Service Update for Inventory and Customer Vehicles-Air Inlet Panel to Windshield Gap-Water Intrusion into Engine Compartment-Expires with Base Warranty

THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER/RETAILER INVENTORY AND CUSTOMER VEHICLES THAT RETURN FOR ANY TYPE OF SERVICE, AND WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD.

This bulletin provides a service procedure to eliminate an area of possible water intrusion into the engine compartment. There may be a gap between the air inlet panel and the windshield that could allow water to run into the engine compartment, causing the engine to run rough or misfire.

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

A list of involved vehicles currently in dealer/retailer inventory is attached to the Administrative Message (GM and Saturn US) or 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/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.

-- GM dealers and Canadian Saturn retailers should use GMVIS.

-- US Saturn retailers should use the AS/400 system.

Parts required to complete this service update 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.

If you do not already have an equivalent rust preventative lubricant on hand, you may place an order to GMSPO. This is the same lubricant used in Product Enhancement bulletin 06224.

A pre-shipment of part number 11570645 has been sent to Saturn US retailers that are involved in this service update. If you do not already have an equivalent rust preventative lubricant on hand, you may place an order to Saturn Service Parts Operation. This is the same lubricant used in Product Enhancement bulletin 06224.

Important: Note the air inlet panel gap to window, which is about 2 mm (5/64 in). Installing a retainer into the air inlet panel is required to remove the gap.





Important: Position the wiper arms away from the air inlet panel before measuring or drilling the hole into the air inlet panel.

1. Drill a hole (1) through the air inlet panel and plenum sheet metal 112 mm (4.4 in) cross vehicle from the center of the passenger-side wiper pivot (2) and 45 mm (1.8in) forward of windshield lace (3). Use an 8.5 mm (5/16 in) drill bit to drill the hole.
2. Treat exposed sheet metal around the location of the hole with GM Vehicle Care Synthetic Lubricant with Teflon or equivalent.

2.1.	Ensure that the area around the hole is dry and clean. Remove any debris and/or water from the hole area with an air tool and shop towel.

2.2.	Apply GM Vehicle Care Synthetic Lubricant with Teflon, or equivalent, to the metal around the hole. Use a Q-Tip or equivalent cotton swab to apply the lubricant.




3. Install the retainer (push pin) (1) into the air inlet grille panel.

For vehicles repaired under this service update, use:

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