New LSJ TSB ....Catalytic coverter
01-16-2010, 10:29 PM
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New LSJ TSB ....Catalytic coverter
Service Information
Document ID: 2382008
--------------------------------------------------------------------------------
#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
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.
WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION
© 2010 General Motors. All rights reserved
Document ID: 2382008
--------------------------------------------------------------------------------
#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
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.
WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION
© 2010 General Motors. All rights reserved
01-17-2010, 09:49 AM
#4
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well **** i punched mine out long ago because it was clogged... wonder if i can bring them just a downpipe and say i had to take it off because it was screwing up the car? if they will weld in a new cat.
01-17-2010, 02:02 PM
#5
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From GM service information. I have a GM dealerworld account.
Is it obvious that you beat it up pretty bad knocking the honey comb out of the converter? You could always say there was a big bang and a bunch of crap came out the exhaust lol. They won't weld in a converter ....they will replace the whole downpipe. Another thing to note...... It is VIN dependent if you qualify for the tsb above.
Is it obvious that you beat it up pretty bad knocking the honey comb out of the converter? You could always say there was a big bang and a bunch of crap came out the exhaust lol. They won't weld in a converter ....they will replace the whole downpipe. Another thing to note...... It is VIN dependent if you qualify for the tsb above.
Last edited by rukkee; 01-17-2010 at 02:03 PM. Reason: Automerged Doublepost
01-17-2010, 09:25 PM
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dont forget to tell them that it happened a few weeks ago and the next day the check engine light came on and the exhaust rattled for a couple days.
01-20-2010, 11:26 AM
#11
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I have prolly posted every TSB on the Cobalt over the last 4 years..... It would have been nice to have them in a sticky. Just like all the 08-09 GM build numbers for the SS from GM tuner source .....must be the sticky gods are sleeping.
01-20-2010, 05:03 PM
#13
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TY Sir 
How's the stage 3 tune treating ya ? I really wish I would have gotten that for my SS/SC . I was almost happy with stage 2 and the 2.99 .... the stage 3 tune would have been the kicker . I know everyone says custom tune and all but I wanted to stay GM with the SC .
How's the stage 3 tune treating ya ? I really wish I would have gotten that for my SS/SC . I was almost happy with stage 2 and the 2.99 .... the stage 3 tune would have been the kicker . I know everyone says custom tune and all but I wanted to stay GM with the SC .
01-20-2010, 08:18 PM
#14
TY Sir
How's the stage 3 tune treating ya ? I really wish I would have gotten that for my SS/SC . I was almost happy with stage 2 and the 2.99 .... the stage 3 tune would have been the kicker . I know everyone says custom tune and all but I wanted to stay GM with the SC .
How's the stage 3 tune treating ya ? I really wish I would have gotten that for my SS/SC . I was almost happy with stage 2 and the 2.99 .... the stage 3 tune would have been the kicker . I know everyone says custom tune and all but I wanted to stay GM with the SC .
01-21-2010, 08:36 PM
#16
I'm loving the Stage 3 tune man. I used to run the Stage 3 pulley on the Stage 2 tune like you did, and when I switched over to the Stage 3 tune I felt a noticable change. The car runs a hell of a lot smoother, and has a better mid-range to top-end feel. The increased rev limiter (mine is set at a safe 7250rpm) is great, and really keeps me in my powerband under WOT runs. I am like you, and like running GM parts. In the spring I will be trying out the high octane mode. I'll let you know how that goes.
I purchased stage 3 with the intention of running nitrous. I do have HPT but still would rather use the GMPP tune with the nitrous.
01-22-2010, 07:16 AM
#17
After two months of being on backorder my GMPP Stage 3 kit just came in. I am running stage two as well with the 2.99 and looking forward to installing it. I also purchased option B and a front mount H/E from OTTP.
I purchased stage 3 with the intention of running nitrous. I do have HPT but still would rather use the GMPP tune with the nitrous.
I purchased stage 3 with the intention of running nitrous. I do have HPT but still would rather use the GMPP tune with the nitrous.
02-24-2010, 10:32 PM
#19
I thought about posting it, saw this way back when t was first released before dlrs and customers were informed, hell Ive seen the bulletin for the Pontiac vibe(Toyota matrix pretty much) regarding the accelaration recall....but about this, it's a special coverage so only if your vehicle is experiencing this problem will it be repaired, also cannot be customer caused. Also there is a pending recall for the cobalt for the power steering on 05-09 cobalts. NHTSA contacted GM asking some questions, they will determine based on the answers if they should investigate further. Just a FYI :p
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