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Here are some tips that will be helpful when you are programming a 2008-09 Saturn Astra (fig. 1). Refer to bulletin for PIC5053 details.

 

REQUIRED TOOLS

The 2008-09 Saturn Astra requires its own separate 10 or 32meg Tech 2 card loaded with its own software. If you can locate the old 10meg card, you can load the software onto it. Or you can use a newer 32meg card. A CANDI module will be needed.

This vehicle does not use NAO software as used for other Saturn vehicles. This software CANNOT be loaded onto the existing Tech 2 card at the same time as the current software. However, it can be installed over the existing NAO software on a current 10 or 32meg card for quick usage, then re-install the NAO software back onto the card if needed.

TIP: All software can be found in TIS2Web. Always use the latest version available.

TIP: Do not leave the NAO and Astra cards installed in the Tech 2 when operating or programming. This will cause issues.

UPDATE TECH 2 CARD

- Install the 10 or 32meg card to be programmed into the Tech 2 by itself. (DO NOT LEAVE OTHER CARDS IN TECH 2). All Astra versions will function and fit on either 10 or 32meg cards.

- Hook up your Tech 2 to your external power supply and the RS232 cable to your computer.

- Turn on Tech 2.

- Open TIS2Web and click on the Software Download SWDL icon from the home page. Then click on Start Software Download to begin the process.

- When the pop-up box appears, select Tech 2 as the diagnostic tool, then select CUSTOM as the update mode. Click NEXT.

- Select the latest ASTRA software from the list.

- Once the correct version is selected, click DOWNLOAD and follow the prompts.

IMMOBILIZER / SECURITY CODE

Before beginning to program the module, it will be necessary to have the Security (Immobilizer) Code. This code can be found in the vehicle glove box on the Security Card/Car Pass. It can also be found in DealerWorld / GM Global Connect under the PARTS tab, then select KEY CODE LOOK UP from the list.

TIP: Late 2008 models may not have come with the Security Card/Car Pass in the glove box due to a cost reduction at the plant. The intent is to put them back into production for the 2009 MY. If a Car Pass is not available, you will have to get the Parts/Service manager to use the KEY CODE LOOK UP feature in DealerWorld.

TIP: The KEY CODE LOOK UP selection in the PARTS tab is available only to Service and or Parts managers. (See your dealership Security Partner Coordinator if needed.)

TIP: The Radio and Immobilizer codes are always the same number. Specifically there is only the Immobilizer/Security/Radio code and it is used for all module programming.

TIP: This should not be confused with the Key No/Key Cut Code also found on the Security Card/Car Pass and DealerWorld Key Code Look up.

The key code has an alphabet letter as the first digit of the code, such as Z4625. Tech 2 does not require security access to reset a module, but is needed to program them.

SECURITY ACCESS

The Astra has a unique feature when programming known as Security Access. This is not to be confused with Security Code or SPS. However, you may be prompted for TIS approval when attempting an SPS event. This is displayed on the Tech 2 as No Programming Approval found. Please get programming approval from TIS.

When prompted No Programming Approval found Please get programming approval from TIS, you will need Security Access from TIS2Web. Power down the Tech 2 at the request screen, then install the external power supply to the Tech 2 and connect the RS-232 cable between the TIS2000 terminal and the Tech 2. Beginning with the Tech 2 at the start up screen and on the TIS2Web home page in DealerWorld, select/click on the Security Access (Security) tab and follow the prompts. When Tech 2 is finished, it will show security access enabled. (Type 2 or 3) Then select OK, power down the Tech 2, and return to the vehicle and resume the previous programming from the start.

TIP: Do not leave both cards installed in the Tech 2 when operating. This will cause issues.

REMAINING SECURITY CODE INPUTS

The Saturn Astra is unique in its programming events. When performing a programming procedure with Tech 2, a counter will denote/track each time the security code is used, starting at 10 and working down to 0. This counter is running with every event, regardless if it was successful or unsuccessful. The number of events is tracked, and with each entry, a time delay may be enabled before a new entry can be made. This number is listed as Remaining Security-Code Inputs.

For example, two wrong entries is indicated as Retry Level #8 and enables a 10 second delay in programming. Three wrong entries equals Retry Level #7 and enables a 10 minute delay before programming may be completed. The module will appear to program but the settings will not take. See PIC5006 for a chart that shows wrong entries vs. timeout levels.

RESET MODULE

The Tech 2 will inform you if the module has already been programmed. The first step in replacing a module is the Reset process. The Reset menu is located under the module programming menu. The Reset procedure should pull the required information from the old module and transfer that into the new module when programming. However, you may not be aware that this has occurred. To review and manually record module information that may be needed for programming the service part, select the desired module on Tech 2 and enter the Programming menu. Then select Info to view module information such as part number, serial number, code index, software, etc. (This is especially helpful with Radio/EHU/ DIS replacements).

If the old module does not communicate, a reset cannot be performed and the module will have to be set up manually. You will be prompted to select variants and bus configurations when the Tech 2 programming is performed. When manually programming modules, each ECU in the vehicle must be updated to Present status with the new bus configuration.

To change the ECU to Present status on the High/Mid/Low Speed CAN Bus:

- select each ECU

- press the Modify key

- select Present

- press the Confirm key.

Follow this procedure for each ECU. Make sure each ECU selected is correct for the vehicle configuration/options. Failure to select the correct options will cause additional codes to set after programming. If incorrect options were selected and new corresponding DTCs set, the module variants must be programmed again correctly.

CLEARING DTCs

When clearing DTCs, the process may seem to be performed twice. The Tech 2 will prompt to confirm the deletion, and then clear the DTC in 2 separate steps. You may not be aware that you have not properly cleared the codes. Make sure the codes are cleared by performing the procedure twice.

RADIO/DISPLAY

If an incorrect selection is made during programming, the Radio/Display may fail to unlock and stay in the Safe/Delivery mode. Check and note any codes setting, then clear them before resuming programming. Be sure to pay special attention to the corresponding code that set and to make the correct selection when prompted. Any configuration mismatch may cause programming to fail or cause theft protection to activate.

INSTRUMENT PANEL CLUSTER (IPC)

One of the last steps displayed when programming the IPC on Tech 2 is Program Seat Belt Reminder with the only option available as Confirm. When programming is completed, a different warning chime will begin to sound that was not present previously. This chime is now the default seatbelt reminder and cannot be changed.

TIP: This is under investigation, but for now is considered normal.

POWER STEERING CONTROL MODULE (CIM-COLUMN INTEGRATION MODULE)

Before beginning to program this module, it is necessary to have the Security Code and the mechanical key cut code. Also check VIS for vehicle options for RPO FX3 (StabiliTrak/Stability Control). If this option is present, the yaw rate sensor will need to be calibrated after programming. The yaw rate sensor is referred to as the Cluster Sensor in Tech 2. Before calibration of the yaw rate sensor, be sure any codes in the EBCM are history and are then cleared (2x), as calibration will not complete with any codes set in the EBCM as present.

You may find that when replacing a module such as the IPC, EHU (radio), DIS/GID/BID (radio display) or EHPS (electro hydraulic power steering), you are unable to complete the programming because you do not have the programming Code Index and Version. This code should not be confused with the Security Code. The Code Index is a 3 digit number and is not listed on the Car Pass/Security Card. The Version may be a one or two digit number. These are only listed in the module and SI.

TIP: In the Radio Programming and Setup document in SI, the INDEX code is listed as 2 digit codes. These codes must have a zero placed in front of each number for correct entry in Tech 2. The Code Index is a variant or version indicator and may change as Tech 2 versions update to later software. Typically the number increases in increments of 1.

When you are replacing the IPC/EHU/DIS or EHPS module, you may seek how to program the Index Code and Version. The code index can be retrieved from the original module. If necessary, reinstall the original module so communications can be established with Tech 2. If this is not possible, review the list below for the applicable variant.

EHU VARIANTS:  

  US = Fading  

  Twin Audio = Not Applicable  

  Nav = Not Applicable  

  Tuner = Select US (may show as invalid)   

  US = Without Aux input 

- Thanks to Jeff Gorenflo

The warranty covers repairs to correct any vehicle defect related to materials or workmanship performed during the manufacturing process. However, dealers are empowered at various levels with the discretion to make case-by-case goodwill decisions that are exceptions to GM's standard policy, for good business reasons, when the circumstances surrounding the transaction are special.

The main purpose is to effect quality repairs and meet reasonable and rational customer expectations. These decisions can be during or beyond the time and mileage limitations of the New Vehicle Limited Warranty.

Sometimes during the warranty period, guidelines that establish what is not covered are not clearly obvious when dealership personnel are discussing the condition with a customer. For this reason, questionable situations that do not have exact proof of what transpired should be reviewed in the same manner as situations outside of the warranty time and mileage. These decisions should also be made on a case by case basis.

If dealership service management elects to pay for the repair or replacement of a component in a questionable situation during the warranty coverage period, they are required to clearly document the repair order with the reasons for the decision and are required to clearly document the term "Goodwill" on the repair order along with the reasons for the decision.

Dealership service management has been given additional tools to ensure customer satisfaction throughout the customer's ownership experience.

Repair order documentation must include the reason for issuing authorization, date approved, signature of service management and the appropriate authorization code(s). Warranty administrators must apply the appropriate labor operation for the repair, a failure code of 98 (Customer Satisfaction) and the appropriate authorization code(s) to the warranty claim submission.

Example:

- Thanks to Frank Angelico

For 2009, the operation of the rear seat belts in the Vibe have changed to a cross buckle design. Information is included in the owner manual and in bulletin 08-09-40-002.

TIP: You can print bulletin 08-09-40-002 and share with customers who do not understand how to use the belts. This can avoid unnecessary warranty repair.

Some customers may comment that the rear seat belt latch plate may not stay retained inside the driver side seat belt buckle. The latch will not retain and is self-ejected from the buckle. This is the result of the customer using the incorrect latch with the buckle.

This vehicle is equipped with a rear seat belt cross buckle design layout. This cross design layout was engineered to provide more comfort to the rear seat passengers when properly restrained by the seat belts.

CAUTION: A safety belt that is improperly routed, not properly attached, or twisted may not provide the protection needed in a crash. The person wearing the seat belt could be seriously injured. Always check to be sure that the safety belts are properly routed, not twisted and latched into the correct seat belt buckle.

The following information should be used when latching the rear seat belts (fig. 2):.

A  Passenger side belt

B  Center belt

C  Driver side belt

The passenger side rear seat belt latch plate is designed to latch into the passenger side seat belt buckle.

The center rear seat belt latch plate is designed to latch into the driver side outer rear seat belt buckle.

TIP: The word CENTER is stamped on the center seat belt buckle (fig. 3).

 

A  Buckle for driver side belt

B  Buckle for center belt (stamped CENTER)

The driver side rear seat belt latch plate is designed to latch into the driver side inner rear seat belt buckle.

If the seat belt latch plate does not fully lock into the buckle, verify the correct buckle is being used. Then pull up on the seat belt latch plate to make sure it is secure and properly latched into the seat belt buckle.

- Thanks to Al Ferry

Please begin submitting your product reports to electronicproductreport@gm.com. This is now your one contact address for all product reports, including GM Service Parts and Accessories.

We have transitioned from voicemail to emailed-only product reports. We feel this change will make it easier to reply to you, contact you directly, and improve communication. The updated Field Product Report Bulletin (02-00-89-002H) is now available in SI.

Reasons to submit a product report:

- Include photos, videos or sound, best taken before any vehicle changes

- Concerns noted at PDI

- New vehicle launch issues

- Walk-home events

- If service bulletins do not seem to resolve the concern

- First time occurrences

- Plant build issues

- Photos of wire harness routing or damage

The Field Product Report form can be found on GlobalConnect, Service Workbench, Service Forms.

TIP: If you think you have a candidate for a product report, please be careful not to damage the part; place it in the replacement part packaging before storing.

- Thanks to Melissa Clifford

Rattle Noise

According to bulletin PIC4997AA, the owner of a Malibu, G6 or Aura with CF5 sunroof may comment of a rattle coming from the sunroof assembly when driving over bumps. This condition could be caused by a loose water channel housing push pin. If the pin is loose it can cause the water channel housing to rattle.

To verify the condition, push up on the rear of the sunshade while the noise is occurring. If noise goes away when pushing on the sunshade, lower the headliner and fully seat the push pin into the roof support. It is not necessary to replace the complete sunroof module to resolve this concern.

Squeak, Creak, Itch or Rattle Noise

According to bulletin PIC5001A, the owner of a Malibu, G6 or Aura with CF5 sunroof may comment of a squeak, creak, itch, and or rattle noisy.

Condition 1. A creak/rattle noise from the left and/or right headliner area of the sunroof may be caused by a metal tab at the top of both left and right B-pillars .

IMPORTANT: This metal tab should be bent flat (fig. 6, shown bent flat) on vehicles equipped with sunroof CF5 only. If the tab is NOT bent flat, the sunroof's side rails may contact the tab, causing a creak/rattle concern.

Inspect the top of the B-pillars and bend the tab flat so it will NOT contact the sunroof rail assembly.

Condition 2. Some customers may comment of a squeak, creak or itch noise coming from the rear of the sunroof or headliner. This condition is caused by the two retaining clips that hold the sunroof frame to the roof reinforcement which may not be FULLY seated.

Remove the sunroof trim lace and carefully pull down the rear edge of the headliner at the rear of the sunroof opening. After the headliner is lowered, check to see if the retaining clips (fig. 7) are fully seated into the roof's inner reinforcement. If the retaining clips are not fully seated, you will be able to see the silver clips sticking out below the roof reinforcement.

- Thanks to Jeff Strausser

The Keyless Entry (RKE) and Tire Pressure Monitoring (TPM) may go inoperative during vehicle low battery voltage conditions (fig. 8).

This information applies to these MY08 vehicles built before April, 2008.

Aura

G6

Malibu

Cobalt

G5

HHR

Sky

Solstice

IMPORTANT: Do not use this procedure/correction for every TPM issue. If 3 of the 5 symptoms described below are not present, STOP! There is no need to perform the below procedure/correction. First check the RCDLR software version. If the software version is CL or greater, there is no need to perform the below procedure/correction, STOP!

To find the software version for RCDLR:

1. Use latest version of Tech 2

2. Build the vehicle with Tech 2

3. Select Remote Control Door Lock Receiver

4. Select Module ID Information

5. Select Module Information

6. Look for parameter called Alpha Code -- software version displayed

Symptoms:

1. Both key fobs inoperative

2. Tire Pressure Monitoring (TPM) pressures show dashes

3. No TPM telltale illuminated

4. Possible DTCs are C0569, C0775, B3105 that set as current

5. NOTE:  RKE module may not show up on Tech 2

Correction:

If this condition occurs, reflash the RCDLR then setup the module.

There are two utility files used to flash the module.

Utility File 1

Use the following Utility File 1 to reflash software to RCDLR when the following symptoms are displayed:

-  Both key fobs inoperative

- Tire Pressure Monitoring (TPM) show dashes

-  No TPM telltale illuminated

-  Possible DTCs are C0569, C0775, B3105 that set as current

Utility File 1 -- CG Version = RCDLR  Remote Control Door Lock Receiver (TSB 08-03-16-001A to correct field issues) Pass-Through Only

Utility File 2

Use the following Utility File 2 to reflash software to RCDLR when the following symptoms are displayed:

-  Both key fobs inoperative

- Tire Pressure Monitoring (TPM) show dashes

-  No TPM telltale illuminated

-  Possible DTCs are C0569, C0775, B3105 that set as current

-  RCDLR is not seen in Tech 2 menu

Utility File 2 -- CL Version = RCDLR  Remote Control Door Lock Receiver (TSB 08-03-16-001A) with E4399 Error -  Pass-Through Only

TIP: If a second reflash fails, replace the RCDLR module with a new module p/n 25974373.

- Thanks to Vivian Williams

Some owners of a 2001-09 truck equipped with the 6.6L Duramax diesel engine RPO LB7, LBZ, LLY or LMM may encounter engine noise, low oil pressure, or abnormal oil sludge build-up in the crankcase.

Certain blends of biodiesel fuel may induce excessive amounts of sludge in the crankcase of the engine.

Complete the current SI diagnostic for any trouble codes or symptoms found. If an excessive amount of sludge is found in the crankcase, the vehicle may be running a high percentage of biodiesel. Check oil change records and verify proper oil change intervals are being followed.

Use the Duramax Diesel Owner Manual Supplement for guidelines on proper fuel usage. At this time (unless directed differently by owner manual) only fuels containing up to 5% biodiesel (B5) are acceptable for use in these vehicles.

The National Biodiesel Board website (www.biodiesel.org) has important information about specifications and guidelines for biodiesel usage.

Biodiesel blends higher than B20 may cause unburned fuel to enter the crankcase past the piston rings. Over time, this may cause engine oil sludge problems.

If a dealer encounters an engine with excessive sludge, and oil change intervals are being followed, ask the customer about the type of fuel is being used. If fuel with higher than owner manual specification is being used, advise the customer the sludge was caused by improper fuel.

- Thanks to Donald Langer

Do not replace an entire exhaust assembly is the only problem is a broken stud. The studs on an exhaust pipe can be replaced separately.

If you must return a Y-pipe assembly (fig. 13) for warranty analysis, DO NOT cut the pipe into pieces before shipping. It must remain intact so it can be properly analzyed.

 

- Thanks to Steve Love

Some owners of a 2WD 2008 Silverado, Suburban, Sierra, or Yukon XL equipped with 6L90 (RPO MYD) automatic transmission may comment on a grind noise, vibration or a leak from the rear of the transmission. Inspection of the transmission may show that the extension bushing is loose or has spun out of the extension housing.

A loose or spun extension housing slip yoke bushing may be caused by missing lube holes in the output shaft. If the extension bushing is loose in the extension housing or has spun out of the extension housing, the transmission assembly should be replaced.

Contact your DVM for approval to replace the transmission if the above concern is found.

DO NOT replace the transmission for an extension oil seal leak if the bushing is still solidly pressed into the extension housing.

- Thanks to Chuck Krepp