08200: Customer Satisfaction – Engine Oil Pan Drain Plug
Contents
1. Involved are certain 2008 model year Chevrolet Cobalt Cobalt SS HHR HHR SS Malibu Malibu Hybrid Pontiac G5 G6 Solstice Solstice GXP Saturn Aura Aura Hybrid SKY SKY Redline VUE VUE Hybrid equipped with a 2 0L or 2 4L 4 Cylinder RPO LNF LAT LE5 VIN X 5 B engine and built within these VIN breakpoints Year Division Model From Through 2008 Chevrolet Cobalt 87278892 87301543 2008 Chevrolet Cobalt SS 87296360 87335873 2008 Chevrolet HHR 8S656180 8S711330 2008 Chevrolet HHR SS 8S677650 8S713009 2008 Chevrolet Malibu Oi a 8F250565 8F282157 2008 Chevrolet Malibu Hybrid 8F255593 8F258278 2008 Pontiac G5 Pursuit 87278915 87294889 2008 Pontiac G6 84252210 84287137 2008 Pontiac Solstice 8Y128077 8Y129806 2008 Pontiac Solstice GXP 8Y128738 8Y131465 2008 Saturn Aura 8F251563 8F262807 2008 Saturn Aura Hybrid 8F255635 8F258162 2008 Saturn SKY 8Y128083 8Y129800 2008 Saturn SKY Redline 8Y128741 8Y133043 2008 Saturn VUE 85669041 8S700330 2008 Saturn VUE Hybrid 85675678 385685599 Important Dealers retailers are to confirm vehicle eligibility prior to beginning repairs by using the system s below Not all vehicles within the above breakpoints may be involved GM dealers and Canadian Saturn Saab retailers should use GMVIS Saturn US retailers should use the Investigate Vehicle History link on the Global Warranty Management application within DealerWorld For dealers retailers with involved vehicles a listing with involved vehicl2. with seal and tighten Tighten Tighten the oil pan drain plug to 25 N m 18 Ib ft 21 Lower the vehicle 22 Install a new engine oil filter for customer owned vehicles ONLY Refer to Engine Oil Filter Replacement in SI Do Not replace the engine oil filter on vehicles in dealer inventory 23 Fill the engine crankcase with 4 7L 5 qt of the specified engine oil Refer to the Owner Manual section in SI under Service and Appearance Care Go to Capacities and Specifications e Vehicles equipped with the 2 4L L4 Engine require a special oil meeting GM Standard GM6094M SAE 5W 30 is best for the vehicle If you are in an area of extreme cold where the temperature falls below 20 F 29 C use either an SAE 5W 30 synthetic oil or an SAE OW 30 oil e Vehicles equipped with the 2 0L L4 Engine only require a special oil meeting GM Standard GM4718M such as Mobil 1 or equivalent Oils meeting this standard may be identified as synthetic However not all synthetic oils will meet this GM standard Use only oil that meets GM Standard GM4718M 25 Start the engine and raise the vehicle 26 Inspect for oil leaks If leaking refer to Oil Leak Diagnosis in SI 27 Lower the vehicle 28 Shut the engine off 29 Check the engine oil level indicator and top off the engine oil to the appropriate normal operating range Courtesy Transportation For US and Canada The General Motors Courtesy Transportation program is intended to m
3. Document I D 2159378 08200 Customer Satisfaction Engine Oil Pan Drain Plug Thread Insert Loose or Damaged Inspect Install New Insert J un 25 2008 08200 Engine Oil Pan Drain Plug Thread I nsert Loose or Damaged Inspect Install New Insert Models 2008 Chevrolet Cobalt Cobalt SS HHR HHR SS Malibu Malibu Hybrid 2008 Pontiac G5 G6 Solstice Solstice GXP 2008 Saturn Aura Aura Hybrid SKY SKY Redline VUE VUE Hybrid Equipped with 2 0L 2 4L 4 Cylinder RPO LNF LAT LE5 VIN X 5 B Engine THIS PROGRAM IS IN EFFECT UNTIL JUNE 30 2009 Condition Certain 2008 model year Chevrolet Cobalt Cobalt SS HHR HHR SS Malibu Malibu Hybrid Pontiac G5 G6 Solstice Solstice GXP Saturn Aura Aura Hybrid SKY SKY Redline VUE and VUE Hybrid vehicles equipped with a 2 0L or 2 4L 4 Cylinder RPO LNF LAT LE5 VIN X 5 B engine may have an undersize engine oil pan drain plug thread insert that will be installed too far into the oil pan hole or will come out with the drain plug when it is removed This condition could result in poor or no retention of the drain plug when it is reinstalled in the course of an engine oil change Important This program will expire on J une 30 2009 because these vehicles should have had the first oil change by that time Correction Dealers retailers are to inspect and if necessary replace the engine oil pan drain plug thread insert with a new insert Vehicles Involved
4. W30 Synthetic Motor Turbo Up to 5 qt 10953468 CN ee Ge can 03536966 Seal Oil Pan Drain Plug 1 if required General Motors recommends the following thread repair kit Dealerships can purchase an equivalent thread repair kit from a local tool part supplier RECOIL WREAD PAIR Kit SME M 15 PART NO 20840 PALL rove LOT ami AD RECOIL Thread Repair Kit P N 2G940 M12 X 1 75 18mm from GRAINGER This repair kit contains tools and 5 inserts Dealers may purchase additional inserts locally or from GRAINGER P N 5VE71 5 pack of inserts To find a store near you go to www grainger com In Canada Acklands Grainger at http www acklandsgrainger com Claim the cost for inserts under Net Item of the Claim Information table We believe this source and their products to be reliable There may be additional manufacturers of such products material Service Procedure Important The service procedure contained in this program is different from the service procedure found in the appropriate service manual s Engine Oil Pan Drain Plug Thread Insert Loose or Damaged Oil Leak Inspect Insert and Install New Insert If Necessary Inspect the engine oil drain plug thread insert using the procedure below 1 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle in SI 2 Position the appropriate drain pan under the engine oil pan drain plug l 4 REE Laem 3 Mark the oil pan drai
5. customers regardless of mileage age of vehicle or ownership through J une 30 2009 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 J une 30 2009 you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle June 2008 Dear General Motors Customer We have learned that your 2008 model year Chevrolet Cobalt Cobalt SS HHR HHR SS Malibu Malibu Hybrid Pontiac G5 G6 Solstice Solstice GXP Saturn Aura Aura Hybrid SKY SKY Redline VUE or VUE Hybrid equipped with a 2 0L or 2 4L 4 cylinder engine may have been produced with an undersize engine oil drain plug thread insert This condition is not cause for immediate concern as the drain plug was properly tightened at the factory If your vehicle has the condition it could result in difficulty reinstalling the
6. drain plug in the course of an engine oil change Your satisfaction with your Chevrolet Cobalt Cobalt SS HHR HHR SS Malibu Malibu Hybrid Pontiac G5 G6 Solstice Solstice GXP Saturn Aura Aura Hybrid SKY SKY Redline VUE or VUE Hybrid is very important to us so we are announcing a program to inspect for this condition in your vehicle and fix it if necessary To minimize your inconvenience this service will be performed along with your first engine oil and filter change which will be done at no cost to you What We Will Do Your dealer retailer will inspect and if necessary replace the engine oil drain plug thread insert with a new insert of the correct size Your dealer retailer will also change your engine oil and filter This service will be performed for you at no charge until June 30 2009 What You Should Do Please refer to your vehicle maintenance schedule to determine when your first engine oil change will be due based on your driving habits When your first oil change is due to limit any possible inconvenience we recommend that you contact your dealer retailer to schedule an appointment for this repair By scheduling an appointment your dealer retailer can ensure that the necessary parts will be available on your scheduled appointment date Customer Reply Form The enclosed customer reply form identifies your vehicle Presentation of this form to your dealer retailer will assist in making the necessary correction in th
7. e shortest possible time If you no longer own this vehicle please let us know by completing the form and mailing it back to us If you have any questions or need any assistance to better understand related repairs please contact your dealer retailer or the appropriate Customer Assistance Center at the number listed below Division Number Text Telephones TTY Chevrolet 1 800 630 2438 1 800 833 2438 Pontiac 1 800 620 7668 1 800 833 7668 Saturn 1 800 972 8876 1 800 833 6000 Guam 1 671 648 8450 Puerto Rico English 1 800 496 9992 Puerto Rico Espanol 1 800 496 9993 Virgin Islands 1 800 496 9994 Courtesy Transportation If your vehicle is within the New Vehicle Limited Warranty your dealer retailer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership facility for this repair Please refer to your Owner s Manual and your dealer retailer for details on Courtesy Transportation We sincerely regret any inconvenience or concern that this situation may cause you We want you to know that we will do our best throughout your ownership experience to ensure that your GM vehicle provides you many miles of enjoyable driving Scott Lawson General Director Customer and Relationship Services Enclosure 08200
8. es containing the complete vehicle identification number customer name and address information has been prepared and will be provided through the applicable system listed below Dealers retailers will not have a report available if they have no involved vehicles currently assigned US GM and Saturn dealers retailers GM DealerWorld Recall Information Canadian GM Saturn dealers retailers GMinfoNet Recall Reports Export dealers sent directly to dealers 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 GM Saturn Canada Only Parts required to complete this program are to be obtained from General Motors Service and Parts Operations GMSPO 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 Part Number Description Qty Vehicle Thread Wire Inserts M12 x 1 75 x 18mm 1 if required 12605566 Filter Engine Oil 1 if required 12345610 US Oil 5W30 Motor iy 00729389 CN i 1275995 US Oil Mobil 1 5
9. inimize 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 GM dealers 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 Customer Notification For US and Canada General Motors will notify customers of this program on their vehicle See copy of customer letter included with this bulletin 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 Dealer Program Responsibility All 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
10. n plug bolt head in relation to the oil pan 1 4 Loosen the drain plug and count five turns Can the drain plug be removed after the fifth turn 4 1 For unsold dealer inventory vehicles If NO the thread insert is positioned correctly Tighten the oil pan drain plug and lower the vehicle 5 Tighten Tighten the oil pan drain plug to 25 N m 18 Ib ft 4 1 Check the engine oil on the engine oil level indicator and add oil if necessary to the normal operating range No further action is required 4 2 For customer owned vehicles If NO the thread insert is positioned correctly Perform a complete engine oil and filter change on the customer owned vehicle 7 Tighten Tighten the oil pan drain plug to 25 N m 18 Ib ft 4 2 Check the engine oil on the engine oil level indicator to the normal operating range No further action is required 4 3 For unsold dealer inventory vehicles If YES drain the engine oil and proceed with this bulletin to install a new insert Do Not replace the engine oil filter 4 4 For customer owned vehicles If YES drain the engine oil remove the oil filter and proceed with this bulletin to install a new insert e If the oil pan thread insert 1 is installed too deeply inside the oil pan drain plug hole refer to Step 5 e If the oil pan thread insert 1 came out with the drain plug install a new insert refer to Step 7 13 Obtain a 3 8 in drive tap socket 1 and a Number 5 Spiral Flu
11. te Screw Extractor 2 or equivalent Caution The spiral extractor may bind when removing the thread insert from the oil pan Reverse the direction of the ratchet 1 to eliminate the bind by turning the spiral retracting tool half a turn back into the oil pan It may be necessary to repeat this several times while removing the thread insert Failure to eliminate the bind may damage the oil pan threads requiring a tap to clean up the threads 14 Remove the old thread insert from the oil pan using a Number 5 Spiral Flute Screw Extractor Important The thread insert tang 1 should be facing up on the installation tool The tool stop 2 may require adjustment prior to installing the insert into the oil pan as shown 15 Place the new thread insert 1 onto the installation tool with the tang up inside the tool slot and then adjust the tool stop 2 until the insert tang is centered in the slot 16 Install the new thread insert into the oil pan drain hole using the installation tool 1 17 Install the new thread insert 1 a half turn below the outer sealing surface of the oil pan 18 Remove the installation tool 19 Twist off the center tang 1 using long needle nose pliers If the tang 1 fell into the oil pan use a small pin or wire magnet to retrieve the tang 20 Inspect the engine oil pan drain plug seal If the seal is damaged replace as necessary Reinstall the engine oil pan drain plug
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