Customer Satisfaction - Engine Harmonic Balancer Not Seated

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.

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.

Dealers are to retorque the harmonic balancer bolt.

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.

No parts are required for this 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.

1. Raise and support the vehicle. Refer to "Lifting and Jacking the Vehicle," SI document number 688236.



2. Remove the three bolts retaining the flywheel inspection cover to the transmission, and remove the flywheel inspection cover.



3. Install the flywheel holder (J 43442). Use a pry bar to hold the flywheel in place if the J 43442 tool is not available.



4. 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.

5. Torque the harmonic balancer bolt to 160 N·m (118 lb ft).



6. Install the right front lower inner splash shield and the four splash shield fasteners.



7. Remove the flywheel holder (J 43442), if required.



8. Install the flywheel inspection cover and the inspection cover bolt.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

9. 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

1. 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




2. Remove the oil pan transmission brace bolts and the oil pan transmission brace.



3. 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.

4. Remove the three most rearward plastic retainers retaining the right front inner splash shield.



5. 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.

6. Torque the harmonic balancer bolt to 160 N·m (118 lb ft).
7. Install the three most rearward plastic retainers on the right front inner splash shield.



8. Remove the flywheel holder (J 37096), if required.
9. 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




10. 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.

11. Tighten, but do not torque, the oil pan brace bolt (2).
12. Torque the transmission brace bolt (4) to 50 N·m (37 lb ft).
13. Torque the oil pan brace bolt (3) to 50 N·m (37 lb ft).
14. Torque the oil pan brace bolt (2) to 50 N·m (37 lb ft).
15. Tighten the oil pan transmission brace bolts to 30 N·m (22 lb ft).
16. Lower the vehicle.

The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

Submit a Product Recall Claim with the information indicated below.

Refer to the General Motors WINS Claim Processing Manual for details on Product Recall Claim Submission.

1. To receive credit, submit a claim with the information below:

2. Check your Saturn SERVICELINE.XL Claim Memorandum daily. Remember to code the claim as a WC sale type, and VC case type. Contact your field representative if you need assistance.

General Motors and Saturn will notify customers of this program on their vehicle (see copy of GM customer letter included with this bulletin). The Saturn customer letter is similar.

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.

All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles.

Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through August 31, 2006.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service prior to September 1, 2006, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

This notice is sent to inform you that General Motors is conducting a customer satisfaction program that affects 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 engine.

We have learned that your vehicle may have been built with an engine harmonic balancer that is not completely seated. An engine harmonic balancer that is not completely seated may cause crankshaft key failure and lead to internal engine damage requiring engine repair or replacement.

To prevent this condition from occurring, your GM dealer will retorque the engine harmonic balancer bolt. This service will be performed for you at no charge until August 31, 2006 .

We recommend that you contact your dealer to arrange a service date. Presenting the enclosed customer reply form to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please check the appropriate box and provide the new owner information, if available.

The enclosed customer reply form identifies your vehicle. Presentation of this form to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us.

If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. The Customer Assistance Center’s hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

If your vehicle is within the New Vehicle Limited Warranty your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner’s Manual and your dealer for details on Courtesy Transportation.

The Owner Center at My GMLink, which is a free online service, offers vehicle and ownership-related information along with tools tailored to your specific vehicle. To join, visit www.gm.com/recall and enter your vehicle's 17-character vehicle Identification number (VIN), shown on the enclosed customer reply form.

We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving.

General Motors Corporation

Enclosure

05548B