For 1990-2009 cars

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

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

Models: | 2005 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
2005 | ION with 2.2L engine (RPO L61) built up to and including VIN 5Z148696 - 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 Engine Control Module (ECM) with Saturn Service Stall System (SSS) software version 2.5 2005 or later data CD. | Don’t replace cluster, BCM, or fuel level sender. | 05-06-04-020
2005 | ION with 2.2L engine (RPO L61) built up to and including VIN 5Z148696 - Service Engine Soon Lamp Illuminated with Diagnostic Trouble Codes (DTC) P0420 "Catalyst System Low Efficiency" | Reprogram Engine Control Module (ECM) with Saturn Service Stall System (SSS) software version 2.5 2005 or later data CD. | Don’t replace catalytic converter. | 05-06-04-020
2003-2004 | ION - with VT25E (VTi) Transaxle - Service Engine Soon (SES) Telltale Illuminated with Diagnostic Trouble Code (DTC) P0742 Set | Reprogram Transaxle Control Module (TCM) with Saturn Service Stall System (SSS) software version 2.5 2005 or later data CD. | Don’t replace torque converter or other transaxle components. | 05-07-30-006
2003-2005 | VUE - with VT25E (VTi) Transaxle - Service Engine Soon (SES) Telltale Illuminated with Diagnostic Trouble Code (DTC) P0742 Set | Reprogram Transaxle Control Module (TCM) with Saturn Service Stall System (SSS) software version 2.5 2005 or later data CD. | Don’t replace torque converter or other transaxle components. | 05-07-30-006
2002-2005 | VUE - Power Windows and Power Sunroof (if equipped) Inoperative with 30A "PWR WDW Maxi" open | Install 30A Circuit Breaker in Underhood Fuse Block. | Don’t simply replace the fuse. | 05-08-64-004
2003-2005 | ION - Key Sticks, Binds, is Hard to Insert or Will Not Rotate in Ignition Cylinder After Repair | Replace Ignition Cylinder, Tumbler, and Retainer Plate. | Don’t re-use the ignition cylinder, tumbler, or retainer plate when servicing any of the components of the assembly. | 05-08-49-006
2005 | Relay- Second Row Center Console (toybox) Latch Damaged | Replace the latch with new design P/N 19130892. | Don’t replace the second row center console. | SSPO message 2421
2005 | Relay with 3.5L V6 Engine (VIN L - RPO LX9) - Whistle Type Noise at Idle, Light or Medium Acceleration | Advise the customer that a repair is in test and validation and is due out soon. | Don’t replace any engine components. | 05-06-01-005
2005 | Relay - Unable to communicate with the new EBCM after replacement | Program EBCM by following SI Document ID# 1265170 and retest. | Don’t replace the EBCM again since a new EBCM will not communicate until programmed. | PIT3427

#### Saturn Field Actions Released in February 2005

Category Type | Subject | Model(s) | Model Year(s) | Bulletin Number
--- | --- | --- | --- | ---
Engine/Propulsion System | Customer Satisfaction Program -- Camshaft Position Sensor Housing Seal Replacement | ION Red Line with 2.0L Engine (VIN P - RPO LSJ) | 2004-2005 with VIN break | 05522*
Engine/Propulsion System | On-Board Diagnostic (OBD) System Software Upgrade -- Enhanced Oxygen Sensor Response Diagnostic (Reprogram Powertrain Control Module [PCM]) | ION Red Line with 2.0L Engine (VIN P - RPO LSJ) | 2004 | 05514

* Printed copy sent to U.S. Saturn retailers; PDF available on DealerWorld.

#### Saturn Advance Service Information (ASI) / ASI Resolution Released in February 2005

Category Type | Subject | Model(s) | Model Year(s) | Bulletin Number
--- | --- | --- | --- | ---
Engine/Propulsion System | Advance Service Information - Whistle Type Noise at Idle, Light or Medium Acceleration (Fix Not Yet Available) | Relay | 2005 | 05-06-01-005
Body and Accessories | Advance Service Information (ASI) Resolution - Various Radio/CD Player Concerns (Replace Radio) | Relay | 2005 | 05-08-44-006

#### Saturn Service Bulletins Released in February 2005

Category Type | Subject | Model(s) | Model Year(s) | Bulletin Number
--- | --- | --- | --- | ---
Body and Accessories | Global Position Sensor (GPS) Performance Degradation | Saturn Vehicles with Navigation Systems and/or OnStar | 2002-2005 | 00-08-46-003B
Body and Accessories | Exterior Lamp Condensation and Replacement Guidelines | Saturn Vehicles | 1993-2005 | 01-08-42-001B
Body and Accessories | Windnoise At Base Of Windshield (Seal Sheet Metal Seams) | Relay | 2005 | 02-08-58-005B
Body and Accessories | XM Digital Radio Receiver Ordering Process | ION VUE Relay with Digital Audio System S-Band (RPO U2K) XM Radio | 2004-2005 2004-2005 2005 | 04-08-44-009A
Body and Accessories | Windshield Wipers Streak During Wiper Operation (Replace Windshield Wiper Blade Assembly) | ION | 2004 | 05-08-43-002
Body and Accessories | Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged | Saturn Vehicles with Rear Seat Entertainment System (RPOs U32, U42) | 2001-2005 | 05-08-44-005
Body and Accessories | Key Sticks, Binds, is Hard to Insert or Will Not Rotate in Ignition Cylinder After Repair (Replace Ignition Cylinder, Tumbler, and Retainer Plate) | ION Sedans and Coupes | 2003-2005 | 05-08-49-006
Body and Accessories | Service Manual Update -- Addition of Frame Brackets and Serviceable Insulator (Bushing) for L66 Frame | VUE with 3.5L V-6 Engine (VIN 4 - RPO L66) | 2004-2005 | 05-08-61-003
Body and Accessories | Power Windows and Power Sunroof (if equipped) Inoperative (Install 30A Circuit Breaker) | VUE | 2002-2005 | 05-08-64-004
Engine/Propulsion System | Insufficient Heat, Service Engine Soon (SES) Light On, DTC P0128 Set (Replace Thermostat Assembly) | VUE L-Series with 3.0L Engine (VIN B or R - RPO L81) | 2002-2003 2002-2005 | 03-06-02-002A
Engine/Propulsion System | Information on Aluminum Heater Core and/or Radiator Replacement | Saturn Vehicles | 1991-2005 | 05-06-02-001
General Information | New Bulletin Categories | Saturn Vehicles | 1991-2005 | 05-00-89-005
General Information | Quick Tips for Warranty Administration | Saturn Vehicles | 1991-2005 | 05-00-89-007
General Information | Car Care Matrix for Warranty Administration | Saturn Vehicles | 2005 | 05-00-90-002
Restraints | Excessive Lateral Movement of Some Aftermarket Child Seats (Replace Rear Seat Buckle) | Relay | 2005 | 00-09-40-001C
Restraints | Avoiding 3rd Row Center Seat Belt Retractor Lock-up | Relay | 2005 | 05-09-40-001
Steering | Power Steering System Noise and/or Leak Diagnosis | L-Series S-Series with Power Steering | 2000-2005 1991-2002 | 02-02-32-009A
Suspension | Service Manual Update -- Lower Control Arm Ball Stud Nut Torque Specification Changes | VUE | 2002-2005 | 05-03-08-003
Transmission/Transaxle | Intermittent Hesitation During Vehicle Launch (Replace Transaxle Input/Output Sensors or Transaxle Case Cover Assembly, If Necessary) | VUE ION with VT25E VTi Transaxle (RPO M16/M75) | 2002-2005 2003-2004 | 05-07-30-003

#### Saturn Service Bulletins Released in March 2005 (as of March 11, 2005)

Category Type | Subject | Model(s) | Model Year(s) | Bulletin Number
--- | --- | --- | --- | ---
Body and Accessories | Compass Zone Adjustment and Calibration Procedure During Pre-Delivery Inspection | Relay | 2005 | 03-08-48-005B
Body and Accessories | Turn Signal Indicator Flashing Faster than Normal and Corresponding Front Turn Signal Bulb Inoperative (Refer to Recall 04095) | ION Sedans | 2003-2004 | 04-08-42-002A
Body and Accessories | Unable to Connect to OnStar® or OnStar® Personal Calling Inoperative in Alaska Only (Change Transceiver ID) | Saturn Vehicles with Analog OnStar® System (RPO UE1) | 2002-2005 | 05-08-46-002A
Body and Accessories | Information - OnStar® Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar® System | Saturn Vehicles with OnStar® | 2003-2005 | 05-08-46-004
Engine/Propulsion System | 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 | ION with 2.2L four-cylinder engine (VIN F - RPO L61) | 2005 with VIN break | 05-06-04-020
General Information | Updated Recreational Vehicle Towing Information and Procedures for 2004-2005 Saturn VUE Vehicles | VUE with 3.5L V-6 (VIN 4 - RPO L66) | 2004-2005 | 05-00-89-014
General Information | Warranty Administration - New Definition for Parts Warranty Case Type | Saturn Vehicles | 2002-2005 | 05-00-89-015
Transmission/Transaxle | Intermittent No Movement in Drive or Reverse with or without Diagnostic Trouble Codes (DTCs) P0841, P1758, and/or P1882 (Replace VT25E Case Cover Assembly, Torque Converter and Oil Cooler Lines, If Necessary) | ION VUE with VT25E (VTi) Transaxle (RPO M16/M75) | 2003-2004 2002-2004 | 05-07-30-004
Transmission/Transaxle | Low Speed Grind Noise and/or Hesitation While Driving (Install New Transmission Control Module [TCM] Calibration and Add New Transmission Fluid and Additive) | ION with VT25E (VTi) Transaxle (RPO M75) | 2003-2004 | 05-07-30-005
Transmission/Transaxle | Service Engine Soon (SES) Telltale Illuminated with Diagnostic Trouble Code (DTC) P0742 Set (Reprogram Transaxle Control Module [TCM]) | VUE ION with VT25E (VTi) Transaxle (RPO M16/M75) | 2002-2005 2003-2004 | 05-07-30-006

#### Parts on Restriction at TAC (as of February 2005)

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)
2004-2005 | Saturn VUE All-Wheel Drive (AWD) Transfer Case Assembly | Bulletin # 03-07-30-039A, Saturn Technical Assistance Center 1-800-828-2112, prompt 1, (Canada English 1-800-263-7740, Canada French 1-800-263-7960)
2004-2005 | Saturn XM Digital Radio Receiver | Bulletin # 04-08-44-009A, Saturn Technical Assistance Center 1-800-828-2112, prompt * (The prompt for XM radio callers is combined with the OnStar® prompt.)