Lighting - Head/Interior Lamps Flicker Intermittently

TECHNICAL

Bulletin No.: 05-06-03-003D

Date: April 28, 2010

Subject: Headlamps and/or Interior Lights Flicker Intermittently (Replace Generator Voltage Regulator)

Models:
2005-2007 Buick Rendezvous, Terraza
2005-2007 Chevrolet Uplander
2005-2007 Pontiac Aztek, Montana SV6
2005-2007 Saturn RELAY

Supercede:
This bulletin is being revised to add models and revise the Parts Information. Please discard Corporate Bulletin Number 05-06-03-003C (Section 06 - Engine/Propulsion System).

Condition

Some customers may comment that the headlamps and/or interior lights flicker intermittently. This condition may occur when other accessories are engaged and may be most noticeable in a fog or at idle.

Cause

This condition may be caused by fluctuations in generator output.

Correction

Do NOT replace the entire generator.

Replace the generator voltage regulator following the service procedure below.

Important
The generator does not need to be removed from the vehicle to perform this procedure.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect in SI.
2. Loosen the drive belt and remove the belt from the generator pulley. Refer to the Drive Belt Replacement procedure in the Engine Mechanical - 3.5 or Engine Mechanical - 3.9 sub-section of SI.
3. Disconnect the electrical connectors off the back of the generator. If equipped, remove the nut holding the power steering lines to the generator and reposition the power steering lines aside.
4. Remove all three mounting bolts on the generator. Keep the mounting bolts in a safe place for use in Step 10. The generator can be rested on the mounting bracket for support in steps 5-9.
5. Remove the end cover and brush protector.
6. Remove the old voltage regulator.
7. Install the new voltage regulator.
8. Install the new brush protector (included in the kit).
9. Install a new end cover (included in the kit).
10. Reinstall the three generator mounting bolts. Ensure that the dielectric grease is still present on the metal contact areas of the mounting bolt holes. If not, place a thin film of dielectric grease on metal contacts.

Tighten
Tighten the bolts to 50 Nm (37 lb ft).

11. On Aztek and Rendezvous vehicles, it is necessary to replace the wiring harness connector on the vehicle. Refer to the parts list below for the replacement connector part.
12. Connect the electrical connectors. If equipped, install the nut holding the power steering lines on the back of the generator.
13. Install the drive belt. Refer to the Drive Belt Replacement procedure in the Engine Mechanical - 3.5 or Engine Mechanical - 3.9 sub-section of SI.
14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect in SI.
15. Test generator function using VAT-40.
16. Ensure that the battery is fully charged. Refer to Battery Charging in SI.

Parts Information





Warranty Information





For vehicles repaired under warranty, use the table above.





Disclaimer