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Subject: L36, L67, L26, L32, LA1, LX9, MN7, M15 Ticking or Knocking Type Noise Coming From Engine or Transmission Area (Replace Flexplate and Torque Converter) Models: 2005 Buick Park Avenue 2005-2006 Buick Allure (Canada Only), LaCrosse, LeSabre, Rendezvous, Terraza 2005 Chevrolet Impala, Monte Carlo, Venture 2005-2006 Chevrolet Malibu, Malibu Maxx, Uplander 2005 Pontiac Aztek, Bonneville 2005-2006 Pontiac Grand Prix, G6 GTP, Montana SV6 2006 Saturn Relay AWD with 3800 3.8L Series III V6 Engine (VINs K, 1, 2, 4, – RPOs L36, L67, L26, L32) or 3500 3.5L V6 Engine (VINs L, 8 RPO LX9) or 3400 3.4L V6 Engine (VIN E – RPO LA1) and Hydra- Matic(R) 4T65-E Transmission (RPOs MN7, M15) Some customers may comment on a ticking or knocking type noise coming from the engine or transmission area. Cause Typically the noise is caused by either the transmission rear dust cover contacting the flexplate (refer to Corporate Bulletin Number 05-06-01-028) or a cracked flexplate (sometimes also referred to as a flywheel). Correction With the vehicle raised and supported on a suitable hoist, verify that the noise is coming from the flexplate area. If the noise is present, follow the procedure below. If the noise is not coming from the flexplate area, refer to Lower Engine Noise, Regardless of Engine Speed in SI. Important: The following information only applies to vehicles with the noise coming from the flexplate area.

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ISSUE On some 2002-04 MY X-TYPE vehicles within the above VIN range, customers may have concerns with the vehicle interior fogging or the climate control cooling the vehicle slowly. The concern may be caused by the air inlet blend door being loose on the actuator shaft. ACTION In case of a customer complaint of the above condition on a 2002-04 MY X-TYPE vehicle within the above VIN range, first test the operation of the air inlet blend door. Set the fan speed to MAX and manually de-select the recirc button, there should be an audible difference in the climate control temperature motor noise. If the volume stays the same then the air inlet blend door is suspect. To rectify follow the workshop procedure outlined below. WORKSHOP PROCEDURE 1. 2. 3. 4. 5. 6. Open door. Turn ignition ‘ON’. Operate front seat fully rearward for access. The air recirculation switch should be in the fresh air mode. Turn ignition ‘OFF’. Remove the glove compartment hinge retaining screws (Fig. 1 ).7. Remove the glove compartment retaining screws (Fig. 2 ). 8. Disconnect the glove compartment lamp electrical connector (Fig. 3 ). 9. Remove the glove compartment. 10. Disconnect the air inlet blend door actuator electrical connector, undo and remove the climate control upper front stepper motor securing screws and displace the climate control stepper motor and reposition to gain working access (Fig. 4 ).

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In case of a customer complaint of the above condition on a 2002-04 MY X-TYPE vehicle within the above VIN range, first test the operation of the air inlet blend door. Set the fan speed to MAX and manually de-select the recirc button, there should be an audible difference in the climate control temperature motor noise. If the volume stays the same then the air inlet blend door is suspect. To rectify follow the workshop procedure outlined below. WORKSHOP PROCEDURE 1. Open door. 2. Turn ignition ‘ON’. 3. Operate front seat fully rearward for access. 4. The air recirculation switch should be in the fresh air mode. 5. Turn ignition ‘OFF’. 6. Remove the glove compartment hinge retaining screws (Illustration 1). 7. Remove the glove compartment retaining screws (Illustration 2). 8. Disconnect the glove compartment lamp electrical connector (Illustration 3). 9. Remove the glove compartment. 10. Disconnect the air inlet blend door actuator electrical connector, undo and remove the climate control upper front stepper motor securing screws and displace the climate control stepper motor and reposition to gain working access (Illustration 4). 11. Remove the air inlet blend door actuator securing screws (Illustration 5). 12. Displace and remove actuator. 13. On all vehicles, align the actuator shaft as follows: Connect the air inlet blend door actuator to the electrical connector, and switch the ignition ‘ON’. By a combination of operating the air recirculation button ON/OFF and disconnecting the electrical connector at the correct time set the shaft to the correct position. The flat opposite the curved face should be set nearest to and parallel with the line on the actuator body (Illustration 6). Note: A DTC will be stored during the alignment procedure since the open circuit will be detected. 14. Turn ignition ‘OFF’. 15. Ensure the air inlet blend door is in the fresh air position.

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Power Steering System Squeaking Noise Repair Procedure AFFECTED VEHICLE RANGE CONDITION SUMMARY: POWER STEERING SYSTEM SQUEAKING NOISE Situation: On some S-Type, X-Type and XJ Range vehicles within the VIN ranges above, a squeaking noise may be apparent from the power assisted steering system when the steering wheel is rotated in either direction. The noise is caused by a seal inside the steering rack. The noise can be transmitted through the steering column and steering wheel, making it difficult to diagnose. This bulletin does not address any other PAS noises, such as pump or drive belt related noises. Action: In the case of a verified customer complaint matching the description above, refer to the Repair Procedure detailed in this bulletin and complete the service fix.REPAIR PROCEDURE PAS SQUEAK/FLUID ADDITIVE Open driver’s door. Ensure the gear lever is in either neutral or park, the parking brake is ‘ON’, and the ignition is ‘OFF’. Open hood and install fender protectors. 4. Remove the power steering fluid reservoir cap (and filter mesh on XJ and S-Type vehicles) and ensure the fluid level is correct. (Figure 1) 5. Using a suitable clean syringe, remove 50 ml of steering fluid. NOTE: The fluid additive must only be added once and the supplied label must then be affixed to the power steering fluid reservoir. 6. Replenish the power steering fluid reservoir with 50 ml of the specified fluid additive (C2S 48887). 7. Affix the supplied label to the power steering fluid reservoir NOTE: Suitable temperature reading equipment must be positioned into the power steering fluid reservoir, (filter mesh must be removed on XJ and S-Type vehicles) and that the temperature can be read while carrying out the heating process. 8. Insert the temperature reading equipment probe into the power steering fluid reservoir (about halfway into the depth of the fluid). HEATING THE STEERING FLUID TO 100°C +/- 5°C (212°F +/- 10°F) 1. Turn ignition ‘ON’ and start the engine. With the engine idling, turn the steering wheel from lock to lock four times to cycle the fluid additive into the system. (Figure 2) CAUTION: Under no circumstances hold the steering wheel on full lock while heating the steering fluid (to avoid damage to the steering system). CAUTION: While carrying out the following procedure, ensure that 105°C (221°F) is not exceeded. 3. While stationary and with the steering wheel in the center position (road wheels in the straight ahead position), turn the steering wheel 90° (quarter turn) right and hold firmly with both hands. (Figure 3) ^ Increase the engine speed to 3000 rpm. ^ Monitor the power steering fluid temperature until 100 +/- 5°C (212°F +/- 10°F) is reached. PERFORMING THE STEERING MANEUVER NOTE: The steering maneuver should be carried out on a hard flat surface outside of the workshop. CAUTION: Do not hold the steering wheel on full lock for more than two seconds as this may cause damage to the steering system. 1. Verify the power steering fluid temperature is at 100 +/- 5°C (212°F +/- 10°F), engine idle speed set between minimum 900 rpm and maximum 1000 rpm. 2. Turn the steering wheel to full lock and hold for two seconds.

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Difficulty Selecting Transmission Ranges – GEARBOX FAULT Message – Reset J-Gate Remove and destroy Bulletin XT307-01, dated 08/01. Replace with this Bulletin. The adjustment procedure has been revised. Issue: Some 2002 MY X-TYPE vehicles with automatic transmissions may experience customer complaints of being unable to select a transmission range, or the message ‘GEARBOX FAULT’ flashing on the message center (or the powertrain malfunction lamp [MIL] illuminating) causing the vehicle to run in limp-home mode. Action: Using WDS, check for any diagnostic trouble codes (DTCs) stored. If any DTC is stored (see table), the J-gate assembly is functioning incorrectly and needs resetting. In order to do this, follow the Workshop Procedure outlined below. Note: Before starting the J-gate setting procedure, ensure the vehicle is cold, or has been left to cool for at least 2 hours.