Check Engine Light On with P0440 or P0442 Stored (Diagnose Evaporate Emission (EVAP) System and/or Reprogram Electronic Control Module (ECM))

This bulletin is being revised to update calibration numbers and the TIS Data CD version. Please discard Corporate Bulletin Number 04-06-04-033 (Section 06 - Engine/Propulsion System).

Some customers may comment that the check engine light is on with diagnostic trouble code (DTC) P0440 (large leak) or P0442 (small leak) stored with no actual system leaks present.

Under certain driving conditions with fuel level over 50%, fuel splash inside the fuel tank may affect the fuel tank pressure sensor reading and cause either of the above diagnostics to fail.

Utilize current published diagnostic procedure to inspect vehicle for source of leak. Refer to "Fuel System Testing" procedure in the 2002-2003 Saturn VUE Revised Engine Service Manual, Vol. II (or in SI, "Fuel Tank Leak Test" procedure, SI Document ID# 1227195). If no leaks are identified, verify engine control module (ECM) calibration I.D. number and, if necessary, reprogram the ECM with the calibration available on Saturn Service Stall data release TIS 7.0 2004 or later.

Verifying Calibration ID Number

Important: You must view calibration numbers using the TECH 2 Scan Tool and NOT the Saturn Service Stall System (SSS).

1. Connect Scan Tool to the vehicle.
2. Navigate to the 2.2L (VIN D) Powertrain Menu.
3. Select ID INFORMATION.
4. Select ENGINE INFORMATION.
5. Read CALIBRATION ID.

•

If the current ECM calibration ID is the same or greater than the calibration listed in the "Calibration Information Table," do not reprogram the ECM. The updated calibration is already installed and reprogramming is not required. Refer to the appropriate model year Service Manual or SI for further diagnostic information.

•	If calibration ID number is not the same or greater than the calibration listed in the "Calibration Information Table," then reprogram ECM with latest available service calibration.

Reprogramming ECM

Important: Before installing new ECM calibration, make sure the Saturn Service Stall System (SSS) version is TIS 7.0 2004 or greater.

Important: While ignition is OFF, apply parking brake to disable daytime running lights (DRLs) prior to starting reprogramming procedure.

Important: Technician must select "Replace and Reprogram" option in order to reprogram the ECM.

Reprogram the ECM with the appropriate updated calibration listed in this bulletin. Refer to the "Calibration Information Table" to select the correct calibration for the vehicle being serviced. (If newer calibrations than those listed below are available, install the latest available service calibration.) Use Saturn Service Stall System (SSS) software version TIS 7.0 2004 or higher data CD. Refer to "Service Programming System (SPS)" in the SSS User Guide for reprogramming procedures.

To receive credit for this repair during the applicable 8-year/80,000 mile (130,000 kilometers) emission controller warranty, submit a claim through the Saturn Dealer System for J6353 (Module, Engine Control - Reprogram).