Recall - Loss of Hybrid Function - Replace Batteries: Overview
PRODUCT EMISSIONBulletin No.: 10136A
Date: January 27, 2011
Subject: 10136A - Loss of Hybrid Function - Replace Batteries
Models:
2008-2010 Chevrolet Malibu
2007-2009 Saturn AURA, VUE
Hybrid Vehicles
Supercede:
The Service Procedure section has been revised to include a Warning Statement before Step 1 and a photo and two Note Statements before Step 7.3. Please ensure that all technicians are aware of these revisions. Please discard all copies of bulletin 10136, issued July 2010.
Condition
General Motors has decided to conduct a Voluntary Emission Recall involving certain 2008-2010 model year Chevrolet Malibu and 2007-2009 model year Saturn AURA and VUE hybrid vehicles. The hybrid function on these vehicles may become inoperative. If this occurs, a "Check Engine Light" will illuminate in the instrument panel and/or a "Service Hybrid" message will illuminate in the Driver Information Center, the engine will run in the gasoline engine mode, and fuel economy would be reduced.
Correction
Dealers are to replace the hybrid batteries and reprogram the engine control module.
Vehicles Involved
Involved are certain 2008-2010 model year Chevrolet Malibu and 2007-2009 model year Saturn AURA and VUE hybrid vehicles built within these VIN breakpoints:
Important
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing of the involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. 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 recall 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 recall.
Parts Information
Parts required to complete this recall 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.
These batteries are excluded from RIM for US and Canada.
Service Procedure
Warning
To help avoid personal injury, always ensure that the ignition switch is in the OFF position and the ignition key has been removed prior to working on any 36V component. After the key has been removed, disconnect the negative 12V battery cable and then open the battery energy control module cover. After waiting for at least 5 minutes, measure the voltage potential using a Digital Multimeter (DMM) between the following:
1. 36V positive and negative battery cables.
2. 36V positive battery cable and vehicle ground.
3. 36V negative battery cable and vehicles ground.
All measure voltage levels must be below 3 volts.
1. Remove generator battery from the vehicle. Refer to Generator Battery Replacement in SI.
2. Inspect the generator battery carrier for corrosion or battery acid.
- If corrosion or battery acid IS present, proceed to Step 3.
- If corrosion or battery acid is NOT present, proceed to Step 6.
3. Clean any corrosion or battery acid that is present on the inside of the hybrid battery case by using a sponge that is lightly dampened with soapy water. It is not necessary to use a neutralizer, such as baking soda.
4. Dry the inside of the hybrid battery case using several shop towels.
5. Apply black paint to any areas inside the of the hybrid battery case where bare metal is present.
6. Install new generator battery. Refer to Generator Battery Replacement in SI.
7. Program the engine control module. Do not attempt to order the calibration number from GM Customer Care and Aftersales. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2(R) and TIS2WEB with the calibration update. When using a MDI or Tech 2(R) for reprogramming, ensure that is updated with the latest software version. Use TIS2WEB on or after 06/24/10 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided.
For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal.
1. Verify that there is a battery charge of 12 to 15 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent to maintain proper battery voltage during programming.
2. Reprogram the engine control module (ECM). Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required.
1. Connect the MDI or Tech 2(R)(R)(R) to the vehicle.
2. Select J2534 MDI or J2534 Tech 2(R)(R)(R) and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen.
3. Select ECM Engine Control Module - Programming from the Supported Controllers screen.
4. Follow the on-screen instructions.
Note
DTCs P1a26, P1a22, P1a30 and other hybrid battery related codes may be set after completing the recall because of an incorrect voltage sensor placement with respect to positive and negative nodes. Inspect the polarity marking underneath the bus bar. Refer to the photograph. Each cell will have positive and negative symbols. One or both symbols may be obstructed by the bus bar and, therefore, may not be visible. The correct sensor connection is at the negative post under the bus bar. Refer to the photograph.
Note
If DTCs P0AF8 or P0AFB set following recall completion, please refer to bulletin PIP4797 for resolution.
3. Clear all DTCs if required.
8. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.
Recall Identification Label - California/Connecticut/Massachusetts/Maine/Oregon/ Vermont/Washington Vehicles Only
Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen.
Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle.
When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering.
Customer Reimbursement - For US
All customer requests for reimbursement of previously paid repairs for the 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
(GM US Only) 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 and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by August 31, 2011.
All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair.
Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS or GWM.
Important
Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification.
Courtesy Transportation - For US and Canada
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 should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.
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 touch-up paint, if needed, to paint the generator battery carrier, not to exceeded $1.00 USD, $1.04 CAD, plus applicable Mark-Up or Landed Cost (for Export).
** The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer.
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).
In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed.
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.
In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed.
Dealer Recall Responsibility
All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles.
Dealers are to service all vehicles subject to this recall 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 provided in this bulletin for your use in contacting customers. Recall 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 recall enters your vehicle inventory, or is in your dealership/facility for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.
***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT***
When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration.
Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering.
Disclaimer