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Subject: Customer Satisfaction - Engine Harmonic Balancer Not Seated #05548B - (08/02/2005)
Models: 2005 Chevrolet Uplander
2005 Pontiac Montana SV6
2005 Buick Terraza
2005 Saturn Relay
2005-2006 Chevrolet Malibu, Malibu Maxx
2005-2006 Pontiac G6
2006 Buick Rendezvous
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THIS BULLETIN IS BEING REVISED TO ADD 2005 CHEVROLET UPLANDER; PONTIAC MONTANA SV6, BUICK TERRAZA; SATURN RELAY, 2005-2006 CHEVROLET MALIBU, MALIBU MAXX; PONTIAC G6 AND 2006 BUICK RENDEZVOUS MODEL VEHICLES. PLEASE DISCARD ALL COPIES OF 05548A.
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THIS PROGRAM IS IN EFFECT UNTIL AUGUST 31, 2006.
Condition
Certain 2005 Chevrolet Uplander; Pontiac Montana SV6; Buick Terraza; Saturn Relay; 2005-2006 Chevrolet Malibu, Malibu Maxx; Pontiac G6 and 2006 Buick Rendezvous model vehicles, equipped with a 3.5L V6 (RPO LX9 - VIN L [trucks], VIN 8 [cars]) engine, may have a condition in which the engine harmonic balancer is not completely seated. An engine harmonic balancer that is not completely seated may cause crankshaft key failure. Crankshaft key failure will cause damage to the sprocket and timing gears, cylinder head and valves, pistons and residual internal engine damage. All of these failures may lead to engine repair or replacement.
IMPORTANT: This program will expire on August 31, 2006.
Correction
Dealers are to retorque the harmonic balancer bolt.
Vehicles Involved
Involved are certain 2005 Chevrolet Uplander; Pontiac Montana SV6; Buick Terraza; Saturn Relay; 2005-2006 Chevrolet Malibu, Malibu Maxx; Pontiac G6 and 2006 Buick Rendezvous model vehicles, equipped with a 3.5L V6 (RPO LX9 - VIN L [trucks], VIN 8 [cars]) engine and built within these VIN breakpoints:
Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]
Important: Saturn US Retailers must verify involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Claims will only be paid on involved vehicles.
For US and Canada
For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a facility VIN List file sent to you at your current email address. Retailers will not have a report available if they have no vehicles currently assigned.
For Export
For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned.
The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program.
Parts Information
No parts are required for this service procedure.
Service Procedure
Important: The service procedure contained in this program is different from the service procedure found in the appropriate service manual. As a result, the labor time allowance has been revised to correspond with this new service procedure. In the near future the service manual and labor time guide will be updated with this new information.
2005 Chevrolet Uplander, Pontiac Montana SV6, Buick Terraza, Saturn Relay and 2006 Buick Rendezouv Vehicles Equipped with 3.5L (LX9) Engines
Harmonic Balancer Bolt Torque Procedure
Tools Required
J 43442 Flywheel Holder
Important: If the J 43442 tool is not available, use a pry bar to hold the flywheel in place. A second technician will be required to perform Step 5 if the J 43442 tool is not available.
Raise and support the vehicle. Refer to "Lifting and Jacking the Vehicle," SI document number 688236.
Remove the three bolts retaining the flywheel inspection cover to the transmission, and remove the flywheel inspection cover.
Install the flywheel holder (J 43442). Use a pry bar to hold the flywheel in place if the J 43442 tool is not available.
Remove the four plastic fasteners retaining the right front lower inner splash shield and remove the splash shield.
Notice: Do NOT use an impact wrench to tighten the balancer bolt. Bolt failure may occur.
Important: If the J 43442 tool is not available, use a pry bar to hold the flywheel in place. A second technician will be required to perform Step 5 if the J 43442 tool is not available.
Torque the harmonic balancer bolt to 160 N·m (118 lb ft).
Install the right front lower inner splash shield and the four splash shield fasteners.
Remove the flywheel holder (J 43442), if required.
Install the flywheel inspection cover and the inspection cover bolt.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
Lower the vehicle.
2005 and 2006 Chevrolet Malibu, Malibu Maxx and Pontiac G6 Vehicles Equipped with 3.5L (LX9) Engines
Tools Required
J 37096 Flywheel Holder
Important: If the J 37096 tool is not available, use a pry bar to hold the flywheel in place. A second technician will be required to perform Step 6 if the J 37096 tool is not available.
Harmonic Balancer Bolt Torque Procedure
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle, SI document 1211728.
First Design Oil Pan Transmission Brace Bolts
Second Design Oil Pan Transmission Brace Bolts
Remove the oil pan transmission brace bolts and the oil pan transmission brace.
Remove the two bolts retaining the flywheel inspection cover to the transmission, and remove the flywheel inspection cover.
Notice: There are 11 plastic retainers and three bolts that retain the right front inner splash shield. To gain access to the harmonic balance bolt, however, only three of the 11 plastic retainers are required to be removed. Remove the three most rearward plastic retainers on the right front inner splash shield as shown in the illustration. To avoid damaging the right front inner splash shield and to gain access to the harmonic balancer bolt, gently pull back on the rear portion of the splash shield.
Remove the three most rearward plastic retainers retaining the right front inner splash shield.
Install the flywheel holder (J 37096). Use a pry bar to hold the flywheel in place if the J 37096 tool is not available.
Notice: Do NOT use an impact wrench to tighten the harmonic balancer bolt. Bolt failure may occur.
Important: If the J 37096 is not available, use a pry bar to hold the flywheel in place. A second technician will be required to perform Step 6 if the J 37096 tool is not available.
Torque the harmonic balancer bolt to 160 N·m (118 lb ft).
Install the three most rearward plastic retainers on the right front inner splash shield.
Remove the flywheel holder (J 37096), if required.
Install the flywheel inspection cover and flywheel inspection cover bolt.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
First Design Oil Pan Transmission Brace Bolts
Second Design Oil Pan Transmission Brace Bolts
Install the oil pan transmission brace and the oil pan transmission brace bolts.
• If the vehicle is equipped with first design oil pan transmission brace, refer to first design illustration and perform steps 11-14.
• If the vehicle is equipped with second design oil pan transmission brace, refer to second design illustration and proceed to step 15.
Tighten, but do not torque, the oil pan brace bolt (2).
Torque the transmission brace bolt (4) to 50 N·m (37 lb ft).
Torque the oil pan brace bolt (3) to 50 N·m (37 lb ft).
Torque the oil pan brace bolt (2) to 50 N·m (37 lb ft).
Tighten the oil pan transmission brace bolts to 30 N·m (22 lb ft).
Lower the vehicle.
Models: 2005 Chevrolet Uplander
2005 Pontiac Montana SV6
2005 Buick Terraza
2005 Saturn Relay
2005-2006 Chevrolet Malibu, Malibu Maxx
2005-2006 Pontiac G6
2006 Buick Rendezvous
--------------------------------------------------------------------------------
THIS BULLETIN IS BEING REVISED TO ADD 2005 CHEVROLET UPLANDER; PONTIAC MONTANA SV6, BUICK TERRAZA; SATURN RELAY, 2005-2006 CHEVROLET MALIBU, MALIBU MAXX; PONTIAC G6 AND 2006 BUICK RENDEZVOUS MODEL VEHICLES. PLEASE DISCARD ALL COPIES OF 05548A.
--------------------------------------------------------------------------------
THIS PROGRAM IS IN EFFECT UNTIL AUGUST 31, 2006.
Condition
Certain 2005 Chevrolet Uplander; Pontiac Montana SV6; Buick Terraza; Saturn Relay; 2005-2006 Chevrolet Malibu, Malibu Maxx; Pontiac G6 and 2006 Buick Rendezvous model vehicles, equipped with a 3.5L V6 (RPO LX9 - VIN L [trucks], VIN 8 [cars]) engine, may have a condition in which the engine harmonic balancer is not completely seated. An engine harmonic balancer that is not completely seated may cause crankshaft key failure. Crankshaft key failure will cause damage to the sprocket and timing gears, cylinder head and valves, pistons and residual internal engine damage. All of these failures may lead to engine repair or replacement.
IMPORTANT: This program will expire on August 31, 2006.
Correction
Dealers are to retorque the harmonic balancer bolt.
Vehicles Involved
Involved are certain 2005 Chevrolet Uplander; Pontiac Montana SV6; Buick Terraza; Saturn Relay; 2005-2006 Chevrolet Malibu, Malibu Maxx; Pontiac G6 and 2006 Buick Rendezvous model vehicles, equipped with a 3.5L V6 (RPO LX9 - VIN L [trucks], VIN 8 [cars]) engine and built within these VIN breakpoints:
Important: GM Dealers and Canadian Saturn Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]
Important: Saturn US Retailers must verify involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Claims will only be paid on involved vehicles.
For US and Canada
For GM dealers and Canadian Saturn Retailers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. For U.S. Saturn Retailers only, the involved vehicles are provided in a facility VIN List file sent to you at your current email address. Retailers will not have a report available if they have no vehicles currently assigned.
For Export
For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned.
The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program.
Parts Information
No parts are required for this service procedure.
Service Procedure
Important: The service procedure contained in this program is different from the service procedure found in the appropriate service manual. As a result, the labor time allowance has been revised to correspond with this new service procedure. In the near future the service manual and labor time guide will be updated with this new information.
2005 Chevrolet Uplander, Pontiac Montana SV6, Buick Terraza, Saturn Relay and 2006 Buick Rendezouv Vehicles Equipped with 3.5L (LX9) Engines
Harmonic Balancer Bolt Torque Procedure
Tools Required
J 43442 Flywheel Holder
Important: If the J 43442 tool is not available, use a pry bar to hold the flywheel in place. A second technician will be required to perform Step 5 if the J 43442 tool is not available.
Raise and support the vehicle. Refer to "Lifting and Jacking the Vehicle," SI document number 688236.
Remove the three bolts retaining the flywheel inspection cover to the transmission, and remove the flywheel inspection cover.
Install the flywheel holder (J 43442). Use a pry bar to hold the flywheel in place if the J 43442 tool is not available.
Remove the four plastic fasteners retaining the right front lower inner splash shield and remove the splash shield.
Notice: Do NOT use an impact wrench to tighten the balancer bolt. Bolt failure may occur.
Important: If the J 43442 tool is not available, use a pry bar to hold the flywheel in place. A second technician will be required to perform Step 5 if the J 43442 tool is not available.
Torque the harmonic balancer bolt to 160 N·m (118 lb ft).
Install the right front lower inner splash shield and the four splash shield fasteners.
Remove the flywheel holder (J 43442), if required.
Install the flywheel inspection cover and the inspection cover bolt.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
Lower the vehicle.
2005 and 2006 Chevrolet Malibu, Malibu Maxx and Pontiac G6 Vehicles Equipped with 3.5L (LX9) Engines
Tools Required
J 37096 Flywheel Holder
Important: If the J 37096 tool is not available, use a pry bar to hold the flywheel in place. A second technician will be required to perform Step 6 if the J 37096 tool is not available.
Harmonic Balancer Bolt Torque Procedure
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle, SI document 1211728.
First Design Oil Pan Transmission Brace Bolts
Second Design Oil Pan Transmission Brace Bolts
Remove the oil pan transmission brace bolts and the oil pan transmission brace.
Remove the two bolts retaining the flywheel inspection cover to the transmission, and remove the flywheel inspection cover.
Notice: There are 11 plastic retainers and three bolts that retain the right front inner splash shield. To gain access to the harmonic balance bolt, however, only three of the 11 plastic retainers are required to be removed. Remove the three most rearward plastic retainers on the right front inner splash shield as shown in the illustration. To avoid damaging the right front inner splash shield and to gain access to the harmonic balancer bolt, gently pull back on the rear portion of the splash shield.
Remove the three most rearward plastic retainers retaining the right front inner splash shield.
Install the flywheel holder (J 37096). Use a pry bar to hold the flywheel in place if the J 37096 tool is not available.
Notice: Do NOT use an impact wrench to tighten the harmonic balancer bolt. Bolt failure may occur.
Important: If the J 37096 is not available, use a pry bar to hold the flywheel in place. A second technician will be required to perform Step 6 if the J 37096 tool is not available.
Torque the harmonic balancer bolt to 160 N·m (118 lb ft).
Install the three most rearward plastic retainers on the right front inner splash shield.
Remove the flywheel holder (J 37096), if required.
Install the flywheel inspection cover and flywheel inspection cover bolt.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
First Design Oil Pan Transmission Brace Bolts
Second Design Oil Pan Transmission Brace Bolts
Install the oil pan transmission brace and the oil pan transmission brace bolts.
• If the vehicle is equipped with first design oil pan transmission brace, refer to first design illustration and perform steps 11-14.
• If the vehicle is equipped with second design oil pan transmission brace, refer to second design illustration and proceed to step 15.
Tighten, but do not torque, the oil pan brace bolt (2).
Torque the transmission brace bolt (4) to 50 N·m (37 lb ft).
Torque the oil pan brace bolt (3) to 50 N·m (37 lb ft).
Torque the oil pan brace bolt (2) to 50 N·m (37 lb ft).
Tighten the oil pan transmission brace bolts to 30 N·m (22 lb ft).
Lower the vehicle.