TSB 06-06-04-048A (S: Ignition System - MIL ON/Misfire DTC's In Wet Weather

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Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL /SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL /SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug (s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug (s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug (s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug (s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer