For 1990-2009 cars

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

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)