#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)

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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.



Inspect the roof sound deadener foil for any areas that are loose and hanging down (1).



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.

 

#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.

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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 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.

 

#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
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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 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.

 

#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
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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 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.

 

#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

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This PI was superseded to add 2009 models and Note about certain IPod. Please discard PIC4738A.

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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.

 

#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
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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.




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.



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.



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.

 

#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.
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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).
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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)

 

#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)
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This PI was superseded to update model years and engines involved. Please discard PIP3535.


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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.

 

#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)

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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




(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




(1) Heater Element (located on the insert and the front thigh area of the cushion)

 

#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
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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 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.