Saturn Field Product Reminder - Vehicle Fix It Right the First Time Issues, Parts Restriction Information and Technical Bulletins Released in April, 2004. Saturn SL 2002

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)