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Go Back   Chevy HHR Network > General Discussion > Problems/Service/Repairs > Official TSB and Recall Thread
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Problems/Service/Repairs If you have a problem with your HHR, want a tip on repairing or performing a particular service to you HHR here is the place to post!

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Old 03-04-2008, 05:02 PM   #1
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Exclamation Official TSB and Recall Thread

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: Old Recall and TSB Number post or create a new thread if you like.

Quote:
Originally Posted by ChevyMgr View Post
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.
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Last edited by ChevyMgr; 05-15-2009 at 10:11 AM.
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Old 03-19-2008, 06:29 PM   #2
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08-05-22-001

#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




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

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.
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Last edited by ChevyMgr; 02-25-2009 at 08:26 AM.
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Old 04-11-2008, 08:50 PM   #3
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08-05-23-003

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




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

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
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2006 HHR LS 2.2 liter 5 speed manual
mods: exhaust tip, rainguards, angel eyes fog lamps, pioneer stereo, planet audio amps, 10" Alpine R-series sub, Polk component series speakers, Silver Racing stripes on hood and liftgate, 17" factory chrome rims, LTZ Badge, front windows tinted to 15%
Future mods: Having the rocker panels coated in Line-X beliner material.




Last edited by ChevyMgr; 02-25-2009 at 08:23 AM.
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Old 04-11-2008, 08:59 PM   #4
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08-06-02-001

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

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
__________________
2006 HHR LS 2.2 liter 5 speed manual
mods: exhaust tip, rainguards, angel eyes fog lamps, pioneer stereo, planet audio amps, 10" Alpine R-series sub, Polk component series speakers, Silver Racing stripes on hood and liftgate, 17" factory chrome rims, LTZ Badge, front windows tinted to 15%
Future mods: Having the rocker panels coated in Line-X beliner material.




Last edited by ChevyMgr; 02-25-2009 at 08:22 AM.
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Old 07-24-2008, 11:38 AM   #5
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08-06-01-017

#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.



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

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.
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Last edited by ChevyMgr; 02-25-2009 at 08:21 AM. Reason: added comments
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Old 07-24-2008, 11:49 AM   #6
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Pic4317d

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

This PI was superseded to update models. Please discard PIC4317C.


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

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.
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Last edited by ChevyMgr; 02-25-2009 at 08:20 AM.
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Old 07-24-2008, 12:01 PM   #7
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Pip4437

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

#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.




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

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.
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Old 07-24-2008, 12:05 PM   #8
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SS only

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

#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)




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

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


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

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.

Attachment 3411

Attachment 3412

Attachment 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.
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Last edited by ChevyMgr; 02-25-2009 at 08:19 AM.
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Old 10-01-2008, 02:51 PM   #9
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Pic4974

#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
--------------------------------------------------------------------------------

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.
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Last edited by ChevyMgr; 02-25-2009 at 08:16 AM.
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Old 10-15-2008, 08:46 AM   #10
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Pip4349a

#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.

--------------------------------------------------------------------------------
This PI was superseded to update model years. Please discard PIP4349.
--------------------------------------------------------------------------------

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.
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