the IP center compartment. Refer to Instrument Panel Center Compartment Replacement.
Remove the instrument cluster. Refer to Instrument Cluster Replacement.
Remove the upper trim pad. Refer to Instrument Panel Upper trim Pad Replacement.
Remove the radio and HVAC controller.
Remove the steering column. Refer to Steering Column Replacement.
Remove the lower IP.
Without disconnecting the brake pipes from the master cylinder, reposition the master cylinder assembly to allow for the removal of the vacuum brake booster.
Remove the four nuts and the booster.
Remove the pushrod retaining clip. Loosen the brake booster mounting nuts to aid in releasing the pushrod from the brake pedal.
Remove the A/C lines from the evaporator and the heater hoses from the heater core.
Remove the barrier pad.
Disconnect the accelerator pedal position (APP) sensor electrical connector. Remove the three nuts and APP sensor from the vehicle.
Remove the bolts from the module plate and the six bolts from the tie bar. Remove the module plate, tie bar and the A/C module as a one assembly.
Install the new module plate, P/N 20842465.
Install the module plate barrier pad and barrier pad.
Install the A/C module and tie bar and tighten the bolts.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).

Install the accelerator pedal assembly and the electrical connector. Install the nuts and tighten.
Tighten
Tighten the nuts to 10 N·m (89 lb in).

Install the A/C lines to the evaporator and the heater hoses to the heater core.
Apply a bead of RTV around the master cylinder gasket and install the master cylinder. Tighten the bolts.
Tighten
Tighten the bolts to 22 N·m (16 lb ft).

Install the buster rod to the brake pedal and install the retainer.
Install the lower IP.
Install the steering column. Refer to Steering Column Replacement in SI.
Install the radio and HVAC controller.
Install the upper trim pad. Refer to Instrument Panel Upper Trim Panel Replacement.
Install the instrument cluster. Refer to Instrument Cluster Replacement.
Install the IP center compartment. Refer to Instrument Panel Center Compartment Replacement.
Install the passenger side air bag. Refer to Inflatable Restraint Instrument Panel Module Replacement.
Install the IP center support bracket. Refer To Instrument Center Support Bracket Replacement.
Install the console. Refer to Front Floor Console Extension Replacement Center.
Recharge the A/C refrigerant and refill the coolant.
Parts Information
Part Number Description

20842465 PLATE ASM-DA PNL REINF

ChevyMgr
09-30-2009, 02:12 PM
#PIC5248: Intermittent Backlighting Flare Or Flicker After BCM Replacement - (Sep 24, 2009)


Subject: Intermittent backlighting flare or flicker after BCM replacement


Models: 2006 Chevrolet HHR
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may observe an intermittent condition where all backlighting (IPC, Radio, HVAC, etc) may flash or flicker. This condition usually occurs after replacement of the Body Control Module (BCM)

Recommendation/Instructions:
DO NOT REPLACE any hardware for this condition.

Engineering has identified a software condition in service BCM (P/N 15910666) that could cause this concern.

Technicians will need to contact the Techline Customer Support Center (TCSC) to obtain a VCI number for this condition.

ChevyMgr
09-30-2009, 02:13 PM
#PIC4677E: No Start No Crank Intermittently / No Communication Over High Speed LAN - (Sep 08, 2010)


Subject: No Start No Crank Intermittently/No communication over High Speed LAN


Models: 2005-2011 Chevrolet Cobalt

2006-2011 Chevrolet HHR

2004-2011 Chevrolet Malibu

2008 Chevrolet Malibu Classic

2008-2009 Pontiac G5

2005-2010 Pontiac G6

2006-2007 Pontiac Pursuit (Canada)

2006-2009 Pontiac Solstice

2007-2009 Saturn Aura

2007-2009 Saturn Sky

With OnStar (UE1)
--------------------------------------------------------------------------------

This PI was superseded to update models and add codes to list. Please discard PIC4677C.

--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A customer may have a complaint of an intermittent no start, no crank condition, and or SES light on with I/P gauges intermittently inoperative while driving. Any of the following DTCs may be accompanied with this complaint. U0121, U0101, U1040, U2100, U2106, U2107, U2108, P0700, P2544, U0073

Recommendation/Instructions:
Before beginning to deep dive into any diagnostics on vehicles equipped with OnStar first check the VCIM connector C3 (Black) to be sure that it has been fully seated. This connector has been increasingly showing up as the root cause for loss of HIGH speed LAN concerns. Verify that the harness is not pulled too tight where the connector could be pulled once installed.

Per engineering request, if the reseating of this connector corrects the concern, please submit a field product report referencing this PI number.

ChevyMgr
09-30-2009, 02:16 PM
#PIC5152E: Brake Grind / Growl Noise - (Sep 24, 2009)


Subject: Brake Grind/Growl Noise


Models: 2009-2010 Chevrolet HHR

2009 Chevrolet Malibu

2009 Pontiac G6

2009 Saturn Aura
--------------------------------------------------------------------------------
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A customer might comment about excessive brake grind/growl noise coming from the front brakes after multiple brake applications during city stop and go type driving. This is a low mileage condition that is not related to rotor corrosion and the noise is not present on initial braking.

Recommendation/Instructions:
If this noise issue exists on a vehicles built between the VIN break points below, replace the brake pads with the updated P/N 20881786.

Use labor operation H0042 for the brake pad replacement.

Important: DO NOT refinish the Rotors for this issue. Claims refinishing rotors for this issue are subject to debit.

2009-2010 Chevrolet HHR Built prior to August 15, 2009

2009 Chevrolet Malibu 1G1ZG57B094162152 - Through end of 2009 Model Year Production (Orion Assembly Built)

2009 Chevrolet Malibu 1G1ZF57509F156269 - Through end of 2009 Model Year Production (Fairfax Assembly Built)

2009 Pontiac G6 1G2ZG57B094162101 - Through end of 2009 Model Year Production

2009 Saturn Aura 1G8ZR57519F156340 - Through end of 2009 Model Year Production


Additional Notes: These pads should only be installed on vehicles when excessive grind/growl noise has been experienced and only for vehicles between the VIN break points above.

Important: With the exception of the Chevrolet HHR all 2010 Model Year vehicles already have this updated brake pads.

ChevyMgr
09-30-2009, 02:18 PM
#PIP4469G: Intermittent DTC P0011 P0014 P0016 P0017 Or Hesitation / Stall - (Nov 3, 2009)


Subject: Intermittent DTC P0011, P0014, P0016, P0017 or Hesitation/Stall


Models: 2009-2010 Chevrolet Cobalt

With RPO LAP 2.2L, LNF 2.0L

2009-2010 Chevrolet HHR

With RPO LNF 2.0L, LE8 2.2L, LE9 2.4L

2009-2010 Pontiac G5

With RPO LAP 2.2L


2009-2010 Chevrolet Malibu

2009-2010 Pontiac G6

2009 Pontiac Solstice

2009 Saturn Sky

2009 Saturn Aura

2009 Saturn Vue

With RPO LE5 2.4L



2009 Saturn AURA Hybrid

2009 Saturn VUE Hybrid

2009-2010 Chevrolet Malibu Hybrid

With RPO LAT 2.4L



2010 Buick LaCrosse

2010 Chevrolet Equinox

2010 GMC Terrain

With RPO LAF 2.4L SIDI

For engines built prior to the following breakpoints:

Block Machining debris breakpoint is August 20th for all engines built in Springhill Tn. (Plant code T)

Head Casting sand breakpoint is September 2nd for all Ecotec Plants.

ADD APPROXIMATLEY 2 WEEKS FOR VEHICLE MANUFACTURING
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
In rare instances a technician may comment that they find DTC's for cam phaser operation and/or have noticed a hesitation/stumble or, even more rarely, a low RPM (idle) stall (typically on a PDI or with very low mileage). They have followed eSI diagnostics and they find one or more of the DTCs listed below.

P0011-Intake Camshaft Position (CMP) System Performance

P0014-Exhaust Camshaft Position (CMP) System Performance

P0016-Crankshaft Position - Intake Camshaft Position Not Plausible

P0017-Crankshaft Position - Exhaust Camshaft Position Not Plausible

Recommendation/Instructions:
Note: Please document on the repair order the type of debris found (i.e. sand or aluminum). When debris is found change the oil and filter before returning to service, in some instances it may be necessary to change the oil and filter multiple times. The filter can be inspected afterwards to ensure no additional debris is present.

Engineering has determined that casting sand and or non-ferrous (aluminum) machining debris in the camshaft phasers/solenoid valves can cause a hesitation/stumble and or these DTCs to set intermittently. This concern typically will occur very early in the vehicle's life or at PDI. When the technician has followed the eSI diagnostic chart for these codes they may be led to ECM replacement; however additional diagnostics should be made before replacement of any parts. When the inspection of the CMP solenoids/actuators and wiring confirms correct electrical operation, check for debris. The recommendations listed below should help.

ENGINEERING HAS REQUESTED WE COLLECT ADDITIONAL INFORMATION. PLEASE FOLLOW THE STEPS LISTED BELOW FOR YOUR APPROPRIATE ENGINE.

FOR RPO LAF 2.4L SIDI ENGINES ONLY (EQUINOX / TERRAIN / LACROSSE) BUILT AFTER 90902 (2009/SEPTEMBER 2ND)

To determine the build date of the engine, look on the sticker/tag on the accessory belt end of the cam cover. Look for the numbers on the right hand side starting with the letter N. The first 5 digits after the N will determine the build date.

• The first digit is the year 9 =2009


• The second and third digits are the month 09 = September


• The fourth and fifth digits are the day of the month 02 = the second


Note: If the engine was built on or after October 2nd 2009 (90902), record the information below on the Repair Order.

• Engine build date-


• Cylinder head casting date and number of wedges found-


• Cylinder head machining date-


• Cylinder head paint mark present-


To determine the build date of the engine look on the sticker/tag on the accessory belt end of the cam cover. Look for the numbers on the right hand side starting with the letter N. The first 5 digits after the N will determine the build date. This number is also etched into a pad on the oil filter housing.

5889

5890


To locate the cylinder head casting date remove the air duct and engine beauty cover. Just below the cam cover and just to the left of the high pressure fuel pump are two bosses with numbers on them. The number on the left boss is the year (09) (See call out #1) and the number on the right boss is the production week (See call out #2). The number on the right boss is inside a circle with 7 wedges around it, if possible count the number of wedges (See call out #3) that have bumps in them. This corresponds to the day of the week.

5891

To locate the cylinder head machining date look at the front of the engine (accessory belt end). Located on a horizontal machined surface on the rear of the head (toward the cowl) are two lines of letters and numbers etched into the cylinder head. Record the 2nd line (all number with 7 digits total) closest to the cam cover.

5892



Inspect for a process paint mark on the cylinder head: The paint mark will be on the front (accessory belt end) vertical face of the cylinder head in a small rectangular depression in the head casting just above the engine block on the left side. Note on the RO if there is any type of paint mark in this depression or if it's bare aluminum.

5893

Remove both CMP solenoids and wrap the lower end of these solenoids with tape so that it will capture debris that is on them for shipment. Wrap tape completely around them so that the tape is sticking to itself. Then put the CMP solenoids in a plastic bag for shipping. Also place a copy of the Repair Order with the information from above: engine build date, head casting date, head machining date and if the there is a paint mark on the identified area.

Return the parts and information to this address:

General Motors - Spring Hill Manufacturing


Proceed with cleaning out debris in the cylinder head solenoid area, install new CMP solenoids, change the engine oil and filter. Drive the vehicle to determine if the DTC(s) reset. In some instances it may be necessary to change the oil/filter multiple times. The filter can be inspected afterwards to ensure no additional debris is present. If there is debris on the new CMP solenoids screens they can be cleaned and reused.

FOR RPO LAF 2.4L SIDI ENGINES BUILT BEFORE 90902 (2009/SEPTEMBER 2ND) AND ALL OTHER ENGINE RPO'S PERFORM THE FOLLOWING:

The technician should inspect each CMP solenoid valve and cam phaser actuator for debris. If debris is found on the solenoid valve screens inspect for torn screens then clean or replace as necessary.

When debris is found on the solenoid valve screens, thoroughly inspect the cam phaser actuators for debris and clean/replace as necessary. If the DTC continues to reset after thorough inspection and cleaning of the cam phaser actuators, replace the affected camshaft actuator(s) depending upon the DTC(s) that set.

Note: When debris is found change the oil and filter before returning to service, in some instances it may be necessary to change the oil/filter multiple times. The filter can be inspected afterwards to ensure no additional debris is present.

ChevyMgr
10-07-2009, 03:30 PM
#PIP4720A: Intermittent Low Power After Stage 1 Turbo Upgrade 2008-2010 Chevrolet HHR SS - (Oct 6, 2009)


Subject: Intermittent Low Power After Stage 1 Turbo Upgrade 2008-10 Chevrolet HHR SS


2008-2010 Chevrolet Cobalt SS

2008-2010 Chevrolet HHR SS

Equipped with 2.0L turbocharged 4 cyl engine (RPO LNF) and Turbo Upgrade Kit installed

--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A technician or customer may comment of an intermittent low power concern, typically no DTC's are present. They may state it feels like they engage the Rev limiter and/or the vehicle will accelerate up to approximately 80-90 MPH before the concern occurs.

Recommendation/Instructions:
Note: This information does not apply to vehicles that have not had the turbo upgrade installed.

When installing the Stage-1 Turbocharger Upgrade for the HHR-SS both map sensors are swapped for Bosch TMAP sensors. The lower sensor located on the CAC (Charge Air Cooler) pipe, is hard to reach and can be difficult to install. When installing these new sensors the technicians must cut the existing wiring and crimp new wiring to a new connector. We have found that the front lower TMAP sensor (on the charge air pipe) wiring can rub/chaff against the A/C compressor or line causing this concern. This sensor is hard to reach and can be difficult to inspect the wiring for damage. It may help to follow eSI navigation: Engine / Engine Controls and Fuel - 2.0L / Repair Instructions / Intake Air Pressure and Temperature Sensor Replacement and Charge Air Cooler Outlet Pipe Replacement documents for instructions on how to access TMAP sensor and wiring for inspection when this concern is noted. Convoluted tubing (protective plastic sleeve) can be installed around the harness to prevent any future concerns. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.

ChevyMgr
10-07-2009, 03:35 PM
#PIP4718A: Oil Leak At Front Crankshaft Seal Area 2008-2009 Ecotec (RPOs - LAP LAT LE5 LE8 LE9 LNF) - (Mar 12, 2010)


Subject: Oil Leak at Front Crankshaft Seal Area 2008-09 Ecotec (RPO- LAP LAT LE5 LE8 LE9 LNF)


Models: 2008-2009 Chevrolet Cobalt SS

2008-2009 Chevrolet Cobalt

2008-2009 Chevrolet HHR

2008-2009 Chevrolet HHR SS

2008-2009 Chevrolet Malibu

2008-2009 Pontiac G5

2008-2009 Pontiac G6

2006-2009 Pontiac Pursuit (Canada Only)

2008-2009 Saturn Aura

2008-2009 Saturn Vue

Equipped with the following engines

2008-2009 2.0L (RPO LNF)

2009 2.2L (RPO LAP)

2009 2.2L (RPO LE8)

2008-2009 2.4L (RPO LE5/LE9/LAT)

--------------------------------------------------------------------------------

This PI was superseded to update the Recommendation/Instructions. Please discard PIP4718.


--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A technician may comment of an oil leak at the front timing cover/crank/pulley seal.

Recommendation/Instructions:
When the technician has determined the front crank seal is leaking replace the seal, harmonic balancer, bolt and drive belt.

ChevyMgr
10-07-2009, 03:36 PM
#PIP4717: Ecotec Misfire DTCs With No Concern Found - Inspect For Aftermarket Components - (Oct 1, 2009)


Subject: Ecotec Misfire DTC's With No Concern Found- Inspect for Aftermarket Components


Models: 2004-07 Saturn Ion Redline

2005-07 Chevrolet Cobalt SS

With 2.0L Supercharged Engine (RPO LSJ)

2008-2010 Chevrolet Cobalt SS

2008-2010 Chevrolet HHR

2007-2009 Pontiac Solstice GXP

2007-2009 Saturn Sky Redline

With 2.0L Turbocharged Engine (RPO LNF)
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A technician may comment of MIL lamp on with DTC's of P0300, P0301, P0302 or P0304. They typically report they cannot determine a root cause. This concern (misfires) usually occurs with extended idling and may be reduced/eliminated by raising the RPM slightly or inducing an engine load (such as A/C).

Recommendation/Instructions:
Engineering has determined that aftermarket parts (such as a light weight aluminum flywheel or accessory belt drive pulleys) can contribute to this issue. Anytime any portion of the rotating assembly is changed to an aftermarket component, there is a potential for this concern. When diagnosing a misfire DTC and no concern can be found following eSI, the technician should inspect for aftermarket components installed. This concern (misfires) usually occurs with extended idling and may be reduced/eliminated by raising the RPM slightly or inducing an engine load (such as A/C).

ChevyMgr
10-07-2009, 03:38 PM
#PIP4716: Sharp Engine Noise At Start Ecotec RPOs - LAF LAP LAT LNF LE5 LE8 LE9 - (Oct 1, 2009)


Subject: Sharp Engine Noise At Start Ecotec RPO's-LAF LAP LAT LNF LE5 LE8 LE9


Models: 2009 Chevrolet Cobalt

With RPO LAP 2.2L, LNF 2.0L

AND

2009 Chevrolet HHR

With RPO LNF 2.0L, LE8 2.2L, LE9 2.4L

AND

2009 Pontiac G5

With RPO LAP 2.2L

AND

2009 Chevrolet Malibu

2009 Pontiac G6

2009 Pontiac Solstice

2009 Saturn Sky

2009 Saturn Aura

2009 Saturn Vue

With RPO LE5 2.4L

AND

2009 Saturn AURA Hybrid

2009 Saturn VUE Hybrid

2009-2010 Chevrolet Malibu Hybrid

With RPO LAT 2.4L

AND

2010 Chevrolet Equinox

2010 GMC Terrain

With RPO LAF 2.4L SIDI

--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
In rare instances a technician may comment they hear a short, sharp rattle noise from the front of the engine on start up.

Recommendation/Instructions:
If the noise is from the front accessory drive area, inspect the engine belt. We have seen concerns with engine belts causing a loud ticking type noise. If found, verify power steering pulley outer edge is aligned flush with shaft and repair as needed. If pulley alignment is correct replace the engine belt.

If the noise is still present and is very short and sharp in duration (2-5 seconds) This may be an issue with the cam phasers not parking properly. Once the noise is verified as the phasers, they must be replaced. If the cam phasers are replaced, remove the CMP actuator solenoids to inspect for debris. If debris is found clean and inspect for torn or loose screens and replace if necessary.

Note: If debris is found in the solenoids and phasers change the oil and filter before returning to service, in some instances it may be necessary to change the oil/filter multiple times with a test drive in between each. The filter and solenoids can be inspected afterwards to ensure no additional debris is present.

ChevyMgr
10-08-2009, 08:39 AM
Date: October 9, 2009

Subject: 09041A / 09077A – Noncompliance Recalls
Shift Lever Indicator May Not Display Correct Gear
Retraction Letter Mailed to Certain Customers

Models: 2009 Buick Enclave
2009 Chevrolet Cobalt, HHR, Malibu, Traverse
2009 GMC Acadia
2009 Pontiac G5, G6
2009 Saturn AURA, OUTLOOK

To: All Buick, Chevrolet, GMC, Pontiac Dealers and Saturn Retailers

Attention: Service Manager and Warranty Administrator

General Motors released Noncompliance Recalls 09041 and 09077 in March 2009 and July 2009 respectively. They were both subsequently amended to expand the involved vehicle population and update other important information. These changes were comprehended in Bulletin 09041A and Bulletin 09077A which remain active and available in eSI. The purpose of this message is to advise of another adjustment to these field actions.

Upon further investigation, we have determined that certain vehicles originally included in these recalls were not built with the shift cable assembly that is being recalled. Consequently, recall notification letters were erroneously sent to those customers. Approximately 8,000 customers are affected.


To correct this situation, we are mailing a retraction letter to each customer on October 8, 2009. The letter explains our mistake and that the shift cable assembly in their vehicle is no longer suspect. It also apologizes for any inconvenience or concern our error may have caused. A generic copy of the letter is attached to this message for your immediate reference.

Additionally, the corresponding recall information displayed in GMVIS has also been modified to show a “closed” status (with no associated paid claim) for each vehicle affected by this error unless, of course, the recall repair was completed prior to this manual correction.


END OF MESSAGE

GM SERVICE AND PARTS OPERATIONS

----------------------------------------------------------------------------
October 2009
Dear General Motors Customer:
General Motors recently notified you regarding a recall involving the repair or replacement of the shift cable assembly in your 2009 model year Buick Enclave; Chevrolet Cobalt, HHR, Malibu, Traverse; GMC Acadia; Pontiac G5, G6; Saturn AURA or OUTLOOK. Upon further investigation, we have determined that your vehicle was not built with the shift cable assembly that is being recalled and you should not have received the notification letter.

If you have already had your vehicle serviced for this recall, we are sorry for any inconvenience our error may have caused you.

If you have not yet had your vehicle serviced for this recall, there is no need for you to take your vehicle to your dealer for service.

Again, we apologize if this error has caused you any concern regarding the integrity of the shift cable assembly in your vehicle. Please be assured that the condition addressed by the recall does not affect your vehicle.

If you have any questions regarding this matter, please contact your dealer/retailer or the GM Customer Assistance Center.

Scott Lawson
Director,
Customer and Relationship Services
09041/77ret

ChevyMgr
10-14-2009, 02:06 PM
#06-01-38-004B: Growl Noise from Engine Compartment (Replace Condenser Tube and Evaporator Hose Assembly) - (Aug 7, 2006)


Subject: Growl Noise from Engine Compartment (Replace Condenser Tube and Evaporator Hose Assembly)


Models: 2006 Chevrolet HHR

--------------------------------------------------------------------------------

Condition
Some customers may comment on a growl noise coming from the engine compartment. The customer may associate the noise with turning on the A/C system.

Correction
Replace the condenser tube and the evaporator hose assembly. Do not replace the A/C compressor assembly.

5782


Technicians are to replace the condenser tube, P/N 15877652, and the evaporator hose assembly, P/N 15877651. Refer to the Condenser Tube Replacement and the Evaporator Hose Assembly Replacement service procedures in SI for more information. Install a clip, P/N 15991719, at the location shown by callout number one in the illustration above. Verify proper operation of the A/C system after replacement of these parts.

Parts Information
Part Number/Description/ Qty

15877651 Hose Assembly-A/C Evaporator 1

15877652 Tube Assembly-A/C Condenser 1

15991719 Clip 1

ChevyMgr
10-29-2009, 09:19 AM
#08-06-04-034: LNF Malfunction Indicator Lamp (MIL), Check Engine Light Illuminated with One or More of the Following DIagnostic Trouble Codes (DTCs) P0096, P0335, P0806, P2199, P2261 (Reprogram ECM) - (Jun 12, 2008)


Subject: LNF Malfunction Indicator Lamp (MIL), Check Engine Light Illuminated with One or More of the Following Diagnostic Trouble Codes (DTCs) P0096, P0335, P0806, P2199, P2261 (Reprogram ECM)


Models: 2008 Chevrolet HHR SS

with ECOTEC® 2.0L I-4 Cylinder Turbocharged Engine (VIN X -- RPO LNF)
--------------------------------------------------------------------------------

Condition
Some customers may comment on Malfunction Indicator Lamp (MIL), Check Engine Light Illumination. Typically, there will be no driveability symptoms or engine performance concerns.

Upon further investigation, one or more of the following DTCs may be stored in the ECM:

• DTC P0096: Intake Air Temperature (IAT) Sensor 2 Performance

• DTC P0335: Crankshaft Position (CKP) Sensor Circuit

• DTC P0806: Clutch Pedal Position (CPP) Sensor Circuit Performance

• DTC P2199: Intake Air Temperature (IAT) Sensor 1-2 Correlation

• DTC P2261: Turbocharger Bypass Valve Stuck Closed

Correction
If routine diagnosis using SI does not reveal any obvious cause, Do Not replace the following components :

• Intake Air Temperature (IAT) Sensor for DTC P0096 or P2199

• Crankshaft Sensor for DTC P0335

• Clutch Pedal Position (CPP) Sensor for P0806

• Turbocharger Bypass Valve for DTC P2261

Important: Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming.

Important: Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. The J2534 MDI will reprogram the modules in less time than the Tech 2® scan tool.

Reprogram the ECM using the latest calibration if the above concern is encountered. A revised engine calibration has been developed to address these issues. Reprogram the ECM with the latest software calibration. The service calibration is available on TIS2WEB using the Service Programming System (SPS). As always, make sure your Tech 2® is updated with the latest software version.

ChevyMgr
11-04-2009, 08:17 AM
#09-01-37-002A: Front and Rear Passenger Floor Carpet Wet (Inspect White Plug in HVAC Evaporator Drain and Apply Sealer to Front of Dash Area) - (Nov 3, 2009)


Subject: Front and Rear Passenger Floor Carpet Wet (Inspect White Plug in HVAC Evaporator Drain and Apply Sealer to Front of Dash Area)


Models: 2008-2010 Chevrolet Cobalt, HHR, Malibu

2008-2009 Pontiac G6

2008-2009 Saturn AURA
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Condition
Some customers may comment that the front and rear floor carpet is wet on the passenger side.

Cause
This condition may be caused by a plugged HVAC evaporator Drain. In some cases, water from the HVAC system will drain back though the front of the dash.

Correction
Note: Reposition of the heat shield is not necessary on a Cobalt and HHR.

1. Verify the customer's concern. If there is water on the passenger side front floor area, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
2. Inspect the operation of the drain.
Note: Make sure that small debris is not plugging up the drain.


5884


3. Reposition the heat shield (1) in order to gain access to the HVAC drain.

5885

4. Remove the white plug (1) and assure there is no debris in the drain tube and/or plug. If debris exists, pull from the drain tube (do NOT force back into evaporator case) and reinstall the plug.

5886

Important: Do not get sealer on the heat shield, on the end of, or within the drain tube.

5. Mask off the areas (1, 2) by the HVAC drain using high-quality automotive tape.

5887

6. Apply high tech seam sealer, Kent Industries P/N P6101*, to the front of dash area as shown in figure below.

5888

7. Remove the high quality automotive tape and reposition the heat shield to it's normal position.
8. Lower the vehicle. Let the vehicle run with A/C on.
Perform a final inspection for the A/C and verify that the system is draining properly.

* We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources.

Parts Information
This product is currently available from Kent Industries (1-888-YES-KENT).

Part Number Description

P6101 HIGH - TECH BLACK SEAM SEALER

ChevyMgr
11-12-2009, 03:13 PM
#PIP4739: Oil Leak In High Pressure Fuel pump Area 2007-10 Ecotec (RPO LNF) - (Nov 9, 2009)


Subject: Oil Leak in High Pressure Fuel Pump Area 2007-10 Ecotec (RPO-LNF)


Models: 2008-2010 Chevrolet Cobalt SS Only

2008-2010 Chevrolet HHR SS Only

2007-2010 Pontiac Solstice GXP

2007-2010 Saturn Sky Redline

With 2.0L Engine RPO LNF Only
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A technician may comment of an oil leak in the high pressure fuel pump area.

Recommendation/Instructions:
Engineering has determined that an oil leak in this area is most likely coming from the #6 intake cam cap at the high pressure fuel pump. To repair this concern the technician should reseal the cam cap. Follow eSI procedure under "Engine | Engine Mechanical - 2.0L | Repair Instructions - On Vehicle | Intake Camshaft and Valve Lifter Replacement " for repair instructions and specific locations to apply sealer for the #6 cap.

ChevyMgr
11-18-2009, 08:45 AM
#09-08-47-002: Information on Body Control Module (BCM) Functionality Across Vehicle Lines - (Nov 17, 2009)


Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines


Models: 2004-2010 Chevrolet Malibu

2008 Chevrolet Malibu Classic

2005-2010 Chevrolet Cobalt

2006-2010 Chevrolet HHR

2005-2009 Pontiac G6

2006-2009 Pontiac Solstice

2007-2009 Saturn AURA, SKY
--------------------------------------------------------------------------------

The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles.

Functions That Do Not Involve the BCM
The following list of features and functions are not controlled or dependent on the BCM:

Important: The BCM should NOT be replaced for conditions in these areas.

• Cooling fans

• Clock display

• Radio display

• Power mirrors

• OnStar®

• Rear wiper (on Malibu Maxx)

• Warning lamps

• Malfunction indicator lamp (MIL)

• Driver seat belt reminder light and chime

• Power windows

Important: The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions.

Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information.

ChevyMgr
11-25-2009, 03:33 PM
#09-06-93-005: Information on Accessory Power Upgrade Kit or Performance Parts LNF Turbo Upgrade Kit - (Nov 24, 2009)


Subject: Information on Accessory Power Upgrade Kit or Performance Parts LNF Turbo Upgrade Kit


Models: 2008-2010 Chevrolet Cobalt SS, HHR SS

2007-2009 Pontiac Solstice GXP

2007-2009 Saturn SKY Red Line

All Equipped with Engine RPO LNF
------------------------------------------------------------------------------

The Accessory Power Upgrade Kit or Performance Parts LNF Turbo Upgrade Kit (P/N 19212670) has been designed and validated by GM Engineers to retain the warranty for the specified vehicle on which it is installed. It does not void the New Vehicle Limited Warranty.

If the Accessory Power Upgrade Kit or Performance Parts LNF Turbo Upgrade Kit is sold and permanently installed by a GM Dealer or a GM-approved Accessory Distributor/Installer (ADI) prior to delivery of the vehicle, it will be covered under the applicable portion (Bumper-to-Bumper, Powertrain, etc.) of the New Vehicle Limited Warranty. In the event this accessory is installed after vehicle delivery, or it is replaced under the New Vehicle Limited Warranty, it will be covered, parts and labor, for the balance of the applicable portion of the New Vehicle Limited Warranty, but in no event less than 12 months/12,000 miles.

If this accessory is installed by anyone other than a GM Dealer or a GM-approved ADI, it will be covered, parts only, for the balance of the applicable portion of the New Vehicle Limited Warranty, but in no event less than 12 months/12,000 miles. Workmanship will not be covered.

ChevyMgr
12-07-2009, 08:54 AM
#09-06-01-014: Oil Leak by High Pressure Fuel Pump (Reseal Camshaft Cap) - (Dec 3, 2009)


Subject: Oil Leak by High Pressure Fuel Pump (Reseal Camshaft Cap)


Models: 2007-2009 Chevrolet Cobalt SS, HHR SS

2007-2009 Pontiac Solstice GXP

2007-2009 Saturn SKY Redline

2008-2009 Opel GT

2008 Daewoo G2X

Equipped with a RPO LNF Engine

Please Refer to GMVIS
--------------------------------------------------------------------------------

Condition
Some customers may comment on an oil leak.

Upon further investigation, a technician may find oil leaking from the high pressure fuel pump area.

Cause
This condition may be caused by a camshaft cap that is not sealed correctly to the cylinder head, causing oil to leak out.

Correction
Verify the customer's concern.
Remove the fuel pump. Refer to Fuel Pump Removal in SI.
Remove the camshaft cover. Refer to Camshaft Cover Removal in SI.

6040

Remove the camshaft cap (1). Remove all excess sealing material from both surfaces.

6041

Note: It is critical during installation to ensure the bearing rear cap and cylinder head alignment is correct and the mating surfaces are flush.

• Ensure that all sealing material has been removed from the components and the sealing surfaces are clean and free of contamination prior to applying the sealer.

• Install and align the rear cap within 20 minutes of applying the sealer.


Apply a 2.5 mm (0.1 in) bead of sealer, GM P/N 12378521 (in Canada, use P/N 88901148) to the cylinder head at the number 6 intake camshaft rear cap mating surface.
Note: Apply the sealer to all locations centrally locating the bead on the rail.

• Run the bead to 5 mm (0.2 in), dimension "a", as shown.

• Where the cap ends on the perimeter rail, extend bead approximately 4 mm (0.2 in) beyond edge of cap.

• Run bead, dimension "c", 32 mm (1.3 in) from the edge of the cylinder head as shown.

• Run bead, dimension "b", 20 mm (0.8 in) from edge of cylinder head as shown.


Install the number 6 intake camshaft rear cap.
6.1. Tighten the cap bolts evenly to 5 N·m(44 lb in).

6.2. Tighten the cap bolts evenly to 10 N·m(89 lb in).

6.3. Back the cap bolts out 120 degrees.

6.4. Tighten the cap bolts evenly a final pass to 10 N·m(89 lb in).

Install the camshaft cover and gasket, GM P/N 12609291. Refer to Camshaft Cover Installation in SI.
Install the fuel pump. Refer to Fuel Pump Installation in SI.
Important: When installing the fuel pump, install a NEW high pressure fuel pump O-ring (GM P/N 12600313), high pressure fuel pump gasket-to-cylinder head (GM P/N12595951) and high pressure fuel pipe (GM P/N12615401).

Parts Information
Part Number
Description

12609291
Camshaft Cover Gasket

12595951 Gasket, High Pressure Fuel Pump Gasket

12600313 High Pressure Fuel Pump O-Ring

12615401 High Pressure Fuel Pipe

12378521 (U.S.)88901148 (Canada) Silicone

ChevyMgr
12-07-2009, 08:58 AM
#PIC5286: Passenger Presence Air Bag And Seat Belt Indicator Information - Canadian Market Vehicles RPO Z49 - (Dec 3, 2009)


Subject: Passenger Presence Air Bag & Seat Belt Indicator Information - Canadian Market Vehicles RPO Z49


Models: 2010 Chevrolet Cobalt (except SS) with Canadian Base Equipment RPO Z49

2010 Chevrolet Colorado with Canadian Base Equipment RPO Z49

2010 Chevrolet HHR (except SS & Panel) with Canadian Base Equipment RPO Z49

2010 GMC Canyon with Canadian Base Equipment RPO Z49

2010 Pontiac G5 with Canadian Base Equipment RPO Z49




--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may question if their vehicle should have the following options:

Passenger Presence System (PPS)
Passenger air bag On/Off indicators
Recommendation/Instructions:
Your examination of the vehicle may find vehicle harness connectors for the Passenger Presence System components, but they are not connected.

On the vehicles listed above, the Passenger Presence System is not part of the vehicle build configuration and cannot be installed.

ChevyMgr
12-07-2009, 09:18 AM
#09-08-46-004: Generation 8 OnStar Modules Unable to Contact OnStar Center, Make or Receive Hands-Free Calls, Receive OnStar Services and Possible Battery Discharge Condition (Replace OnStar VCIM) - (Nov 23, 2009)


Subject: Generation 8 OnStar® Modules Unable to Contact OnStar® Center, Make or Receive Hands-Free Calls, Receive OnStar® Services and Possible Battery Discharge Condition (Replace OnStar® VCIM)


Models: 2009 Buick Enclave

2010 Buick LaCrosse

2008-2009 Cadillac CTS

2009 Cadillac Escalade, Escalade ESV, Escalade EXT, STS, XLR

2009-2010 Cadillac SRX

2009 Chevrolet Avalanche, Cobalt, Corvette, HHR, Silverado, Suburban, Tahoe, Traverse

2009-2010 Chevrolet Equinox

2010 Chevrolet Camaro, Equinox

2009 GMC Acadia, Sierra, Yukon, Yukon XL

2010 GMC Terrain

2009 Pontiac G5, G8, Solstice, Torrent

2009 Saturn OUTLOOK, SKY, VUE

All Equipped with OnStar® (RPO UE1)

--------------------------------------------------------------------------------

Condition
Important: This bulletin is being issued to provide the dealers with information regarding a condition pertaining to vehicles equipped with a Generation 8 OnStar® Vehicle Communication Interface Module (VCIM).

Some customers may comment that they are not able to contact the OnStar® Center and that the vehicle is unable to make or receive OnStar® hands-free calls. This condition also affects vehicles enrolled in OnStar® vehicle diagnostics such that the monthly e-mail may not be sent to the subscriber as scheduled. OnStar® may also be unable to perform any outbound services, such as door unlocks. In some instances, under certain circumstances, a battery discharge condition may also be experienced.

Affected Unit StID Ranges
29,800,000 - 31,125,426

38,000,000 - 39,175,239

47,500,000 - 47,515,592

49,000,000 - 49,015,638

Customer Notification
OnStar® will notify subscribers on a case-by-case basis. OnStar® customer notification letters will include a reference to this bulletin. Some customers may also be referred to the dealer by OnStar® Technical Assistance following attempts to resolve any of the listed concerns. Subscribers will be directed to contact their GM dealer to schedule an appointment to have the OnStar® VCIM replaced.

Correction
In an effort to maintain the highest customer satisfaction level, dealers are being urged to obtain the necessary information from the customer (name, VIN, odometer reading) to pre-order a replacement OnStar® module, allowing for a single repair visit. Dealer technicians should replace the OnStar® VCIM per the applicable procedure outlined in the vehicle specific Service Information. Refer to Communication Interface Module Replacement in SI. Make sure to perform the applicable module set-up and activation procedures. Refer to Communication Interface Module Programming and Setup in SI.

Parts Information
Important: DO NOT ORDER ONSTAR® MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO) OR THE TECHNICAL ASSISTANCE CENTER (TAC).

US: OnStar® modules required for this procedure are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com and selecting the catalog item that contains this bulletin number or by calling 1-800-336-3998. The dealer must provide the VIN, Repair Order (R.O.) number and the current vehicle odometer reading.

Canada: OnStar® modules required for this procedure are to be obtained by contacting MASS Electronics at XXXXXX. The dealer must provide the VIN, R.O. number and the current odometer reading.

ChevyMgr
12-09-2009, 08:07 AM
#08-09-41-002E: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026 - (Dec 7, 2009)


Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer)


Models: 2005-2007 Buick Rainier

2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne

2008-2010 Buick Enclave

2006-2010 Cadillac DTS

2007-2010 Cadillac Escalade Models

2008-2009 Cadillac SRX, XLR

2008-2010 Cadillac CTS, STS

2005-2006 Chevrolet SSR

2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT

2005-2010 Chevrolet Cobalt

2006-2007 Chevrolet Monte Carlo

2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic)

2007-2009 Chevrolet Equinox

2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe

2008-2010 Chevrolet Express

2009-2010 Chevrolet Traverse

2005-2009 GMC Envoy Models

2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL

2008-2010 GMC Savana

2005-2006 Pontiac Pursuit

2005-2009 Pontiac G6

2006-2009 Pontiac Solstice

2007-2009 Pontiac G5, Torrent

2008-2009 Pontiac G8

2005-2009 Saab 9-7X

2007-2009 Saturn AURA, OUTLOOK, SKY

2008-2009 Saturn VUE

2008-2009 HUMMER H2

2007-2008 Daewoo G2X

2007-2009 Opel GT
--------------------------------------------------------------------------------

Condition
• Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC).


Important: This bulletin only applies to the following DTCs:


• Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM).

Cause
This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector.

Correction
Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs.

Perform the Diagnostic System Check-Vehicle.
Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI.
Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI.
Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI.
BEFORE removing, INSPECT the CPA retainer at the electrical connector.
Note: The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly.

⇒ If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely.

⇒ If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.

Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions:
• Corrosion

• Contamination

• Terminal tension.

• Damage

Important: The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit.

⇒ If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI.

Note: The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly.

Connect the electrical connector, and install the CPA retainer.
Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI.
Clear the DTC with a scan tool.
Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
⇒ If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI.

Parts Information
Part Number Description

12052834 RETAINER, CPA

88988974 RETAINER, CPA

54590003 RETAINER, CPA

(J38125 SIR/SRS Tray)

GM P/N 12345579 (in Canada, use P/N 10953481)
LUBRICANT, DIELECTRIC SILICONE (1 oz / 29 ml TUBE)


Note: If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools @ 1-800-GM-TOOLS and order P/N 54590003-PKG to obtain a package of 5.

ChevyMgr
12-09-2009, 08:13 AM
#08-09-41-001: Air Bag Readiness Light/Supplemental Inflatable Restraint (SIR) Light On, Diagnostic Trouble Code(s) (DTC) B0057, B0058, B0059, B0064, B0065, B0066 (Inspect/Repair Wiring Connector) - (Jan 25, 2008)


Subject: Air Bag Readiness Light/Supplemental Inflatable Restraint (SIR) Light On, Diagnostic Trouble Code(s) (DTC) B0057, B0058, B0059, B0064, B0065, B0066 (Inspect/Repair Wiring Connector)


Models: 2008 Chevrolet HHR
--------------------------------------------------------------------------------

Condition
Some customers may comment that the Air Bag Readiness Light/SIR light is on.

Diagnosis with a scan tool may reveal DTC(s) B0057, B0058, B0059, B0064, B0065, B0066 current or in history.

Cause
The possible cause of the DTC(s) may be a poor and/or intermittent connection at the front seat belt retractor/pretensioner.

Diagnostic Information
• DTC B0057, B0058, B0059 (Passenger Side Seat Belt Retractor/Pretensioner) -- SI Document ID# 1208945.

• DTC B0064, B0065, B0066 (Drivers Side Seat Belt Retractor/Pretensioner) -- SI Document ID# 1208948.

• Testing for Intermittent and Poor Connections -- SI Document ID# 303631.

Correction
Do This
Inspect the front seat belt retractor/pretensioner connectors for proper connection prior to replacing SIR components.

Don't Do This
DO NOT replace the front seat belt retractors/pretensioners P/Ns: 15935664 15935665 15935666 25776212 25776213 25776214 prior to inspecting the seat belt retractor/pretensioner connectors.


Repair Information
Remove the B pillar lower trim panel to gain access to the front seat belt retractor/pretensioner connector.
Disconnect and Reconnect the appropriate seat belt retractor/pretensioner two wire connector to insure a proper connection.
With a scan tool, inspect for a current DTC.
• If a current DTC is still present, refer to the Diagnostic Information above.

• If a current DTC is not present, continue with the next step.

With a scan tool, clear the DTC history information.

ChevyMgr
01-15-2010, 10:24 AM
#PIC5309: w Or Muffled Audio When Using BlackBerry Tour And OnStar Bluetooth - keywords black berry - (Jan 14, 2010)


Subject: Low or muffled Audio when using BlackBerry Tour and OnStar Bluetooth


Models: 2008 - 2010 Cadillac CTS, CTS-V

2009 Chevrolet Trailblazer

2009 -2010 Buick Enclave, Lacrosse, Lucerne

2009 - 2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT, SRX, XLR

2009 - 2010 Cadillac STS with RPO YQ1 or YQ2

2009 - 2010 Chevrolet Cobalt, Corvette, Equinox, HHR, Impala, Malibu, Silverado, Suburban, Tahoe, Traverse

2009 - 2010 GMC Acadia, Envoy, Sierra, Yukon, Yukon XL

2009 Hummer H2. H3

2009 Pontiac G5, G6, G8, Solstice, Torrent

2009 SAAB 9-3, 9-7x

2009 Saturn Aura, Outlook, Sky, Vue

2010 Chevrolet Camaro

2010 GMC Terrain

with OnStar UE1 and Bluetooth UPF or UWE
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some Verizon Wireless Customers using the Blackberry Tour may experience a low (sometimes half) volume or muffled audio when using the Bluetooth system in their vehicle.

Recommendation/Instructions:
This issue is a known issue for the phone/software releases prior to version OS 4.7.1.61. RIM/Verizon has released the new software to resolve this issue and we have determined that this fixes the low audio level. Customers should be referred to their cellular provider for assistance with upgrading their phones software.

Further information on this issue can be found at the link below.

http://www.wirelessandmobilenews.com/2009/11/verizon_blackberry_tour_updates_2day_blackberry_os _47161.html

OnStar hardware should not be replaced for this concern.

ChevyMgr
01-15-2010, 10:28 AM
#PI0017: Engine Coolant Detected in Engine Oil, Foaming Milky Oil, Runs Rough, Intermittent Misfire, Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300, P0301, P0302, P0303 or P0304 Set - (Jan 14, 2010)


Subject: Engine Coolant Detected in Engine Oil, Foaming Milky Oil, Runs Rough, Intermittent Misfire, Malfunction Indicator Lamp (MIL) Illuminated, DTCs P0300, P0301, P0302, P0303, or P0304 Set


Models: 2009 Chevrolet HHR, Malibu

2009 Pontiac G6

2009 Saturn AURA, VUE

Equipped with Engine RPO LE5, LE9

Built Between July 2008 and December 2008

Please Refer to GMVIS
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptoms described in this PI.

Condition / Concern
Some customers may comment that the vehicle engine oil has the appearance of a milkshake and is full of bubbles. They may also comment that the engine runs rough and/or lacks power and the MIL is illuminated. The technician may find DTCs P0300, P0301, P0302, P0303, or P0304, set as current or in history.

Upon further examination, the technician may observe evidence of engine coolant intrusion into the engine oil, oil filter, on the dipstick and in the crankcase area. This condition may also contribute to leaks and foam dripping from the engine and the underhood area.

This condition may be caused by an internal engine crack in the crankcase area that allows engine coolant to enter the engine oil.

Recommendation / Instructions
Inspect and verify that the above conditions exist as described.
If during the inspection any oil or the oil filter was removed from the engine, replace the oil filter and add the correct amount of engine oil.
Warning: Under pressure, the temperature of the solution in the radiator can be considerably higher, without boiling. Removing the radiator cap while the engine is hot (pressure is high), will cause the solution to boil instantaneously, with explosive force. The solution will spew out over the engine, fenders and the person removing the cap. Serious bodily injury may result. Flammable antifreeze, such as alcohol, is not recommended for use at any time. Flammable antifreeze could cause a serious fire.

Warning: In order to help avoid being burned, do not remove the radiator cap while the engine and the radiator are hot. Scalding fluid and steam can be blown out under pressure if the cap is removed too soon.

Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI.
Install a cooling system pressure tester. Refer to Cooling System Leak Testing in SI.
Start the engine and bring the engine coolant temperature (ECT) to the normal operating range.
Verify that the cooling system pressure tester indicates more than 12 psi (83 kPa).
Turn off the ignition.
Raise and suitably support the vehicle. Refer to Lifting and Jacking in SI.
Drain the engine oil and remove the oil pan. Refer to Oil Pan Replacement in SI.
Inspect for engine coolant leaking into the lower crankcase area.
⇒ If engine coolant is leaking into the lower crankcase area, remove and replace the engine assembly. Refer to Engine Replacement for the appropriate vehicle in SI.

ChevyMgr
01-28-2010, 01:42 PM
#PI0021B: Instrument Panel (IP) Center or Outer Air Outlet (Vanes) Broken or Inoperative - (Oct 27, 2010)


Subject: Instrument Panel (IP) Center or Outer Air Outlet (Vanes) Broken or Inoperative


Models: 2006-2011 Chevrolet HHR
--------------------------------------------------------------------------------

This PI is being revised to add the 2011 model year, update the repair information and add Parts Information. Please discard PI0021A.
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Condition/Concern
Some customers may comment that one of the center or outer IP air outlet vanes is broken or inoperative.

http://www.chevyhhr.net/gallery/files/4/8/6/5/O1.gif

Various customer use situations may cause an over-rotation of the center or outer IP air outlets, which can damage the vanes (1) or their connecting mechanism.

Recommendation/InstructionsThe air outlet vanes are now released as a service component separate from the air outlet assembly. For any affected air outlet location, order the part number listed in the part table below and replace the vanes following the steps below:

http://www.chevyhhr.net/gallery/files/4/8/6/5/O2.gif

Starting with the smaller vane (without the thumb impression), remove the vane from the assembly by inserting a small flat-bladed screwdriver (1) between the outer edge of the vane and the flat sidewall of the retainer.
Carefully push the retainer wall outboard, away from the vane, while pulling the vane forward to disengage the end retaining pin from the wall.

http://www.chevyhhr.net/gallery/files/4/8/6/5/O3.gif

With the small vane pin released, use the screwdriver to disengage the larger vane retaining pin on the same side.

http://www.chevyhhr.net/gallery/files/4/8/6/5/O4.gif

Once the pins on one side are free, pull the vane toward the free side and use the screwdriver to release the opposite side pins and remove the vanes from the assembly.

http://www.chevyhhr.net/gallery/files/4/8/6/5/O5.gif

Note: When installing the new vanes into the air outlet assembly, ensure that the smaller vane is installed into the hole (1) closest to the end of the retainer wall, and the large vane is installed into the hole (2) further from the end. The air outlet assembly, in the graphic above, is shown removed from the vehicle for illustration purposes.

http://www.chevyhhr.net/gallery/files/4/8/6/5/O6.gif

Install the large and small vane retaining pins into the proper holes on one side of the assembly.

http://www.chevyhhr.net/gallery/files/4/8/6/5/O7.gif

Use the screwdriver to carefully push the retainer wall outboard and install the retaining pins on the opposite side.
Verify proper function of the air outlet.

Parts Information

Part Number Description Qty

20933887 Outlet-I/P Otr Air 1

ChevyMgr
02-05-2010, 08:23 AM
#PIC5324: Pop Noise Heard Over Speakers When Ending OnStar Call - (Feb 4, 2010)


Subject: Pop noise heard over speakers when ending OnStar call


Models: 2009 Buick Allure, LaCrosse

2009 - 2010 Buick Lucerne

2010 Buick Enclave

2009 - 2010 Cadillac DTS

2010 Cadillac Escalade

2009 Chevrolet Trailblazer

2009 - 2010 Chevrolet Aveo, Colorado, Impala, Malibu

2010 Chevrolet Avalanche, HHR, Silverado, Suburban, Tahoe, Traverse

2009 GMC Envoy

2009 - 2010 GMC Canyon

2010 GMC Acadia, Sierra, Yukon

2009 - 2010 Hummer H2, H3

2009 Pontiac G6

2009 - 2010 Pontiac G5, Wave

2009 Saab 9-5

2009 - 2010 Saab 9-3

2009 Saturn Aura

with OnStar GEN8.1/8.2L VCIM
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may notice a "pop" sound when an OnStar or handsfree call is ended by the OnStar center or caller. The volume of the "Pop" will depend upon the level the OnStar volume is set to.

Recommendation/Instructions:
DO NOT REPLACE any hardware for this concern. Engineering has determined this is an inherit design/software anomaly to both the Gen 8.1 and 8.2 LG OnStar modules to which no resolution is available.

Radio or VCIM replacement will not change this concern.

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.

ChevyMgr
02-18-2010, 12:37 PM
#PI0011: Door Latch Diagnosis Procedure - (Dec 15, 2009)


Subject: Door Latch Diagnostic Procedure


Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn)

2010 and Prior HUMMER H2, H3

2009 and Prior Saab 9-7X
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Condition/Concern
Some customers may comment that the front or rear side door has one or more of the following conditions:

• The door will not open from the inside or outside handle.

• The door will not unlock with the key fob or electrical switch on the interior door trim.

• The door will not unlock with the inside lock knob.

• The door will not unlock with the key cylinder.

The primary cause of these symptoms is a condition called "preload," resulting from incorrect attachment of the outside handle rod to the latch. If the outside handle release lever on the latch is not in the full up position when the rod is attached by the clip on the latch, the latch will not operate correctly.

Another condition causing latch malfunction, especially lock/unlock, is caused by high effort on the inside lock knob. Resistance to the travel of the lock knob may cause the latch not to unlock.

A third condition causing malfunction is the improper or incomplete attachment of the outside handle rod and inside handle rod/cable. If the outside handle rod clip is not completely secured, the clip can come unlatched and the outside handle will not function.

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described above.

Recommendation/Instruction
Note: Verify the latching function after each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.

Perform these preliminary inspections:

Inspect the inside and outside door handle for debris, that all parts are present and working properly, and that they are securely attached.
Inspect the inside lock knob for smooth, low effort functioning manually and full travel with power locks. If high effort and/or partial travel are present, inspect for interference with the following components:
• the trim pad

• the inside lock knob rod grommet

• the side impact foam

• the water deflector

• the inner belt seal

• the wire harness

• other parts in the rod environment

For rear doors on which the inside handle will not function, verify that the child security feature is not engaged.
If no issues were found when performing the preliminary inspections, proceed with the following steps.

Note: Verify the latching function after each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.

http://www.chevyhhr.net/gallery/files/4/8/6/5/l1.gif

Remove the door trim while maintaining the inside handle cable attachment. DO NOT LET THE TRIM PAD HANG FROM THE HANDLE CABLE OR THE WIRE HARNESS.

http://www.chevyhhr.net/gallery/files/4/8/6/5/l2.gif

http://www.chevyhhr.net/gallery/files/4/8/6/5/l3.gif

http://www.chevyhhr.net/gallery/files/4/8/6/5/l4.gif

Inspect the connections of the inside handle cable to the inside handle and latch. Assure that the cable is not kinked and that the lever on the latch moves when the inside handle is actuated. If the condition persists at this point, disconnect the inside handle cable from the handle and set aside the trim.
Verify that the key cylinder rod is attached to the key cylinder pawl and the latch. Reattach as required.
Verify that the outside handle rod is present, properly attached to the handle and is the correct part.

http://www.chevyhhr.net/gallery/files/4/8/6/5/l5.gif

Unlatch the clip holding the outside handle rod to the latch. Make sure the outside handle rod lever on the latch is in the full up position and hard against stop on the latch. While maintaining this lever position, re-attach the rod using the clip. Pull on the bottom of the rod fore/aft and cross-car to assure secure attachment.
Verify that the electrical connector to the latch is fully seated. Remove and inspect for corrosion and electrical output when actuating the electrical switch on the door trim. If power is lacking, perform electrical diagnostics. Reconnect and assure that the connector is fully seated.

http://www.chevyhhr.net/gallery/files/4/8/6/5/l6.gif

Unbolt the latch and remove the latch from the door cavity with the electrical connector still attached. Function the power locks using the switch on the door trim (reattach the switch module to the electrical harness.) Verify that the lock/unlock lever shows full travel (refer to the green arrow in the picture above). If the latch properly functions (DO NOT replace latch), properly reassemble in order to correct the bind/attachment issue.

ChevyMgr
02-23-2010, 02:00 PM
#PI0039: Wind Noise/Humming Noise from Roof Rack Area (Reposition Roof Rack Cross Rails) - (Feb 17, 2010)


Subject: Wind Noise / Humming Noise from Roof Rack Area (Reposition Roof Rack Cross Rails)


Models: 2006-2010 Chevrolet HHR with Dealer Installed Accessory Roof Rack Cross Rails




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Condition/Concern:
Some customers may comment that they hear a wind noise or a humming noise coming from the roof rack area of the vehicle. This condition is most noticeable between 55-110 km/h (35-70 mph). This condition may be caused by the roof rack cross rails being installed backwards on the vehicle.

Recommendation/Instructions:

6401


The roof rack cross rails have a ridge (1) on the front edge to reduce wind noise concerns. If the roof rack cross rails are installed with the ridge facing rearward on the vehicle, this bead will not perform as designed. Inspect the roof rack cross rails and verify that both of the cross rails are installed on the vehicle with the ridge facing forward on the vehicle. If the rails are improperly installed, reposition the cross rails with the ridges facing forward on the vehicle.

ChevyMgr
03-04-2010, 06:56 PM
#PIC3956E: Red Brake Light/Low Brake Fluid Message On Intermittently - keywords C0267 DIC display GMT001 information int intermittent lamp PIC3959 PIC3959A PIC3959B - (Nov 16, 2007)


Subject: Red Brake Light/Low Brake Fluid Message On Intermittently


Models: 2006 Chevrolet HHR
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A customer may comment about a intermittent RED brake light coming on with a possible message on the Driver Information Center (DIC) displaying "low brake fluid". This condition is more likely to occur during cold weather and will be intermittent as the fluid is more viscous

Recommendation/Instructions:
Follow the diagnostics to check and make sure that the brake fluid is not low. If the brake fluid is NOT low then replace the brake Master Cylinder Brake Fluid Reservoir KIT (P/N below) as it has been modified to resolve this concern.

Automatic Transmission Should be MN5 Auto Transmission Master Cylinder Brake Fluid Reservoir KIT Part # 15939572

Manual Transmission Should be M86 5-Sp Manual Transmission Master Cylinder Brake Fluid Reservoir KIT Part # 15939485

ChevyMgr
03-06-2010, 02:10 PM
#06-07-30-004E: Various Concerns with Shifter and/or Ignition key (Perform Repair as Outlined) - (Mar 1, 2010)


Subject: Various Concerns With Shifter and/or Ignition Key (Perform Repair as Outlined)


Models: 2005-2010 Chevrolet Cobalt

2006-2010 Chevrolet HHR

2005-2006 Pontiac Pursuit (Canada Only)

2007-2010 Pontiac G5

with Automatic Transmission 4T45-E (RPO MN5)
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This bulletin is being revised to add the 2010 model year and include an Important statement on initial inspections to perform. Please discard Corporate Bulletin Number 06-07-30-004D (Section 07 - Transmission/Transaxle).


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Important: When servicing a vehicle for any type of shifter/key concern, please perform the following initial inspections prior to replacing any parts.

• Verify the electrical operation of the ignition lock cylinder solenoid. Refer to the Ignition Key Can/Cannot Be Turned Off With Transmission in Any Gear in SI.

• Verify the adjustment of the automatic transmission shift cable. Refer to the Shift Control Cable Adjustment procedure in SI.

• If these initial inspections do not resolve the customer concern, check the potential causes listed in this bulletin.


Condition #1 (2005-2008 Cobalt, G5 and Pursuit Only)
Some customers may comment that the shifter binds.

Cause #1
The cause of this condition may be the shifter button sticking in the handle.

Correction #1
Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI.

Parts Information #1 Part Number Description Qty

22706231 Handle, A/Trans Cont Lvr (Model AL with MN5, TY8, VY7) 1

22706232 Handle, A/Trans Cont Lvr (Model AJ, AK and MN5; Model AL with MN5 [exc VY7]) 1

22719080 Handle, A/Trans Cont Lvr (Model AL with MN5, VY7 [exc TY8]; Model AM with MN5; Model AL with MN5, R1V) 1


Condition #2 (2005-2008 Cobalt, G5 and Pursuit Only)
Some customers may comment they cannot remove the ignition key.

Cause #2

http://www.chevyhhr.net/gallery/files/4/8/6/5/ign1.gif

The pin that activates the micro-switch may have moved out of position (refer to illustration above). This causes the micro-switch to fail to engage when the vehicle is placed in Park. If this condition is present, the customer will not be able to remove the key from the ignition.

http://www.chevyhhr.net/gallery/files/4/8/6/5/ign2.gif

The illustration above shows the switch in a correct position.

Correction #2
Important: A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low).

Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI.

Parts Information #2 Part Number Description Qty

15926820 Control Asm, A/Trans 1


Condition #3 (2005-2008 Cobalt, G5 and Pursuit Only)
Some customers may comment that the shifter is hard to move.

Cause #3
The slider may be binding in the guides. This may cause the shifter to become difficult to operate.

Correction #3
Replace the slide indicator and guides in the shifter following the procedure below:

Apply the parking brake.
Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI.
Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI.
Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs.
Remove the shifter indicator lens.
Pull up on the indicator and remove it from the assembly.
Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly.
Install the new guides. Place the hook end into the assembly and push down. It will snap into place.
Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear.
Important: Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly.

Install the shift indicator lens.
Install the shift indicator plate.
Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI.
Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI.
Parts Information #3
Part Number Description Qty

15872229 Slide Indicator 1

15872228 Guide - Rails 2

15872230 Lens 1

Condition #4
Some customers may comment that the ignition key cannot be removed from the ignition cylinder.

Correction #4
Check for power and ground in the ignition circuit. Verify for proper connection/contact at circuit B1, connector X4 at the BCM.


Condition #5 (All Years, All Models)
Some customers may comment that the ignition key is difficult to remove or that the key sticks or binds in the ignition cylinder.

Correction #5
Refer to Corporate Bulletin Number 09-02-35-005A for additional information.

ChevyMgr
03-29-2010, 11:52 AM
#10-08-44-002: Popping and/or Reduced Audio on AM Radio Stations When Radio is Powered Up or Turned On (Verify Condition/Replace and Reprogram Radio Using SPS) - (Mar 26, 2010)


Subject: Popping and/or Reduced Audio on AM Radio Stations When Radio is Powered Up or Turned On (Verify Condition/Replace and Reprogram Radio Using SPS)


Models: 2007-2008 Chevrolet Cobalt, HHR

2008 Chevrolet Malibu

2007-2008 Pontiac G5, Solstice

2007-2008 Saturn AURA, SKY

Equipped with RPO US8 or US9 Only
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Condition
Important: The popping, station interference and/or reduced audio conditions as described ONLY occur when listening to AM radio stations.

Some customers may comment on the following conditions:

• When listening to a very strong AM station (50kW or greater) and operating their vehicle within 1.6-3.2 km (1-2 mi) of the transmitting tower of that AM station, they will begin to hear a popping noise and/or experience reduced audio. The closer the distance to the tower, the greater the noise and an accompanying increase in the signal distortion.

• When listening to a moderate to strong AM station, another AM station will cause interference.

Cause
This condition may be caused by an AM frequency overload.

Correction
Verify the customer concern by operating the vehicle with the radio on an AM band within a 1.6-3.2 km (1-2 mi) distance of a strong AM radio station.
⇒ If the conditions as described above are present, remove and replace the radio. Refer to Radio Replacement in SI.

You must call TCSC to obtain a VCI for programming the new radio.
In order to calibrate the radio properly you will need the radio RPO, speaker system RPO and indicate if the vehicle is equipped with XM (RPO U2K).

Parts Information
DO NOT OBTAIN PARTS FROM GMSPO.

ChevyMgr
04-05-2010, 03:35 PM
#PI0085: Itch/Creak Noise from Right Side of Instrument Panel - (Mar 31, 2010)


Subject: Itch/Creak Noise from Right Side of Instrument Panel


Models: 2010 Chevrolet HHR
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Condition/Concern
Some customers may comment about a itch/creak noise coming from the right side of the instrument panel. This noise is usually heard when the vehicle body is under load (accelerating, braking or sharp turns). This noise may be caused by a loading condition between the instrument panel tie bar mounting bracket and the inner hinge pillar.

Recommendation/Instructions
Have the customer describe what driving condition creates the noise (turning, accelerating or braking). Use the following steps to tighten the instrument panel tie bar fasteners. If the concern is still present, use the additional steps to revise the instrument panel tie bar mounting bracket.

Note: On sunroof equipped vehicles, use care to not damage the drain tube located in the repair area.

6676

Remove the right instrument panel outer trim cover. Use a plastic trim tool to release the retainers.

6677

Locate the two tie bar mounting bolts and loosen them (do not remove the bolts), then tighten the bolts.
Tighten
Tighten the mounting bolts to 25 N·m (18 lb ft).

Road test the vehicle. Apply hard acceleration followed by hard stops to verify that the customer's concern is corrected. If the concern is corrected, proceed to step #8. If the concern is not corrected, proceed to step #4.

6678

Locate the tie bar mounting bracket that is welded to the inner hinge pillar (the bracket is outboard of the mounting bolt area and cannot be seen in the photo). Remove the two tie bar mounting bolts.

6679

Insert a large screwdriver between the bracket and the hinge pillar as shown. Use a hammer on the screwdriver to create a gap between the bracket and the inner hinge pillar.
Reinstall the two bolts.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).

Road test the vehicle. Apply hard acceleration followed by hard stops to verify that the customer's concern is corrected.
Reinstall the right instrument panel outer trim cover.

ChevyMgr
04-16-2010, 02:18 PM
#10-08-44-003B: Buzz Noise During Call When Using Bluetooth (Replace Microphone and Bezel) - (Oct 13, 2010)


Subject: Buzz Noise During Call When Using Bluetooth® (Replace Microphone and Bezel)


Models: 2009-2011 Buick Enclave, LaCrosse, Lucerne

2008-2011 Cadillac CTS, CTS-V

2009-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT, SRX, STS (with RPO YQ1 or YQ2), XLR

2009-2010 Chevrolet Cobalt, Corvette, Equinox, HHR, Impala, Malibu, Silverado, Suburban, Tahoe, TrailBlazer, Traverse

2010-2011 Chevrolet Camaro

2009-2010 GMC Envoy

2009-2011 GMC Acadia, Sierra, Yukon, Yukon XL

2009-2010 Pontiac G5, G6, Solstice, Torrent

2009-2010 HUMMER H2, H3

2009-2010 Saturn AURA, OUTLOOK, SKY, VUE

2009 Saab 9-7X

All Equipped with OnStar® (UE1) and Bluetooth (UPF)
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This bulletin is being revised to replace the microphone and bezel (if needed) and update model years. Please discard Corporate Bulletin Number 10-08-44-003A (Section 08 - Body and Accessories).


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Condition
Some customers may comment on a buzz noise (from the land-line side only) during a call.

On any vehicle equipped with OnStar® (UE1) and Bluetooth® (UPF), an electromagnetic compatibility (EMC) buzz can be heard from the land-line side only of the phone during a Bluetooth® phone call made with an older model global system for mobile communications (GSM) phone. The buzz is only heard with older model GSM phones and is dependent on the distance of the phone from the microphone. The newer 3G GSM phones or other cellular phones (CDMA, TDMA, etc.) have not shown this concern.

Correction
Equipped with Headliner Microphone (Cobalt, HHR (non-sunroof) H2, H3)

7733


A new microphone and bezel has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Also replace the bezel. Refer to the parts information table below for correct color/part number.

Equipped with Overhead Console Microphone


7734



A new microphone has been developed to address this concern. Replace the existing microphone with GM P/N 20951265.

Parts Information Part Number Description

20951265 Microphone

25932003 LT. Titanium Bezel

25932004 Neutral Bezel

25966446 LT Opel Grey Bezel

ChevyMgr
04-16-2010, 02:20 PM
#07-09-41-010C: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary) - (Apr 15, 2010)


Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary)


Models: 2005-2007 Buick Terraza

2006-2010 Buick Lucerne

2006-2010 Cadillac DTS

2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT

2005-2009 Chevrolet Uplander

2006-2007 Chevrolet Monte Carlo

2006-2010 Chevrolet HHR

2006-2008 Chevrolet Impala

2007-2010 Chevrolet Avalanche, Cobalt, Colorado, Silverado, Suburban, Tahoe

2007-2010 GMC Canyon, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL

2005-2009 Pontiac Montana SV6

2007-2010 Pontiac G5

2005-2007 Saturn RELAY

2008-2010 Saturn VUE

2006-2010 HUMMER H3

2009-2010 HUMMER H3T
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This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 07-09-41-010B (Section 09 - Restraints).


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Condition
Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in the sensing and diagnostics module (SDM).

Correction
Do This
Don't Do This

Diagnose and replace the right front seatbelt buckle, if necessary.
Do not replace the passenger presence system or the sensing and diagnostic module.


Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal, voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension sensor.

Important: The seat belt tension sensor is not serviced separately. The seat belt buckle with the tension sensor must be serviced as a complete unit.

Parts Information
For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog.

ChevyMgr
04-16-2010, 02:33 PM
#PI0100: Stability Control Inoperative Due to Different Tire Sizes or Manufacturers, Service ESC Indicator Illuminated, DTC C0460 Set - (Apr 15, 2010)


Subject: Stability Control Inoperative Due to Different Tire Sizes or Manufacturers, Service ESC Indicator Illuminated, DTC C0460 Set


Models: 2006-2010 Chevrolet HHR
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern
The Service Electronic Stability Control (ESC) light is on due to DTC C0460-42 "Steering Position Signal Initialization Not Accomplished" being set. Stability control will be inoperative.

Customers may have one or more tires that are different sizes or produced by different manufacturers or have low air pressure sensors that are mounted on the vehicle. It has been determined that some tires of different brands may have rolling diameters that are either large or small enough in comparison to the other original tire(s) on the vehicle that may allow DTC C0460 to set.

Important: DO NOT replace the steering angle sensor in the vehicle without confirming the tire, size, brand and pressure.

Recommendations/Instructions
Before attempting any repairs:

• Confirm that all tires are of the proper size and that all are matching brands.

• Check and adjust all tires to the stated cold air pressure as identified on the tire placard. Low tire pressure may induce DTC C0460.

• Check and diagnose all EBCM wheel speed sensor related DTCs first (example: C0035, C0040, C0045 and C0050).

If a mis-sized or non-matching brand tire is present, inform the customer that in order for the electronic stability control system to function normally, tires need to be a uniform size and rolling diameter and match the original equipment tire sizes and specifications.

If the tires are found to be satisfactory, please refer to normal diagnostics in SI for DTC C0460.

ChevyMgr
04-16-2010, 02:34 PM
#PIE0041B: EI10006-Engineering Information-SIR/Airbag Indicator/Light On, DTC B0019 or B0020 Set (Repair Inflatable Restraint I/P Connector) - (Apr 15, 2010)


Subject: EI10006 -- Engineering Information -- SIR/Airbag Indicator/Light On, DTC B0019 or B0020 Set (Repair Inflatable Restraint I/P Connector)


Models: 2009-2010 Chevrolet HHR
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This PI is being revised to end the need for information from the field and provide repair information. Please discard PIE0041A.


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Condition
Some customers may comment on the SIR/Airbag indicator/light on in the Instrument Panel Cluster (IPC). Upon investigation, the technician may find SIR DTCs B0019.0D, B0019.04, B0020.0D, and/or B0020.04 set.

Note: This concern only involves the SIR/Airbag indicator (shown below). Do not proceed with this bulletin if only the Passenger Airbag indicator is On.


Cause
This condition may be caused by fretting corrosion on the terminals of inflatable restraint I/P harness to body harness connector X211 due to excessive vibration.

Correction
If a vehicle is encountered with the above condition, follow the steps below:

If DTCs B0019 and/or B0020 is set, the connection from the body harness to the I/P passenger inflatable restraint harness (X211) needs to be inspected. The symptom byte B0019.0D or B0020.0D set in history and the SIR/airbag indicator/light turning on intermittently are usually the first symptoms that fretting corrosion is beginning to occur on the terminals of this connector. A history DTC will clear once 100 malfunction-free ignition cycles have occurred. X211 is located in the front passenger kick panel area. Refer to Harness Routing Views in SI. If DTCs B0019 and/or B0020 are not set, proceed with step 2.
• If the DTC is set in history, remove the passenger side kick panel. Locate the passenger inflatable restraint I/P harness to body harness connector X211. Turn the ignition ON. Wait for the self test to complete. The SIR/airbag indicator/light will turn off. Wiggle this connection and see if the SIR/airbag indicator/light turns on. If not, drive the vehicle over bumps and see if the SIR/airbag indicator/light turns on. This DTC typically sets when the connector experiences some vibration.

• If the airbag light turns on and the DTC is set current, turn off the ignition. Inspect the terminals for corrosion. If corrosion is found, clean the terminals with a small wire brush. Brush on a small amount of dielectric grease, GM P/N 12345579 (in Canada, use 10953481) to the female side of the terminals. Reconnect the connector. To stiffen up the connection, wrap with electrical tape in a double layer around the body harness about 50 mm (2 in) down from the connector, wrap over the connector, and about 50 mm (2 in) up the airbag pigtail. Reinstall the harness behind the trim. Clear DTCs. Test drive to ensure that the DTC does not reoccur. Check DTCs to ensure that no history DTC (B0019 or B0020) is reported by the SDM.

If any other DTC(s) are set, refer to diagnosis and repair procedures in SI.

ChevyMgr
04-21-2010, 09:08 AM
#10037: Customer Satisfaction - Unwanted Repeat Calls to OnStar - (Apr 20, 2010)


Subject: 10037 - Unwanted Repeat Calls to OnStar®


Models: 2003 Buick LeSabre

2004-2006 Buick Rendezvous

2005 Buick LeSabre, Terraza

2005-2006 Buick LaCrosse/Allure

2006-2008 Buick Lucerne

2008 Buick LaCrosse/Allure

2008-2009 Buick Enclave

2003 Cadillac CTS

2004 Cadillac Escalade

2004-2005 Cadillac CTS-V, Deville

2005 Cadillac Escalade ESV, SRX

2005-2006 Cadillac STS

2005-2008 Cadillac CTS

2006-2008 Cadillac DTS

2007 Cadillac Escalade, Escalade EXT

2007-2008 Cadillac Escalade ESV

2008 Cadillac SRX, STS

2002 Chevrolet Impala

2003-2008 Chevrolet Suburban

2003-2009 Chevrolet Silverado

2004-2008 Chevrolet Impala

2005 Chevrolet Colorado, Corvette, Malibu

2005-2006 Chevrolet Uplander

2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer

2006 Chevrolet HHR, Monte Carlo

2006-2008 Chevrolet Equinox

2007-2008 Chevrolet Corvette

2008 Chevrolet HHR

2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander

2003 GMC Envoy XL, Sierra, Yukon XL

2004-2008 GMC Yukon

2005-2009 GMC Sierra

2005-2008 GMC Yukon XL

2006-2008 GMC Envoy

2007 GMC Canyon

2007-2009 GMC Acadia

2006 HUMMER H2

2006-2008 HUMMER H3

2008 HUMMER H2

2003 Oldsmobile Silhouette

2005 Montana SV6

2005-2008 Pontiac Grand Prix

2006 Pontiac G6, Vibe

2007 Pontiac Montana SV6

2007-2008 Pontiac Solstice

2008 Pontiac G6, Torrent

2008-2009 Pontiac G5, G8

2009 Pontiac G3, Montana SV6

2005-2007 Saturn ION

2006-2009Saturn VUE

2007-2008 Saturn AURA, OUTLOOK, SKY

Equipped with OnStar® (RPO UE1)




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THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.

Condition
Certain 2002-2009 model year vehicles equipped with OnStar® may have a condition in which the vehicle's OnStar® system repeatedly makes incomplete calls to OnStar® without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar® Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar® advisor; however, the advisor will not get crucial customer data such as vehicle identification and location.

Correction
Dealers/retailers are to replace the OnStar® module (VCIM).

Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar®, and built within these VIN breakpoints:

Note: Some model years/models have only one vehicle involved.


Service Procedure
Note: Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue.

Remove the OnStar® module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions.
Note: Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly.

Install the new OnStar® module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions.

Post #5000 :D

ChevyMgr
05-07-2010, 08:08 AM
#PI0117: SIR/Airbag Indicator Light On, DTC B0019 or B0020 Set - (May 4, 2010)


Subject: SIR/Airbag Indicator Light On, DTC B0019 or B0020 Set


Models: 2009-2010 Chevrolet HHR
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may comment on the SIR/Airbag indicator/light on in the Instrument Panel Cluster (IPC). Upon investigation, the technician may find SIR DTCs B0019.0D, B0019.04, B0020.0D, and/or B0020.04 set.

Note: This concern only involves the SIR/Airbag indicator (shown below). Do not proceed with this bulletin if only the Passenger Airbag indicator is On.


This condition may be caused by fretting corrosion on the terminals of inflatable restraint I/P harness to body harness connector X211 due to excessive vibration.

Recommendation/Instruction:
If a vehicle is encountered with the above condition, follow the steps below:

If DTCs B0019 and/or B0020 is set, the connection from the body harness to the I/P passenger inflatable restraint harness (X211) needs to be inspected. The symptom byte B0019.0D or B0020.0D set in history and the SIR/airbag indicator/light turning on intermittently are usually the first symptoms that fretting corrosion is beginning to occur on the terminals of this connector. A history DTC will clear once 100 malfunction-free ignition cycles have occurred. X211 is located in the front passenger kick panel area. Refer to Harness Routing Views in SI. If DTCs B0019 and/or B0020 are not set, proceed with step 2.
• If the DTC is set in history, remove the passenger side kick panel. Locate the passenger inflatable restraint I/P harness to body harness connector X211. Turn the ignition ON. Wait for the self test to complete. The SIR/airbag indicator/light will turn off. Wiggle this connection and see if the SIR/airbag indicator/light turns on. If not, drive the vehicle over bumps and see if the SIR/airbag indicator/light turns on. This DTC typically sets when the connector experiences some vibration.

• If the airbag light turns on and the DTC is set current, turn off the ignition. Inspect the terminals for corrosion. If corrosion is found, clean the terminals with a small wire brush. Brush on a small amount of dielectric grease, GM P/N 12345579 (in Canada, use 10953481) to the female side of the terminals. Reconnect the connector. To stiffen up the connection, wrap with electrical tape in a double layer around the body harness about 50 mm (2 in) down from the connector, wrap over the connector, and about 50 mm (2 in) up the airbag pigtail. Reinstall the harness behind the trim. Clear DTCs. Test drive to ensure that the DTC does not reoccur. Check DTCs to ensure that no history DTC (B0019 or B0020) is reported by the SDM.

If any other DTC(s) are set, refer to diagnosis and repair procedures in SI.

ChevyMgr
05-15-2010, 12:16 PM
#PI0128: Engine Misfire/Low Compression - (May 12, 2010)


Subject: Engine Misfire/Low Compression


Models: 2008-2010 Chevrolet Cobalt, HHR

2008-2010 Pontiac Solstice

2008-2010 Saturn SKY

2008-2009 Daewoo G2X

2008-2010 Opel GT

Equipped with 2.0L Engine (VIN X - RPO LNF)
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Condition/Concern:
Some 2.0L Turbo engines may come in with a misfire on one cylinder.

For further misfire diagnosis, a technician should perform a compression test. The results may lead to a cylinder with low compression (85-90 psi). This may be the cause the misfire. The cylinder with the low compression may have a burned/ damaged piston from detonation. The damage to the piston is usually above and below the first compression ring in an area about 25.4 mm (1 in) in length.

Recommendation/Instructions:
Damage of this type to the piston is usually caused by aftermarket equipment (examples are: air induction systems, intercooler cooling devices, NOS systems, ECM calibrations), all designed to boost the output of the engine. This increased output of the engine can lead to severe detonation in certain conditions. If diagnosed with this condition, the vehicle should be inspected for aftermarket performance equipment and/or calibrations (Refer to bulletin 08-06-04-033C for help on Identifying calibrations) and it should be noted on the repair order.

The GM Accessories power upgrade kit by itself is designed for this engine and should be the recommended performance enhancing equipment. Using the GM accessory kit with other aftermarket components could damage the engine as well.

If repairs to the engine are the result of the installation or use of a non-GM approved part, the warranty will not be honored.

ChevyMgr
05-21-2010, 04:43 PM
#08-05-22-004A: Information on Brake Squeal/Squeak Noise - (May 20, 2010)


Subject: Information on Brake Squeal/Squeak Noise


Models: 2008-2010 Cobalt SS, HHR SS
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This bulletin is being revised to add 2010 model year. Please discard Corporate Bulletin Number 08-05-22-004 (Section 05 - Brakes).
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Do This:
Inform the customer that this is a normal characteristic of the high performance brake system.

Don't Do This:
DO NOT repair or replace the rotors or brake pads.


Under certain weather or operating conditions, occasional brake squeal, squeak, or other noise may be heard with the above vehicle's performance braking system. The brake system is designed for superior fade resistance and consistent operation using high performance brake pads. Some brake noise and brake dust is considered normal and do not affect system performance.

DO NOT attempt to repair or replace any parts for this kind of noise concern. The squeal or squeak noise is not indicative of any concerns with the braking system. You may wish to give the customer a copy of this bulletin.

ChevyMgr
06-21-2010, 04:49 PM
#10-08-50-007: Information on Driver and/or Passenger Seat Concerns with Armrest Comfort, Angle Adjustment and Height - (Jun 17, 2010)


Subject: Information on Driver and/or Passenger Seat Concerns with Armrest Comfort, Angle Adjustment and Height


Models: 2007-2010 Chevrolet HHR
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Note: Do not replace the armrest for customer concerns of incorrect armrest angle or height. Installing a new armrest will not change the angle or height, and will not fix the customer concern.

Some customers may comment that the driver and/or passenger seat armrest is uncomfortable or that the armrest is tilting on a downward or upward angle or that the height of the armrests is not the same on both front seats.

The front driver and passenger seats are equipped with armrests that have been built into the seat back assembly. The angle of the armrests is determined by the angle of the seat back. The height of the armrest is determined by the height of the seat. Instruct the customer of the interaction of the seat back angle to the angle of the armrest, and the seat height to the height of the armrest. Reclining the seat back will raise the front of the armrest, adjusting the seat back to a more upright position will lower the front of the armrest. Raising the seat height will raise the armrest, and lowering the seat will lower the armrest.

These adjustments may cause the driver and passenger armrests to be at different heights and angles relative to one another.

It is recommended that dealership personnel demonstrate the seat adjustment functions to the customer. This will aid the customer in finding suitable seat position.

ChevyMgr
06-21-2010, 04:53 PM
#06-02-32-002D: Information for Normal Operating Characteristics of Electric Power Steering (EPS) System During Extended Lock-to-Lock Turns or When Held at Maximum Steering Wheel Rotation and/or DTCs C0176 and C0476 - (Jun 17, 2010)


Subject: Information for Normal Operating Characteristics of Electric Power Steering (EPS) System During Extended Lock-to-Lock Turns or When Held at Maximum Steering Wheel Rotation and/or DTCs C0176 and C0476 Set


Models: 2004-2011 Chevrolet Malibu, Malibu Maxx

2005-2011 Chevrolet Cobalt, Equinox

2006-2011 Chevrolet HHR

2010-2011 GMC Terrain

2005-2010 Pontiac G6

2005-2006 Pontiac Pursuit (Canada Only)

2006-2009 Pontiac Torrent

2007-2010 Pontiac G5

2002-2009 Saturn VUE

2003-2007 Saturn ION

2007-2009 Saturn AURA

Equipped With Electric Power Steering (EPS) Only
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This bulletin is being revised to add model years and clarify the information. Please discard Corporate Bulletin Number 06-02-32-002C (Section 02 - Steering).
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• The purpose of this bulletin is to inform technicians of the normal operating characteristics of the electric power steering system (EPS) when the steering wheel is turned in either direction or held at maximum rotation for an extended period of time.

• When the steering wheel is cycled repeatedly or turned to its maximum rotation, the power steering control module (PSCM) will command the maximum amount of current to the EPS motor. If the steering wheel is held in this position for an extended period of time, the PSCM will go into overload protection mode to avoid system thermal damage. In this mode, the PSCM will limit the amount of current commanded to the EPS motor, which will reduce the power steering assist level.

• If the PSCM detects a high system temperature and the overload protection mode is initiated, DTC C0176 System Thermal Error may set. On some models, DTC C0476 Electric Steering Motor Circuit Range/Performance may also set. These DTCs indicate normal PSCM action, to reduce the steering assist in order to prevent thermal damage to power steering system components.

• Refer to Power Steering System Description and Operation in SI or the appropriate Service Manual for more information about this and other vehicle-specific information on electric power steering systems.

• For customer inquiries regarding this characteristic, please guide the customer to the Steering section under Driving Your Vehicle in their vehicle Owner Manual. This information is reproduced below for quick reference.

Owner Manual Information
If you turn the steering wheel in either direction several times until it stops, or hold the steering wheel in the stopped position for an extended amount of time, you may notice a reduced amount of power steering assist. The normal amount of power steering assist should return shortly after a few normal steering movements.

ChevyMgr
06-23-2010, 08:23 AM
#PI0160: Unable to Open Hood, Inside Hood Latch Release Cable Inoperative (Reattach Hood Release Cable) - (Jun 22, 2010)


Subject: Unable to Open Hood, Inside Hood Latch Release Cable Inoperative (Reattach Hood Release Cable)


Models: 2010 Chevrolet HHR
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Condition/Concern

7070

Some customers may comment that they are unable to open the hood, the hood release cable is not fully seated in the hood release handle or the release handle is not secured to the mounting bracket. There are also instances that, over time and use, some of these cables can become detached from the handle or the handle becomes loose.

Recommendation/Instructions
Important: DO NOT replace the hood latch cable release assembly.

Snap the release cable end to the handle back in place and secure the handle to the mounting bracket.

ChevyMgr
06-23-2010, 08:27 AM
#PI0158: Intermittent Tapping or Clunk Noise from Rear at Low to Moderate Speeds During Light to Moderate Brake Apply (Refinish Rear Brake Drums) - (Jun 21, 2010)


Subject: Intermittent Tapping or Clunk Noise from Rear at Low to Moderate Speeds During Light to Moderate Brake Apply (Refinish Rear Brake Drums)


Models: 2010 Chevrolet HHR
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The following procedure may be helpful if the vehicle exhibits the symptoms described in this PI.

Condition/Concern
• Some customers may comment on an intermittent tapping noise coming from the rear of the vehicle upon applying the brakes when driving between 35-40 mph (56-64 km/h).

• They may also comment on an intermittent clunk noise coming from the rear of the vehicle during a light to moderate brake apply at speeds of 10 mph (16 km/h) or less.

• These conditions may be caused by brake drums that are out of round.

Recommendation/Instructions
Important: DO NOT replace the brake drums. Refinish both of the brake drums.

Test drive the vehicle and verify that the above condition or conditions exist as described.
⇒ If either condition exists as described, proceed to Step 2.

Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Remove both tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in SI.
Warning: Refer to Brake Dust Warning in the Preface section in SI.

Remove the brake drums. Refer to Brake Drum Replacement in SI.
Refinish the brake drums. Refer to Brake Drum Refinishing in SI.
Note: Failure to clean any existing corrosion from the wheel hub flange mating surface may result in increased lateral runout of the brake drum and brake system pulsation.

Clean the wheel hub flange mating surface of any corrosion.
Install the brake drums. Refer to Brake Drum Replacement in SI.
Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in SI.
Lower the vehicle.
Test drive the vehicle and verify that the concern has been corrected.

ChevyMgr
06-23-2010, 08:36 AM
#PIC5356A: AC Compressor Will Not Engage - AC Pressure In The ECM Data Reads 0 PSI - No DTCs - (Jun 22, 2010)


Subject: AC Compressor Will Not Engage AC Pressure in the ECM Data Reads 0 PSI No DTC's


Models: 2008-2010 Chevrolet Cobalt

2008-2010 Pontiac G5

2008-2011 Chevrolet HHR

Equipped with RPO C60 or C67

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This PI was superseded to update models. Please discard PIC5356.
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
A customer may comment that their AC is inoperative. Upon diagnosis the technician will find the AC compressor will not engage and there are no codes stored. The technician may find the scan tool ECM data indicates No for the AC Request and AC Relay Command, and the AC Pressure Sensor value is 0 psi. No codes are setting current or history. This concern could be caused by incorrect BCM Setup during a previous repair.

Recommendation/Instructions:
Attempt to enable the AC option in the BCM. If the option is not listed, replace the BCM. Use caution when setting up the BCM to ensure all the correct vehicle options are selected. Some of the options only appear during the initial BCM Setup procedure.

ChevyMgr
06-25-2010, 11:09 AM
#02-08-42-001D: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses - (Jun 21, 2010)


Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses


Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn)

2010 and Prior HUMMER H2, H3

2009 and Prior Saab 9-7X
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This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories).
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The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance.

A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing.

Warning: Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses.

Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps.

Warning: Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color.

Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp.

Notice: Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty.

ChevyMgr
06-25-2010, 11:12 AM
#99-09-40-005F: Seat Belt Extender Availability - (Jun 23, 2010)


Subject: Seat Belt Extender Availability


Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn)

2009 and Prior HUMMER H2

2010 and Prior HUMMER H3

2005-2009 Saab 9-7X
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This bulletin is being revised to add the 2009-2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 - Restraints).
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Important: DO NOT use belt extenders when securing a child restraint.

The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal.

Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended.

Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender.

Parts Information
Contact GM Parts.

Warranty Information
• Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles.

• Dealers should not be charging part costs since these extenders are supplied by GM to the dealers.

• Dealers should not be charging labor costs since the extender can be customer installed.

ChevyMgr
06-25-2010, 11:13 AM
#10-08-50-007: Information on Driver and/or Passenger Seat Concerns with Armrest Comfort, Angle Adjustment and Height - (Jun 17, 2010)


Subject: Information on Driver and/or Passenger Seat Concerns with Armrest Comfort, Angle Adjustment and Height


Models: 2007-2010 Chevrolet HHR
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Note: Do not replace the armrest for customer concerns of incorrect armrest angle or height. Installing a new armrest will not change the angle or height, and will not fix the customer concern.

Some customers may comment that the driver and/or passenger seat armrest is uncomfortable or that the armrest is tilting on a downward or upward angle or that the height of the armrests is not the same on both front seats.

The front driver and passenger seats are equipped with armrests that have been built into the seat back assembly. The angle of the armrests is determined by the angle of the seat back. The height of the armrest is determined by the height of the seat. Instruct the customer of the interaction of the seat back angle to the angle of the armrest, and the seat height to the height of the armrest. Reclining the seat back will raise the front of the armrest, adjusting the seat back to a more upright position will lower the front of the armrest. Raising the seat height will raise the armrest, and lowering the seat will lower the armrest.

These adjustments may cause the driver and passenger armrests to be at different heights and angles relative to one another.

It is recommended that dealership personnel demonstrate the seat adjustment functions to the customer. This will aid the customer in finding suitable seat position.

ChevyMgr
06-25-2010, 12:01 PM
xTooltipElement
Service Information
Document ID: 2491676
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#PIP4453A: No ISS Signal At Low Speeds - (Jun 17, 2010)


Subject: No ISS Signal at Low Speeds


Models: 2007-2010 Chevrolet Cobalt, Malibu, HHR

2007-2010 Pontiac G5, G6

2007-2009 Saturn Aura, Ion, Vue

equipped with 4T45E transmission (RPOs MN5, ME7)




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This PI was superseded to update model years and condition. Please discard PIP4453.
-------------------------------------------------------------------------------
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Recently several cases have surfaced where DTC P0717 sets and there is no ISS signal until 5 mph or 1000-1200 rpm.

Recommendation/Instructions:
If the air gap and resistance checks are ok, but concern continues, the cause may be the internal trans wiring harness has been chaffed by a sharp edge on a hold down clip and is grounding out until sufficient vibration at higher RPM's interrupts the ground out. Checking 20 Way Connector pins 'S' and 'V' to ground may show some resistance readings when there should be none. For this condition (no ISS until higher RPM), replace the transmission internal wiring harness. This applies to both RPO's: MN5, ME7.

For pin out locations see SI Doc 1887360, connector #11 (engine to transmission).

7077

ChevyMgr
07-20-2010, 03:27 PM
#PI0178: Front Door Power Locks Will Not Unlock with Key Fob or Switch (Revise Lock Rod Anti-Rattle Foam) - (Jul 16, 2010)

Subject: Front Door Power Locks Won't Unlock with Key FOB or Switch (Revise Lock Rod Anti-Rattle Foam)


Models: 2009-2010 Chevrolet HHR
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Note: For vehicles built before 8/17/2009, refer to Corporate Bulletin Number 09-08-64-029 for other possible causes.

Condition/Concern
Some customers may comment that the front door power lock(s) fails to unlock when using the key FOB or the interior mounted power door lock switch. The door lock knob does actuate using the power door lock, but fails to unlock the latch. The doors will unlock using the manual lock knob when it is pulled up to the unlock position. This condition may be present on both the left and/or right front doors.

This condition may be caused by friction between the lock rod anti-rattle foam, located on the door trim, and the lock rod. This friction may cause the lock rod to bind and prevent power actuation of the lock.

Recommendation/Instructions
Important: DO NOT replace the front side door trim panel, door lock actuator or door lock rod to correct this condition.

Use the following procedure to revise the lock rod anti-rattle foam to prevent future binding.

Remove the affected door trim panel. Refer to Front Side Door Trim Panel Replacement in SI.

7183

Locate the lock rod anti-rattle foam.
Remove the anti-rattle foam by pulling the foam off of the trim panel. Use care to not tear the anti-rattle foam.

7184

Using a pair of sharp scissors, cut the anti-rattle foam as shown in the graphic. Cut along the dotted green line to create the correct shape.
Apply spray trim adhesive, such as 3M™ General Trim Adhesive Clear, Part # 051135-08088* or the equivalent, to the anti-rattle foam as shown. Use care to not get adhesive on the mylar anti-friction surface of the anti-rattle foam.

7185

Close the opening in the anti-rattle foam to create the shape shown in the graphic.

7186

Reinstall the anti-rattle foam in the original location on the door trim panel.
Reinstall the door trim panel. Refer to Front Side Door Trim Panel Replacement in SI.
Verify the function of the power door locks.
*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources.

Parts Information
3M products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada).

ChevyMgr
08-06-2010, 08:14 AM
#PIE0070B: EI10105-Engineering Information-Electronic Stability Control (ESC) Message Displayed in Driver Information Center (DIC), DTC C0460 Set - (Aug 4, 2010)


Subject: EI10105 -- Engineering Information --Electronic Stability Control (ESC) Message Displayed in Driver Information Center (DIC), DTC C0460 Set


Models: 2009-2010 Chevrolet HHR

Equipped with Electronic Traction Control (RPO NW9)


Attention: Proceed with this PI ONLY if the customer has commented about this concern AND the EI number is listed in GWM IVH. If the customer has not commented about this condition or the EI does not show in GWM IVH, disregard the PI and proceed with diagnostics found in published service information. THIS IS NOT A RECALL -- refer to Service Bulletin 04-00-89-053C for more details on the use of Engineering Information PIs.

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This PI is being revised to update the Instructions. Please discard PIE0070A.
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Condition
Important: If the customer did not bring their vehicle in for this concern, DO NOT proceed with this PI.

Some customers may comment that the Service Electronic Stability Control (ESC) message appears in the Driver Information Center (DIC).

Cause
GM Engineering is attempting to determine the root cause of the ESC message. Engineering has a need to gather information on vehicles, PRIOR to repair, that may exhibit this condition. As a result, this information will be used to "root cause" the customer's concern and develop/validate a field fix.

Instructions
Note: This EI is only concerned with those cases where the DTC C0460 is responsible for the service ESC message. Multiple DTCs may be present, but C0460 must be one of them.

For first time occurrences of this condition to correct DTC C0460, refer to Brakes-Antilock Brake System-Diagnostic Information and Procedures in SI. Follow the procedure ending with Steering Angle Sensor Centering and clearing the DTCs. Road test the vehicle to ensure that steering angle is reading correctly. Call the engineer listed below for additional information if required.

If the vehicle has returned to the dealership for service for the same issue more than once, and before any codes are cleared, capture a snapshot (F3 on EBCM menu) of the EBCM VSES Data with a manual trigger and the trigger point set to end. Make sure to record the enhanced DTC data for each code set after driving the vehicle at 88 km/h (55 mph) or more in a relatively straight stretch of road for a minute. E-mail the snapshot file to dave.orth@gm.com. For instructions on emailing snapshots, refer to Corporate Bulletin Number 07-07-30-010B. Please call the engineer listed below for further instructions.

Below is additional information about C0460 set in the EBCM for HHR vehicles equipped with ESC (VSES).

The steering angle sensor (SAS) is a relative sensor and requires a two stage initialization that happens at each ignition cycle. The first stage is accomplished when the steering wheel is moved a few degrees in either direction (the steering angle will jump from the default value to the true value when this is complete). The second stage of the initialization happens usually when the vehicle speed reaches 15-20 km/h (9-12 mph) if the vehicle is driven in a straight line (when complete, the VSES Failed value found under VSES data changes from yes to no).

The EBCM automatically adjusts the steering angle when the vehicle is driven to compensate for a steering angle that is not zero when the vehicle is driven in a straight line. This steering angle can be adjusted up to 15 degrees without setting a DTC.

Common Causes for Particular C0460 DTC Symptom Codes:

Symptom Code 4B
This is commonly set when there is a short or open circuit present when the vehicle is keyed up. The fault will no longer be current if the short is not present at a later ignition cycle. This scenario usually also sets one or all of the following DTCs: U2142, U2143, U1500, C0292 39. A chaffing point has been identified on some vehicles on the harness on the female side of the X203 connector about 101 mm (4 in) from the connector.
This is also set when a new SAS has been installed. If a new sensor is installed it will be necessary to perform the SAS centering (calibration) procedure before the fault will clear.

Symptom Code 42
This code can be set if there are tires with different rolling diameters or there is a problem with a wheel speed sensor. Taking a snapshot of the VSES data while driving the vehicle in a straight line at highway speeds is a good way to identify this condition. Wheel speeds should be within 1.6 km/h (1 mph) in those conditions.
This code can also be set (sometimes in conjunction with the 5A symptom code) if the steering angle is not reading 0 when driving the vehicle in a straight line. If this is the case, perform the SAS centering (calibration) procedure.

Symptom Code 5A
The most common cause of this fault is identified by checking the enhanced DTC information item 4 DTC Subcode. If the value of the subcode is 20, then the EBCM has attempted to adjust the steering angle more than the 15 degree limit. This fault cannot be cleared unless a SAS centering (calibration) procedure is done first. By performing the calibration you will have also provided a new reference point for the 15 degrees of allowable adjustment. It is a good idea to test drive the vehicle to ensure that the steering angle reads 0 after the centering procedure is done to ensure there are no steering wheel alignment issues. If an alignment is required the centering procedure and test drive should be performed after the alignment.

Symptom Code 72
This most common cause of this code is a short or open circuit that occurs after the vehicle has been keyed up. This scenario usually also sets one or all of the following DTCs: U2142, U2143, U1500, C0292 39. A chaffing point has been identified on some vehicles on the harness on the female side of the X203 connector about 101 mm (4 in) from the connector.

Symptom Code 71
This code can be set if the steering angle sensor has been damaged internally and is often set in conjunction with the 72 symptom code.

Note: If the SAS Centering (calibration) procedure will not complete, it can be due to a damaged sensor or a sensor that will not communicate with the EBCM. It could also be due to an open or short circuit in the wiring.

Contact Information (DELETED)

ChevyMgr
08-13-2010, 10:46 AM
#PIP4820: Low Turbocharger Boost Pressure Or Possible DTC P0299 - (Aug 11, 2010)


Subject: Low turbocharger boost pressure or possible DTC P0299


Models: 2008-2010 Chevrolet Cobalt, HHR

2008-2010 Pontiac Solstice

2008-2010 Saturn SKY

2008-2009 Daewoo G2X

2008-2010 Opel GT

Equipped with 2.0L 4 cyl turbocharged engine (RPO LNF)
--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may comment of a low power or low turbo boost condition. Technicians may find DTC P0299 present. Technicians may also find the turbo wastegate actuator rod nut missing. Most parts of the turbocharger are not serviceable. Until now, if the wastegate actuator rod nut was missing, replacement of the complete turbo assembly would have been required.

Recommendation/Instructions:
If the turbo wastegate actuator rod nut is missing, a kit (WPC 562) can be ordered using the form below. The kit contains two nuts and a retaining clip. One nut goes on either side of the wastegate lever/arm. Replace one or both as needed, depending on which are missing. Adjust the wastegate actuator per SI document 2246965. Once the wastegate actuator is properly adjusted, install the locking clip from the kit around both nuts to keep them in place. See the images below.

7313

7314

7315

ChevyMgr
09-07-2010, 03:26 PM
#PIC5364: SIR Light / Indicator Illuminated No DTC Present - (Aug 23, 2010)


Subject: Sir light/ Indicator Illuminated No DTC Present


Models: 2011 HHR Only
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Technician may find the SIR light is illuminated all the time. upon diagnosis no codes/DTCs will be present in the SDM,

Recommendation/Instructions:
If technician finds the above concern dealer should replace the SDM with current SPO stock.

ChevyMgr
09-14-2010, 08:45 AM
#PI0086A: Info for Intermittent Bluetooth Interactive Issues with Blackberry Phone Devices-Inform Customer of Corrective Actions - (Sep 13, 2010)


Subject: Information for Intermittent Bluetooth Interactive Issues with Blackberry® Phone Devices -- Inform Customer of Corrective Actions


Models: (Most)

2009-2011 HHR
Equipped with OnStar® RPO UE1 and Bluetooth UPF or UWE

Attention: Advise the customer that they should always have the latest Blackberry® software (via their Blackberry® desktop software) downloaded in their phone. To guarantee future customer satisfaction, inform the customer of the Bluetooth information that can be found at this internet website: www.gm.com/Bluetooth .

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Condition/Concern
The following is a list of conditions that a customer may comment about. Review the numbered Conditions in the list below and then refer to the appropriate numbered Correction that follows.

When using the Blackberry® phone, the Bluetooth function fails to connect, does not consistently connect or won't connect to the vehicle even after the customer tries to force a connection from the phone.
Audio is not heard in the vehicle with a Bluetooth phone call although the function previously worked properly. The customer has to transfer to the phone handset to listen to the call.
After turning ON the ignition and after the Bluetooth phone connects, the desired audio selection such as: AM/FM/XM/CD/AUX is no longer heard in the vehicle. A phone icon may appear on the radio indicating a call is in progress when actually it is not. Pressing the control buttons may not allow the customer to exit from this mode.
The Blackberry® phone using Bluetooth will not pair or connect to the vehicle, displaying an hourglass on the phone as if it were working, even though the customer has not been able to use the Bluetooth feature.
The customer receives a continuous request on the cell phone to connect to a device that is no longer shown on the phone, due to the pairing being deleted from the phone but not from the vehicle.
The Blackberry® phone using Bluetooth will not complete a call when dialing a number from the phone or complete a call through the vehicle's stored nametags in the voice recognition system.
With a Bluetooth call with a Blackberry® phone, the customer ends the call by pressing the Blackberry® phone: End Call button and the vehicle displays: Private Call .
When using the Blackberry® phone, an incoming call may ring 2-3 times before the ring is heard in the vehicle. It may take multiple presses of the steering wheel controls to answer the call, or to make an outgoing call.
Recommendation/Instructions for Condition #1
When using the Blackberry® phone the Bluetooth function fails to connect, does not consistently connect or won't connect to the vehicle even after the customer tries to force a connection from the phone.

Inspect the customer's phone and verify that the General Motors vehicle is selected as a: Trusted Device to Always Connect .
After the phone has been paired to the vehicle, verify the setting in the phone is correct by:

1.1. Displaying the phone's: Bluetooth menu.

1.2. Observing the: Device Properties of the General Motors vehicle that is paired.


Note: Selecting General Motors as a trusted Bluetooth device enables the phone to allow the vehicle to automatically connect to the phone when the vehicle ignition is turned to ON/RUN or ACC/ACCESSORY.


1.3. Verify that the item displayed is: Trusted: Yes .

To guarantee future customer satisfaction, advise the customer of the following phone pairing instructions (print a copy of this PI if necessary).
2.1. At the phone's main menu press the: MENU key.

2.2. Select: Options .

2.3. Select: Bluetooth .

2.4. Press the: MENU key.

2.5. Select: Add Device .

2.6. Select: Search for Devices .

2.7. Select: General Motors .

2.8. Enter the: PIN Code provided by the vehicle.

2.9. Press the: Trackball or Enter key to submit the code.


Note: You MUST perform the following steps:


2.10. Observe the: Prompt that states: Accept Connection Request from General Motors. Scroll to: Don't ask this again . Press the trackball in order to insert a check mark in the box.

2.11. Select: Yes .

INFORM the customer that the connection process can take up to two minutes to complete after the ignition is turned to ON/RUN as indicated in the vehicle's Owner Manual.
Recommendation/Instructions for Condition #2
Some customers may comment that they were successfully using Bluetooth in their vehicle for days, weeks or even months at a time, but suddenly the phone no longer allows phone calls to be heard in the vehicle.

A typical scenario is when a call is being made or an incoming call is received, the Bluetooth call is ringing in the vehicle but when the call is answered there is no audio. The customer has to transfer to the phone handset to listen to the call.

Remove the battery from the customer's Blackberry® phone for at least 10 seconds.
Note: Inform the customer of the cell phone reset process since they may need to do it again sometime in the future.

Install the battery in order to reset the cell phone.
Verify that the condition has been corrected.
Recommendation/Instructions for Condition #3
After turning ON the ignition and after the Bluetooth phone connects, the desired audio selection such as: AM/FM/XM/CD/AUX can no longer be heard in the vehicle. They may notice a phone icon on the radio indicating a call is in progress when it actually is not. Pressing the control buttons may not allow the customer to exit from this mode.

Remove the battery from the customer's Blackberry® phone for at least 10 seconds.
Note: Inform the customer of the cell phone reset process since they may need to do it again sometime in the future.

Install the battery in order to reset the cell phone.
Verify that the condition has been corrected.
Recommendation/Instructions for Condition #4
The Blackberry® phone using Bluetooth will not pair or connect to the vehicle, revealing an hourglass on the phone as if it were working, even though the customer has not been able to use the Bluetooth feature.

Verify the Blackberry® phone does not have either of the following capabilities as part of the Bluetooth Options setting since the vehicles listed in this PI do not support this feature:

• If the phone has a Contacts Transfer feature, "Contacts Transfer" should be set to: disabled .

• If the phone has an Address Book Transfer feature, "Address Book Transfer" should be set to: disabled .

Recommendation/Instructions for Condition #5
The customer receives a continuous request on the cell phone to connect to a device that is no longer shown on the phone, due to the pairing being deleted from the phone but not from the vehicle.

• This recommendation involves referring the customer to their vehicle's Owner Manual -- Bluetooth section titled: Deleting a Paired Phone .

• Advise the customer that when a paired device is deleted from the cell phone it MUST also be deleted from the vehicle.

Recommendation/Instructions for Condition #6
• The Blackberry® phone using Bluetooth will not complete a call when dialing a number from the phone or complete a call through the vehicle's stored nametags in the voice recognition system.

• If the customer dials a number from the phone, dialing is not heard and the call will not be made.

• The customer may try to use a stored nametag in the vehicle system and the system may respond with: OK Dialing and then the call is ended and the vehicle system returns to the previous audio selection such as: AM/FM/XM/CD/AUX that was playing.

Remove the battery from the customer's Blackberry® phone for at least 10 seconds.
Note: Inform the customer of the cell phone reset process since they may need to do it again sometime in the future.

Install the battery in order to reset the cell phone.
Verify that the condition has been corrected.
Recommendation/Instructions for Condition #7

Important: In this condition, if the customer uses the: Transfer Call vehicle feature while Private Call is displayed when a call IS NOT in progress, the previous audio selection may be lost and the display: Private Call will remain. If this occurs ADVISE the customer that they will have to press the vehicles: Phone Button to hear: Call Ended to clear this condition.


• With a Bluetooth call with a Blackberry® phone, the customer ends the call by pressing the Blackberry® phone: End Call button and the vehicle displays: Private Call .

• The call has ended and the vehicle returns to the previous audio selection such as: AM/FM/XM/CD/AUX that was playing but the vehicle system continues to display: Private Call .

• The customer may notice that turning OFF the ignition and opening the door will clear the display.

Remove the battery from the customer's Blackberry® phone for at least 10 seconds.
Note: Inform the customer of the cell phone reset process since they may need to do it again sometime in the future.

Install the battery in order to reset the cell phone.
Verify that the condition has been corrected.
Recommendation/Instructions for Condition #8
When using the Blackberry® phone, an incoming call may ring 2-3 times before the ring is heard in the vehicle. It may take multiple presses of the steering wheel controls to answer the call, or to make an outgoing call.

Access: Bluetooth® Setup Menu, on the phone.
Select: Full Menu.
Select: Options.
Ensure that: Contact Transfer is disabled.
Un-pair ALL previously paired devices.
Re-pair the phone to the vehicle.
Verify that the condition has been corrected.

ChevyMgr
09-14-2010, 08:46 AM
#PIC5363A: In Rare Cases Customers May Comment That The Fuel Gauge Is Inaccurate Or Vehicle May Run Out Of Fuel At 1/8 Tank - keywords cluster instrument IPC - (Oct 21, 2010)


Subject: In rare Cases Customers May Comment That The Fuel Gauge Is Inaccurate Or Vehicle May Run Out Of Fuel At 1/8 Tank


Models: 2007-2010 HHR
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This PI was superseded to eliminate replacement of Jumper harness and add complete pump assembly. Please discard PIC5363.


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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
In rare cases customers may comment the vehicles fuel gauge is inaccurate or runs out of fuel with 1/8th tank fuel left or Vehicle may crank with a no start. Upon diagnosis a Technician may find no change in the condition after a replacement Sending unit card has been installed. Concern may be conductive deposits building up in the over molded pin area bridging the gap between the middle terminals of the Sending unit/Fuel pump harness.

Recommendation/Instructions:
This harness can be tested by disconnecting the X401 connection and the terminals at the sending unit card. Check resistance between circuit 1599 and circuit 510, if any resistance is found, replace the Fuel Pump Module Assembly with current SPO / CCA stock.

ChevyMgr
10-13-2010, 07:32 AM
SERVICE UPDATE
SUBJECT: Service Update for Inventory and Customer Vehicles
Airbag Readiness Light Illumination – Reprogram Sensing and Diagnostic
Module (SDM) - Expires with Base Warranty

MODELS: 2011 Chevrolet HHR, Malibu

This service update includes vehicles in dealer inventory and customer vehicles that return to the dealership for any reason. This bulletin will expire at the end of the involved vehicle's New Vehicle Limited Warranty period.

PURPOSE
This bulletin provides a service procedure to reprogram the Sensing and Diagnostic Module (SDM) on certain 2011 model year Chevrolet HHR and Malibu vehicles. The SDM in these vehicles may have an internal fault that can cause the airbag readiness light to illuminate and may or may not set DTC B1000. With this condition, the airbags will still be active and functional. This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period.

VEHICLES INVOLVED
A list of involved vehicles currently in dealer inventory is available on the “Service Update Bulletin Information” link under the “Service” tab in GM GlobalConnect (US) or attached to the GlobalConnect message (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are
within the VIN breakpoints provided below, should be checked for vehicle eligibility.

Year Division Model From Through
2011 Chevrolet HHR BS500019 BS522867
2011 Chevrolet Malibu BF100002 BF162386

Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved.

ChevyMgr
11-15-2010, 08:45 AM
#PI0296: MIL Illuminated, DTC P0201, P0300 and/or P0301 Set, Engine Misfire (Inspect Wiring Harness Insulation of Fuel Injector #1 for Chafing, Repair as Outlined) - (Nov 11, 2010)


Subject: Malfunction Indicator Lamp (MIL) Illuminated, DTC P0201, P0300 and/or P0301 Set, Engine Misfire (Inspect Wiring Harness Insulation of Fuel Injector #1 for Chafing, Repair as Outlined)


Models: 2008-2011 Chevrolet Cobalt, HHR, Malibu

2008-2010 Pontiac G5, G6

Equipped with 2.4L Engine RPO LE5 or LE9

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The following information may be helpful if the vehicle exhibits the symptoms described in this PI.

Condition/Concern
Some customers may comment that the malfunction indicator lamp (MIL) is illuminated and the engine has a misfire.

The technician may observe on a scan tool DTC P0201, P0300 and/or DTC P0301 set as Current or in History.

This condition may be caused by chafing of the wiring harness insulation for fuel injector #1.

Recommendation/Instructions
Important: DO NOT replace the ECM or the fuel injector for the above condition.

Perform the Diagnostic System Check - Vehicle.
⇒ If DTC P0201, P0300 and/or P0301 are set as Current or in History, proceed to Step 2.

⇒ If DTC P0201, P0300 and/or P0301 are not set as Current or in History, refer to > Symptoms - Vehicle > Symptoms - Engine Controls in SI.

Turn OFF the ignition.
Inspect the wiring harness insulation of fuel injector #1 for chafing in the area of the alternator and the upper radiator cooling hose at the engine.
⇒ If the wiring harness insulation of fuel injector #1 has chafing, then repair as needed. Refer to Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Repairing Damaged Wire Insulation in SI.

⇒ If the wiring harness insulation of fuel injector #1 does not have chafing, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.

7846


Cut a piece of plastic convoluted tube (2), approximately 38 mm (1.5 in) in length to install on the wiring harness (1) of fuel injector #1.

7847

Wrap and secure the wiring harness of fuel injector #1 in the plastic convoluted tube.
Turn ON the ignition. Clear all DTCs with a scan tool.
Start the engine and observe the following control circuit status parameters for fuel injector #1:
• Injector Ckt Short Gnd Test Status

• Injector Ckt Open Test Status

• Injector Ckt Short Volts Test Status

Each parameter should display OK or Not Run.

With the engine running, observe the DTC information with a scan tool. DTC P0201 should not set.

ChevyMgr
02-01-2011, 11:03 AM
#10413: Product Safety - Loss of Power Steering Assist - Replace Electric Power Steering Motor (Canada Only) - (Jan 27, 2011)


Subject: 10413 - Loss of Power Steering Assist - Replace Electric Power Steering Motor (Canada Only)

Models: 2003-2007 Saturn ION

2006-2010 Chevrolet HHR (Non-Turbo)
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The 2004-2007 model year Saturn ION vehicles involved in this Special Coverage were originally involved in Special Coverage 10187. Vehicles that have not had the repair performed under Special Coverage 10187 have been transferred to this Special Coverage.

Condition
General Motors of Canada has decided that a defect, which may relate to motor vehicle safety, may exist in certain 2003-2007 model year Saturn ION and 2006-2010 model year Chevrolet HHR non-turbo vehicles, equipped with electric power steering. Some of these vehicles may have a condition where a sudden loss of power steering assist could occur at any time while driving the vehicle. If the power steering assist is lost, the vehicle can still be steered, however, with greater effort (manual steering). The slower the vehicle is moving, the higher the steering effort. Unless a driver compensates for this additional steering effort, loss of power steering assist may increase the risk of a crash. When the power steering assist is lost, a chime will be heard and the Message Centre will display a "PWR STR" warning message. Typically the next time the vehicle is started, the power steering assist will return and the "PWR STR" message would no longer be displayed.

Special Coverage Adjustment
This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership.

Dealers are to replace the power steering motor at the request of the customer, whether the above condition is present or not. The repairs will be made at no charge to the customer.

For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after January 27, 2011, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to January 27, 2011, must be submitted to the Service Contract provider.

Vehicles Involved
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverage Adjustments are displayed in the Applicable Warranties section.

Parts Information
Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A).

Part Number Description Qty/ Vehicle

19257876 or 19257875 Motor Kit, P/S Asst 1


Customer NotificationGeneral Motors will notify customers of this special coverage on their vehicles (see copy of customer letter included with this bulletin).

Service Procedure
Remove the power steering assist motor. Refer to Power Steering Assist Motor Replacement in SI.
Install the new power steering assist motor. Refer to Power Steering Assist Motor Replacement in SI.

Customer Reimbursement
Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by February 29, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 km, whichever occurs first.

When a customer requests reimbursement, they must provide the following:

- Proof of ownership at time of repair.

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

If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership.

Courtesy Transporation
The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

January 2011
Dear General Motors Customer:

General Motors has decided that a defect, which may relate to vehicle motor safety, may exist in certain 2003-2007 model year Saturn ION or 2006-2010 Chevrolet HHR vehicles equipped with electric power steering.

This letter is intended to make you aware that some 2003-2007 model year Saturn ION vehicles or 2006-2010 Chevrolet HHR (non-turbo), equipped with electric power steering, may have a condition where a sudden loss of power steering assist could occur at any time while driving the vehicle. If power steering assist is lost, the vehicle can still be steered, however, with greater effort (manual steering). The slower the vehicle is moving, the higher the steering effort. Unless a driver compensates for this additional steering effort, loss of power steering assist may increase the risk of a crash. When the power steering assist is lost, a chime will be heard and the Message Centre will display a "PWR STR" warning message to inform you of the condition. Typically, the next time the vehicle is started, the power steering assist will return and the "PWR STR" message would no longer be displayed.

General Motors is providing owners with additional protection for the power steering assist motor. If this condition occurs on your 2003-2007 model year Saturn ION or 2006-2010 Chevrolet HHR (non-turbo) vehicle within 10 years of the date your vehicle was originally placed in service or 240,000 km, whichever occurs first, the condition will be repaired for you at no charge . Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program.

Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to call the service department at your dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Please be advised that you may take your vehicle to the General Motors dealership of your choice to have this service work completed, whether the above condition exists or not . Otherwise, keep this letter with your other important glovebox literature for future reference.

If you have already paid to have this special coverage condition corrected and you have not received reimbursement under a Vehicle Service Contract, you should contact your dealer as you may be eligible to receive reimbursement. Please provide your dealer with your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair. Reimbursement will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your request for reimbursement, including the information and documents mentioned above, must be received by your dealer before February 29, 2012.

We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your safety and continued satisfaction with our products.

Customer Care and Aftersales

ChevyMgr
02-07-2011, 02:05 PM
#PI0362: Vibration at 60-70 MPH - (Feb 2, 2011)


Subject: Vibration at 60-70 MPH


Models: 2009-2010 Chevrolet HHR
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Condition/ConcernSome customers may comment about a vibration in the vehicle around 97-113 km/h (60-70 mph) that may not be caused by tire or wheel road force variation.

The vehicle may have a leaking shock in the rear or one that is not operating properly.

Recommendation/InstructionsThere are many reasons for a vehicle to have a vibration. Technicians, please get in the habit of looking in SI for information that can help you with the diagnostic procedure and/or repair. Replace only the one suspect shock. Do not replace both under warranty.

Parts Information - Part Number Description - Qty

15780243 - Absorber, Rear Shock (FE1) - 1

15806888 - Absorber, Rear Shock (FE3) -1

ChevyMgr
05-23-2011, 12:15 PM
#11-05-25-001: Electronic Stability Control (ESC) Message Displayed in Driver Information Center (DIC), DTC C0460, C0280 or C0196 Set - (Mar 30, 2011)


Subject: Electronic Stability Control (ESC) Message Displayed in Driver Information Center (DIC), DTC C0460, C0280 or C0196 Set


Models: 2009-2011 Chevrolet HHR Equipped with Engine RPO LE8 or LE9

Equipped with Electronic Stability Control System (RPO JL4)
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Condition
In rare cases, customers may comment that the Service Electronic Stability Control (ESC) message appears in the Driver Information Center (DIC) and/or the ESC system activates (modulates brakes and/or limits engine torque) at inappropriate times.

When diagnosing the condition, the technician may find Diagnostic Trouble Code (DTC) C0460, C0280 or C0196 Set.

Cause
This condition may be caused by the steering angle being inadvertently recalibrated. The condition may also be the result of the steering angle sensor (SAS) not being properly centered after an alignment or other repair.

The amount of steering deviation from the proper center location and the type of driving conditions encountered will determine which DTC or DTCs will set. The known DTCs that can be set by this condition are: C0460 5A, C0460 42, C0280 and C0196.

Correction
Use the following steps to correct the condition:

Use SPS to update the EBCM software. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest software currently available in TIS2WEB.
Recalibrate the SAS. Use the scan tool to recalibrate the SAS (see EBCM/special functions for Non-SS) in SI.
When using a Tech 2® or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version.

During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics® PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming.

ChevyMgr
05-23-2011, 01:41 PM
#PI0470: Engine Oil Weep from Behind Exhaust Manifold - (May 13, 2011)


Subject: Engine Oil Weep from Behind Exhaust Manifold


Models: 2011 Chevrolet HHR, Malibu

Equipped with Engine RPOs LE5 or LE9
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Condition/Concern
Some customers may comment on a slight oil weep or seep from the back side of the engine, behind the exhaust manifold.

9230

Further inspection will show that the oil leak is coming from the center oil galley plug.

Recommendation/Instructions

9231

9232

The center oil galley plug may have been damaged during installation when the engine was built.

There may be a witness mark (1) and damage to the galley plug (2).

Replace the oil galley plug.

Remove the exhaust manifold. Refer to the current procedure in SI for removal.

9233

Remove and replace the center oil galley plug. The plug should be tightened to 35 N·m (26 lb ft).
Install the exhaust manifold.
Parts Information
Part Number Description Qty

11588547 Oil Galley Plug 1

ChevyMgr
11-02-2011, 10:10 AM
#PI0568: Inadvertent Horn, Light, Remote Start, Lock/Unlock Activation or Charging Schedule Change - (Sep 19, 2011)
Subject: Inadvertent Horn, Light, Remote Start, Lock/Unlock Activation or Charging Schedule Change



Models: 2010-2011 Buick Lucerne

2010-2012 Buick Enclave

2011-2012 Buick LaCrosse, Regal

2010-2011 Cadillac DTS

2010-2012 Cadillac CTS, Escalade

2011-2012 Cadillac SRX

2010-2011 Chevrolet HHR

2010-2012 Chevrolet Avalanche, Impala, Suburban, Tahoe, Traverse

2011-2012 Chevrolet Camaro, Cruze, Equinox, Express, Malibu, Silverado

2012 Chevrolet Volt

2010-2012 GMC Acadia, Yukon

2011-2012 GMC Savana, Sierra, Terrain

Equipped with OnStar®

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Condition/Concern

Some customers may comment on an inadvertent horn and light activation, inadvertent vehicle remote starting, inadvertent vehicle unlock/lock or Volt charging schedule inadvertently changing. Remote start will not activate if the hood latch switch is open.

Unwanted commands may be sent via OnStar Remote Link Mobile Apps source. Volt owners may also experience unwanted commands from www.myvolt.com.

Recommendation/Instructions

If inadvertent commands to the vehicle are suspected, call TAC (Technical Assistance Center) for further instructions. Otherwise continue with vehicle diagnostics.

ChevyMgr
04-19-2012, 09:02 AM
#12045 Customer Satisfaction
SUBJECT: Ignition Lock Cylinder May Bind - Replace Ignition Lock Cylinder
MODELS:
2009 Chevrolet Cobalt
2009-2010 Chevrolet HHR
2009 Pontiac G5

THIS PROGRAM IS IN EFFECT UNTIL MAY 31, 2014.

CONDITION
Certain 2009 model year Chevrolet Cobalt and Pontiac G5 vehicles, and 2009-2010 model year Chevrolet HHR vehicles may develop a binding condition between the ignition lock cylinder and the housing. If this occurs, it may be difficult to turn the ignition key and/or remove it from the ignition. If the vehicle is running, the driver may not be able to turn the vehicle off.

CORRECTION
Dealers are to replace the ignition lock cylinder.

VEHICLES INVOLVED
All involved vehicles are identified by Vehicle Identification Number on the Investigate Vehicle History screen in GM Global Warranty Management system. Dealership service personnel should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs.

PART INFORMATION
Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A). Please refer to your “involved vehicles listing” before ordering parts.

CUSTOMER REIMBURSEMENT - For US
Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by May 31, 2013, unless otherwise specified by state law. If this is not convenient for the customer, they may mail the completed Customer Reimbursement Request Form and all required documents to the GM Customer Assistance Center. All reasonable and customary costs to correct the condition described in this bulletin
should be considered for reimbursement. Any questions or concerns should be
reviewed with your District Service Manager – Aftersales prior to processing the request. When a customer requests reimbursement, they must provide the following:
 A completed Customer Reimbursement Request Form. This form is mailed to the customer or can be obtained through GM GlobalConnect.
 The name and address of the person who paid for the repair.
 Paid receipt confirming the amount of the repair expense, a description of the repair, and the person or entity performing the repair.

CUSTOMER REIMBURSEMENT - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by May 31, 2013.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership.

ChevyMgr
04-19-2012, 10:56 AM
Special Coverage

MODELS: 2007-2008 Chevrolet Cobalt
2008-2009 Chevrolet HHR
2007-2008 Pontiac G5

CONDITION
On some 2007-2008 model year Chevrolet Cobalt and Pontiac G5, and 2008-2009 Chevrolet HHR vehicles may develop a binding condition between the ignition lock cylinder and the housing. If this occurs, it may be difficult to turn the ignition key and/or remove it from the ignition. If the vehicle is running, the driver may not be able to turn the vehicle off.

SPECIAL COVERAGE ADJUSTMENT
This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to replace the ignition lock cylinder. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 19, 2012 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 19, 2012 must be submitted to the Service Contract provider.

ChevyMgr
07-19-2012, 09:07 AM
#09-04-95-001D: Clicking Type Noise from Front or Rear of Vehicle When Shifting Between Reverse and Drive or on Hard Acceleration (Add Washer to Wheel Drive Shaft) - (Jul 16, 2012)
Subject: Clicking Type Noise from Front or Rear of Vehicle When Shifting Between Reverse and Drive or on Hard Acceleration (Add Washer to Wheel Drive Shaft)


Models: 2010-2011 Buick LaCrosse

2011 Buick Regal

2008-2011 Cadillac CTS, CTS Wagon, Coupe (Includes V Series)

2010-2011 Cadillac SRX

2009-2011 Chevrolet HHR

2010 Chevrolet Camaro Built Prior to June 1, 2009 (V8 Engine (All) and V6 Engine (Manual)) or February 17, 2010 (V6 Engine (Automatic))

2010-2011 Chevrolet Equinox

2011 Chevrolet Cruze

2010-2011 GMC Terrain

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This bulletin is being revised to add the HHR model. Please discard Corporate Bulletin 09-04-95-001C (Section 04 – Driveline/Axle).
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Condition (Cruze, Equinox, HHR, LaCrosse, Regal, SRX, Terrain)

Some customers may comment on a clicking type noise coming from the front of the vehicle when shifting between reverse and drive or on a hard acceleration.

Correction (Cruze, Equinox, HHR, LaCrosse, Regal, SRX, Terrain)

Add a washer between the front wheel drive shaft and the bearing hub assembly using the procedure listed below.


Note: • Some vehicles may have been built with the washer. If there is a washer already installed, remove and discard the washer. DO NOT re-use the washer, replace with NEW only.


• Anytime the wheel drive shaft is separated from the steering knuckle, the washer must be replaced with a NEW washer only.



1. Remove the front wheel bearing and hub assembly. Refer to Front Wheel Bearing and Hub Replacement procedure in SI.

13070


2. Install the washer (1) onto the front wheel drive shaft (2) as shown above.


Note: For Cruze, Equinox and Terrain, DO NOT reuse wheel drive shaft nut. Discard and replace with a NEW nut only.


3. Install the front wheel bearing and hub assembly. Refer to Front Wheel Bearing and Hub Replacement procedure in SI.

4. Repeat Steps 1 through 3 for the opposite side.

Condition (CTS, Camaro)

Some customers may comment on a clicking type noise coming from the rear of the vehicle when shifting between reverse and drive or on a hard acceleration.

Correction (CTS, Camaro)

Add a washer between the rear wheel drive shaft and the bearing hub assembly using the procedure listed below.


Note: • Some vehicles may have been built with the washer. If there is a washer already installed, remove and discard the washer. DO NOT re-use the washer, replace with a NEW washer only.


• Anytime the wheel drive shaft is separated from the steering knuckle, the washer must be replaced with a NEW washer only.



1. Remove the rear wheel bearing and hub assembly. Refer to Rear Wheel Bearing and Hub Replacement procedure in SI.

13070



2. Install the washer (1) onto the rear wheel drive shaft (2) as shown above.


Note: DO NOT reuse wheel drive shaft nut. Discard and replace with a NEW nut only.


3. Install the rear wheel bearing and hub assembly. Refer to Rear Wheel Bearing and Hub Replacement procedure in SI.

4. Repeat Steps 1 through 3 for the opposite side.

Parts Information:

Part Number * Usage * Description * Qty
11611964 * HHR * Washer, Front Wheel Drive Shaft * 2

ChevyMgr
08-08-2012, 09:43 AM
#12-03-08-001: Clunk or Thump Type Noise from Front Suspension - (Aug 6, 2012)
Subject: Clunk or Thump Type Noise from Front Suspension

Models: 2008-2009 Buick Allure (Canada)

2008-2011 Buick Enclave, LaCrosse, Lucerne

2011-2012 Buick Regal
2005-2010 Chevrolet Cobalt (Including SS)
2006-2011 Chevrolet HHR (Including SS)
2008-2009 Chevrolet Uplander
2008-2011 Chevrolet Aveo
2008-2012 Chevrolet Equinox, Impala, Malibu
2009-2012 Chevrolet Traverse
2010-2012 Chevrolet Camaro
2011-2012 Chevrolet Cruze, Volt
2008-2012 GMC Acadia
2010-2012 GMC Terrain
2005-2006 Pontiac Pursuit (Canada)
2007-2010 Pontiac G5
2008 Pontiac Grand Prix
2008-2009 Pontiac Montana SV6, Torrent
2008-2010 Pontiac G3, G6, Vibe, Wave

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Condition

Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole.

Cause

This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking.

Correction

Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft.

13184

1. Clean the surface area of the upper spring seat using fine sandpaper.

2. Apply a light coat of *3M™ Automotive Adhesion Promoter, P/N 06396 or equivalent, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes.

13185

3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M™ Duramix™ Super Fast Adhesive, P/N 04747 or equivalent. Allow to cure thoroughly 5-10 minutes at room temperature.

4. Apply a light coat of *3M™ Automotive Adhesion Promoter, P/N 06396 or equivalent, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes.

13186

5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly.

*We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources.

Parts Information

Part Number * Description * Qty

04747 * 3M™ Duramix™ Super Fast Adhesive * 1

06396 * 3M™ Automotive Adhesion Promoter *2

For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog.

For part numbers and usage of the boot/shield, see Strut Boot/Shield in Group 07.371 of the appropriate Parts Catalog.

For part numbers and usage of the bumper, see Strut Bumper in Group 07.395 of the appropriate Parts Catalog.

ChevyMgr
09-28-2012, 12:14 PM
#12-08-64-003: Interior Door Handle Replacement Kit - (Sep 14, 2012)
Subject: Interior Door Handle Replacement Kit

Models: 2006-2011 Chevrolet HHR
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Condition
Some customers may comment the interior door handle is inoperative or that the chrome finish is peeling.

Cause
This condition may be caused by a fracture in the chrome portion of the door handle assembly where it attaches to the inside handle cable.

Correction
Important: Do Not replace the interior door trim panel to correct the condition. Use the kit listed below to service the chrome handle portion of the handle assembly.

Use the following steps to install the door handle repair kit. Each kit services one door and contains one handle, pin and spring.


Note: The drivers side handle is shown in the following steps. The procedure applies to both driver and passenger side handles.

1. Remove the interior trim panel on the effected door. Refer to Side Door Trim Panel Replacement in SI.

2. Place the trim panel on a suitable work table. Use care to not damage or scuff the interior side of the panel.

13496

3. Release tension on the handle’s return spring by removing the end of the spring (1) from the spring land on the housing (2).

13497

4. Using a pair of wire cutters, or similar tool, cut the retaining barbs off the end of the plastic pin, allowing the pin to be removed. Use care to not damage the black plastic handle housing.

5. Taking note of the original configuration, remove the pin, handle, and spring from the housing.

13498

6. Install the new handle and spring into the housing in the original configuration. The end of the spring must be installed behind the arm of the chrome handle, as shown, or it will not function properly.

7. Insert the new pin through the housing, handle, and center of the spring. The head of the pin should be fully seated. When it is installed properly, the retaining barbs will not allow the pin be removed once installed.

13499

8. Restore tension to the spring by hooking the exposed end of the spring (1) under the spring land on the black housing (2).

9. Reinstall the interior trim panel on the affected door. Refer to Side Door Trim Panel Replacement in SI. Verify correct operation of the handle.

Parts Information

Note: The kit will service either the front or rear door. The kits are handed (left or right).


Part Number - Description

19299613 - Side Door Inside Handle Kit (RH)

19299614 - Side Door Inside Handle Kit (LH)

ChevyMgr
02-26-2013, 11:05 AM
#PIC5346A: Normal Characteristic - Unable To Answer a Second Incoming Bluetooth call or Continues To Ring After Answering a Second Incoming Call - (Jan 31, 2013)

Subject:

Normal Characteristic - Unable To Answer a Second Incoming Bluetooth call or Continues To Ring After Answering a Second Incoming Call

Models:

2008 - 2010 Cadillac CTS
2009 Buick Enclave
2009 Cadillac Escalade, SRX, XLR
2009 Chevrolet Equinox, HHR, Silverado, Suburban, Tahoe, Traverse
2009 GMC Acadia, Sierra, Yukon, Yukon XL
2009 Pontiac G5, G8, Solstice, Torrent
2009 Saturn Outlook, Sky, VUE
2009 - 2011 Cadillac STS
2009 - 2010 Chevrolet Cobalt, Corvette
2010 Chevrolet Silverado (Except Silao built)
2010 GMC Sierra (Except Silao built)

Equipped with Bluetooth (RPO UPF or UWE)
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This PI was superseded to update recommended field and add Customer Info section. Please discard PIC5346.
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Condition/Concern


In rare instances, if a Bluetooth call is transferred from the vehicle to the phone and, while on that call, a second Bluetooth call comes in, the customer will hear ringing in the vehicle. Pressing the Push to Talk button on the steering wheel controls will stop the ringing, but will not answer the second call. If the call is answered from the phone, the ringing will not stop.

Recommendation/Instructions


The concern has been identified as normal operation. Do NOT replace any parts for this concern.

When a Bluetooth call has been transferred to the handset the VCIM will send incoming ringing from a subsequent call to the radio. The call must be answered from the handset and the SWC pressed to stop the ringing. Ending the first call or disconnecting the Bluetooth will also solve the concern.

Customer Information


Please communicate to the customer this condition is a normal operating characteristic of their vehicle. It will not impact the designed performance or reliability of the vehicle. Please share this information with the customer, including a copy of this message.

ChevyMgr
02-26-2013, 11:27 AM
#PIP5029B: Engine Misfires Due To Major Carbon Deposits On The Intake And Or Exhaust Valves - (Sep 24, 2012)

Subject:

Engine Misfires Due To Major Carbon Deposits On The Intake And Or Exhaust Valves

Models:

2009 - 2013 Buick Enclave
2009 - 2013 Buick Lacrosse
2008 - 2013 Cadillac CTS, STS
2010 - 2013 Cadillac SRX
2013 Cadillac ATS, XTS
2008 - 2010 Chevrolet Cobalt SS, HHR SS
2009 - 2013 Chevrolet Traverse
2010 - 2013 Chevrolet Camaro, Equinox
2012 - 2013 Chevrolet Impala
2009 - 2013 GMC Acadia
2010 - 2013 GMC Terrain
2007 - 2010 Pontiac Solstice GXP
2009 - 2010 Saturn Outlook
2007 - 2010 Saturn Sky Redline

With any of the Following Direct Injected Gasoline Engines:

2.0 (RPO LNF)
2.4L (RPO LAF, LEA, or LUK)
2.8L (RPO LAU)
3.0L (RPO LF1 or LFW)
3.6L (RPO LFX or LLT)
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This PI was superseded to update photo and part numbers. Please discard PIP5029A.
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern


Some customers may complain of a MIL and engine misfire. In some cases, the misfire may be more apparent on a cold start, may count on a single cylinder or several cylinders, and may or may not be felt by the driver. Upon inspection, the technician will find one or more misfire codes (DTC P0300-P0306) stored in the ECM and SI diagnosis may or may not isolate the cause of the misfire depending on whether the intake/exhaust valves are sticking at the time of the diagnosis.

This may be the result of major carbon build up on the intake and/or exhaust valves as shown below so the misfires should not have appeared until at least 5,000 miles or more.

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http://www.chevyhhr.net/gallery/files/4/8/6/5/6.gif (http://www.chevyhhr.net/gallery/showimage.php?i=35117&c=2)

http://www.chevyhhr.net/gallery/files/4/8/6/5/7.gif (http://www.chevyhhr.net/gallery/showimage.php?i=35118&c=2)

Recommendation/Instructions


If this concern is encountered, perform SI diagnosis. If SI diagnosis isolates a valve sealing concern and/or eliminates everything else external to the engine, decarbon the engine with Upper Engine and Fuel Injector Cleaner by following the guidelines below:
Important: Extreme care must be taken not to hydro lock the engine when inducing the cleaner, especially if it is induced without Kent Moore Tool # J-45076 / J-35800-A or equivalent. If too much cleaner is induced at too low of a RPM, or if you force the engine to stall by inducing too much cleaner at once, the engine may hydro lock and bend a connecting rod(s).

http://www.chevyhhr.net/gallery/files/4/8/6/5/88.gif (http://www.chevyhhr.net/gallery/showimage.php?i=35122&c=2)



1. In a well-ventilated area with the engine at operating temperature, slowly/carefully induce a bottle of GM Upper Engine and Fuel Injection Cleaner into the engine with RPM off of idle enough to prevent the engine from stalling (typically around 2,000 RPM or so). Depending on the engine configuration, induce the cleaner through the throttle body or an engine vacuum hose/pipe. For best results, it is suggested to induce the cleaner through the throttle body with Kent Moore Tool # J-45076 / J-35800-A or equivalent (shown below).

2. Turn the engine off after inducing the cleaner and allow the cleaner to soak with the engine off for 2.5 to 3 hours (Do not let cleaner soak for more than 3 hours as remaining deposits may start to harden back up again).

3. Add a bottle of GM Fuel System Treatment Plus to the fuel tank and fill the vehicle with one of the Top Tier gasolines listed at http://www.toptiergas.com and/or in the latest version of 04-06-04-047 (USA) or 05-06-04-022 (Canada). See Bulletin 05-00-89-078 for more details on GM Fuel System Treatment Plus.

4. Test drive the vehicle extensively to circulate the GM Fuel System Treatment Plus.

5. Re-evaluate the concern to determine if it is repaired or improved at all. If the concern is improved but not repaired, it may be necessary to perform the above decarboning process a 2nd time.

6. To complete the repairs, advise the customer to only use one of the Top Tier Gasolines listed at http://www.toptiergas.com and/or in the latest version of 04-06-04-047 (USA) or 05-06-04-022 (Canada) to minimize future deposits. It can also be recommended to add a bottle of GM Fuel System Treatment Plus at every oil change as mentioned in the latest version of 04-06-04-051.


Kent Moore Tool Kit # J-45076
1. Pressurized Canister from J-45076 is shown - J-35800-A is similar

2. Throttle Body Cleaning Adapters J-45076-46 and J-45076-55 Shown (Equivalent Adapters Acceptable)

Notice: J-45076 was originally released to Cadillac dealers for decarboning Northstar engines but it has since been discontinued. This kit came with the pressurized canister and throttle body cleaning adapters shown above. As mentioned above, the J-35800-A is another pressurized canister that can be used. It was originally released in the 1990s for cleaning fuel injectors on the 4.3L, 5.0L, and 5.7L truck engines. If these tools are not available, it is also acceptable to use equivalent tools to perform this decarboning procedure.

Parts Information

Upper Engine and Fuel Injector Cleaner
1 - 88861013 Fuel System Treatment Plus

P0301 P0302 P0303 P0304 P0305

ChevyMgr
02-26-2013, 11:57 AM
#PIP4495D: Cylinder Head Tick Noise And/Or Damage - Possible Plugged Oil Feed Orifice - (Jan 4, 2013)

Subject:

Cylinder Head Tick Noise And/Or Damage - Possible Plugged Oil Feed Orifice

Models:

2010 Buick Allure (Canada Only)
2010-2013 Buick LaCrosse
2011-2013 Buick Regal
2012-2013 Buick Verano
2012-2013 Chevrolet Captiva Sport
2002-2005 Chevrolet Cavalier
2005-2010 Chevrolet Cobalt, Cobalt SS
2010-2013 Chevrolet Equinox
2006-2011 Chevrolet HHR
2008-2010 Chevrolet HHR SS
2004-2013 Chevrolet Malibu
2004-2005 Chevrolet Malibu Classic
2010-2013 GMC Terrain
2002-2004 Oldsmobile Alero
2007-2010 Pontiac G5
2006-2010 Pontiac G6
2002-2005 Pontiac Grand Am, Sunfire
2005-2006 Pontiac Pursuit (Canada Only)
2006-2010 Pontiac Solstice
2007-2010 Pontiac Solstice GXP
2007-2010 Saturn Aura, Aura Hybrid
2003-2007 Saturn Ion
2004-2007 Saturn Ion Redline
2001-2005 Saturn L Series
2007-2010 Saturn Sky, Sky Redline
2002-2010 Saturn Vue
2007-2010 Saturn Vue Hybrid

With any of the following engines:

2.0L Engine (RPO LHU, LNF or LSJ)
2.2L Engine (RPO L61, LAP or LE8
2.4L Engine (RPO LAF, LAT, LE5, LE9, LEA or LUK)
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This PI was superseded to update recommended field. Please discard PIP4495C.
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The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern


Some customers may complain of a loud tick/rattle noise under the hood at all operating conditions. In some cases, the noise may have started shortly after an oil change or previous internal engine repairs. During diagnosis, the technician will find that the noise is coming from the cylinder head area and believes that several/all of the valve lash adjusters (lifters) are making noise.

The cylinder head is equipped with oil feed orifice (2) that may become plugged with debris, such as excessive RTV/sealer or broken down oil filter material. If this occurs, this noise may occur as a result of no/low oil pressure to the valve train.

Recommendation/Instructions


If a major valve train noise is encountered that sounds like several/all valve lash adjusters (lifters), it is suggested to compare the lower end oil pressure to the upper end oil pressure as outlined below:




1. Check the lower end oil pressure by attaching an oil pressure gauge to the oil pressure sender port or to one of the gallery plug ports in the engine block.

2. Check the upper end oil pressure by attaching another oil pressure gauge to one of the oil gallery plug ports on the back of the cylinder head (1).

3. Start the engine and note the oil pressure gauge readings from both locations while at the same engine RPM and engine temperature.

4. Turn the engine off.

5. Compare the oil pressure readings.

5.1 If the lower end oil pressure is below SI specification, this PI does not apply so normal SI diagnosis should be followed to diagnose and repair the noise.

5.2 If the upper end oil pressure is near 0 PSI/KPA but the lower end oil pressure is within SI specification, the oil feed orifice (2) is most likely plugged with debris. Please note that it is not uncommon for the upper end oil pressure of a normally functioning engine at idle to measure as much 35% less than the bottom end oil pressure. This is due to the large amount of oil pressure bleed off that normally occurs in the valve train, combined with the small size of the oil feed orifice (2).


If you suspect a plugged oil feed orifice after performing the test above, remove the cylinder head and visually inspect the oil feed orifice (2) for debris. If debris is present, it can normally be cleaned out to repair the noise. Please note that the orifice is not available separate from the cylinder head and cannot be inspected/cleaned without cylinder head removal.

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Important: To prevent future concerns, care must be taken not to use excessive amounts of engine sealant during internal engine repairs, use the proper oil filter that is listed in the parts catalog, and change the engine oil/filter according to the schedule in the owner's manual.


Notice: The oil gallery plug port threads (1) on the back of the cylinder head are M12x1.75 and it is unlikely that a related oil pressure gauge adapter will be found at a hardware or auto parts store. The 509376 Kent Moore Fitting that comes with the Engine Preluber Kit (EN-45299/J-45299) will screw into the head and may be adapted to some oil pressure gauges. Or, there are also several online retailers that can supply a fitting that will work as an adapter - the male end has to be M12x1.75 while the female end has to be 1/8"x27 NPTF so a standard oil pressure gauge hose can screw into it. It has also been found that some automotive gauge companies, such as Auto Meter, offer the necessary adapter/fitting (M12x1.75 / 1/8"x27 NPTF) for $5-$20. Some technicians have also reported success in making a temporary fitting out of an oil pressure sender body.


KEYWORDS:

adjuster cam camshaft follower installation lash lifter replacement valve