SI Regarding Saturn VUE DOHC 2.2L (L61) Engine Exchange Program (U.S. Only)

The purpose of this bulletin is to outline the Engine Exchange Program for the 2002 model year Saturn VUE equipped with L61 2.2L engines. The Engine Exchange Program will be used to provide quick and reliable product feedback that product engineering will use to identify and resolve product concerns. The program will be administered for the first 6 months of Saturn VUE production.

The Engine Exchange Program will be administered through the Saturn Technical Assistance Center (TAC) at 1-800-828-2112, prompt 1; Monday, 9:30 a.m. - 6:30 p.m. CST; Tuesday through Friday, 7:30 a.m. - 6:30 p.m. CST.

There are certain repairs that can be performed on DOHC 2.2 L (L61) engines that do not require an engine to be exchanged. During the six-month Engine Exchange program period, Retailers may replace any of the components listed below without participating in the Engine Exchange program:

Oil leaks coming from any of the components in the above list should be repaired at the Retailer without exchanging the engine. If the engine has an oil leak that is not coming from the above list, the engine must be exchanged. Contact Technical Assistance for further procedures.

If any internal components of the engine require replacement, the engine must be exchanged. The new replacement engine will arrive as a assembly including intake and exhaust manifolds, fuel rail, ignition system, engine sensors, flexplate, and the flywheel and clutch assembly. All of these components must be assembled on the failed engine prior to shipment if they have been removed. For effective engineering analysis, please do not remove any components from the engine assembly. Any components that are reinstalled on the failed engine must be torqued to specification to avoid operator injury during pre-teardown testing. Refer to the 2002 VUE service manuals for proper torque specifications. Retail facilities that return partially disassembled engines will be billed for all materials furnished.

When a Saturn Retailer contacts the Technical Assistance Center to request an exchange engine, the Technical Assistance Engineer will arrange to ship a new engine to the retailer overnight at no charge. Exchange engines will be shipped with a quantity of oil. Check engine oil level before starting the engine. Exchange engines will also be shipped with return engine shipping instructions, including a return shipping label (freight collect at destination) and a partially completed Bill of Lading document.

Important: All fluids must be drained from the removed engine.

1. To completely drain coolant from engine assembly, a drain valve is located at the bottom of the water pump assembly.
2. If engine is being returned for an oil leak, mark position of leak on engine with grease pencil.
3. Crate removed engine in the original shipping container.
4. Attach completed Core Return Shipping Tag to engine block of core return.
5. Attach completed Engine Return Check List/Product Feedback Form to a copy of the Customer Service Order.
6. Return these forms in plastic press on envelope received with exchange engine.
7. Attach plastic envelope to core return's shipping container.

Remove the original shipping tag and attach the return shipping label to the container. The Bill of Lading is provided with the exchange engine and is the only document required to return the removed engine.

Important: To make arrangements to have an engine core picked up, contact Yellow Freight System INC. at 1-800-610-6500. Yellow Freight System INC. will coordinate all exchange engine returns. ALL ENGINES ARE REQUIRED TO BE RETURNED USING GUARANTEED DELIVERY SERVICE.

After the Bill of Lading has been dated and signed by the carrier, retain the last copy with your service order. Provide the other copies to the carrier.

Important: Your copy of the Bill of Lading, signed by the carrier, is your proof that the engine was returned.

The removed engine is to be shipped by Yellow Freight System INC. - collect - to the warranty parts center. Once again, contact Yellow Freight System INC. if you have any questions regarding proper engine core return procedures. Please ensure the Retailer address (return address) and Technical Assistance case number can be identified on the outside of the crate.

If the envelope containing the shipping information is lost, the Saturn Retailer should contact the Saturn Service Parts Assistance Center at 1-800-828-2112. prompt 2.

To receive credit for replacing a L61 engine assembly during the VUE Engine Exchange Program, submit a claim with the following information:

Important: Applicable miscellaneous parts, such as engine oil and coolant, are to be sold to the Customer Service Order (CSO) following standard CSO preparation procedures.

* Engine Exchange Program administrative allowance

** Engine Exchange Program part allowance