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