Service Update for Inventory and Customer Vehicles-Alternator Regulator Corrosion

THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN TO THE DEALERSHIP FOR ANY REASON. IT WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD.

This bulletin provides a service procedure to apply silicon adhesive to seal the regulator hole on certain 2009 Chevrolet Aveo and Pontiac G3 Wave vehicles. On some of these vehicles, water may enter the regulator hole, causing corrosion.

This service procedure should be completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period.

A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in DealerWorld (US) or attached to the Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below.

Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved.

Parts required to complete this service update 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.

1. Open the engine hood.
2. Disconnect the negative battery cable.



3. Lift up the vehicle. Refer to Lifting and Jacking the Vehicle in SI. The alternator (1) is located behind the center side of the engine.



4. Disconnect the B+ terminal (1) and the regulator connector (2).



5. Remove the alternator rear cover by removing the two cover screws (1) with a 13mm socket.



6. Apply 10 g (0.4 oz) of the silicon sealant into the regulator hole (1) with the injector.
7. Install the alternator rear cover and tighten.

Tighten
Tighten the two nuts to 20 N·m (15 lb ft).




8. Connect the B+ terminal and tighten the nut (1).

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

9. Connect the regulator connector (2).
10. Connect the negative battery cable.

For vehicles repaired under this service update, use:

* The amount identified in the "Net Item" column should represent the actual sum total of the current GMSPO Dealer net price for the adhesive needed to perform the required repairs, not to exceed $1.00 USD, $1.06 CAD, plus applicable Mark-Up or Landed Cost (for Export).