Saturn Field Product Reminder - Vehicle Fix It Right the First Time Issues, Parts Restriction Information and Technical Bulletins Released in November 2004. Saturn L200/LW200 2004

Subject:

Saturn Field Product Reminder -- Vehicle "Fix It Right the First Time" Issues, Parts Restriction Information and Technical Bulletins Released in November 2004

Models:

2005 and Prior Model Year Saturn Vehicles

In order to access this bulletin electronically, go to the SI Home Page (http://service.gm.com) and select the "Latest News" icon. The documents are arranged by sub-section and then by date (newest to oldest). Scroll down to "General Information" then click on the latest "Field Product Reminder" bulletin.

Saturn Field Product Reminder -- Vehicle Issues -- Fix It Right the First Time

Model Year(s)	Vehicle Line(s) / Condition	Do This	Don't Do This	Reference Information/Bulletin
New Issues
2003 - 2004	IONs Built Prior to VIN Breakpoint 4Z210712 - No Crank, No Start When Ambient Temperature is Cold - Diagnostic Trouble Codes (DTCs) B2960 and/or B3033 are Set in BCM History	Navigate to BCM history with TECH 2 and inspect for DTC(s). If found replace ignition switch with P/N 10392423. If an ignition switch was replaced prior to June 2004, replace ignition switch again.	Don’t replace the ignition housing, which does not contain the passlock sensor.	04-08-45-005
2003 - 2005	ION - Alignment Specifications	Reference the appropriate year service information in Electronic Service Information (ESI) for the most up to date and accurate alignment specifications.	Don’t rely on alignment specs that are resident within the alignment machine as some may be incorrect.	Reference the appropriate year service information in Electronic Service Information (ESI).
2004	VUE with 3.5L V-6 Engine (VIN 4 - RPO L66) Cruise Control Inoperative and/or Service Engine Soon (SES) Telltale Illuminated with DTC P0571 Stored in Powertrain Control Module (PCM)	Clear DTC with Tech 2 and wait for future software updates and field communication.	Don’t reprogram PCM or replace other cruise control system components.	Service bulletin in process.
2004	VUE with 5-speed Automatic Transaxle (RPO MJ7/MJ8) Service Engine Soon (SES) Telltale Illuminated with DTC P0873 Stored in Transaxle Control Module (TCM)	Replace 4th clutch pressure switch.	Don’t replace the 3rd clutch pressure switch. The Tech 2 software will incorrectly describe P0873 as a 3rd clutch pressure switch problem when, in fact, it is a 4th clutch pressure switch problem.	Reference the appropriate year service information in Electronic Service Information (ESI).
2005	Relay - Interior Lights Flicker or Dim	Refer to PI for description of condition being "normal".	Don’t replace generator or any other electrical components.	PI PIT3246
2002 - 2003	VUE Vehicles with 3.0L V-6 Engine (VIN B - RPO L81) - Service Engine Soon (SES) and/or Reduced Power Lamp Illuminated, Limited Throttle Response Following Cold Engine Start Up, DTC P0638	Re-locate primary Positive Crankcase Ventilation (PCV) Hose and re-route secondary PCV hose per procedures in bulletin.	Don’t replace throttle body, PCM, or other related throttle control components.	04-06-04-074
2000 - 2005	L-Series with 3.0L V6 Engine (VIN R - RPO L81) Service Engine Soon Lamp Illuminated with DTCs P0130 "HO2S Circuit Bank 1Sensor 1", P0135 "HO2S Heater Circuit Performance Bank 1 Sensor 1", P0150"HO2S Circuit Bank 2 Sensor 1" and/or P0155 "HO2S Heater PerformanceBank 2 Sensor 1"	Perform oxygen sensor conditioning drive cycle.	Don’t replace oxygen sensor(s).	04-06-04-008A
2003 - 2005	ION Vehicles with Air Conditioning (RPO C60) - Moisture (Air Conditioning Condensation) Leaking onto Vehicle Floor when A/C Systemis Running	Remove obstruction from evaporator drain hole.	Don’t replace HVAC case half or any other A/C components.	04-01-38-016
2003 - 2004	ION - Squeak, Rattle, Pop or Clunk Noise from Front of Vehicle During Suspension Movement	Use chassis ears to verify the noise is coming from the sway bar bushing and replace if necessary.	Don’t replace steering rack, upper strut mounts, sway bar end links or lower control if chassis ears indicate noise is coming from sway bar bushing.	04-03-08-003A
2003	ION - Clunk, Thump or Rattle Noise from Front Suspension while Driving Over Rough Road Conditions or when Braking	Replace ION lower control arm bushings by pressing the old bushing out and pressing a new one in.	Don’t replace the complete lower control arm just for a lower control arm rear bushing concern.	04-03-08-006
2004	VUE with 3.5L V-6 Engine (VIN 4 - RPO L66) - B1372 along with various U-codes (i.e. U2105, U2106, etc.)	Clear DTC with Tech 2 and wait for future field communication.	Don’t replace controllers/modules.	ESI PI PIC3258
2004	ION - Cruise Control Inoperative and/or Service Engine Soon (SES) TelltaleIlluminated with Diagnostic Trouble Code (DTC) P1574 Stored in PowertrainControl Module	Clear DTC with Tech 2 and wait for future field communication.	Don’t replace cruise switch, brake switch or other cruise control system components.	PI in process. Reference ESI for latest information.
2003 - 2004	ION Sedans - Instruction On When or If To Install Headlamp Harness on Vehicles Involved in Safety Recall 04095	Follow Safety Recall instructions and install 2 new bulbs (and resistance if needed). If after new bulb(s) is installed and new bulb(s) will not illuminate, then and only then install new headlamp harness.	Don’t replace the harness just because the socket appears deformed.	Safety Recall 04095
2002 - 2004	VUE - with 5-speed AF33-5 Automatic Transaxle - No 3rd Gear (with or without p1719) After Trans Fluid Service	Remove trans fluid fill plug when adding transaxle fluid.	Don’t remove the 3rd gear anchor bolt, which can be mistaken for the trans fluid fill plug. Removing the incorrect bolt will dislocate internal components, cause a no 3rd gear concern and require transaxle removal to correct.	03-07-30-018

Saturn Technical Bulletins Released in November 2004

Category Type	Subject	Model(s)	Model Year(s)	Bulletin Number
Brakes	Brake Pedal Pulsation and/or Vehicle Vibration During Brake Application (Diagnosis/Service Procedures)	S-Series	1991-1995	04-05-22-022
Engine/ Propulsion	Service Manual Update for Diagnostic Trouble Codes (DTC) P0033, P0068, P0101, P0102, P0171, P0172, P0230, P0335, P0507, P1101, P1182, P1516, P1682, P2125, P2176, and Fuel Injector Balance Test with Tech 2	ION Red Line Coupe w/ VIN P - RPO LSJ	2004-2005	04-06-04-084
General Information	Revised Pre-Delivery Inspection (PDI) Form	All Saturn vehicles	2004-2005	04-00-89-054

Parts on Restriction at TAC (as of November 2004)

Model Year(s)	Component on Restriction	Reference Info/Bulletin/Phone Number
2004	Saturn VUE MJ7/MJ8 Automatic Transmission Assemblies	Bulletin # 03-07-30-040 Saturn Technical Assistance Center 1-800-828-2112, prompt 1, (Canada English 1-800-263-7740, Canada French 1-800-263-7960)
2004-2005	Saturn VUE All-Wheel Drive (AWD) Transfer Case Assembly	Bulletin # 03-07-30-039A Saturn Technical Assistance Center 1-800-828-2112, prompt 1, (Canada English 1-800-263-7740, Canada French 1-800-263-7960)
2004-2005	Saturn XM Digital Radio Receiver	Bulletin # 04-08-44-009 Saturn Technical Assistance Center 1-800-828-2112, prompt * (The prompt for XM radio callers is combined with the OnStar prompt.)