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

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

Models:2004 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

Field Product Reminder -- Car Issues -- Fix It Right the First Time

Model Year(s)

Vehicle Line(s) / Condition

Do This

Don’t Do This

Reference Information/Bulletin

2002-2004

ION with AF23-5 Transaxle or VUE with AF33-5 Transaxle - No Reverse after Valve Body Replacement

Inspect for damaged or missing O-rings on underside of valve body.

Don’t replace valve body again.

Refer to appropriate year and model service manual.

2004

VUE AWD with 3.5 L L66 Engine - Grind Noise after RDM Clutch Drum Replacement

For 3.5L AWD L66, use RDM clutch drum P/N 22730517.

Don’t use P/N 22714938. This part number should not be used for the 3.5L AWD L66.

See Parts Catalog.

2003-2004

L-Series - Projection Headlamp Pattern Aim

Show customer bulletin 04-08-42-007

Don’t replace or align headlamp assembly

04-08-42-007

2002-2005

L-Series Vehicles with Chrome Clad Wheels (RPO PY1) - Clicking Noise from Chrome Clad Wheels at Low Speeds

Show customer bulletin 04-03-10-003.

Don’t replace wheels.

04-03-10-003

2003-2004

ION - Turn Signal Indicator Flashes Faster than Normal and Corresponding Front Turn Signal Bulb is Inoperative with B3948 and/or B3949 (Turn Signals Operate Correctly When Key is Cycled)

Install capacitor per bulletin 03-08-42-009.

Don’t replace bulb or BCM.

03-08-42-009

2003-2004

ION Sedans - Turn Signal Indicator Flashes Faster than Normal and Corresponding Front Turn Signal Bulb is Inoperative (Turn Signals Bulbs will not Illuminate/Operate Correctly Due to Bulb being Burnt Out, When Key is Cycled.)

Install harness kit.

Don’t simply replace the bulb or install capacitor (as outlined in Bulletin 03-08-42-009).

04-08-42-002

2002-2004

VUE - Rattle - Pop, Clunk, Thump, or Knock Noise From the Front End of the Vehicle

Use chassis ears to pinpoint the source of the noise.

Don’t replace any components without verifying the source of the noise with chassis ears.

04-03-08-002 04-02-35-005 04-02-35-006

2001-2004

L-Series with 4T40E or 4T45E Transaxles - Service Vehicle Soon Lamp with P1811

Replace pressure control solenoid.

Don’t replace valve body assembly

04-07-30-020

2002-2004

VUE and ION Vehicles with VT25E Transaxles - New Service Procedures for Torque Converter, Differential Housing, and Case Cover Assembly

Apply 1-2 mm bead P/N 22722716 to surface.

Don’t apply bead larger than 2 mm which would could lead to subsequent transaxle noise and damage.

04-07-30-011A

2003-2004

ION Service Engine Soon Telltale Illuminated with P0606

Install new calibration in ECM per bulletin 04-06-04-010.

Don’t replace PCM.

04-06-04-010

2003-2004

ION - Squeak, Rattle, Pop or Clunk Noise from Front of Vehicle During Suspension Movement

Replace front stabilizer shaft insulators and clamp.

Don’t replace strut, stab bar link, or strut mount.

04-03-08-003

2000-2004

L-Series and VUE Vehicles Equipped with 3.0L L81 Engine - Blue Smoke at Engine Start-Up

Inspect for brown valve stem seals and replace with new (green) valve stem seals.

Don’t replace cylinder heads.

04-06-01-010

Field Product Reminder -- Car Issues -- Fix It Right the First Time

Model Year(s)

Vehicle Line(s) / Condition

Do This

Don’t Do This

Reference Information/Bulletin

2003-2004

ION - Erratic Engine Speed Control at Closed Throttle - Elevated Engine RPM and/or Stall

Diagnose and replace IAC valve/ECM, if necessary.

Don’t replace fuel pump, crankshaft position sensor, and ignition switch.

04-06-04-029

2002-2003

VUE and ION - Squeak or Squeal Noise While Turning Vehicle

Apply lubricant P/N 22731003 to intermediate shaft.

Don’t use any substitute lubricant.

03-02-34-002

2003

ION Built Up To and Including VIN Breakpoint 3Z162616 - Front Side Door Lock Cylinder is Missing or Does Not Sit Flush to the Outer Door Panel

Replace front side door lock cylinder retainer P/N 20650005.

Don’t re-use door lock retainer.

03-08-64-035

2002-2003

ION - Windshield Washer Nozzles Do Not Spray Washer Fluid

Replace both nozzles for front windshield.

Don’t replace only one nozzle.

03-08-43-003

2002-2003

VUE - Built Prior to VIN Breakpoint 3S857939 - Fuel Gauge Displays a False Low Reading or is Stuck on Empty

Replace both the primary and secondary fuel level senders.

Don’t replace only the primary or only the secondary fuel level sender.

02-06-04-021A

Saturn Technical Bulletins Released in April 2004

Category Type

Subject

Model(s)

Model Year(s)

Bulletin Number

Body & Accessories

Service Information Regarding Installation of a Saturn Radio with Tape Player into a 2004 or 2005 Model Year Saturn Vehicle

L-Series w/ RPO U1C

ION & VUE

2004

2004-2005

04-08-44-006

Body & Accessories

Service Manual Update Regarding Headlamp Alignment

L-Series

2003-2004

04-08-42-007

Body & Accessories

Instrument Cluster Needle Pointers Do Not Light Up When Key is in the "Run" Position and the Headlamps are Off - Normal Operating Condition

ION

w/ VIN Break

2003

04-08-49-010

Driveline Axle

Service Manual Update for RTV Sealant Usage on the Rear Drive Module

VUE w/ RPO GQ1

2002-2004

04-04-20-002

Driveline Axle

Moan/Groan Noise/Vibration from Rear of Vehicle when Turning at Low Speeds (Replace Rear Drive Module Differential Clutch Drum)

VUE w/ AWD

2003-2004

03-04-20-003A

Engine

Engine Control Module (ECM)/Transmission Control Module (TCM)/Ignition Module Ground Location Change

ION

2003

03-06-03-005A

Engine

Blue Smoke at Engine Start-Up (Inspect Valve Stem Seal Color and Perform Service Procedure)

L-Series

VUE

w/ VINs R, B RPO L81

2000-2004

2002-2003

04-06-01-010

Engine

Service Manual Update - Add DTC P0504

L-Series

VUE

w/ VINs R,B,4 RPO L81, L66

2003-2004

2003-2004

04-06-04-027

Engine

Oil Leak from Front Cover Seal During Extremely Cold Weather (Replace Seal)

L-Series

VUE

ION

w/ VINs D, F RPO L61

2000-2003

2002-2003

2003

04-06-01-009

Engine

Rattle/Buzz Noise from Exhaust System Under Slight Load (Replace Exhaust Resonator)

VUE

w/ VIN 4 -RPO L66 w/ VIN Break

2004

04-06-05-004

Engine

Erratic Engine Speed Control at Closed Throttle - Elevated Engine RPM and/or Stall (Diagnose, Replace IAC Valve/ECM, if Necessary)

ION

w/ VIN F - RPO L61

2003-2004

04-06-04-029

Steering

Pop, Clunk, Thump, or Knock Noise From the Front End of Vehicle During Suspension Movement (Adjust Intermediate Shaft Connection at Steering Gear Assembly)

VUE

w/ RPO L66

2004

04-02-35-005

Steering

Rattle Noise from Steering Column (Replace Steering Column)

VUE

L-Series

2002-2004

2003-2004

04-02-35-006

Suspension

Squeak, Rattle, Pop or Clunk Noise from Front of Vehicle During Suspension Movement (Replace Front Stabilizer Shaft Insulators)

ION

2003-2004

04-03-08-003

Suspension

Information on Clicking Noise from Chrome Clad Wheels at Low Speeds - Normal Characteristic/No Service Required

L-Series

w/ RPO PY1

2002-2005

04-03-10-003

Transaxle

Service Manual Update for Anaerobic Sealant Application Requirements

VUE

ION

w/ RPO M75/M16

2002-2004

2003-2004

04-07-30-011A

Transaxle

Service Vehicle Soon Lamp Illuminated with Diagnostic Trouble Code (DTC) P1811 "Maximum Adapt and Long Shifts" (Inspect Transaxle and Replace Pressure Control Solenoid)

L-Series

2001-2004

04-07-30-020

Parts on Restriction at TAC (as of April 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 800 263 7740, Canada French 800 263 7960)