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Service bulletins for the 2005 Saturn Relay

A bulletin is a manufacturer's communication to its dealers, as NHTSA indexes it. The summary is NHTSA's. The document is the manufacturer's: read it at NHTSA. A bulletin is not a recall, and listing a model year does not mean every vehicle of it is concerned.

547 on file from NHTSA, as of 2026-10-19.

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Bulletins, newest first
PIT5074J2016-10-21. Service bulletin. ELECTRICAL SYSTEM. THIS PRELIMINARY INFORMATION COMMUNICATION PROVIDES INFORMATION TO THE TECHNICIAN ABOUT THE USE OF J-35616-64B TERMINAL TEST PROBE, REPLACEMENT TERMINALS, AND TERMINATED LEADS. THE J-35616-64B IS THE LATEST TEST PROBE RELEASED FOR CHECKING TENSION OR PROBING THE .64 SERIES TERMINALS. THE TEST PROBE TERMINAL HAS BEEN RELEASED IN THE TERMINAL REPAIR KIT (J-38125-620H) LOCATED IN LEAR TRAY 7 PART NUMBER 963716-2. THERE ARE 5 TERMINATED LEADS IN A PACKAGE PART NUMBER IS 13505346, WHICH CAN BE ORDERED THROUGH YOUR NORMAL GENERAL MOTORS CUSTOMER CARE AND AFTERSALES PARTS CHANNEL
PIP4786C2016-10-20. Service bulletin. ENGINE AND ENGINE COOLING. THIS PRELIMINARY INFORMATION COMMUNICATION PROVIDES INFORMATION TO THE TECHNICIAN ABOUT VEHICLES THAT MAY HAVE LOW OIL PRESSURE MESSAGE. TECHNICIAN MAY ALSO FIND A DIAGNOSTIC TROUBLE CODE P0521 IN THE ENGINE CONTROL MODULE. TECHNICIAN SHOULD FOLLOW ALL PUBLISHED SERVICE INFORMATION DIAGNOSIS. WHEN USING A SCAN TOOL IF THE OIL PRESSURE IS LOW BUT THE OIL PRESSURE AT THE OIL FILTER HOUSING IS CORRECT, TECHNICIAN SHOULD INSPECT THE VALVE LIFTER OIL FILTER FOR DEBRIS/SLUDGE THAT COULD BE RESTRICTING OIL FLOW TO THE OIL PRESSURE SENSOR. TECHNICIAN SHOULD REMOVE THE VALVE LIFTER OIL FILTER AND CLEAN IT. IF THE VALVE LIFTER OIL FILTER CANNOT BE CLEANED REPLACE IT.
PI1394A2016-10-19. Service bulletin. ENGINE. THIS INFORMATIONAL BULLETIN PROVIDES ADDITIONAL INFORMATION ON HOW TO INSTALL PISTONS AND SUGGEST WHAT TOOLS TO USE.
030604017I2016-10-18. Service bulletin. ENGINE AND ENGINE COOLING:ENGINE:DIESEL. THIS INFORMATIONAL BULLETIN EXPLAINS THE USE OF DIESEL FUEL ADDITIVES IN AN ENGINE, ARE NOT REQUIRED UNLESS THE CUSTOMER DESIRES ADDITIVES TO PREVENT FUEL CONCERNS DEPENDING ON FUEL OR TEMPERATURE RELATED CONDITIONS.
030603004R2016-10-18. Service bulletin. ENGINE; ELECTRICAL SYSTEM:12V/24V/48V BATTERY. THIS INFORMATIONAL BULLETIN PROVIDES INFORMATION ON HOW TO TEST A BATTERY AND WHAT IS NEEDED TO WARRANTY A BATTERY.
000601026I2016-10-18. Service bulletin. ENGINE. THIS INFORMATIONAL BULLETINS PROVIDES INFORMATION ON THE INTAKE MANIFOLD INSPECTION/REPLACEMENT AFTER SERVERE INTERNAL ENGINE DAMAGE.
000601012F2016-10-18. Service bulletin. ENGINE. THIS INFORMATIONAL BULLETIN PROVIDES INFORMATION TO GM DEALERS ON THE CORRECT CLEANING METHODS WHEN CLEANING ENGINE GASKET SEALING SURFACES.
16NA2602016-10-17. Service bulletin. EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.. THIS TECHNICAL BULLETIN PROVIDES A PROCEDURE TO REPROGRAM THE MEDIA DISC PLAYER WITH THE LATEST CALIBRATIONS TO CORRECT A CONDITION OF THE REAR ENTERTAINMENT SYSTEM NOT OPERATING AS INTENDED IN COLDER AMBIENT TEMPERATURE AREAS DUE TO CALIBRATION CONCERNS.
PIP5094A2016-09-26. Service bulletin. ELECTRICAL SYSTEM. THIS PRELIMINARY INFORMATION COMMUNICATION ADVISES THE TECHNICIAN THAT ,WHEN TESTING ANY CIRCUIT FOR OPEN OR RESISTANCE, IT IS IMPERATIVE THAT ALL RELATED TERMINAL PIN FIT AND TENSION BE CHECKED WHEN THE TEST STEPS REQUIRE DISCONNECTION OF THE CONNECTOR OR COMPONENT, PRIOR TO ANY COMPONENT REPLACEMENT. ALWAYS USE THE RECOMMENDED TERMINAL TEST TOOL DURING THESE TESTS.
PIT-5485-B2016-08-17. Service bulletin. EQUIPMENT:ELECTRICAL; EQUIPMENT. THIS PRELIMINARY INFORMATION COMMUNICATION ADVISES THE TECHNICIAN IF UNABLE TO PLACE AN ONSTAR CALL IN THE IGNITION ON MODE AFTER THE ONSTAR CANADA UPGRADE, TO CONTACT THE GM TECHNICAL ASSISTANCE CENTER ONSTAR GROUP FOR FURTHER ASSISTANCE.
PIC-4935-E2016-08-17. Service bulletin. ELECTRICAL SYSTEM:12V/24V/48V BATTERY; ELECTRICAL SYSTEM. THIS PRELIMINARY INFORMATION COMMUNICATION PROVIDES INFORMATION TO HELP THE DEALERSHIP TECHNICIANS PERFORM A PARASITIC DRAIN TEST FOR THE ONSTAR MODULE. WHEN PERFORMING BATTERY PARASITIC DRAIN TEST, THERE MAY BE SOME CONFUSION AS TO WHAT THE NORMAL POWER CONSUMPTION READING SHOULD BE FROM THE ONSTAR SYSTEM.
PIC-5050-A2016-08-17. Service bulletin. ELECTRICAL SYSTEM. THIS PRELIMINARY INFORMATION COMMUNICATION ADVISES THE TECHNICIAN THE STEPS ON REPAIRING THE CONCERN. A CUSTOMER MAY IDENTIFY A CONCERN OF UNABLE TO REACTIVATE A VEHICLE'S ONSTAR THAT HAS BEEN PREVIOUSLY DISABLED BY ONSTAR. DEALER IS TO CALL GENERAL MOTORS TECHNICAL ASSISTANCE CENTER FOR FURTHER ASSISTANCE IF THE CONCERN IS STILL PRESENT.
PIC-5260-A2016-08-11. Service bulletin. STRUCTURE:BODY; ELECTRICAL SYSTEM; VISIBILITY:SUN/MOON ROOF ASSEMBLY. THIS PRELIMINARY INFORMATION COMMUNICATION ADVISES THE TECHNICIAN THE STEPS ON DIAGNOSING THE CONCERN. VEHICLE'S SUNROOF OPERATION INTERMITTENT, BIND, NOISE, AUTO-REVERSE, AND/OR WATER LEAKS.
PIP-5064-B2013-04-10. Service bulletin. ENGINE. BUICK/CHEVROLET/PONTIAC/SATURN: AFTER INSTALLING REMAN HVV6 ENGINE, WOULD BE CONCERN WITH ROUGH RUNNING OR MISFIRE ON ONE OR BOTH BANKS OF ENGINE OR IDLE SURGING. MODELS 2005-11 LUCERNE, RENDEZVOUS, TERRAZA, IMPALA, MALIBU, MONTE CARLO, UPLANDER, G6, MONTANA SV6, AURA, RELAY, VUE. *PE UPDATED 4/9/13. *PE
09-09-40-001A2011-06-14. Service bulletin. SEAT BELTS:FRONT:WARNING LIGHT/DEVICES; SEAT BELTS. GM: THERE ARE SEAT BELT PROBLEMS: DIFFICULTY LATCHING AND UNLATCHING BUCKLE. BUCKLE RELEASE BUTTON IS STICKING. SEAT BELT WARNING LIGHT ILLUMINATED. LIKELY CAUSED BY STICKY BEVERAGES THAT ARE SPILLED INTO THE BUCKLE ASSEMBLY. *RM UPDATED 4/3/12. *PE
05-09-40-002E2011-05-11. Service bulletin. SEAT BELTS:FRONT:WEBBING; SEAT BELTS:FRONT:RETRACTOR. GM: SERVICE BULLETIN EXPLAINING WHEN THE SAFETY BELTS ARE SUPPOSED TO LOCK. *RM UPDATED 12/6/11. *PE
PIT-48552009-09-02. Service bulletin. STRUCTURE:BODY:DOOR; LATCHES/LOCKS/LINKAGES:DOORS:LATCH. BUICK/CHEVROLET/PONTIAC/SATURN: POWER SLIDING DOOR DOES NOT POWER OR MANUAL UNLOCK. DIAGNOSTICS MAY REVEAL THAT SLIDING LOCK BUTTON ON INSIDE DOOR PANEL WILL NOT MOVE FROM LOCKED TO UNLOCKED POSITION. *PE
SB-07-06-04-019A2009-06-02. Service bulletin. POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM); ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL; ENGINE AND ENGINE COOLING:ENGINE. GENERAL MOTORS: INTERMITTENT MIL/SES/ DTC P2138 WITH REDUCED ENGINE POWER (REPAIR INSTRUMENT PANEL (IP) TO BODY HARNESS CONNECTOR). 2005-08 GM PASSENGERS CARS/LIGHT DUTY TRUCKS (INCL. SATURNS). *PE UPDATED 11/5/10. *PE UPDATED 4/4/11. *PE UPDATED 2/3/16. *PE
PIT-3046E2008-12-05. Service bulletin. FUEL SYSTEM, OTHER:STORAGE:FUEL GAUGE SYSTEM. GMC: FUEL GAUGE FLUCTUATION IN PARK OR NEUTRAL, CAUSING THE LOW FUEL LIGHT TO ILLUMINATE. *PE
PIT-46632008-12-04. Service bulletin. STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS; STRUCTURE:BODY:DOOR. GMC: POWER SLIDING DOOR ONLY OPENS FROM INSIDE/OUTSIDE DOOR HANDLE(S). NEITHER RIGHT/LEFT SLIDING DOOR WILL NOT OPEN FROM THE OVER HEAD CONSOLE SWITCH, B-PILLAR SWITCH, OR RKE KEY FOB. *PE
PIC48452008-07-14. Service bulletin. STRUCTURE:BODY:DOOR. PART RESTRICTION - POWER SLIDING DOOR ACTUATOR CONTROL MODULE ASSEMBLY. *NJ
0807300022008-07-09. Service bulletin. POWER TRAIN:AUTOMATIC TRANSMISSION. INFORMATIONAL ON 4T65-E MN7, M15 AND M76 FRONT WHEEL DRIVE AUTOMATIC TRANSMISSION VALVE BODY RECONDITIONING, DTCS P0741, P0742, P0757, P842, HARSH SHIFTS OR SLIPS. *PE
37432007-12-13. Service bulletin. SERVICE BRAKES, AIR:ANTILOCK:ABS WARNING LIGHT. VARIOUS ABS DTC'S AND INTERMITTENT CONCERNS. *NJ
46072007-11-14. Service bulletin. FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY. RUNNING OUT OF GAS WHILE PARKED WITH 1/4 TANK OR LESS WHEN DOWNWARD ON INCLINE. *NJ
0705230032007-10-09. Service bulletin. SERVICE BRAKES, AIR:DISC:ROTOR. PULSATION/VIBRATION WHEN APPLYING BRAKES (REPAIR ROTOR VARIATION AND INSTALL NEW FRONT BRAKE SHIELDS) *NJ

The summaries are NHTSA's. Each bulletin's page links NHTSA's copy of the manufacturer's document.