For 1990-2009 cars

# Car and Truck Fix It Right the First Time Issues

Subject: | Car and Truck "Fix It Right the First Time" Issues

Models: | 2009 and Prior Passenger Cars and Trucks (including Saturn)

| 2009 and Prior HUMMER H2, H3

| 2009 and Prior Saab 9-7X

This bulletin is being revised with updated information. Please discard Corporate Bulletin Number 08-00-89-029 (Section 00 - General Information).

In order to access this bulletin electronically, go to the SI Home Page and select the "Newest Bulletins" icon. The documents are arranged by sub-section and then by date (newest to oldest). Scroll down to "General Information" then click on the latest "Field Product Reminder" bulletin.

#### Field Product Reminder -- Car Issues -- Fix It Right the First Time

Model Year(s) | Vehicle Line(s) / Condition | Do This | Don't Do This | Reference Information/Bulletin
--- | --- | --- | --- | ---
2006-2008 | G6 Convertible - Top Will Not Cycle Open or Closed with DTCs Set | Follow the proper DTC diagnosis - repair the circuit, repair the hydraulic seal/line leak and/or replace the switch. Labor Operation: N6620, B3442, N2233, N2240, N2241 | Do not replace the FTC module or the hydraulic pump/motor. | 07-08-67-010 (April 2008)
2006-2008 | DTS - Inoperative Headlamp | Perform diagnosi and if it is determined that a headlight light bulb or ballast is at fault, replace the light bulb or ballast only. P/N: 25735604, 25806714 Labor Operation: N0280, N0281, N0440, N0441 | Do not replace the complete headlamp assembly. | 08-08-42-002 (May 2008)
2007-2009 | Cobalt, G5 - Outside Rear View Mirror (OSRV) Difficult to Adjust, Will Not Move Through Full Range of Adjustment | Follow bulletin 08-08-64-00 before replacement. Labor Operation: B9782 | Do not replace the mirror until proper seating is verified. Do not replace manual OSRV mirrors. | 08-08-64-009 (May 2008)
2007-2008 | Vehicles with 2.8L or 3.6L High Feature V6 Engine - Malfunction Indicator Lamp On - Check Engine Light, DTCs | Install a camshaft thrust washer. Labor Operation: J7534, J7535, J7536 | Do not replace the cylinder head. | 08-06-01-011A (August 2008)
2006-2008 | Impala - Key Cannot be Removed from Ignition with Gear Selector in Park, Shifter Cannot be Moved From Park Position | Repair wiring damage at the BTSI connector and reroute wiring to create available slack to avoid future occurrences. Labor Operation: K9517 | Do not replace the shifter. | 08-07-30-007A (April 2008)
2006-2008 | All vehicles with Tire Pressure Monitoring (TPM) System - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements | Remove and install TPM sensors from the wheel being replaced under warranty to the new wheel. Transfer sensors to the same tire location that they were taken from. | Do not install new TPM sensors for the newly replaced wheel under warranty. | 08-03-16-003 (May 2008)
2006-2007 | HHR -- No A/C, Engine Coolant Leak, Engine Overheating | Install the plastic protector. P/N: 25829960 Labor Operation: J7611 | Do not replace any other components. | 08-06-02-001 (February 2008)
2006-2008 | HHR - Intermittent Check Engine Light On, Engine Power Reduced Message Displayed in DIC, DTC P2135 Set | If not engine wiring harness chafe, short to ground or voltage is discovered, remove ECM connector C2, remove the four TPS circuits mentioned above and solder the wire to the terminal at the terminal crimp. Recrimp wires. Labor Operation: J7720 | Do not replace the ECM or the throttle body. | 08-06-04-022A (April 2008)
2003-2006 | 9-3 Sport Sedan/Sport Combi/Convertible - Surface Coating of ACC Panel Peels Off | Replace the buttons or the faceplate. P/N: 12 781 997, 12 781 996, 12 781 994 Labor Operation: 87095 | Do not replace the complete ACC control unit. | 870-2700
2006-2008 | Vehicles with Aluminum Wheels - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum wheel Bead Seat Corrosion | Repair the wheel and paint. Labor Operation: E9745 | Do not replace the wheel for an air leak. | 08-03-10-006 (May 2008)
2006-2008 | All vehicles (excluding Saturn and Saab) - Replacing Batteries on Vehicles in Dealership Inventory | Maintain the batteries for vehicles in inventory. Dead batteries while the vehicle is in the dealership's inventory are the dealership's responsibility. | Do not allow the battery to discharge through lack of maintenance. | --
2004-2009 | Corvette, XLR - Rear Axle Clunk and/or Chatter Type Noise on Turns | Drain and fill the rear axle using DEXRON® LS gear oil. P/N: 88862624 (US); 88862625 (Canada) Labor Operation: F9709 | Do not replace the differential clutch discs or remove any axle covers in order to wash down differential components to flush the axle. | 07-04-20-002A (January 2008)
2006-2007 | HHR - Front and Rear Carpet Wet, Water/Blower Motor Inoperative | Remove the wiper arms, cowl screen and inspect the HVAC case cover butyl patch for incorrect installation or warping of the patch that allows water to enter. P/N: 25785783 Labor Operation: D9731 | Do not reinstall the old butyl patch using RTV. | 07-08-57-001A (August 2007)

#### Field Product Reminder -- Truck Issues -- Fix It Right the First Time

Model Year(s) | Vehicle Line(s) / Condition | Do This | Don't Do This | Reference Information/Bulletin
--- | --- | --- | --- | ---
2006-2007 | Silverado, Sierra, Savana, Express, TopKick, Kodiak - Engine MIL/SES Light On With DTC P0403 Set | Clean the EGR motor commutator. Normal diagnostics should be followed and the most current calibration should be installed. Labor Operation: J6353 | Do not replace the EGR motor or valve assembly. | 06-06-04-066C (July 2008)
2007-2008 | Silverado/Sierra - Wet Headliner/Water Leaking Past Sunroof Glass Panel Seal | Inspect the glass panel seal appearance at the corners. If the seal looks depressed or concave in the middle, replace the seal. P/N: 1591203 Labor Operation: C1440 | Do not replace the sunroof glass panel. | PIT4621 (April 2008)
2007-2008 | Acadia, OUTLOOK, Enclave - HVAC Performance, A/C Not Cool, A/C Compressor Noise | Replace the HVAC hose with suction line. P/N: 20757021 Labor Operation: D3064 | Do not replace the A/C compressor. | 07-01-39-005A (June 2008)
2001-2009 | All Vehicles - Identifying Aftermarket Engine Calibrations | Block the warranty claim for a major engine or transmission repair if an aftermarket calibration is installed and is responsible for the damage. Also, flag the warranty system to block future repairs. | Do not submit a warranty claim for a major engine repair if an aftermarket calibration is installed. | 08-06-04-033 / Gas Engines (May 2008) 08-06-04-006B / Diesel Engines (June 2008)
2007-2008 | Colorado, Canyon, H3 -- Rattle Noise from Under IP, Underhood, Under Vehicle, Heat Shield Rattle | Place a hose clamp around the forward portion of the heat shield. P/N: 10186112 Labor Operation: L9717 | Do not replace the exhaust/converter pipe assembly. | 08-06-05-003 (May 2008)
2005-2008 | TrailBlazer SS, 9-7X/Aero - Jerk/Jump Sensation with Growl/Groan Noise, Shudder, Bind From Rear of Vehicle While Turning | Remove the rear differential fluid. Fill the differential with DEXRON® LS gear oil. P/N 88862624 (US), 88862625 (Canada) Labor Operation: F9709 | Do not replace the differential gear case unless damage to the clutch plates is too extensive to be repaired by this drain and fill procedure. | 08-04-20-002 (March 2008)
2004-2007 | Colorado, Canyon, H3 - MIL/SES, DTCs P060E, P1516, P2135 and/or P2138 with Reduced Engine Power | Check the battery state of charge and charge or replace as necessary. Labor Operation: N0100, N0110 | Do not replace the throttle body, throttle body module, accelerator pedal, accelerator position sensor, PCM or ignition switch. | 08-06-04-014 (March 2008)
2008 | Sierra, Silverado -- Service Engine Soon/Malfunction Indicator Lamp, DTC P1174 Fuel Trim Cylinder Balance Bank 1 | Reprogram ECM using TIS2Web. Labor Operation: J6354 | Do not replace the catalytic converter, PCM, injector(s), fuel rails or fuel pumps. | 08-06-04-028 (April 2008)
2006-2008 | Colorado, Canyon, H3 - Loose Module/Broken Tab Under Passenger Seat | Reattach the ECU with 3M™ two-way tape. Labor Operation: C9833 | Do not replace the entire ECU and seat sensing pod assembly. | 08-08-50-003 (February 2008)
2007-2008 | Escalades, Avalanche, Silverado, Suburban, Tahoe, Denali, Sierra, Yukon, Yukon XL - 1500 Series - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly | Before replacing the power steering rack assembly for fluid leaks, determine the source of the leak. Assembly plant fill equipment may leave some excess fluid on the rack. Wipe the fluid off and follow bulletin directions. | Do not replace the power steering rack until you have followed all the steps in this bulletin. | 07-02-32-002C (October 2007)
2001-2004 | Vehicles with LB7 Duramax™ Diesel Engine - Injector High Pressure Lines Are Being Replaced for External Corrosion | Clean the connection area of the line and nut of the injector high pressure lines as required. Labor Operation: J7805 | Do not replace the lines for external corrosion. | 03-06-04-036A (October 2006)