Product Safety - Throttle Body Icing - Install PCV Kit

General Motors has decided that a defect, which relates to motor vehicle safety, exists in 2004 - 2005 Chevrolet Aveo and 2005 Pontiac Wave model vehicles, equipped with a 1.6L 4-cylinder (RPO L91 - VIN 6) engine and sold in Canada. Some of these vehicles have a condition in which the engine throttle may stick open due to throttle body icing in temperatures near or below -20 degrees Celsius in high humidity environments after an initial cold engine start or while driving. If the engine throttle sticks open while the vehicle is moving, a crash could result without prior warning.

Dealers are to install a new PCV system kit.

Involved are all 2004 - 2005 Chevrolet Aveo and 2005 Pontiac Wave model vehicles equipped with a 1.6L 4-cylinder (RPO L91 - VIN 6) engine and built within these VIN breakpoints:

* Due to assembly plant non-sequence vehicle build, some vehicles will require a visual engine inspection before determining the correct kit application.

Important: GM dealers 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.]

For GM dealers, 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 GMinfoNet (Canada) Recall Reports. Dealers will not have a report available 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 recall 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 recall.

Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

Important: Hose Kit 2 contains 2 more parts (a new design air cleaner elbow and breather) than contained in Kit 1. 75% of the recalled population will require Kit 2, with the extra parts. Please order part kits accordingly.

Important: The labor time allowance listed in this recall is new. In the near future, the labor time guide will be updated with this new information.

Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

Important: Compare the vehicle air cleaner outlet duct with the first and second designs on page 9 of this bulletin to determine what kit is required to complete the repair.

1. Disconnect the negative battery cable.



2. Remove the air cleaner intake duct.

2.1.	Disconnect the electrical connector from the intake air temperature (IAT) sensor.

2.2.	Disconnect the breather tube from the crankcase ventilation tube.

2.3.	Remove the air cleaner intake duct.




3. Disconnect the idle air control (IAC) valve connector.



4. Disconnect the throttle position (TP) sensor connector.




Caution: To avoid being burned, do not remove the radiator cap, surge tank cap or coolant hoses while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap, surge tank cap or a coolant hose is removed while the engine and radiator are still hot.

5. Remove the coolant inlet/outlet hose from the backside of the throttle body.



6. Remove the crankcase ventilation hose from the throttle body. Discard the crankcase ventilation hose.




Caution: To avoid being burned, do not remove the radiator cap, surge tank cap or coolant hoses while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap, surge tank cap or a coolant hose is removed while the engine and radiator are still hot.

7. Remove the coolant outlet hose and ABS test connector (if equipped) from the coolant surge tank side of the throttle body. Discard the coolant outlet hose.



8. Remove the bottom throttle body retaining bolt. Discard the retaining bolt.

Important: Apply Super Lube® multi purpose lubricant, P/N 12346241, or equivalent to the inside ends of the coolant hoses and crankcase ventilation tubes before installing the A1-PCV T/Body hose assembly, P/N 96469943 (from the kit).

9. Install the A1-PCV T/Body hose assembly, P/N 96469943.




9.1.

Tie wrap the protective material (from the kit) around the backside of the throttle body portion of the crankcase ventilation tube of the A1-PCV T/Body hose assembly, as shown in illustration 1692477. The length of the protective material should be 10 mm (0.39 in.) longer than the end of the crankcase tube. The tie strap must be located on the curved portion of the A1-PCV T/Body pipe. Do not tie wrap the hose above the curved portion of the pipe. Remove excess tie strap.

9.2.	Install the A1-PCV T/Body hose assembly to the rear of the throttle body.

9.3.

Install the backside of the throttle body portion of the new crankcase ventilation tube of the A1-PCV T/Body hose assembly to the pipe on the backside of the throttle body. Insert a second tie strap through the space under the throttle body in order to tie wrap the protective material near the tube opening. Remove excess tie strap.

9.4.	Install a new bolt, P/N 94500416 (from the kit), through the hole of the A1-PCV T/Body hose assembly bracket.

9.5.	Install the backside portion of the new coolant inlet/outlet hose of the A1-PCV T/Body hose assembly to the throttle body





9.6.	Install the new coolant outlet hose, P/N 96469324 (from the kit), to the coolant surge tank and the side of the throttle body.

9.7.	Install the crankcase ventilation hose to the cam cover and A1-PCV T/Body assembly.

9.8.	Tie wrap the crankcase ventilation hose to the coolant outlet hose, P/N96469324.

9.9.	Install and tie wrap the anti-lock brake system (ABS) test connector on vehicles equipped with ABS.





Caution: To avoid being burned, do not remove the radiator cap, surge tank cap or coolant hoses while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap, surge tank cap or a coolant hose is removed while the engine and radiator are still hot.

9.10.

Disconnect the radiator upper hose at the side of the thermostat.





9.11.

Disconnect the coolant inlet hose to the thermostat. Discard the coolant inlet hose.

9.12.

Connect the new coolant inlet hose of the A1-PCV T/Body hose assembly to the thermostat.

9.13.

Connect the radiator upper hose.




10. Install the IAC valve connector.



11. Install the TPS connector.

First Design (1) and Second Design (2) Air Cleaner Outlet Duct and Breather Hose.





Important: Vehicles produced before December 2004 contain the first design air cleaner assembly and will require the removal of the existing air cleaner outlet duct and breather hose; and the installation of the second design air cleaner outlet duct, P/N96439858, and the second design breather hose, P/N96437830 from Kit 2 . Vehicles produced during and after December 2004 contain the second design air cleaner assembly and will not require installation of the new air cleaner outlet duct and breather hose. Please use Kit 1 on these later vehicles and reuse the existing air cleaner outlet duct and breather hose. Refer to VIN breakpoint information in this bulletin.




12. Install the air cleaner outlet duct. Reuse the old screw band on the second design air cleaner duct.
13. Install the breather hose to air cleaner duct.
14. Install the IAT sensor connector.
15. Replace the oil filler cap with the new oil filler cap, P/N 96469205 (from the kit).
16. Connect the negative battery cable.
17. Add required engine coolant to the coolant system, P/N 993089, (12378560-US), or equivalent. Refer to SI document 1298421.

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 recall 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 Claims Processing Manual for details on Product Recall Claim Submission.

General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).

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

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

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. Recall 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 recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

General Motors has decided that a defect, which relates to motor vehicle safety, exists in all 2004 - 2005 Chevrolet Aveo and 2005 Pontiac Wave model vehicles equipped with a 1.6L 4-cylinder engine. Some of these vehicles have a condition in which the engine throttle may stick open due to throttle body icing in temperatures near or below -20 degrees Celsius in high humidity environments after an initial cold engine start or while driving. If the engine throttle sticks open while the vehicle is moving, a crash could result without prior warning.

Your GM dealer will install a new Positive Crankcase Ventilation (PCV) kit. This service will be performed for you at no charge .

This service correction will take approximately 55 minutes. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the listed number below. The Customer Assistance Center’s hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

If, after contacting the appropriate Customer Assistance Center, you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 40990; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov.

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 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.

More information about this recall, including answers to frequently asked questions, can be found at the Owner Center at My GMLink. This 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.

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products.

General Motors Corporation

Enclosure

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