Campaign - ECM/TCM/Wiring Update For Battery Charging: Overview
Subject:Customer Satisfaction - Battery Not Charging-Limited Drive Time
# 07195 - (08/24/2007)
Models:
2007 Saturn VUE Green Line
Condition
On certain 2007 Saturn VUE Green Line vehicles, when high resistance in the resolver circuit is detected, recharging of the 12-volt battery stops. If this occurs, the battery light or check engine light will be on, the charge assist gauge will not move, and hybrid operation (such as engine shutdown when stopped) is disabled. When the 12-volt battery is not being recharged, the vehicle can only be driven for approximately 20 to 60 minutes, depending on the electrical accessories being used, before the engine will stop running and potentially not restart. If the vehicle is turned off and then restarted when the condition is first observed, the system may reset and the battery warning light will go off. The vehicle will operate as intended; however, the condition may occur again the next time the ignition is turned on.
Correction
Retailers are to add a wire harness and reprogram the engine control module (ECM) and transmission control module (TCM).
Vehicles Involved
Important:
Retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s). Not all vehicles within the above breakpoints may be involved.
-- Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Retailers will not have a report available if they have no involved vehicles currently assigned.
- Canadian Saturn/Saab retailers - GMinfoNet Recall Reports
- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
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 program 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 program.
Parts Information
Canadian Saturn/Saab Retailers: Parts required to complete this program 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.
US Saturn Retailers: A pre-shipment of the required part to perform this repair has been sent to involved Saturn US retailers from Saturn Service Parts Operations (SSPO).
Service Procedure
DO NOT REPLACE THE SGCM, THE STARTER/GENERATOR (MGU), OR THE ENGINE WIRING HARNESS.
1. Reprogram the engine control module (ECM) with TIS2WEB, version 8.5 or later.
2. Reprogram the transmission control module (TCM) with TIS2WEB, version 8.5 or later.
3. Install an engine wiring harness jumper (between the SGCM and MGU) using the following procedure:
3.1. Perform the Hybrid Battery Service Disconnect procedure found in SI.
3.2. Disconnect the 12-volt battery negative cable.
3.3. Remove the air cleaner outlet duct.
3.4. Disconnect the SGCM C1 (Black) and C2 (Grey) connectors.
3.5. Reroute the SGCM C1 (Black) connector so that it is underneath the vacuum hose.
3.6. Remove the conduit and tape between the SGCM C2 (Grey) connector and the main harness.
3.7. From the C2 connector, carefully remove the following four circuits from the old 24W connector. These four circuits will be installed in the new SGCM C2 connector in the wiring harness jumper.
Tip
To remove the circuit/terminal from the connector, remove the clear cover, then while pulling up on the white "finger", slightly pull up on the pin while pushing it in. Refer to the C2 Connector Circuit/Terminal Removal diagram.
C2 Connector - Circuit/Terminal Removal
Important:
Make sure the four circuits listed above are NOT cut.
3.8. Cut off the remaining circuits just after the connector (C2). This will leave approximately 51 mm (2 in) remaining from the main bundle to the end of the stub.
3.9. Tape the end of the wires (stub) with high temperature electrical tape.
3.10. Tie-strap the stub to the engine harness.
Important:
When installing the circuits into the new SGCM connector, do not twist or wrap the wires. This can cause the wiring to become too tight.
3.11. Install the four circuits (1, 3, 8, and 21) into the SGCM C2 connector of the wiring harness jumper. Be careful not to bend the terminals. After installing the four circuits into the new connector, replace the clear connector cover.
3.12. Install conduit over the four circuits and tape in place. Start the conduit at the main bundle to ensure all of the wiring is covered.
3.13. Reconnect the SGCM C1 and C2 connectors.
3.14. Route the wiring harness jumper under the brake vacuum hose, coolant hose, and main engine harness bundle and then back up and over to the MGU. Refer to the diagram.
Important:
DO NOT cut the 8-way connector at the MGU.
3.15. Remove both MGU (10-way resolver and 7-way field and thermistor) connectors and connect the new MGU connectors from the jumper harness.
3.16. Tie-strap the wiring harness jumper to the rear of the silver post and to the existing engine harness, utilizing the tie straps on the jumper. Refer to the above diagram.
3.17. Cut off the old MGU connectors (on the main engine wiring harness) at the end of the conduit.
3.18. Tape the end of the wires (stub) with high temperature electrical tape and tie strap back to the engine harness.
3.19. Make sure nothing (i.e., forward lamp harness, shifter cable, etc.) is interfering with the wiring harness jumper routing.
3.20. Reinstall the air cleaner outlet.
3.21. Reconnect the 12-volt battery.
3.22. Reconnect the Hybrid battery.
4. Test drive the vehicle to confirm that the customer's concern has been corrected. If the condition has not been corrected, contact GM Technical Assistance for further diagnostic and repair information.
Courtesy Transportation
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 program 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. Saturn US retailers should refer to GM messenger bulletins SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject.
Claim Information - Saturn/Saab Canada Only
Submit a Product Claim with the information shown.
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission.
Claim Information - Saturn US Only
1. To receive credit, submit a claim with the information shown.
Customer Notification - For US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin).
Dealer Program Responsibility
All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles.
Dealers are to service all vehicles subject to this program 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 shown in this bulletin for your use in contacting customers. Program 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 program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle.
Disclaimer