TSB #'s and Recall #'s

[WopOnTour]

Subject: Water Leaks Into Front Driver and/or Passenger Foot Wells Near Front Speaker Grill Area After Sustained Heavy Rain (Seal Speaker Drip Cover to Speaker Frame)
TSB #03-08-44-012A Released 04/19/2006

Models: 2003-2006 Saturn ION

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This bulletin is being updated with additional model years.

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Condition
Some customers may comment that the front foot well carpet is wet after the vehicle is exposed to sustained heavy rain.

Cause
After sustained heavy rain, water may accumulate between the speaker frame and the speaker plastic drip cover. The accumulated water may wick through the lower speaker attachment bolt hole and run down the inner door panel and leak into the interior compartment under the doorsill trim plate.

Correction
Remove the drip cover from the speaker frame and apply KENT® HIGH TECH SEAM SEALER - CLEAR TRANSPARENT, or equivalent, to the back of the speaker frame where the drip cover contacts the speaker frame following the procedure

[WopOnTour]

Subject: Creak or Popping Noise from Rear Access Door Area (Adjust Lower Rear Door Striker) TSB#06-08-64-015 - Released 03/28/2006

Models: 2003-2006 Saturn ION Quad Coupe

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Condition
Some customers may comment on a creak or popping noise coming from behind the driver and/or front passenger, which may originate from the rear access door area.

Cause
The noise from the rear access door(s) may be caused by a lower rear door striker that is mounted too far forward. This may cause the striker to rub against the rear door structure.

Correction
Inspect the rear door striker for witness marks (shiny area) where the lower rear door striker comes into contact with the door. Also inspect along the forward edge of the latch opening on the bottom side of the rear access door. If any evidence of rubbing is found, adjust the lower rear door striker rearward approximately 3 mm (0.12 in)

[WopOnTour]

Subject: Warranty Admin. - Warranty Coverage for Emission-Related Reprogramming Events (PCM, ECM and TCM) #04-06-04-036A - (04/03/2006)

Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn)

2003-2007 HUMMER H2

2006-2007 HUMMER H3

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This bulletin is being updated with additional models and model years. Please discard Corporate Bulletin Numbers 04-06-04-036 and 05-06-04-013 (Saturn 04-I-08) (Section 06 - Engine).
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The coverage for emission-related reprogramming has the same coverage as the emission controller under the emission controller warranty - 8 years/80,000 miles (130,000 km).

Reprogramming that is not emissions-related is covered for 3 years/36,000 miles (60,000 km). (For additional information regarding labor codes for use in non-emission-related reprogramming, refer to Corporate Bulletin Number 06-08-47-001A.)

Emissions-related calibration updates will be announced through a GM Technical Service Bulletin with specific guidelines of coverage for each model affected. A special emission-related reprogramming labor operation will be used. The labor operation to be used for claims relating to emission-related reprogramming is J6353 and will only be referenced in the bulletins addressing emission-related calibrations. This labor operation must NOT be used for non-emissions-related reprogramming or for any other vehicle that is not referenced in an emission-related reprogramming technical service bulletin.

Example:
The PCM on 2004 model light duty vehicles is covered by the emission controller warranty for 8 years/80,000 miles (130,000 km). If GM released an "emission-related" calibration update for one of these vehicles, this reprogramming event would also be covered for 8 years/80,000 miles (130,000 km). If GM released a driveability-related calibration update (for example, to eliminate a hesitation) for one of these vehicles, this reprogramming event would be covered for 3 years/36,000 miles (60,000 km).

An emission-related calibration for medium duty and diesel applications are also covered by the emission warranty that is applicable to that vehicle's emissions controller.

Example:
The PCM on 2004 model medium duty vehicles is covered by the emission controller warranty for 5 years/50,000 miles (80,000 km). If GM released an "emission-related" calibration update for one of these vehicles, this reprogramming event would also be covered for 5 years/50,000 miles (80,000 km).

[ion20redline04]

UMM ya'll forgot i belive its the 0171 the lean code or w/e i cant guarentee thats the number but I know there is the lean problem have they come up with a fix for it yet???? 04 owners only i belive

[WopOnTour]

Subject: Water Leak, Wet or Stained Carpet in Trunk, Water or Dirt Accumulates Under Carpet in Spare Tire Well (Inspect Tail Lamp Wiring Harness and Rewrap, If Necessary) #06-08-66-009 - (05/22/2006)

Models: 2005-2006 Saturn ION

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Condition
Some customers may comment on a water leak or wet or stained carpets in the trunk of their vehicle. Other customer comments may include water or dirt accumulation under the carpet or in the spare tire well.

Cause
This condition may have two potential causes:

• Water may enter through the rear tail lamp wire harness sheath.

• Water may enter through the pressure relief valve (PRV) if it is not properly seated. (This occurs much less frequently than the previous potential cause.)

Correction
Inspect the rear compartment (trunk) and use the waterleak test procedures found in the General Information section of SI to diagnose this condition.

• If the source is determined to be the tail lamp wiring harness (i.e., the tail lamp wiring harness is completely wrapped solid with tape instead of in a spiral pattern which allows water to drip out), follow these steps:

1. Remove the tail lamp assembly.
2. Disconnect the wiring harness.
3. Remove the electrical tape. With new tape, re-wrap the harness using a spiral wrapping pattern. Refer to the illustration above.
4. Repeat for the opposite side.

• If source is determined to be the PRV, inspect the PRV and re-seat. Replace the PRV if it is damaged.

[WopOnTour]

thread subscribers check your emails for this date/time

[WopOnTour]

check your emails

[WopOnTour]

Subject: Intermittently Unable to Read Radio Display During Daylight Hours (Reprogram BCM) #05-08-44-037A - (06/15/2006)

Models: 2006 Saturn ION 3

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This bulletin is being updated with revised Correction and Warranty Information. Please discard Corporate Bulletin Number 05-08-44-037 (Section 08 - Body & Accessories).


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Condition
Some customers may comment that they are intermittently unable to read the display on the radio during the daylight hours.

Cause
This may be due to the headlamps coming on when the wipers are turned on or the headlamps are manually turned on during the day. This causes the instrument panel lamps to come on and the radio display to dim (both of these features are on the park lamp circuit).

Correction
On affected vehicles, perform body control module (BCM) reprogramming using the Service Programming System (SPS) (also referenced as the Saturn Service Stall system). The new software will allow the interior instrument panel lights to stay off along while keeping the radio display at full intensity when the "ambient light sensor" informs the BCM that it is still light outside - even though the headlights have been turned on manually or been commanded on when the wipers are engaged. It is important to also reconfigure the radio using SPS after the BCM has been reprogrammed

[WopOnTour]

Subject: Waterleak at Front Door Window Frame (Fill In/Refinish Step Area on Door Frame) #05-08-57-003A - (06/13/2006)

Models: 2005 Buick Allure (Canada Only), LaCrosse
2003-2006 Saturn ION

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This bulletin is being revised to add the Saturn ION. Please discard Corporate Bulletin Number 05-08-57-003 (Section 08 -- Body and Accessories).
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Condition
Some customers may comment that water drips from the door frame, just above the mirror.

Cause
There may be a step in the door frame where the door frame is welded. This step allows water past the primary seal and on to the door pad.

Correction
Important: All refinish operations require the use of products found in the 2005 GM4901M Approved Refinish Materials Manual.

Remove the existing finish down to the metal.
Feather-edge the surface.
Apply polyester body filler to fill in the sheet metal step.
Refinish per GM 4901M Approved Refinish Materials Booklet. The information for the 2005 GM Approved Refinish Materials booklet is now available online at the GM Goodwrench® website ONLY. Printed books have been discontinued. Follows these steps to access the site:
1. Go to www.gmgoodwrench.com.
2. Click on GM Collision Parts.
3. Click on GM Technical Repair Information.
4. Click on Paint Shop.
5. Refinish the area using materials compliant to GM4901M standards.

[WopOnTour]

Subject: Water Leak, Wet or Stained Carpet in Trunk, Water or Dirt Accumulates Under Carpet in Spare Tire Well (Inspect Tail Lamp Wiring Harness and Rewrap, If Necessary) #06-08-66-009 - (05/22/2006)

Models: 2005-2006 Saturn ION

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Condition
Some customers may comment on a water leak or wet or stained carpets in the trunk of their vehicle. Other customer comments may include water or dirt accumulation under the carpet or in the spare tire well.

Cause
This condition may have two potential causes:

• Water may enter through the rear tail lamp wire harness sheath.
• Water may enter through the pressure relief valve (PRV) if it is not properly seated. (This occurs much less frequently than the previous potential cause.)

Correction
Inspect the rear compartment (trunk) and use the waterleak test procedures found in the General Information section of SI to diagnose this condition.

• If the source is determined to be the tail lamp wiring harness (i.e., the tail lamp wiring harness is completely wrapped solid with tape instead of in a spiral pattern which allows water to drip out), follow these steps:

1. Remove the tail lamp assembly.
2. Disconnect the wiring harness.
3. Remove the electrical tape. With new tape, re-wrap the harness using a spiral wrapping pattern. Refer to the illustration above.
4. Repeat for the opposite side.

• If source is determined to be the PRV, inspect the PRV and re-seat. Replace the PRV if it is damaged.