Campaign - Heater Core Leak, Modify Hoses: Overview
CUSTOMER SATISFACTIONBulletin No.: 09206A
Date: January 27, 2011
Subject: 09206A - Heater Core Leak - Modify Hoses
Models:
2008 Saturn VUE
Equipped with 4-Cylinder Engine (RPO LE5)
Supercede:
The expiration date of this program is being extended until January 31, 2012. Please discard all copies of bulletin 09206, issued December 2009.
THIS PROGRAM IS IN EFFECT UNTIL JANUARY 31, 2012.
Condition
Certain 2008 model year Saturn VUE vehicles equipped with a 4-cylinder engine (RPO LE5) may have been built with a heater core that could eventually fracture due to pressure fluctuations within the heater core. If the heater core fractures, the customer would notice a strong coolant smell, vapor or mist coming out of the heater vents, and/or an oily film on the windshield.
Correction
Dealers are to modify the heater hose routing to eliminate the pressure fluctuations within the heater core.
Vehicles Involved
Involved are certain 2008 model year Saturn VUE vehicles equipped with a 4-cylinder engine (RPO LE5) and built within these VIN breakpoints:
Important
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty System. Not all vehicles within the above breakpoints may be involved.
For dealers 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 to dealers through the GM GlobalConnect 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 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
Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A). 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.
Service Procedure
Required Tools
J 38185, Hose Clamp Pliers
Part Kit, P/N 19256223, consists of:
- Hose Tee, P/N 15793367, QTY: 1
- Cap-Htr Wat Otlt, P/N 15544596, QTY: 1
- Hose Clamp, P/N 11571080, QTY: 6
- Hose Clamp, P/N 11570616, QTY: 1
1. Drain the cooling system. Refer to Cooling System Draining and Filling in SI.
2. Remove the radiator surge tank outlet hose. Refer to Radiator Surge Tank Outlet Hose/Pipe Replacement (LE5) in SI. Do NOT discard the hose.
Caution
To avoid damaging the radiator surge tank outlet hose, apply heat to the clamp before attempting to remove it from the hose. The hose clamps are glued on to the hose.
3. Carefully remove the radiator surge tank outlet hose clamps from the hose using heat gun and hose clamp pliers. Apply heat to the clamp only. Wipe hose end clean with water and shop towel after removing hose clamps.
4. Install a rubber cap (1), P/N 15544596 and new clamp, P/N 11570616 to the thermostat housing (2).
5. Remove the heater core outlet hose (1). Refer to Heater Outlet Hose Replacement (LE5) in SI.
Caution
To avoid damaging the radiator surge tank outlet hose, apply heat to the clamp before attempting to remove it from the hose. The hose clamps are glued on to the hose.
6. Carefully remove the heater core outlet hose clamps from the hose using a heat gun and hose clamp pliers. Apply heat to the clamp only. Wipe hose end clean with water and shop towel after removing hose clamps.
7. Measure 121 mm (4-3/4 in) from the engine side end (1) of the heater core outlet hose. This measurement should be between the first and second bend (2) (3) in the hose. Refer to illustration.
8. Mark the location of the measurement (4) with a yellow or white marker. Refer to illustration.
9. Cut the heater core outlet hose along the mark made in step 8. Do NOT discard either piece of the heater core outlet hose.
10. Cut 44.5 mm (1-3/4 in) off the engine side end of the radiator surge tank outlet hose.
11. Connect the two sections of the heater core outlet hoses (1) using the hose tee, P/N 15793367 (2) and hose clamps, P/N 11571080. Install the hose tee in the 2 o'clock position. Tighten clamp: 5 Nm (45 lb-in).
12. Install the engine side end of the heater core outlet hose (1) to the engine with a hose clamp, P/N 11571080. Tighten clamp: 5 Nm (45 lb-in).
13. Install the heater core outlet hose (1) to the heater core outlet with a hose clamp, P/N 11571080. Tighten clamp: 5 Nm (45 lb-in).
14. Install the engine side portion of the radiator surge tank outlet hose (3) to the hose tee (2) with a hose clamp, P/N 11571080. Tighten clamp: 5 Nm (45 lb-in). Refer to illustration. You will have to rotate the hose approximately 180 degrees from the production orientation.
15. Install the surge tank portion of the radiator surge tank outlet hose (1) to the surge tank (2) with a hose clamp, P/N 11571080. Tighten clamp: 5 Nm (45 lb-in).
Heater Core Outlet Hose
Hose Tee
Radiator Surge Tank Outlet Hose
Fuel Line
Brake Booster Hose
Master Cylinder
16. Ensure the new hose assembly (heater core outlet hose, hose tee, radiator surge tank outlet hose) does NOT contact the fuel line, master cylinder or brake booster vacuum hose. Refer to illustration.
17. Fill the cooling system. Refer to Cooling System Draining and Filling in SI.
18. Start the engine and inspect the heater core outlet hose and radiator surge tank outlet hoses for leaks.
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 Warranties. 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. US retailers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject.
Warranty Transaction Information
Submit a transaction using the table below.
* The amount identified in "Net Item" should represent the actual sum total of the current GMCC&A Dealer net price for the coolant needed to perform the required repairs, not to exceed $15.68 USD, $8.87 CAD, plus applicable Mark-Up.
Customer Notification
General Motors will notify customers of this program on their vehicle (see copy of customer letter included with 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, through January 31, 2012.
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. 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 through January 31, 2012, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle.
Disclaimer