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Old 11-17-2004, 10:35 PM   #1
WopOnTour
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Default Quick warning for Saturn techs (RE: 2005 Relay)

Just a warning on the new Relay for you Saturn techs out there - DO NOT attempt to remove the screws for the rear tailights! If you do, there is a very good chance they will strip out of the body nut/stud they are installed with.

There is a PSB coming out that will show you how to "back-up" the nuts from inside the d-pillar body panel ( a bit of trim will need to be removed). After the lamp assembly is out, you can then easily remove the stud and remove the Loc-tite that was improperly installed at the factory. Once they are cleaned up and reinstalled the screws can then be removed/installed without issue.

Should see a PI on it this week and a PSB in next couple weeks

Regards
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Old 11-17-2004, 11:35 PM   #2
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Thumbs Up Re: Quick warning for Saturn techs (RE: 2005 Relay)

Thanks for the heads up.

So far we don't have to worry about anything like that. Have you guys gotten your hands on one yet?

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Old 11-17-2004, 11:38 PM   #3
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

Quote:
Originally Posted by ssicarman
Thanks for the heads up.

So far we don't have to worry about anything like that. Have you guys gotten your hands on one yet?
Unfortunately that's how we "discovered" this small but annoying oversight
issed:
WOT

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Old 11-17-2004, 11:52 PM   #4
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

OOOPS!

Any training coming up for it in the near future?

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Old 11-21-2004, 08:13 PM   #5
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

they have been doing training for the Relay for a little while now. I was down the Newark, DE. facility for module 2, in oct. and they were having a 2 day course for the Relay.

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Old 11-22-2004, 11:08 PM   #6
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

Quote:
Originally Posted by JPDucketts
they have been doing training for the Relay for a little while now. I was down the Newark, DE. facility for module 2, in oct. and they were having a 2 day course for the Relay.

Canada runs their training differently than you guys down south do. We tend to get it after you do but then we are just getting the Relays now. So in the end it evens out.

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Old 11-23-2004, 12:59 AM   #7
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

Quote:
Originally Posted by JPDucketts
they have been doing training for the Relay for a little while now. I was down the Newark, DE. facility for module 2, in oct. and they were having a 2 day course for the Relay.

Just wondering... where the training is given? The GM Boxwood Rd. assembly plant? My brother-in-law works there.

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Old 11-23-2004, 10:02 AM   #8
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

training is in spring hill, newark deleware, and ontario calif.

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Old 11-24-2004, 09:53 PM   #9
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

Just think... You get to work on the 60V6... There has been a ton of problems with the lower intake gaskets. The 3.5l got a new plastic gasket, although I have not heard if it is doing any better - I hope so!

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Old 11-25-2004, 01:03 AM   #10
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

Quote:
Posted by Specalist:
The 3.5l got a new plastic gasket, although I have not heard if it is doing any better - I hope so!
No Kidding Water pumps and sometimes alternators used to be be caca as well on the 3100/3400

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Old 12-04-2004, 06:43 PM   #11
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

Bulletin for this tail lamp issue released, refer to:
04-08-42-014
BEFORE attempting to remove the tail lamp assemblies

Regards
WOT

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Old 12-07-2004, 06:47 PM   #12
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

Also, another heads up on the Relays, DON'T loose the master keys. At the moment, you'll need to head to the local Chevy dealer to get the new keys cut and then programmed, not to mention having to replace the ignition cylinder and all the locks...had something like this happen up here on LI and it wasnt pretty, over several hundred dollars and takes approx 4-5 hours to complete.

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Old 12-08-2004, 01:15 AM   #13
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

Quote:
Originally Posted by TBone1082
Also, another heads up on the Relays, DON'T loose the master keys. At the moment, you'll need to head to the local Chevy dealer to get the new keys cut and then programmed, not to mention having to replace the ignition cylinder and all the locks...had something like this happen up here on LI and it wasnt pretty, over several hundred dollars and takes approx 4-5 hours to complete.
Er well... sort of... but actually NO. In fact not much of what you have said is technically correct.
Both keys being supplied with the Relay (black heads) are MASTER keys.It's true that the keys are special, the Relay uses Pass Key III and the key contains a transponder which when "excited" transmits a code to the PKIII antenna. This code must be learned/programmed into the system in order for the vehicle to start. So even a PK3 blank, that is coded correctly (i.e. turns the IGN ON) BUT has not been "learned" WILL NOT start the vehicle.

If ALL keys to the vehicle have been lost- new keys must be cut using the original key code (and a PK3 blank) then the TECH2 will be required to reprogram (learn) at least one key to create a new master key.

Your Chevy dealer has the EXACT SAME software in their TECH2 as the Saturn TECH2.The most up-to-date version should always be used -which is currently 24.009. This version will allow the Saturn technician to reprogram a new master key in about 30 minutes following the THEFT SYSTEM RELEARN procedure in eSI. This procedure also ERASES all previouly learned keys (lost or stolen) preventing them from starting the Relay.


As long as you have at least ONE master key adding additional keys is easy.
To add additional master (black head) or valet keys (grey head)

1.With a previously learned master key, turn ON the ignition, with the engine OFF
2.Turn OFF the ignition and remove the key.
3.Within 10 seconds insert the key to be learned
4. Turn ON the ignition with the engine OFF
* The vehicle has now learned the new key. Up to 9 additional keys (master or valet) to 10 keys in total can be programmed into the system

*USING THIS PROCEDURE TO ADD KEYS IS NOT RECOMMENDED IF A KEY WAS LOST AS THE OLD KEY WILL STILL FUNCTION UNLESS THE TECH2 THEFT RELEARN PROCEDURE WAS PERFORMED PRIOR TO THIS PROCEDURE.

In CANADA the procedure for adding keys is only slightly different due to different software (not really sure why) This is because the procedure for adding keys requires TWO "learned" master keys (using the TECH2 and the THEFT DETTERANT REPROGRAMMING PROCEDURE to learn them - taking twice as long)

1.With a previously learned master key #1, turn ON the ignition with the engine OFF
2.Turn OFF the ignition and remove the key.
3.Within 10 seconds insert a second previously learned master key #2
4.Turn ON the ignition with the engine OFF
5.Turn OFF the ignition and remove the key
6.Within 10 seconds insert the key to be learned
7.Turn ON the ignition with the engine OFF.
*The vehicle has now learned the new key.
*Up to 10 master and/or valet keys can be added/programmed using this method

So I'm not sure what kind of bad experience you have recently endured T-bone, but whoever is feeding you this information is not up-to-speed IMO

HTH
WopOnTour

Last edited by WopOnTour; 12-08-2004 at 01:21 AM..

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Old 12-08-2004, 11:02 AM   #14
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

Was only our service manager lol. Anyways, I wouldnt be surprised.

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Old 12-08-2004, 09:21 PM   #15
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Default Re: Quick warning for Saturn techs (RE: 2005 Relay)

yea thanks for the info
we have see some weird stuff the the relay
i have had dash bulbs out and a ton of the plastic trim peices falling off
i have found just to use some good 3M tape to reattach the trim

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