LZE, LZ4, LZ9 Ticking or Clicking Noise Heard Inside Vehicle on Passenger Side at Idle (Install Updated Heater Inlet and Outlet Coolant Hoses/Pipes)

This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 06-06-02-002B (Section 06 -- Engine/Propulsion).

Some customers may comment on a ticking or clicking noise heard inside the vehicle on the passenger side. The noise may be noticeable with the engine on and at idle, with the vehicle in PARK, and with the HVAC and radio off.

The noise may be caused by normal EVAP purge valve operation. The EVAP purge valve operation may be internally grounding out, creating a noise path through the coolant inlet and outlet hoses/pipes

Perform the diagnosis FIRST to determine if the EVAP purge valve operation is normal. Confirm the customer concern by using a Tech  2® to disable the EVAP purge valve. If the ticking or clicking noise heard inside the passenger side of the vehicle is gone, perform the following steps:

1. Drain the cooling system. Refer to Draining and Filling Cooling System in SI.
2. Remove the intake manifold cover, if equipped. Refer to Intake Manifold Cover Replacement in SI.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in SI.



4. Release the rubber coolant inlet and outlet hoses/pipes clamps at the engine pipes using the J 38195 hose clamp pliers, or equivalent.
5. Remove the coolant inlet and outlet hoses/pipes clamp nuts from the throttle body studs.
6. Remove the quick connect fitting from the coolant inlet and outlet hoses/pipes. Refer to Quick Connect Fitting(s) Service (Metal Collar) in SI.
7. Remove the coolant inlet and outlet hoses/pipes from the engine pipes and the throttle body studs.
8. Remove the coolant inlet and outlet hoses/pipes from the vehicle. Discard the old coolant hoses/pipes assembly.
9. Remove the two lower throttle body studs from the upper intake manifold and discard.
10. Replace the coolant inlet and outlet hoses/pipes with the revised part number listed below:

Important: All 2006 models listed in this bulletin use two 10 mm (0.4 in) longer throttle body studs, P/N 11562429.

11. Replace the throttle body studs with longer 10 mm (0.4 in) studs. Refer to revised part numbers listed below:

•	2006 Buick Rendezvous, Terraza - use P/N 12603835.

•	2006 Chevrolet Impala, Monte Carlo - use P/N 12603834.

•	2006 Chevrolet Malibu, Malibu Maxx, Malibu SS - use P/N 12603833.

•	2006 Chevrolet Uplander - use P/N 12603835.

•	2006 Pontiac G6, G6 GT, G6 GTP - use P/N 12603833.

•	2006 Pontiac Montana SV6 - use P/N 12603835

•	2006 Saturn Relay - use P/N 12603835

12. Install two lower 10 mm (0.4 in) longer throttle body studs with threadlock, P/N 12345382 (for Saturn U.S., use P/N 21485277; in Canada/Saturn Canada, use P/N 10953489) to the upper intake manifold.

Tighten
Tighten the two studs to 6  N·m 53 lb in)




13. Install the revised coolant inlet and outlet hoses/pipes assembly.
14. Install the coolant inlet and outlet hoses/pipes clamp nuts to the throttle body studs.

Tighten
Tighten the nuts to 10 N·m (89 lb in).

15. Install the quick connect fitting from coolant inlet and outlet hoses/pipes. Refer to Quick Connect Fitting(s) Service (Metal Collar) in SI. Ensure that the quick connect fittings are positively engaged.
16. Fill the cooling system. Refer Draining and Filling Cooling System in SI.
17. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in SI.
18. Install the intake manifold cover, if equipped. Refer to Intake Manifold Cover Replacement in SI.

For vehicles repaired under warranty, use: