Product Emission - PCM Integrated Circuit Chip Damage-Replace PCM

THIS BULLETIN IS BEING REVISED TO ADD 2005 AND 2006 MODEL YEAR VEHICLES TO THE RECALL. PLEASE DISCARD ALL COPIES OF 05539.

General Motors has decided to conduct a Voluntary Emission Recall involving certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6. Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles. The Powertrain/Engine Control Module (PCM/ECM) in these vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints.

Dealers are to replace the Powertrain/Engine Control Module (PCM / ECM).

Involved are certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6, Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles 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 U.S. retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. Recall 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 attachment to the Saturn Bulletin, located on DealerWorld.. Dealers/Retailers will not have a report available if they have no involved 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 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" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order.

A pre-shipment of the required parts to perform this program has been sent to involved Saturn U.S. retailers from Saturn Service Parts Operations (SSPO).

Important: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information.

Prep the vehicle for PCM / ECM replacement. Refer to PCM / ECM replacement in the appropriate vehicle SI service manual and replace the PCM / ECM. The following SI document numbers are for your reference:

CALIFORNIA, MASSACHUSETTS, MAINE, & VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof Of Correction" certificate upon recall completion.

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle.

When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering.

Important: (GM Dealers Only) Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Request Item Number S-1015 when ordering.

Important: (Saturn U.S. Dealers Only) Additional Recall Identification Labels may be ordered from Saturn publications (1-800-828-2112, prompt 3, Item Number S03 00013A for the Recall Identification Label, and item number S03 00013B for the Clear Protective Cover).

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 Claim Processing Manual for details on Product Recall Claim Submission.

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

* The parts allowance should be the sum total of the current SSPO Retailer net price plus 40% of all parts required for the repair.

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

In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed.

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.

In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed.

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.

***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT***

When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration.

Additional Certificates can be obtained, at no charge, from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for GM Item Number 1825 when ordering.

Dear General Motors Customer:

This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle.

General Motors has decided that the Powertrain/Engine Control Modules (PCM/ECM) in certain 2005 Chevrolet Malibu, Uplander, Equinox, Classic, Silverado; GMC Sierra; Pontiac Sunfire, Grand Am, G6 Grand Prix, Montana SV6; Buick LaCrosse/Allure, Terraza; Saturn Relay; and 2006 Pontiac G6 model vehicles may have been manufactured with damaged internal IC chips, which may affect the Fuel Pump Control and the EGR outputs of the PCM; or the Fuel Pump Control and Variable Nozzle Turbo Control (VNTC) outputs of the Diesel ECM. Customers may experience illumination of the Malfunction Indicator Lamp (MIL) or driveability complaints.

Your dealer will replace the Powertrain / Engine Control Module (PCM / ECM). This service will be performed for you at no charge.

This service correction will take approximately 40 to 70 minutes. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle.

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.

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 card 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.

In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished.

In order to assure your full protection under the emission warranty provisions, it is recommended that you have your (vehicle or engine) serviced as soon as possible. Failure to do so could legally be determined as lack of proper maintenance of your (vehicle or engine). Failure to reprogram the PCM may cause your vehicle to fail a state or local emission inspection or I/M smog check test.

The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration.

At the time of emission recall completion, your California dealer will issue a "Proof Of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion.

This free online service offers vehicle and ownership related information and tools tailored to your specific vehicle. To get the most personalized information for your vehicle, visit www.mygmlink.com , and enter your vehicle's 17-character vehicle identification number (VIN) shown on the enclosed customer reply form.

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

General Motors Corporation

Enclosure

05539