For 1990-2009 cars

# Saturn Field Product Reminder-Vehicle Fix It Right the First Time Issues, Parts Restriction Information and Service Bulletins Released in May, 2005

Subject: | Saturn Field Product Reminder -- Vehicle "Fix It Right the First Time" Issues, Parts Restriction Information and Service Bulletins Released in May, 2005

Models: | 2006 and Prior Model Year Saturn Vehicles

In order to access this bulletin electronically, go to the Service Information (SI) Home Page 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
2003-2005 | ION squeak, rattle, pop or creak noise from front end of vehicle. | Replace front stabilizer shaft bushing and/or clamp. | Don't replace stabilizer link. | 04-03-08-003A
2005 | ION battery discharged after vehicle has not been used for approximately 5 days. | Reprogram Engine Control Module (ECM) with TIS version 5.0 or greater. | Don't recharge battery without updating calibration. | 05-06-04-036
2005 | ION - fuel gauge stays on empty with fuel remaining and/or SES lamp illuminated with DTC P0461 "Fuel Level Sensor Performance" set. | Reprogram ECM with TIS version 5.0 or greater. | Don’t replace instrument cluster, ECM, BCM, or fuel level sender. | 05-06-04-020A
2005 | ION - SES lamp Illuminated with DTC P0420 "Catalyst System Low Efficiency" set. | Reprogram ECM with TIS version 5.0 or greater. | Don’t replace ECM, O2 sensor, or catalytic converter. | 05-06-04-020A
2005 | ION - fluctuating speedometer and/or tachometer with DTC U1064 "Lost Communication with BCM Dash Integration Module (DIM) set. | Reprogram ECM with TIS version 5.0 or greater. | Don’t replace BCM or instrument cluster. | 05-06-04-020A
1993-2005 | Saturn vehicles with exterior lamp condensation. | Reference bulletin for guidelines on when an exterior lamp should be replaced. | Don't replace an exterior lamp when lamp exhibits normal amounts of moisture or condensation. | 01-08-42-001C
2006 | ION w/ 2.4 LE5 Relay w/ 3.9 LZ9 | Reference bulletin for guidelines on engine exchange program for RPO LE5 and RPO LZ9. | Don't perform repairs on engine or engine components before referencing the engine exchange program bulletin. | 05-06-01-012

#### Saturn Field Actions Released in May, 2005

Category Type | Subject | Model(s) | Model Year(s) | Bulletin Number
--- | --- | --- | --- | ---
Engine | Inventory Upgrade - Engine Control Module (ECM) Software Upgrade (Reprogram ECM) | ION Vehicles with 2.2L Four-Cylinder Engine (VIN F - RPO L61) with VIN Breakpoints | 2005 | 05538B
Engine | Product Emission - PCM Integrated Circuit Chip Damage (Replace PCM) | Relay Vehicles built between 5D251975 and 5D260394 | 2005 | 05539A
Body & Accessories | Customer Satisfaction Program - Automatic Door Lock Feature | Relay Vehicles built between 5D112157 and 5D204366 | 2005 | 05024

#### Saturn Service Bulletins Released in May, 2005

Category Type | Subject | Model(s) | Model Year(s) | Bulletin Number
--- | --- | --- | --- | ---
General Information | Saturn Technical Assistance Center (TAC) Changes (U.S. Only) | Saturn Vehicles | 1991-2006 | 05-00-89-020A
General Information | General Motors Dealership Critical Equipment Requirements and Recommendations (Canada Only) | Saturn Vehicles in Canada only | 1991-2006 | 05-00-89-029
HVAC | Updated Requirement for A/C Refrigerant System Repairs That Are Submitted for Warranty Reimbursement (Canada Only) | Saturn Vehicles in Canada only | 2001-2006 | 05-01-38-008
Steering | Power Steering Inoperative/Steering Wheel Hard to Turn, PWR STR Displayed on DIC After Jump Starting Vehicle (Replace Fuse and Instruct Owner How to Jump Start Vehicle) | ION | 2003-2006 | 05-02-32-002
Suspension | Rear Suspension Torque Specifications | VUE | 2002-2003 | 05-03-09-004
Suspension | Rear Suspension Torque Specifications | VUE | 2004 | 05-03-09-005
Suspension | Trim Height Specifications | ION | 2003-2005 | 05-03-06-002
Suspension | Front Suspension Fastener Tightening Specifications | ION | 2003-2005 | 05-03-08-008
Engine | DEX-COOL Coolant - New Leak Detection Dye J-46366 - Replaces J-29545-6 | Saturn Vehicles | 1996-2005 | 05-06-02-002
Engine | Instructions for Using GE-47716 Vac-N-Fill Coolant Refill Tool | Saturn Vehicles | 1991-2005 | 05-06-02-006
Engine | SES Lamp Illuminated with DTC P0300, P0315, P0507, P1574, and/or P1621 Set and/or Cruise Control is Inoperative (Reprogram ECM with Updated Calibration) | ION | 2005 | 05-06-04-005A
Engine | SES Lamp On w/DTCs U1064, P0461 and/or P0420 Set, Fuel Gauge Stays on Empty w/Fuel Remaining, Fluctuating Speedometer/Tachometer and/or Vehicle Theft Security Lamp On (Reprogram ECM) | ION | 2005 | 05-06-04-020A
Engine | Engine No Crank, No Start, Battery Discharged after the Vehicle Has Not Been Used for Approximately Five Days (Reprogram ECM) | ION | 2005 | 05-06-04-036
Engine | 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 (Inform Customer of Normal EVAP Vent Solenoid Operation) | VUE | 2002-2006 | 04-06-05-009B
Transmission/Transaxle | Transaxle Gear Rattle Noise in Cold Ambient Temperatures with Clutch Pedal Released (Up) at 1500-2500 RPM (Install Leaf Springs Between Blocker Ring/Synchronizer Hub for 3rd, 4th, 5th, Reverse Gears) | ION Red Line | 2004-2005 | 05-07-29-004
Body & Accessories | Exterior Lamp Condensation and Replacement Guidelines | Saturn Vehicles | 1993-2006 | 01-08-42-001C
Body & Accessories | Compact Disc (CD) Player Inoperative - Will Not Load, Will Not Eject or Will Not Play (Remove Both Radio Fuses to Reset Radio) | S-Series L-Series VUE ION with U1C, US8, or US9 radio | 2000-2002 2000-2005 2002-2005 2003-2005 | 04-08-44-018A
Body & Accessories | Various Radio/CD Player Concerns (Replace Radio) | Relay | 2005 | 04-08-44-023B
Body & Accessories | Exchange Program - Saturn Relay Radio Receiver Ordering Process | Relay | 2005 | 05-08-44-007A
Body & Accessories | Hard/No Start, Stall, Fuel Gauge Inoperative/Fluctuates, SES/Check Engine Light On, ABS Warning Light On, TCS Warning Light On, TCS Activation, Service Traction System Message Displayed, All-Wheel Drive Disable Message Displayed, DTCs Set (Repair Connector) | Relay | 2005 | 01-08-45-005C
Body & Accessories | Information on Service Support and Technical Assistance for OnStar® (U.S. Only) | Saturn Vehicles with OnStar® | 2002-2006 | 05-08-46-003A
Body & Accessories | Service Support and Technical Assistance for OnStar® and/or XM® Radio | L-Series VUE ION Relay with OnStar® (RPO UE1) and/or XM® Radio (RPO U2K) | 2002-2005 2002-2006 2003-2006 2005-2006 | 04-08-46-001A
Body & Accessories | Erratic Fuel Gauge Readings (Reprogram ECM) | ION | 2005 | 05-08-49-004A
Body & Accessories | Intermittent Security Light On, False B3055 DTC Set (Reprogram BCM) | Relay | 2005 | 05-08-49-016
Body & Accessories | Speedometer Drops to Zero When Using OnStar (Reprogram IPC) | Relay | 2005 | 05-08-49-017
Body & Accessories | Pop, Snap or Creak Type Noise In Front End (Adjust Bumper Clearance) | Relay | 2005 | 05-08-62-003

#### Parts on Restriction at TAC (as of May, 2005)

Model Year(s) | Component on Restriction | Reference Info/Bulletin/Phone Number
--- | --- | ---
2004-2005 | XM Digital Radio Receiver | Bulletin 04-08-44-009A, GM Technical Assistance Center 1-877-446-8227, prompt 3, prompt 0