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TSB's

a couple of TSB's for cobalts


This is a discussion on a couple of TSB's for cobalts within the TSB's forums, part of the Tech category!
#08-06-05-002B: EI08085 - 2.0L, MIL Lamp On, DTC P0420, Exhaust Noise, Poor Engine Performance (Engineering Information Closed) - (Jun 3, ...




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Old 04-06-2010, 07:35 PM   #1 (permalink)
 
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#08-06-05-002B: EI08085 - 2.0L, MIL Lamp On, DTC P0420, Exhaust Noise, Poor Engine Performance (Engineering Information Closed) - (Jun 3, 2009)


Subject: EI08085 -- 2.0L, MIL Lamp On, DTC P0420, Exhaust Noise, Poor Engine Performance (Engineering Information Closed)


Models: 2005-2007 Chevrolet Cobalt SS Supercharged

2004-2007 Saturn ION Redline

with 2.0L Engine (VIN P - RPO LSJ)




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This bulletin is being revised to conclude the EI and end the parts restriction on catalytic convertors. Please discard Corporate Bulletin Number 08-06-05-002A (Section 06 - Engine).


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GM Engineering investigated vehicles with your assistance in the field, but did not identify a single-point issue (root cause) for this condition. Please refer to SI and follow the established diagnostics for correction of this customer concern.

The prior parts restriction on catalytic convertors has been canceled.



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#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.

Warranty Information
Labor Operation
Description
Labor Time

E8434
Power Steering Assist Motor Replacement
Use Published Labor Operation Time

E7680
Steering Column Replacement


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#05-07-29-001D: Service Tools Released for Five-Speed Manual Transaxle/Transmission (RPO MU3) - (Oct 10, 2008)


Subject: Service Tools Released For Five-Speed Manual Transaxle/Transmission (RPO MU3)


Models: 2005-2009 Chevrolet Cobalt SS

2008-2009 Chevrolet HHR SS

2005-2007 Saturn ION Red Line

with 5-Speed Manual Transaxle (RPO MU3)




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

This bulletin is being revised to add the 2008 and 2009 model years and the Chevrolet HHR SS model. Please discard Corporate Bulletin Number 05-07-29-001C (Section 07 - Transmission/Transaxle).


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The models above have been released with a 5-speed manual transaxle. This transaxle is used behind the 205-horsepower, supercharged and intercooled, 2.0L DOHC, 16-valve 4-cylinder engine and the 260-horsepower, turbocharged and intercooled, 2.0L DOHC, 16-valve 4-cylinder engine.

Failed transmissions have the option to be repaired or replaced by the dealership.

Special service tools are available to all Chevrolet dealerships and Saturn retailers through Kent-Moore/SPX Service Solutions.

Important:

• Dealers should not attempt manual transaxle unit repair without the specified special tools.

• Repair without these special tools is not possible.

• Dealers are encouraged to purchase the special tools for the MU3 manual transaxle repair.


The service strategy allows for full service of the MU3 5-speed manual transaxle only when the necessary tools have been purchased. Service procedures will be available in SI and selected internal components will be available from GMSPO.

Although special tools are available, they will not be shipped essential to the dealership. Dealerships must purchase the tools to perform MU3 manual transaxle repairs.


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#06-03-08-001D: Info - Availability of Steering Knuckles for Competitive Driving - (Sep 27, 2006)


Subject: Availability of Steering Knuckles for Competitive Driving


Models: 2005-2007 Chevrolet Cobalt

2005-2006 Pontiac Pursuit (Canada Only)

2007 Pontiac G5

2004-2007 Saturn ION, ION Redline




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This bulletin is being revised to add a statement in the Alternate Steering Knuckles section. Please discard Corporate Bulletin Number 06-03-08-001C (Section 03 - Suspension).


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Alternate Steering Knuckles
This is to advise owners who intend to use their vehicles for competitive driving, of the availability of alternate steering knuckles, and to provide recommended alignment specifications for those owners who use their vehicles for competitive driving. These steering knuckles are available through GM service parts and are suggested for use on the Cobalt (Pursuit)/ION Redline. Refer to the Parts Information below for ordering instructions. (This steering knuckle may also be installed and the alignment specifications used, at the customer's discretion, for non-competition purposes.)

Replacement Procedure
Service replacement instructions can be found in SI (Steering Knuckle Replacement).

Alignment Settings
The following alignment settings provide for even tire wear in competitive driving.

Please use the following alignment specifications for competitive driving only:

Camber
Front
-1.5 +/- .75 deg.

Rear
-1.5 +/- .75 deg.

Caster
Front
3.65 +/- .75 deg.

Toe
Front
.20 +/- .5 deg.

Rear
.25 +/- .5 deg.


The original vehicle alignment specifications can be found in SI (Wheel Alignment Specifications).

Parts Information
Part Number
Description

88958710
Knuckle, LH Steering

88958711
Knuckle, RH Steering


Warranty Information
The above modifications are considered to be a customer option and should be performed at the customer's expense.

Prior to using your vehicle for competitive driving, refer to your vehicle warranty book or General Motors dealership for information on the General Motors new vehicle factory warranty, and how competitive driving may effect your warranty.




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#06-06-04-015: Information on Vehicles with LSJ Engine Repeatedly Started Cold - Inventory Maintenance - (Mar 28, 2006)


Subject: Information On Vehicles with LSJ Engine Repeatedly Started Cold -- Inventory Maintenance


Models: 2005-2006 Chevrolet Cobalt

2004-2006 Saturn ION

with 2.0L Ecotec 4 Cylinder Engine (VIN P --RPO LSJ)



Attention: This Bulletin ONLY applies to vehicles in which the LSJ engine has been repeatedly started cold. All others should disregard this bulletin and proceed with diagnostics found in published Service Information.



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

Dealerships may encounter a concern with fouled spark plug(s) on the 2.0L engine (RPO LSJ). This type of concern may be present when the vehicle is repeatedly started cold. The engine should be brought to normal operating temperature each time it is started before shutting down. This type of fueling calibration is done to prevent cold driveability issues.

In the future, dealerships should allow vehicles to reach operating temperature before moving them around their lot.

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


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Originally Posted by SportLt View Post
1. your a fucking tard if you meet someone in a chatroom
2. your not a girl so why did you suck it up and stay with someone you dont care for
3. how many god damn fucking times where you dropped on your head/ thrown across the room?

Last edited by ff_drift_lol; 04-07-2010 at 06:21 PM.
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Old 04-06-2010, 07:54 PM   #2 (permalink)
 
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thanks for the info


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Old 04-06-2010, 07:55 PM   #3 (permalink)
 
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np, most of it is useful. if there are any questions as far as the terminology used feel free to ask i'm on her often.


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Originally Posted by SportLt View Post
1. your a fucking tard if you meet someone in a chatroom
2. your not a girl so why did you suck it up and stay with someone you dont care for
3. how many god damn fucking times where you dropped on your head/ thrown across the room?
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Old 04-07-2010, 06:21 PM   #4 (permalink)
 
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#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).


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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)


Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

E7200
Ignition Lock Cylinder Replacement
Use Published Labor Operation Time


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Subject: Instrument Panel (I/P) Outer Compartment Bin is Inoperative or Loose (Replace Steering Column Opening Filler Panel)

Models: 2005-2010 Chevrolet Cobalt

2007-2009 Pontiac G5

2010 Pontiac G5 (Canada Only)




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

Condition




Some customers may comment that the instrument panel (I/P) outer compartment bin (1) is inoperative or loose.

Cause




This condition may be caused by the outboard pivot (1) on the steering column opening filler panel breaking and not properly holding the compartment bin in place.

Correction
Do This
Don't Do This

Replace the steering column opening filler panel.
Do not replace the steering column opening filler assembly.


Replace the steering column opening filler panel and transfer the compartment bin and necessary components to the new panel. Refer to Steering Column Opening Filler Replacement in SI.

Parts Information
Part Number
Description
Qty

20911279
Filler Asm - I/P Strg Col Opg (GRAY)
1

20911280
Filler Asm - I/P Strg Col Opg (EBONY)
1

20911281
Filler Asm - I/P Strg Col Opg (NEUTRAL)
1


Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

C2170
Tray and Pivot, Convenience - Replace
Use Published Labor en Operation Time



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#06-03-09-005C: Squawk/Squeak Type Noise from Rear Suspension While Driving Over Bumps at Low Speeds (Replace Rear Suspension Insulators) - (Aug 6, 2009)

Subject: Squawk/Squeak Type Noise From Rear Suspension While Driving Over Bumps At Low Speeds (Replace Rear Suspension Insulators)


Models: 2005-2009 Chevrolet Cobalt

2005-2006 Pontiac Pursuit (Canada Only)

2007-2009 Pontiac G5




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

This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 06-03-09-005B (Section 03 - Suspension).


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

Condition
Some customers may comment on a squawk or squeak type noise coming from the rear suspension. This noise typically occurs while driving over bumps at low speeds.

Cause
The cause of this noise may be the rear suspension insulators.

Correction
Replace the rear suspension insulators following the Control Arm Bushing (Suspension Insulator) Replacement procedure in SI.

Parts Information
Part Number
Description
Qty

15844181
Insulator, Rear Suspension (RPO FE1)
2

22729411
Insulator, Rear Suspension (RPO FE3, FE5 with LSJ Engine Through 2008)
2

25782808
Insulator, Rear Suspension (RPO FE5 with LNF Engine, 2008-2010)
2


Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

E4090
Insulator, Rear Suspension Support - Right - Replace
Use Published Labor Operation Time

E4091
Insulator, Rear Suspension Support - Left - Replace


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


#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.











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.




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.



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


__________________

Originally Posted by SportLt View Post
1. your a fucking tard if you meet someone in a chatroom
2. your not a girl so why did you suck it up and stay with someone you dont care for
3. how many god damn fucking times where you dropped on your head/ thrown across the room?
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Old 04-07-2010, 06:25 PM   #5 (permalink)
 
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#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)




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

This bulletin is being updated to include the Pontiac Pursuit and to add an Important statement. Please discard Corporate Bulletin Number 08-06-04-001A (Section 06 -- Engine /Propulsion System).


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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


Warranty Information
Important: For claims to be paid, injector balance test results must be recorded on the repair order.

For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

J7808*
Perform Injector Balance Test and Replace Injectors (Includes Programming)
1.0 hr

*This is a unique labor operation for bulletin use only. It will not be published in the Labor Time Guide.

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#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 10C (32F to 50F).

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.

Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

K5364
Transmission Control Module Transmission Reprogramming with SPS
Use Published Labor Operation Time


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


__________________

Originally Posted by SportLt View Post
1. your a fucking tard if you meet someone in a chatroom
2. your not a girl so why did you suck it up and stay with someone you dont care for
3. how many god damn fucking times where you dropped on your head/ thrown across the room?
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Old 04-07-2010, 06:36 PM   #6 (permalink)
 
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#04-03-08-006D: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repairs) - (Feb 24, 2009)


Subject: Steering and Front Suspension Noise Concerns -- Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair)


Models: 2005-2009 Chevrolet Cobalt (Including SS)

2006-2009 Chevrolet HHR (Including SS)

2005-2006 Pontiac Pursuit (Canada Only)

2007-2009 Pontiac G5

2003-2007 Saturn ION




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

This bulletin is being revised to add Condition #3. Please discard Corporate Bulletin Number 04-03-08-006C (Section 03 - Suspension).


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

This bulletin provides information on seven different steering/front suspension noise conditions.

Condition #1
Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface.

This condition can be duplicated by the technician using the following procedure:

On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable.
Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition.




Remove the 60 amp EPS fuse (1) in the underhood fuse block.
Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism).
Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel.
Correction #1
If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column.

Important: The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack.

If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI.

Parts Information #1
For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle.

Warranty Information #1
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

E7680
Column Assembly, Steering - Replace
Use Published Labor Operation Time


Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only)
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 #2
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 #2
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.






Clean the surface area of the upper spring seat using fine sandpaper.
Apply a light coat *of 3M™ Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes.



Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M™ Duramix™ Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature.
Apply a light coat of *3M™ Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes.




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 #2
Part Number
Description
Qty
Material Allowance

21992520
Shield, Frt Suspension Strut
-
-

22712118
Bumper, Frt Suspension Strut
-
-

04747
3M™ Duramix™ Super Fast Adhesive
1
$22.00

06396
3M™ Automotive Adhesion Promoter
2
$4.00


For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog.

Warranty Information #2
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

E9478*
Replace Front Strut and Secure Bumper and Shield to Spring Seat
1.5 hrs

Add
To Perform Repair on Other Side
1.3 hrs

Add
For alignment times, refer to operation E2020 and add the applicable times to the regular hours.

* This is a unique labor operation for bulletin use only. The number will not be published in the Labor Time Guide.


Condition #3
Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces.

Cause #3
This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture.

Correction #3
Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part.

Parts Information #3
Part Number
Description
Usage
Qty

20784686
Link Asm., Front Stabilizer Shaft (300 mm Shaft)
2006-2009 HHR (FE1, FE3)

2005-2009 Cobalt (FE1, FE3)

2005-2006 Pursuit (FE1, FE3)

2007-2009 G5 (FE1, FE3)

2003-2007 ION (FE1, FE2, FE3)
2

20784687
Link Asm., Front Stabilizer Shaft (250 mm Shaft w/Washer)
2008-2009 HHR (FE5)

2005-2009 Cobalt (FE5)

2007-2009 G5 (FE5)
2

20784688
Link Asm., Front Stabilizer Shaft (250 mm Shaft)
2006-2009 HHR (FE1, FE3)

2005-2009 Cobalt (FE5)

2005-2006 Pursuit (FE5)

2007-2009 G5 (FE5)
2


Warranty Information #3
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

E2147
Stabilizer Shaft Link Replacement (Both Sides)
Use Published Labor Operation Time


Condition #4
Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90 of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel.

The following are characteristics of this noise:

• This noise is very random.

• This noise is independent of the steering wheel angle and independent of the bumpiness of the road.

• This noise is a low frequency dull one and can be felt in your feet.

• This noise can normally be heard from the driver seat.

• This noise can be felt upon touching the steering gear from outside of the vehicle.

Note: You might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it.

Cause #4
This condition may be caused by inadequate lubrication of the steering intermediate shaft.

Correction #4
Important: DO NOT replace the steering gear or steering column assembly.

Replace the intermediate shaft.

Important: If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft.

If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI.

Parts Information #4
Part Number
Description

15800140
Shaft, Intermediate Steering (Cobalt/G5/Pursuit)

15799676
Shaft, Intermediate Steering (ION)

22730246
Shaft, Intermediate Steering (HHR)


Warranty Information #4
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

E7700
Shaft, Steering Intermediate - Replace
Use Published Labor Operation Time


__________________

Originally Posted by SportLt View Post
1. your a fucking tard if you meet someone in a chatroom
2. your not a girl so why did you suck it up and stay with someone you dont care for
3. how many god damn fucking times where you dropped on your head/ thrown across the room?
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Old 04-07-2010, 06:39 PM   #7 (permalink)
 
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Condition #5
Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps.

Correction #5
The following steps have been found to be very effective in removing this condition.





Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam.



Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat.
Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving.

If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI.

Warranty Information #5
Labor Operation
Description
Labor Time

E9458*
Repair to Correct Rattle/Clunk Noise in Front of Vehicle
0.2 hr

* This is a unique labor operation number for bulletin use only. The number will not be published in the Labor Time Guide.


Condition #6 (FE1 Suspension Only)
Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking.

Cause #6




This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months.

Correction #6
If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve.

If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise.

Parts Information #6
Part Number
Description

25984679
Bushing, Front Lower Control Arm (Cobalt/G5/HHR/Pursuit)

22688205
Bushing, Front Lower Control Arm (ION)


Warranty Information #6
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

E3550
Bushings ad/or Shaft, Front Control Arm Lower (Right) - Replace
Use Published Labor Operation Time

E3551
Bushings ad/or Shaft, Front Control Arm Lower (Left) - Replace

E3557
Bushings ad/or Shaft, Front Control Arm Lower (Both) - Replace


Condition #7 (Saturn ION Only)
Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement.

Cause #7
This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp.

Correction #7
Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure.

Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI.
If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps:

Important: Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type.


On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI.

On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI.

Verify the repair by repeating Step 1.
Parts Information #7
Part Number
Description
Qty

15820162
Insulator, Front Stabilizer Shaft (2007 FE1 Suspension)
2

15820163
Insulator, Front Stabilizer Shaft (2007 FE2 Suspension)
2

15820164
Insulator, Front Stabilizer Shaft (2003-2007 FE3 Suspension)
2

22722387
Clamp, Front Stabilizer Shaft
2


Warranty Information #7
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

E2180
Insulator and/or Bracket, Front Stabilizer Shaft - Replace
Use Published Labor Operation Time


Condition #8
Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below.

Correction #8
Important: DO NOT replace the steering column.





Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI.



---------- Post added at 06:37 PM ---------- Previous post was at 06:37 PM ----------

#08-05-23-003B: Front Brake Noise, Brake Pulsation, Front Brake Inner Pad Wear (Replace Front Brake Pads and Add Splash Shields) - (Jul 21, 2008)


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


Models: 2005-2008 Chevrolet Cobalt (Excludes SS Models)

2006-2008 Chevrolet HHR (Excludes SS Models)

2006 Pontiac Pursuit (Canada Only)

2007-2008 Pontiac G5




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

This bulletin is being revised to clarify the vehicles involved in the model and parts information. Please discard Corporate Bulletin Number 08-05-23-003A (Section 05 -- Brakes).


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

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
Model
Usage

25884778
Shield, Front Brake (RH)
HHR

(EXC SS)
All

(EXC JL9)

Cobalt/G5/Pursuit

(EXC Cobalt SS)
w/ JL9 (level 3) (296 mm rotor)

(EXC JL4)

25884779
Shield, Front Brake (LH)
HHR

(EXC SS)
All

(EXC JL9)

Cobalt/G5/Pursuit

(EXC Cobalt SS)
w/ JL9 (level 3) (296 mm rotor)

(EXC JL4)

25931624
Shield, Front Brake (RH)
Cobalt/G5/Pursuit

(EXC Cobalt SS)
w/ J41 or

JM4 & PFD/PG1 or

JM4 & NZ0/NZ6

(level 0, 1 & 2) 256 and 280 mm rotors)

25931625
Shield, Front Brake (LH)


Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

H9730*
Replace Front Brake Pads and Add Splash Shields (Inc Refinish Rotors)
2.2 hrs

*This labor operation number is for bulletin use only. This number will not be published in the Labor Time Guide

---------- Post added at 06:39 PM ---------- Previous post was at 06:37 PM ----------

#05-02-32-005E: EI05093 - Clunk Noise in Steering System at Slow Speeds While Turning and/or Driving Over Bumps (Bulletin Canceled - See Bulletin 04-03-08-006B) - (Aug 31, 2007)


Subject: EI05093 -- Clunk Noise in Steering System at Slow Speeds While Turning and/or Driving Over Bumps (Replace Intermediate Shaft)


Models: 2005-2007 Chevrolet Cobalt

2006-2007 Chevrolet HHR

2005-2007 Pontiac Pursuit (Canada Only)

2003-2007 Saturn ION




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

This bulletin is being canceled and replaced by Corporate Bulletin 04-03-08-006B. Please discard Corporate Bulletin Number 05-02-32-005D (Section 02 - Steering).


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

Condition
Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90 of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel.

The following are characteristics of this noise:

• This noise is very random.


• This noise is independent of the steering wheel angle and independent of the bumpiness of the road.


• This noise is a low frequency dull one and can be felt in your feet.


• This noise can normally be heard from the driver seat.


• This noise can be felt upon touching the steering gear from outside of the vehicle.


Note that you might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it.

Cause
This condition may be caused by inadequate lubrication of the steering intermediate shaft.


__________________

Originally Posted by SportLt View Post
1. your a fucking tard if you meet someone in a chatroom
2. your not a girl so why did you suck it up and stay with someone you dont care for
3. how many god damn fucking times where you dropped on your head/ thrown across the room?
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Old 04-07-2010, 06:41 PM   #8 (permalink)
 
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#07-07-29-001A: MG3, M86 Manual Transaxle Grinding or Growling Noise in 3rd or 4th Gear, Excessive Engagement or Disengagement Effort While Shifting into 5th or Reverse Gear, Will Not Shift into Either 5th or Reverse - (Apr 16, 2007)


Subject: MG3, M86 Manual Transaxle Grinding or Growling Noise in 3rd or 4th Gear, Excessive Engagement or Disengagement Effort While Shifting into 5th or Reverse Gear, Will Not Shift into Either 5th or Reverse Gear (Replace Complete Output Shaft Assembly)


Models: 2005-2007 Chevrolet Cobalt

2006-2007 Chevrolet HHR

2005-2006 Pontiac Pursuit (Canada Only)

2007 Pontiac G5

2003-2007 Saturn ION, VUE

with Getrag™ 5-Speed Manual Transaxle (RPOs MG3, M86)




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

This bulletin is being updated to add additional information on 5th or reverse gear in the Subject, Condition and Cause sections of this bulletin. Please discard Corporate Bulletin Number 07-07-29-001 (Section 07 -- Transmission/Transaxle - Manual Transmission).


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

Condition
Some customers may comment on any or all of the following conditions:

• A grinding or growling noise in 3rd or 4th gear.

• Excessive engagement/disengagement effort while shifting into 5th or reverse gear.

• The vehicle will not shift into either 5th or reverse gear.

Cause
Diagnosis of the concern will lead the technician to replace the 5th/reverse gear synchronizer assembly and/or the 5th/reverse gear blocking rings on the output shaft of the transaxle to correct the condition. In order to access either the synchronizer assembly, the blocking rings, or any other components on the output shaft, the 4th gear must first be removed from the output shaft and then reinstalled after parts have been replaced.

The Service Manual procedure for output shaft assembly states that the 4th gear will install very tight. Some dealers have been unsuccessful in achieving the press loads required to completely seat the 4th gear on the output shaft during re-assembly, resulting in these dealers replacing the entire manual transaxle assembly.

Correction
Important: Some technicians may have trouble when pressing gears on or off the output shaft of the Getrag™ MG3/M86 five-speed manual transaxle. The output shaft gears are not splined to the output shaft and are a very tight press fit.

If diagnosis leads to replacement of any components on the output shaft, dealers should follow published Service Information (SI) procedures and use the appropriate special tools to correctly re-assemble the output shaft.

Pressing Output Shaft Gears
Important: When pressing these gears on or off of the output shaft, care needs to be taken to ensure that the shaft is not nicked or have any burrs on it. (The shaft and gear need to be free of dirt or debris) Extreme care should be taken not to bind or cock the gear on the shaft. If this happens, press the gear back off the shaft and start over.

Press loads can reach 2-3 tons on the 4th fixed gear and 12-17 tons on the 3rd fixed gear (both located on the output shaft). The 3rd and 4th speed gears (on the input shaft) come off with minimal pressure but if trying to remove the 5th fixed gear and the 3rd speed gears at the same time, press loads in excess of 20 tons will not move the gear. Gears need to be removed and installed one at a time.

If dealers are not able to properly seat the 4th gear on the output shaft, a complete output shaft assembly for MG3 and M86 manual transaxles is being released as a field fix and should be used rather than replacing the manual transaxle assembly.

Part numbers for these output shaft assemblies and their applications are listed below:

Parts Information
Part Number
Description

19133215
Output Shaft Assembly, MG3

2003-2007 Saturn VUE

19133216
Output Shaft Assembly, M86

2003-2007 Saturn ION

Output Shaft Assembly, M86

2005-2007 Chevrolet Cobalt

Output Shaft Assembly, M86

2005-2006 Pontiac Pursuit

Output Shaft Assembly, M86

2007 Pontiac G5

19133217
Output Shaft Assembly, M86

2006-2007 Chevrolet HHR


Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

K3155
Shaft and/or Gears, Output Shaft - R&R or Replace
Use Published Labor Operation Time

---------- Post added at 06:41 PM ---------- Previous post was at 06:40 PM ----------

#07-06-04-003: LSJ, L61, LK5, L52, LL8 Engine - Reduced Engine Power, MIL/SES Light, DTC P1516, P2135, P2138 (Replace PCM) - (Jan 19, 2007)


Subject: LSJ, L61, LK5, L52, LL8 Engine -- Reduced Engine Power, MIL/SES Light, DTC P1516, P2135, P2138 (Replace PCM)


Models: 2005-2006 Chevrolet Cobalt, Cobalt SS, Malibu

2006 Chevrolet Colorado, TrailBlazer

2006 GMC Canyon, Envoy

2006 HUMMER H3

2005-2006 Saturn ION, ION Red Line

2006 Saab 9-7X

with ECOTEC™ 2.0L, 2.2L I-4 Cylinder Engine (VINs P, F-- RPOs LSJ, L61) or

VORTEC™ 2.8L I-4, 3.5L I-5, 4.2L I-6 Cylinder Engine (VINs 8, 6, S -- RPOs LK5, L52, LL8)



Attention: The following bulletin information is only to be used if the customer has returned for REPEAT repairs for DTCs P1516, P2135 and/or P2138.



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

Condition
Some customers may comment on engine operation in the Reduce Engine Power mode with the MIL/SES light illuminated. This condition may be repeated and upon investigation, the technician may find the following DTCs set as current or in history:

• DTC P1516 Throttle Actuator Control (TAC) Module Throttle Actuator Position Performance

• DTC P2135 Throttle Position (TP) Sensor 1-2 Correlation

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

Cause
This condition of a repeat DTC P1516, P2135 and/or P2138 may be caused by an internal concern with the PCM.

Correction




Important: DO NOT replace the APP sensor. Inspect the PCM build date first.

Before following the diagnostic information in SI on DTCs P1516, P2135 and/or P2138, an inspection of the PCM serial number year and Julian (PCM build) date will be necessary to determine if the PCM will need to be replaced to correct the repeat DTC P1516. Refer to Engine Control Module Replacement in SI in order to remove the PCM. Refer to the above graphic illustration (1) for the location of the PCM serial number.

The serial number is read left to right. The last digit of the year is the 9th character and the Julian date is comprised of the 10th, 11th and 12th characters and is used to determine the PCM build date. Refer to the example below to read a build date from the PCM serial number:

* 8 6 Y N AU K 1 5 3 2 5 0 R P N *

If the PCM year and Julian dates are between 5182 and 5304 , replace the PCM. Refer to the Part Catalog to order the correct PCM for your vehicle application, if necessary.

Vehicles with PCM built outside the dates should refer to SI diagnostics for DTCs P1516, P2135 and/or P2138.

Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

J6360
Powertrain Control Module Replacement
Use Published Labor Operation Time


Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use:

Labor Operation
Description
Failed Object
Fault/Reason Code
Location Code
Warranty Type
Repair/Action Code
Labor Time

2481001
Powertrain Control Module Replacement
24810
67
0
01
01
Use Published Labor Operation


__________________

Originally Posted by SportLt View Post
1. your a fucking tard if you meet someone in a chatroom
2. your not a girl so why did you suck it up and stay with someone you dont care for
3. how many god damn fucking times where you dropped on your head/ thrown across the room?
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Old 04-07-2010, 06:44 PM   #9 (permalink)
 
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#06-06-04-058: Engine Wont Crank After Battery Disconnect, Dead Battery Condition or After A Reprogramming Event, Theft Deterrent Light Illuminated, DTC B3060 Stored, (Reprogram Keys into Theft Deterrent Module) - (Oct 25, 2006)


Subject: Engine Will Not Crank After A Battery Disconnect, Dead Battery Condition Or After A Reprogramming Event, Theft Deterrent Light Illuminated, DTC B3060 Stored, One Key Starts Vehicle But Second One Does Not (Reprogram Keys into Theft Deterrent Module)


Models: 2006 Chevrolet Cobalt, HHR

2006 Pontiac Pursuit (Canada Only), Solstice

2007 Saturn SKY Built Prior to June 30, 2006




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

Condition
Some customers may comment on the following conditions after experiencing a loss of battery power in their vehicle. Technicians may encounter a vehicle with the following conditions after disconnecting a battery during a service procedure or after reprogramming any module on the vehicle.

• The engine will not crank using the key the customer currently has in their possession.

• If the customer has both keys, one key starts the vehicle but the vehicle will not crank using the second key.

• The Theft Deterrent Light may be illuminated during the no crank condition.

Technicians may find Diagnostic Trouble Code (DTC) B3060 (Unprogrammed Transponder Identification Code Received) stored as a current or a history code.

Cause
This condition may be caused by the failure of the key programming information for both keys to be permanently stored in the Theft Deterrent Module (TDM) during the vehicle assembly process. The information for one key is stored permanently while the information for the other key will be lost if the vehicle's battery voltage drops below 7.8 volts.

The failure condition will also occur when the key programming information for one of the vehicle's keys is lost after a battery disconnect during a service procedure, a dead battery condition or after a reprogramming event for any module and the key that has lost its programming is used to start the vehicle. The vehicle's other key programming information will not be lost due to the loss of battery voltage or a reprogramming event and that key will still start the vehicle. It may also be possible to unknowingly render the customer's second key inoperative after a battery disconnect or a reprogramming event performed during other service procedures on the vehicle.

It is recommended that the customer be asked for both keys to their vehicle when their vehicle is brought in for any service requests in which a battery disconnect or reprogramming event will occur. Technicians should verify that both keys work before returning the vehicle to the customer.

Correction
Do This
Don't Do This

Reprogram the keys into the Theft Deterrent Module.
Replace the Theft Deterrent Module.


Important: In order to prevent the technician from possibly having to perform a very long diagnostic procedure, every effort should be made to obtain both keys to the vehicle before any repairs are attempted on the vehicle. If the customer only brings in one key, their second key will no longer start the vehicle after these repairs are completed unless the second key is programmed into the TDM at a later date using the Adding Keys procedure. Having both keys available will also prevent the possible situation where the second key cannot be programmed into the TDM and the vehicle would have to be returned to the dealership again.

Technicians should use one of the following procedures to repair this condition depending on the number of keys available:

Procedure #1. Both keys available at dealership. One key starts the vehicle but the second key does not.
Make sure that the vehicle's battery is fully charged before attempting this procedure.
If you have one key that starts the vehicle, use the Adding Keys procedure in SI (Document ID# 1686394) to program the second non-working key into the TDM.
If the second key cannot be programmed, then replace the non-working key and program the new key into the TDM using the Adding Keys procedure in SI. The new key must be the correct part number with a circle plus mark on the key shank.
If both keys now start the vehicle, clear all DTCs and return the vehicle to the customer.
If one key still does not start the vehicle, refer to the Diagnostic System Check-Vehicle procedure in SI to begin your diagnosis.
Procedure #2. One key available at the dealership that will not start the vehicle. Second key not available.
Make sure that the vehicle's battery is fully charged before attempting this procedure.
Program the available key into the TDM using one of the following programming methods:
• For Domestic vehicles, technicians may use the either the 10-Minute or the 30-Minute Relearn Procedure using a single key. If the 10-Minute Relearn procedure is used, select the "Vehicle Theft Deterrent Learn For Learning Replacement Keys" calibration in the service programming system. Refer to the Set Up a Theft Deterrent Module (TDM) Using New Keys section of the Programming Theft Deterrent System Components (Domestic) procedure in SI (Document ID# 1686399).

• For Canadian vehicles, technicians must use the 10-Minute Relearn Procedure to learn the first key. The calibration "Vehicle Theft Deterrent Learn For Learning Replacement Keys" must be selected in the service programming system. Refer to the Set Up a Theft Deterrent Module (TDM) Using New Keys section of the Programming Theft Deterrent System Components (Canada) procedure in SI (Document ID# 1686437).

• For Saturn vehicles, technicians must refer to the Theft Deterrent Control Module Programming and Setup procedure in SI (Document ID# 1864651). Use the Set Up a Theft Deterrent Module (TDM) Using New Keys procedure contained in this document.

If the first key cannot be programmed using either the 10-Minute or 30-Minute Relearn Procedure, then replace the first key with a new key. Use the appropriate procedure above to program the new key into the TDM. The new key must be the correct part number with a circle plus mark on the key shank.
After the first key or the new replacement key is successfully programmed into the TDM, instruct the customer to bring their second key to the dealership. Program the second key into the TDM using the Adding Keys procedure in SI.
If both keys now start the vehicle, clear all DTCs and return the vehicle to the customer.
If one or both of the keys you now have cannot be programmed into the TDM, refer to the Diagnostic System Check-Vehicle to begin your diagnosis.
Warranty Information
For vehicles repaired under warranty, use:

Important: If the 30 minute key learn procedure is used, the additional labor time must be authorized by your service manager.

Labor Operation
Description
Labor Time

R9724*
Reprogram key using 10 minute learn procedure
0.3 hr

*This is a unique labor operation for bulletin use only. The number will not be published in the Labor Time Guide.

---------- Post added at 06:44 PM ---------- Previous post was at 06:43 PM ----------

#06-06-04-012A: Erratic Fuel Gauge Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor) - (Oct 31, 2006)


Subject: Erratic Fuel Gauge Readings (Does Not Go to Full or Moves Off Full Too Quickly) (Replace Fuel Level Sensor)


Models: 2006 Chevrolet Cobalt

2006 Pontiac Pursuit (Canada Only)

Built Prior to VIN Breakpoints 67735784 (Chevrolet) and 67735794 (Pontiac)




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

This bulletin is being revised to update the warranty information. Please discard Corporate Bulletin Number 06-06-04-012 (Section 06 - Engine).


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

Condition
Some customers may comment on erratic fuel gauge readings. A typical comment might be that the gauge does not go to full or moves off full too quickly.

Cause
This condition may be caused by an improperly calibrated fuel level sensor.

Correction
Do This
Don't Do This

Replace the fuel level sensor
Do not replace the fuel pump module


Replace the fuel level sensor. Refer to the Fuel Level Sensor Replacement procedure in the service information.

Parts Information
Part Number
Description

88967308
Sensor Kit, Fuel Level


Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

L1200
Sender and/or Pump Assembly, Fuel (Tank Unit) - Replace
Use Published Labor Operation Time


__________________

Originally Posted by SportLt View Post
1. your a fucking tard if you meet someone in a chatroom
2. your not a girl so why did you suck it up and stay with someone you dont care for
3. how many god damn fucking times where you dropped on your head/ thrown across the room?
ff_drift_lol is offline   Reply With Quote
Old 04-07-2010, 06:47 PM   #10 (permalink)
 
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#06-08-49-016B: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM) - (Sep 12, 2006)

Subject: Instrument Panel Cluster (IPC) Backlighting Inoperative During Daylight Hours (Reprogram BCM)


Models: 2004-2006 Chevrolet Malibu, Malibu Maxx

2005-2006 Chevrolet Cobalt

2006 Chevrolet HHR

2005-2006 Pontiac G6, Pursuit (Canada Only)

2006 Pontiac Solstice

2007 Saturn Sky Built Prior to VIN Breakpoint 7Y102344




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

This bulletin is being revised to add a statement that backlighting is only active during daylight hours with headlamps manually turned on. Please discard Corporate Bulletin Number 06-08-49-016A (Section 08 -- Body & Accessories).


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

Condition
Some customers may comment that the backlighting on the IPC does not illuminate in the daylight hours with headlamps manually turned on. They may further state that the backlighting does function at night, but not in the day time.

Cause
On these vehicles, backlighting for the IPC is not enabled unless the vehicle's lighting photocell determines that there is a nighttime ambient condition. Backlighting is not controlled through the use of the park lamp or headlamp switch. The conditions under which the photocell activates the backlighting may not satisfy each particular customer’s personal expectations, or the customer may simply prefer to have the backlighting always illuminated on the IPC when headlamps are manually turned on.

Correction
Important: Module reprogramming must be done using the Pass-Thru method. Select "Instrument Panel (Backlight Dimming Fix ONLY)" from the Supported Controllers list.

For customers who wish to have the IPC backlighting illuminated, a new service calibration is now available that will activate the backlighting to full intensity during daytime hours with headlamps manually turned on. Reprogram the BCM using SPS. The new calibrations are currently available on TIS2WEB.

Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

N9518*
BCM Reprogramming with SPS
0.4 hr

*This is a unique labor operation for bulletin use only. It will not be published in the Labor Time Guide.

#06-06-04-039: LSJ Fluctuating, Unstable or Incorrect Engine Idle (Reprogram ECM) - (Aug 10, 2006)


Subject: Fluctuating, Unstable or Incorrect Engine Idle -- LSJ (Reprogram ECM)


Models: 2005-2006 Chevrolet Cobalt SS Supercharged

2004-2006 Saturn ION Redline

with Ecotec™ 2.0L I-4 Engine (VIN P -- RPO LSJ)




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

Condition
Some customers may comment that the engine idle may fluctuate (idle roll) a hundred rpm for several seconds when the engine is started hot or cold. Further diagnostic investigation with a scan tool may not reveal the cause. No other driveability or performance concerns may be reported.

Cause
The most likely cause of this issue may be that the engine calibrations need to be updated to correct the fluctuating engine idle .

Correction
DO NOT replace the throttle body, the ECM or any other parts.

Important:

• Chevrolet Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers on June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June, 2006 or later.

• Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later.

• While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures

• The technician must select the "Reprogram" option in order to reprogram the ECM.


Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this fluctuating engine idle concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2 is updated with the latest software version

Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

J6354
Module, Powertrain Control - Engine Reprogramming with SPS
Use Published Labor Operation Time

---------- Post added at 06:47 PM ---------- Previous post was at 06:45 PM ----------

#06-06-04-033: 2.0L/2.2L LSJ/L61 Engine Malfunction Indicator Lamp (MIL)/Service Engine Soon (SES) Lamp Illuminated with DTC P0171, Fuel Trim System Lean, Set (Reprogram ECM) - (Jun 21, 2006)


Subject: L61 Engine Malfunction Indicator Lamp (MIL)/Service Engine Soon (SES) Lamp Illuminated with DTC P0171 "Fuel Trim System Lean" Set (Reprogram ECM)


Models: 2005-2006 Chevrolet Cobalt, Cobalt SS Supercharged

2006 Chevrolet HHR

2004-2006 Chevrolet Malibu

2005-2006 Pontiac Pursuit (Canada Only)

2004-2005 Saturn ION Redline

2005-2006 Saturn ION

with Ecotec™ 2.0L or 2.2L I-4 Engine (VINs P, F - RPOs LSJ, L61)




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

Condition
Some customer may comment that the MIL/SES lamp is Illuminated. Further diagnostic investigation with a scan tool may reveal a DTC P0171 Fuel Trim System Lean. No other driveability or performance concerns may be reported.

Cause
The most likely cause of this issue may be that the engine calibrations need to be updated to correct a variation in the Mass Air Flow Sensor.

Correction
DO NOT replace the MAF sensor, the ECM or any other parts.

Important:

• Chevrolet/Pontiac Dealers: The ECM calibration is available to dealerships as part of TIS2000 incremental satellite update version 6.5, which was broadcast to dealers June 12, 2006 or later. For the dealerships that use CDs, they were mailed out June 2006 or later.

• Saturn Retailers: Before installing the new ECM calibration, make sure the Saturn Service Stall (SSS) version is TIS 6.5 2006 or later.

• While the ignition is OFF, apply the parking brake to disable the daytime running lights (DRLs) prior to starting reprogramming procedures

• The technician must select the "Reprogram" option in order to reprogram the ECM.


Reprogram the ECM with the latest calibration. This calibration, or any that follow, is designed to address this DTC P0171 concern. Refer to Service Programming System (SPS) in SI for reprogramming procedures. As always, make sure your Tech 2 is updated with the latest software version

Warranty Information
For vehicles repaired under the 8-year/80,000 mile (130,000 km) emission controller warranty, use:

Labor Operation
Description
Labor Time

J6353
Reprogram ECM with SPS
0.4 hr*

* U.S. Saturn Retailers: Refer to Saturn Electronic Labor Time Guide.



#06-06-01-013: L61 Engine Oil Leak (Replace or Reseal Rear Oil Galley Engine Block Plug(s)) - (Jun 9, 2006)

Subject: L61 Engine Oil Leak (Replace or Reseal Rear Oil Galley Engine Block Plug(s))


Models: 2006 Chevrolet Cobalt, HHR, Malibu

2006 Pontiac Pursuit (Canada Only)

2006 Saturn Ion, VUE FWD

with 2.2L Ecotec I-4 Engine (VINs D, F -- RPO L61)




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

Condition
Some customers may comment on an engine oil leak. Upon investigation, the technician may find engine oil seepage at the rear of the engine, often misdiagnosed as the engine rear main seal.

Cause




(1) Rear Engine Oil Galley Plugs

The oil galley plug(s) on the rear of the engine block may have been damaged during assembly. This may result in a loss of clamp load allowing the plug(s) to come loose creating an engine oil leak.

Correction
If there is oil seepage at the rear of the engine, remove the engine flywheel to gain access to the oil galley plugs. Refer to SI for Engine Flywheel Replacement. Once the flywheel is removed, inspect the rear oil galley plugs shown in the above illustration (1) for leakage. If leakage is found, replace or reseal oil galley plug(s) as outlined below.

• To replace a plug(s), install a new plug(s) and tighten.

Tighten
Tighten the new oil galley plug(s) to 60 Nm (44 lb ft).

• Replacement plug(s) come with pre-applied thread sealant, so it is not necessary to install sealant to the threads.

• To reseal an old plug(s), apply sealant P/N 12346004 (Canadian P/N 10953480) to the threads and tighten.

Tighten
Tighten the old oil galley plug(s) to 60 Nm (44 lb ft).

Parts Information
Part Number
Description

11588949
Plug, Engine Oil Galley-Rear

12346004
Sealant (U.S GM)

10953480
Sealant (Canada GM)

21485278
Sealant (Saturn)


Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

*J7515
Rear Engine Oil Galley Plug(s) - Replace or Reseal
5.5 hrs (Auto)

6.0 hrs (Manual)

* This labor operation is for bulletin use only. It will not be published in the Labor


__________________

Originally Posted by SportLt View Post
1. your a fucking tard if you meet someone in a chatroom
2. your not a girl so why did you suck it up and stay with someone you dont care for
3. how many god damn fucking times where you dropped on your head/ thrown across the room?
ff_drift_lol is offline   Reply With Quote
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