This Safety Recall replaces Safety Recall 06515 because vehicles repaired under that service procedure may experience throttle icing under certain conditions.
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 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 the new Throttle Body PCV Valve kit by following the detailed service procedure.
Involved are 2004 - 2005 Chevrolet Aveo and 2005 Pontiac Wave model vehicles sold in Canada, equipped with a 1.6L 4-cylinder (RPO L91 - VIN 6) engine and built within these VIN breakpoints:
Year
Division
Model
From
Through
2004
Chevrolet
Aveo
4B094570
4B278323
2005
5B269067
5B494156
Pontiac
Wave
5B269062
5B494077
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 listing of affected vehicles containing the complete vehicle identification number, customer name, and address information 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 listing 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 Pre-Ship Information:
Important: An initial supply of PCV Valve Kit (P/N 96892259) and Crankcase Breather Tube Insulation (P/N 96941983) required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled for November 20, 2007 and will be approximately 10% of each dealer’s involved vehicles. Pre-shipped parts will be charged to dealer’s open parts account.
Additional parts, if required, are to be obtained from General Motors Service and 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.
Part Number
Description
Qty/ Vehicle
96892259
Kit, PCV Valve
1
96941983
Insulation, Crankcase Breather Tube
88862158 (CN)
Antifreeze, Radiator 1L
As required
Important: Before starting, please watch the Product Safety Bulletin Number 07047 Service Procedure Video on the GM Service and Parts Operations website (http://service.gm.com/index_en-CA.html (English)), or (http://service.gm.com/ index_fr-CA.html (French)), then select "Service Information". Read all of the information provided in this service procedure carefully before installing the PCV Kit. Failure to install the PCV Kit as outlined in the service procedure may result in personal injury and/or part damage.
Notice: If the vehicle was towed in due to throttle body icing, the vehicle will have to be thawed out. The engine will need to run at idle for two hours before shutting off the engine. Then the engine oil and filter will have to be changed before starting this service procedure.
Important: Product Safety Bulletin Number 07047 replaces Product Safety Bulletin Numbers 05521 and 06515.
Important: The Inspection Checklist at the end of this Service Procedure is necessary to ensure that the critical steps in Safety Recall bulletin 07047 have been performed correctly, and requires the signature of the Service Manager or designated Inspector.
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.
Once the nuts are jammed together turn counterclockwise to remove the stud bolt (1). Repeat the process for the other stud bolts then discard all three stud bolts.
Caution: Extreme care must be taken not to damage the intake manifold port when using the reamer tool.
Important: Special Tool EN-48981 Reamer and the Brass Sleeve are required for this procedure. Your Dealership should have received the reamer by Mid-October 2007 (SPX- Kent Moore 1-800-GM-TOOLS) and the brass sleeve in November 2007.
Prior to starting the reaming procedure on the intake manifold port, ensure that the intake manifold is at shop temperature.
Important: Take your time reaming the port and do not push down hard or force the tool through the port. Excess force could result in cracking the intake manifold port during the reaming operation.
Important: Retain Special Tool EN-48981 Reamer and the Brass Sleeve for the next Product Safety Bulletin 07047 to be performed.
Important: If the intake manifold requires replacing due to damage caused by the reaming process (1), the new intake manifold MAP sensor vacuum port may also require reaming to 6mm using the reaming operation outlined in this bulletin.
Tighten Tighten the MAP sensor bracket bolt/screw (3) to 10-12 N·m (90 lb in).
Important: The MAP sensor hose and bracket position (1) is critical. The hose should not contact the MAP sensor bracket (see above).
Tighten Tighten the MAP sensor bolt/screw (2) to 10-12 N·m (90 lb in).
Tighten Tighten the four throttle body adapter bolts/screws to 10-12 N·m (90 lb in).
Important: The routing of the throttle body coolant hoses is very critical.
Important: The picture above is for illustration purposes only. The intent is to show the correct routing of the coolant hoses with the paint mark facing upwards and connected at the PCV valve assembly.
Ensure both connectors are fully engaged by lightly pulling on them.
Tighten Tighten the accelerator cable clamp bolt to 10-12 N·m (90 lb in).
Tighten Tighten the accelerator cable bracket bolt to 10-12 N·m (90 lb in).
Install the IAT sensor connector. Ensure proper connection by lightly pulling on the connector.
Coolant hose spring clip contact with the throttle body accelerator cable cam.
Important: When handling the fiberglass crankcase breather tube insulation sleeve you may want to wear gloves.
Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle while the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end the components are being removed, and strap the vehicle to the hoist.
Important: Make sure that the insulator sleeve is bottomed out against the engine block.
Important: The worm clamp should be installed toward the back of the valve cover with the clamp screw (1) positioned up so that the engine cover will install properly.
Open the worm clamp (1) p/n 94530121. Install and secure the clamp around the external ventilation hose.
Important: If Recall 05521 was not performed, you must install engine oil filler cap P/N 96469205.
Important: Make sure that the Throttle Control Cable Does Not Hold the Throttle Open. With the Engine OFF, Check to See That the Accelerator Pedal is Free.
On a properly adjusted throttle cable, the metal cable (1) should be no higher than the top on the cam groove. If the cable is too high or loose remove clip (3) pull back on cable casing (4) away from throttle body until cable (1) at cam is no higher than the top of the groove.
Caution: Failure to install the PCV Kit as outlined in the service procedure may result in personal injury and/or part damage.
The purpose of this inspection checklist is to ensure that the critical steps in Safety Recall bulletin 07047 have been performed correctly. The revised Throttle Body, PCV Valve and Crankcase Ventilation system is designed to ensure that the accumulation of moisture in the crankcase is kept to a minimum, and any moisture that accumulates is allowed to pass through the PCV system without freezing . Doing so will prevent ice buildup and the potential for throttle freezing in extreme cold temperatures. It is CRITICAL that the following step have been performed and installed exactly as described in the bulletin service procedure. Failure to do so could cause the procedure to be ineffective and thus, cause risk to our customers. Please verify that the following service procedures have been completed correctly:
1. MAP Sensor Lower Intake Manifold port was enlarged from 4mm to 6mm with the GM Special Tool EN-48981 reamer and brass sleeve. Refer to Service Procedure steps 19-22 in this service bulletin.
2. Installation of the copper washer (gasket) provided in the kit under the right upper bolt. Refer to Service Procedure step 32 in this service bulletin.
3. The attaching hoses must have the white paint mark at the PCV valve assembly. Refer to Service Procedure steps 36 in this service bulletin.
4. Installation of the protective webbing sleeve over the coolant inlet hose close to the foam insulator. Refer to Service Procedure step 37 in this service bulletin.
5. Ensure that the accelerator bracket retaining plate is positioned with the rounded corner oriented upwards and the depression is oriented toward the mounting bolt head. The bracket retaining plate should not protrude beyond the intake manifold mounting tab. This is critical for proper throttle cable alignment and operation. Refer to Service Procedure step 45 in this service bulletin.
6. Ensure that the insulator sleeve over the external crankcase ventilation pipe assembly to the engine block/crankcase is installed correctly. Refer to Service Procedure step 54 in this service bulletin.
Circle Yes or No for each inspection point question. If any inspection point is circled "No", return the vehicle to the technician for repair correction.
1. Did the Service Manager or designated inspection person view the product Safety Recall Bulletin Number 07047 Service Procedure Video? Yes -- No
2. Was GM Special Tool EN-48981 reamer and brass sleeve used to enlarge the MAP sensor vacuum port at the intake manifold? Yes -- No
3. Was Recall 05521 performed? If the Recall was not performed, did you install the correct engine oil filter cap p/n 96469205? Yes -- No
4. Were the MAP sensor, MAP sensor bracket, and vacuum hoses re-located and correctly positioned to the new location on the intake manifold? Yes -- No
5. Was the new PCV valve installed with Teflon tape on the threads and installed at a horizontal plane? Yes -- No
6. Were the throttle body assembly and all hoses installed correctly? Yes -- No
7. Was the accelerator cable bracket re-located to the old MAP sensor bracket location on the intake manifold? Yes -- No
8. Was the accelerator cable adjusted per the service information in this bulletin? Yes -- No
9. Was the new crankcase breather tube insulator sleeve installed correctly over the external ventilation pipe assembly to the engine block? Yes -- No
Important: Print this checklist and staple it to the dealer copy of the repair order.
The service procedure was performed as written in Safety Recall Bulletin 07047. The service procedure and inspection of the critical steps included in the service procedure were completed on _________________(M/D/Y).
VIN ____________________________________
Signature of Service Manager / Inspector: ____________________________________
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:
Repair Performed
Part Count
Part No.
Parts Allow
CC-FC
Labour Op
Labour Hours
Net Item
Complete full installation of new PCV kit.
--
*
MA-96
V1708
1.2
**
Add: Idle Learn Procedure A/C
0.3
Idle Learn Procedure no A/C
0.2
Change Engine Oil, only if vehicle was towed in due to icing.
0.4
Courtesy Transportation for vehicles within the New Vehicle Limited Warranty (US & Canadian GM Dealers)
N/A
***
****
* The "Parts Allowance" should be the sum total of the current GMSPO Dealer net price plus applicable Mark-Up for PCV kit needed to complete the repair.
** The amount identified in the "Net Item" column should represent the actual sum total of the current GMSPO Dealer net price plus applicable Mark-Up for coolant needed to perform the required repairs.
*** Submit courtesy transportation using normal labour operations for courtesy transportation as indicated in the GM Service Policies and Procedures Manual for vehicles within the New Vehicle Limited Warranty.
**** The amount identified in the "Net Item" column should represent the actual dollar amount for courtesy transportation.
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:
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. As a result, GM is conducting a safety recall.
Some of these vehicles may experience 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.
You may have previously received safety recall letters (ref # 05521 and 06515) for this condition and may have had the repairs performed at your GM dealership. However, the repairs may not have been effective in preventing the throttle icing condition. Therefore, we are asking you to schedule another appointment at your GM dealership to correct this condition at no charge. If the earlier recalls were not completed on your vehicle, you should schedule an appointment at your GM dealership to complete this repair at no charge.
To limit any possible inconvenience, we recommend that you contact your General Motors 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.
You may be contacted by a dealer other than the dealer who sold or is currently servicing your vehicle. Please be advised that you may take your vehicle to the General Motors dealership of your choice to have the recall service work completed.
This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.
We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products.
Customer Support Department
General Motors of Canada Limited
07047
