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

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

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

2004

VUE with 3.5L V-6 Engine - Service Engine Soon (SES) Telltale with Diagnostic Trouble Code (DTC) P0453

Select the "Replace and Reprogram" option on the service stall and recalibrate the PCM with Calibration I.D. number 12594438 or later.

Don’t replace the fuel tank pressure sensor.

04-06-04-052

2002-2004

VUE - Pop/Clunk Noise From the Rear of the Vehicle on Initial Cold Start and/or During the Warm-Up Drive Cycle

Refer customer to bulletin 04-06-05-009 and/or demonstrate noise using Tech 2.

Don’t replace the vent solenoid.

04-06-05-009

2004

ION Redline w/ 5-speed Manual Trans - Manual Transaxle Fluid Information

If it is necessary to perform manual transaxle fluid change, install Saturn P/N 21018899.

Don’t substitute any other fluid.

Reference Parts Catalog

2000-2005

All Vehicles with Compact Discs (CD) or Digital Versatile Discs (DVD) Player - CD or DVD Stuck in CD Player When Returned as a Core Return

Complete return form as called out in bulletin 04-08-44-015.

Don’t attempt to disassemble the radio to remove CDs.

04-08-44-015

2003-2004

ION Sedans Built Up To VIN 4Z190767 and Coupes Built Up To VIN 4Z191744 - Sunroof Inoperative and/or Inside Rearview Mirror Electrical Functions Inoperative

Replace fuse and install new sunroof switch P/N 22687360.

Don’t replace sunroof module.

04-08-45-006

2004

VUE - Extended Engine Crank Time Before Engine Starts

Determine if fuel pressure bleed down is outside specification. If so, replace primary fuel pump.

Don’t replace other fuel system components.

04-06-04-048

2004

VUE w/ 3.5L V-6 Engine - Service Engine Soon (SES) Lamp Illuminated with Diagnostic Trouble Code (DTC) P0496 Set and/or Hard Start or Extended Crank After Adding Fuel

Determine if fuel pressure bleed down is within specification. If so, replace EVAP Canister Purge Solenoid Valve.

Don’t replace fuel pump.

04-06-04-046

2004

ION - Headliner Sags Near Center High Mounted Stop Lamp (CHMSL)

Replace headliner.

Don’t attempt to re-attach headliner.

Reference service manual for replacement procedure.

2003 - 2004

VUE Built After VIN 3S844189 - A/C Compressor On In Floor Mode

Normal condition to reduce window moisture. Refer customer to bulletin 04-01-38-007.

Don’t replace HVAC control head.

04-01-38-007

2004

ION Redline w/ 2.0L LSJ Engine - Engine Cranks But Will Not Start and/or Engine Has Extended Crank Before Starting

Contact technical assistance to verify the timing of the Camshaft Position Trigger.

Don’t replace fuel pump or other ignition components.

Contact Saturn Technical Assistance Center 1-800-828-2112, prompt 1, (Canada English 1-800-263-7740, Canada French 1-800-263-7960)

2000 - 2004

L-Series w/ 3.0L L81 Engine - Service Engine Soon (SES) Lamp Illuminated with DTC P0135 "HO2S Heater Circuit Performance Bank 1 Sensor 1" and/or DTC P0155 "HO2S Heater Performance Bank 2 Sensor 1"

Perform Oxygen Sensor Conditioning Drive Cycle procedure in bulletin.

Don’t replace heated oxygen sensor(s).

04-06-04-008

2002-2003

VUE w/ 3.0L L81 Engine - Service Engine Soon (SES) Lamp Illuminated with DTC P0135 "HO2S Heater Circuit Performance Bank 1 Sensor 1" and/or DTC P0155 "HO2S Heater Performance Bank 2 Sensor 1"

Perform Oxygen Sensor Conditioning Drive Cycle procedure in bulletin.

Don’t replace heated oxygen sensor(s).

04-06-04-008

2004

L-Series w/ 3.0L L81 Engine - Service Engine Soon (SES) Lamp Illuminated with Diagnostic Trouble Code (DTC) P0606 Set

Reprogram Engine Control Module (ECM).

Don’t replace ECM.

04-06-04-026

Saturn Technical Bulletins Released in June and July 2004

Category Type

Subject

Model(s)

Model Year(s)

Bulletin Number

Technical Bulletins for June 2004

Body & Accessories

Erratic Front Turn Signal Operation When Using a Cell Phone Charger in Either Accessory Power Outlet (Install Capacitor In Accessory Outlet Wiring)

ION

2003-2004

03-08-42-009A

Body & Accessories

Service Manual Update - Rear Seat Entertainment System (DVD) Diagnostics and Service Procedures

VUE w/ RPO U32

2004

04-08-44-012

Body & Accessories

Theft Deterrent Feature Will Not Set On Cassette Single CD Player Radio (Replace Radio)

Various Models w/ RPO UP0

Various Model Years

04-08-44-013

Body & Accessories

No Crank, No Start When Ambient Temperature Is Cold - DTCs B2960 and/or B3033 Are Set (Replace Ignition Switch)

ION w/ VIN Break

2003 & 2004

04-08-45-005

Body & Accessories

Sunroof Inoperative and/or Inside Rearview Mirror Electrical Functions Inoperative (Replace Fuse and Install New Sunroof Switch)

ION Coupe & Sedan w/ VIN Break

2003 - 2004

04-08-45-006

Body & Accessories

Squeak Noise from Front Inner Door Armrest/Pull Handle (Replace Front Inner Door Pull Handle Pushnuts)

VUE

2002-2004

02-08-64-019A

Body & Accessories

Itch/Squeak Type Noise Coming From the Sunroof Area (Trim Sunroof Reinforcement Flange Tabs)

ION Coupe w/ RPO CF5

2004

04-08-67-004

Engine /Propulsion System

Service Engine Soon (SES) Lamp Illuminated with Diagnostic Trouble Code (DTC) P0496 Set and/or Hard Start or Extended Crank After Adding Fuel (Replace EVAP Canister Purge Solenoid Valve)

VUE w/ VIN 4 - RPO L66

2004

04-06-04-046

Engine /Propulsion System

Extended Engine Crank Time Before Engine Starts (Replace Primary Fuel Pump)

VUE

2004

04-06-04-048

HVAC

Information on Proper Mode Switch Setting (Between Defrost and Heater/Defrost) to Prevent Window Moisture and HVAC Controller Assembly Logic Revision

VUE

2002 - 2003

04-01-38-007

Transmission/ Transaxle

Vehicle Does Not Shift or Move After Running For a Period of Time and/or Check Engine Light is ON and DTC P0741 is Set (Replace Torque Converter, Valve Body, Clean Out Transaxle and Install New Flex Plate Bolts and Washers)

VUE w/ RPO M09/M45

ION w/ RPO M43

2002 - 2003

2003

03-07-30-023A

Transmission/ Transaxle

Remanufactured Transmission and Remanufactured Valve Body Information Requirements

S-Series

1991 - 2002

04-07-30-026

Technical Bulletins for July 2004

Body & Accessories

Return Form for Compact Discs (CDs) or digital Versatile Discs (DVDs) That Are Stuck in CD Player When Returned as a Core Return

S-Series

L-Series

VUE

ION

2000 - 2002

2000 - 2005

2002 - 2005

2003 - 2005

04-08-44-015

Body & Accessories

Additional Power Distribution Information for Body Control Module Electrical ("BCM ELECT") Fuse in the Instrument Panel Fuse Block (IPFB)

ION

2003 - 2005

04-08-45-007

Engine/ Propulsion System

Engine Squeak/Chirp Noise from Bank 2 (Front Bank) Camshaft Sprockets/Behind Timing Belt Cover with Engine Speeds of 600-3500 RPM (Replace Bank 2 [Front Belt] Timing Belt Sprockets)

L-Series w/ VIN R - RPO L81 w/ VIN Break

2005

04-06-01-024

Engine/ Propulsion System

Extended Engine Crank Time Before Engine Starts (Replace Primary Fuel Pump)

VUE

2004

04-06-04-048

Engine/ Propulsion System

Service Engine Soon (SES) Telltale with Diagnostic Trouble Code (DTC) P0453 Stored in the Powertrain Control Module (PCM) (Recalibrate PCM)

VUE w/ VIN 4 - RPO L66

2004

04-06-04-052

Engine/ Propulsion System

Service Information Regarding a Pop/Clunk Noise From the Rear of the Vehicle on Initial Cold Start and/or During the Warm-Up Drive Cycle

VUE

2002 - 2004

04-06-05-009

Parts on Restriction at TAC (as of June 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

Saturn ION Supercharged 2.0L LSJ Ecotec Engine

Bulletin #04-06-01-014 Saturn Technical Assistance Center 1-800-828-2112, prompt 1, (Canada English 1-800-263-7740, Canada French 1-800-263-7960)