Engine Runs Rough After Extended Crank and/or Engine Hesitation on Acceleration after Initial Cold Start During Ambient Temperatures Below 10 Degrees C (50 Degrees F) (Reprogram PCM)

Some customers may comment that the engine has an extended cranking period during initial cold start, followed by the engine running rough. Some customers may comment that the engine hesitates on acceleration after initial cold start. Both conditions may occur during ambient temperatures below 10° C (50° F).

This condition may be caused by the PCM calibration.

Reprogram PCM with new calibration. The new calibration improves ambient cold start ability and drivability. Refer to service procedures in this bulletin.

Verify Calibration ID Number

Important: You must view calibration numbers using the TECH 2 Scan Tool and NOT the Saturn Service Stall System (SSS).

1. Connect TECH 2 scan tool to the vehicle.

Important: You must select 2004 model year for either 2004 or 2005 model year vehicles. The 2005 TECH 2 software does not support the Calibration ID function.

2. Select 2004 model year for both 2004 and 2005 model year vehicles.
3. Navigate to the 2.0 L Powertrain Menu.
4. Select ID Information.
5. Select ENGINE INFORMATION.
6. Read Calibration ID.

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If the current PCM calibration number is the same or newer than the calibration number in the "Calibration Information" table, do not reprogram the PCM. The updated calibration is already installed and reprogramming is not required. For further diagnostic information, refer to "Symptoms - Engine Controls" in the Engine Controls -- 2.0L (LSJ) section of the 2005 Saturn ION Service Manual, Vol. 2 (SI Document ID #1522229).

•	If the calibration ID number is not the same or newer than the calibration number in the "Calibration Information" table, then reprogram the PCM with the part number listed for that vehicle option content. Refer to "Reprogramming PCM" in this bulletin.

Reprogramming PCM

Important: Before installing new PCM calibration, make sure the Saturn Service Stall (SSS) version is TIS 1.0 2005 or later.

Important: While ignition is OFF, apply parking brake to disable daytime running lights (DRLs) prior to starting reprogramming procedures.

Important: Technician must select "Replace and Reprogram" option in order to reprogram the PCM.

Reprogram the PCM with the appropriate calibration listed in this bulletin.

Refer to the "Calibration Information" table to select the correct calibration for the vehicle being serviced. (If newer calibrations than those listed in the "Calibration Information" table are available, install the latest available service calibration.)

Use the Saturn Service Stall System (SSS) software version 1.0 2005 or later data CD. Refer to "Service Programming System" (SPS) in the SSS User Guide and "Service Programming System (SPS)" in the Vehicle Control Systems section of the 2005 Saturn ION Service Manual, Vol. 3 for reprogramming procedures.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for J6354 (EE PROM - Reprogramming [Install New PCM Calibration]), or if another procedure is performed, refer to the appropriate Electronic Labor Time Guide for the correct Labor Operation Code and Time.