For 1990-2009 cars

# Intermittent SES Light Due To DTCs P060E P2135 And/Or P2138 - keywords chaff circuit connection controls ECM engine ground L61 LSJ no PCM short terminal wire wiring

Subject: | Intermittent SES Light due to DTCs P060E, P2135, and/or P2138

Models: | 2005-2007 Chevrolet Cobalt SS

| 2005-2008 Chevrolet Cobalt

| 2006 Chevrolet HHR

| 2007-2008 Pontiac G5

| 2005-2006 Pontiac Pursuit (Canada Only)

| 2005-2007 Saturn Ion

| 2004-2007 Saturn Ion Redline

| with 2.0L Engine (VIN P - RPO LSJ)

| or 2.2L Engine (VIN F - RPO L61)

This PI was superseded to update models. Please discard PIP4175A.

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

### Condition/Concern:

On rare occasions, an intermittent SES light may be experienced due to DTCs P2135 and/or P2138. In some instances, a P060E may also be stored as a result of either DTC.

### Recommendation/Instructions:

If any of the DTCs above are setting consistently, perform the SI diagnostics and repair as necessary. If the SI diagnostics do not isolate a cause for this concern due to the intermittent nature of this, perform the following suggestions as necessary:

1. Review 07-06-04-003 and determine if it applies to the vehicle you are working on. If so, perform the bulletin and evaluate the concern. This bulletin relates to a potential ECM/PCM that can cause this concern on select vehicles and PCM build dates.
2. For P2138 DTCs, review bulletin 07-06-04-019 and inspect corrosion or water intrusion in C201. Also inspect for a poor connection or poor terminal tension on the APP circuits while this connector is disconnected.
3. Inspect the engine harness for potential shorts to ground in the following locations, and repair and reposition the circuits/harness as necessary:

• | at the air conditioning line about 3-6 inches from the ECM/PCM connectors.

• | on the ECM/PCM case and/or on the edge of either ECM/PCM connector body.

• | at the air conditioning line bracket at the rear of the head, above the transmission.

• | at the edge of the aluminum oil filter housing on the engine block.

• | at the UBEC/UHJB bracket.

• | at the EVAP purge valve bracket.

• | at the rear of the cylinder head/upper edge of transmission bell housing.

| Notice: Since this PI is written for multiple models and engine RPOs, some of the locations listed above may not exist on certain model and engine RPO combinations. Inspect each location to determine which locations exist on the vehicle that you are working on and ensure that there are no shorts to ground present in these locations.

4. Inspect all of the APP (P2138) or TP (P2135) circuits to determine if duraseal splice sleeves were used during previous repairs, such as service pigtail harness installation. If so, the incorrect crimp tools may have been used to install the splice sleeves and this could be causing the concern. If the incorrect tools were used, or if it is unknown what tools were used to install the splice sleeves, replace the splice sleeves again by using the correct tools and following the "Splicing Copper Wire Using Splice Sleeves" Procedure in SI.
5. Inspect all of the APP (P2138) or TP (P2135) circuits for poor terminal tension using test probe J-35616-2A on the APP/TP sensor terminals and J35616-64B on the ECM/PCM terminals. Also, inspect all of these circuits for high resistance or possible shorts to ground while wiggling the harness around. And, also inspect the connector face to ensure that none of the terminals have backed out and that the connector face cover is latched into position properly. If the connector face cover is not latched to the connector, it may become unfastened and stick in the sensor, preventing the connector from seating properly once the connector is plugged into the sensor. If any concerns are found, repair as necessary by following SI procedures.
6. If there is no problem found above, follow SI procedures and replace all of the ECM terminals for the APP sensor circuits if a P2138 is stored, or all of the ECM terminals for the TP sensor circuits if a P2135 is stored.

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.