I have a gm k&n CAI, When i get into boost it makes a weird noise and doesnt feel like it is boosting but my gauge goes up past 17 lbs where it usually stops and goes to 20 and sounds almost like there is a limiter on it. It makes a real high pitch whine when it does this. It all started the other day when my car just died all of a sudden and wouldnt start back up. I left it sit for 10 min and it started and ran fine. I got a code to come up PO420 something about the cat being clogged but i just had it replaced not to long ago bc of the recall. I cleared the code and it hasnt came back. It seems to be worse once the car warms up. Any help would be greatly appreciated!

 

Clogged car will raise levels. Take it to gm get new under recall or cut it out and put test pipe in there

 

the code hasnt came back up is it still possible that the cat is clogged?

 

yes take to gm and they will replace it they had a recall on the cats.

 

i already had it replace for the recall once will they replace it again?

 

iirc, gm stage 2 should up boost from about 12.5 to 15. if you are seeing 17 and sometimes 20 im thinking your cat would be a good place to start

 

they should replace it emmissin equpiment is warranted around 100k

 

take it into service obivously ur still warrantied u have gm stage 2.

 

no my warrenty is up but i guess i will have to have it checked out but it usually boost up to 17 lbs now its going past 20

 

5/100,000 mile power train warranty on all Chevy cars and trucks.
What octane gas are you running in the car?

 

2006's only had a 60K powertrain.

 

i had an extended warenty for 84k mi. I run 91-93 usually 93 from QT. My CEL came back on today and i had it checked and it was the cat again code PO420 so im gonna take it to the dealership tomorrow and hopefully it will be covered on the recall.

 

emissions have a longer warranty by federal law

 

That's my point. Thanks Mr B. I remember a couple of years ago with my cavy I had two cats replaced in about 150,000.

 

if you're making more boost than you should, how could it be considered a boost leak? just saying

definitely a clog somewhere because boost is a measure of restriction

 

Service Information
Document ID: 2382008
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#08020: Special Coverage Adjustment - Extended Catalytic Converter Warranty Coverage - (Jan 13, 2010)


Subject: 08020 - SPECIAL COVERAGE ADJUSTMENT - EXTENDED CATALYTIC CONVERTER WARRANTY COVERAGE


Models: 2004-2007 SATURN ION RED LINE

2005-2007 CHEVROLET COBALT SS

EQUIPPED WITH 2.0L 4-CYLINDER (RPO LSJ) ENGINE




--------------------------------------------------------------------------------
Condition
Some customers of 2004-07 model year Saturn ION Red Line; and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine, may comment on illumination of the malfunction indicator lamp (MAL) and/or lack of engine power. This may be caused by failure of the catalytic converter.

Special Coverage Adjustment
This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership.

Dealers/retailers are to replace the catalytic converter. The repairs will be made at no charge to the customer.

Customers should not be charged for performing a system check when it is determined that the catalytic converter is not the cause of the customer complaint. Labor code T5725 is provided to submit claims for such system checks. Any additional necessary diagnosis and repairs that are not related to the catalytic converter are NOT covered by this special coverage. The customer should be informed that any further service that is not covered by the new vehicle warranty will not be covered by this policy.

For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after January 14, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to January 14, 2010, must be submitted to the Service Contract provider.

Vehicles Involved
Involved are certain 2004-07 model year Saturn ION and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine, and built within the following VIN breakpoints:

Year
Division
Model
From
Through

2005
Chevrolet
Cobalt SS
57500350
57673203

2006
Chevrolet
Cobalt SS
67600131
67887017

2007
Chevrolet
Cobalt SS
77100033
77398019

2004
Saturn
ION Red Line
4Z185538
4Z232057

2005
Saturn
ION Red Line
5Z100038
5Z181820

2006
Saturn
ION Red Line
6Z100021
6Z204142

2007
Saturn
ION Red Line
7Z100001
7Z140513


Important: Dealers/retailers using the Global Warranty Management (GWM) system are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverages are displayed in the Applicable Warranties section.

Parts Information
GM: Parts required to complete this special coverage are to be obtained from General Motors Service and Parts Operations (GMSPO).

Saturn US Only: Due to the limited number of affected vehicles, Saturn will not be doing a pre-shipment of parts. Retailers should order parts as needed from Saturn Service Parts Operations (SSPO).

Part Number
Description
Qty/ Vehicle

20889271
Asm, Catalytic Converter (2004 ION)
1

20889269
Asm, Catalytic Converter (2005-06 ION, Cobalt)
1

20889270
Asm, Catalytic Converter (2007 ION, Cobalt)
1

15231157
Gasket, Ctltc Conv
1

11514596
Nut, Ctltc Conv (2004 ION)
2

11517996
Nut, Ctltc Conv (2005-07 ION, Cobalt)
2

15235773
Gasket, Exhaust Manifold
1

11517996
Nut, Exhaust Manifold
3

Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly).

Service Procedure
The purpose of this field action bulletin is to determine if it is necessary to replace the catalytic converter on certain 2004-07 model year Saturn ION Red Line and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with 2.0L 4-cylinder (RPO LSJ) engine. The catalytic converter is an emission control device added to the engine exhaust system in order to reduce hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) pollutants from the exhaust gas.

All diagnostics on a vehicle should follow a logical process. Strategy Based Diagnostics is a uniform approach for repairing all systems. The diagnostic flow is the place to start when repairs are necessary and may always be used in order to resolve a system problem. For a detailed explanation, refer to Strategy Based Diagnosis in SI.

Determine the condition of the catalytic converter. Refer to Symptom - Engine Exhaust and Restricted Exhaust in SI.

• If diagnosis indicates that the catalytic converter must be replaced, replace the Catalytic Converter. Refer to Catalytic Converter Replacement in SI.

• If diagnosis indicates that the catalytic converter does NOT require replacement, determine the cause of the customer-reported exhaust concern using the diagnostic service information in SI. Diagnostic time and service repairs for exhaust system components other than the catalytic converter are NOT covered by this field action. Diagnostic time and service repair work for exhaust system components other than the catalytic converter must be billed under warranty or customer pay.

Customer Reimbursement
1. Submit a claim using the table below.

2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code.

Labor Code
Description
Labor Time
Net Item

T5725
System Check Diagnostics - No Catalytic Converter Replacement Needed
0.0-0.3
N/A

T5726
Replace Catalytic Converter
0.6
N/A

Add: Diagnostics
0.0-0.3


T5727
Customer Reimbursement (Canadian & Export Dealers, Saturn US Retailers, & US CAC)
0.2
*


* The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer.

Customer Reimbursement - For GM US
All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers.

A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter.

Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.

Customer Reimbursement - For Canada
Customer requests for reimbursement of previously paid repairs to replace the catalytic converter are to be submitted to the dealer prior to or by January 31, 2011. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000 km, whichever occurs first.

When a customer requests reimbursement, they must provide the following:

• Proof of ownership at time of repair.


• Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair.


If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership.

Customer Reimbursement - For Saturn US Only
All customer requests for reimbursement for previous repairs for this condition are handled by submitting a reimbursement claim form directly to Saturn retailers for processing; however, if customers choose, they may file a claim through the Saturn Customer Assistance Center.

A Saturn Customer Reimbursement Procedure and Claim Form is included with the customer letter.

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. Dealers/retailers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

January 2010
Dear General Motors Customer:

As the owner of a 2004-07 model year Saturn ION Red Line or 2005-07 model year Chevrolet Cobalt SS, equipped with a 2.0L 4-cylinder supercharged engine, your satisfaction with our product is very important to us.

This letter is intended to make you aware that some 2004-07 model year Saturn ION Red Line and 2005-07 model year Chevrolet Cobalt SS vehicles, equipped with a 2.0L 4-cylinder supercharged engine, may have a condition where the malfunction indicator lamp illuminates, and/or there is a lack of engine power. This may be caused by failure of the catalytic converter.

Do not take your vehicle to your GM dealer/retailer as a result of this letter unless you believe that your vehicle has the condition as described above.

What We Have Done: General Motors is providing owners with additional protection for the catalytic converter. If this condition occurs on your 2004-2007 model year Saturn ION Red Line or 2005-2007 model year Chevrolet Cobalt SS, equipped with a 2.0L 4-cylinder supercharged engine, within 10 years of the date your vehicle was originally placed in service or 120,000 miles (193,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program.

What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a GM dealer/retailer. If you believe that your vehicle has the condition covered by this special coverage, you may want to contact your GM dealer/retailer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer/retailer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference.

Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by January 31, 2011.

If you have any questions or need any assistance to better understand related repairs, please contact your dealer/retailer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center.

We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products.

Scott Lawson

Director,

Customer and Relationship Services

Enclosure

08020



WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION


Š 2010 General Motors. All rights reserved

 

Wow thanks for all the great info guys. I will take it in today and update when i find out whats up.

 

if you drive and your pedal pressure seems really light, then you have what cobalts so to be famous for and thats a dirty fuel filter or bad fuel pump. cobalts unlike most i4's have two one in the rear and one in the front and that can dramatically reduce your engine pressure and cause your car to even over heat and go into protective mode because its not getting fuel.

 

no the pedal pressure seems normal. i talked to the dealership and i have to take it in to them in the morning so i will post what i find out

 

I took my car in this morning and they changed the cat that ive had for 4000 miles. He took it off and **** just fell out everywhere. They also changed the power steering pump and its running good again finally. Thanks for all the great info guys!