For 1990-2009 cars

# 2001 Saturn L-Series Vehicle Equipped with 4-Cylinder (L61) Engines

Subject: | INTERMEDIATE FUEL RAIL FITTING REPLACEMENT

Models: | 2001 SATURN L-SERIES VEHICLES eQUIPPED WITH 4-YLINDER (L61) ENGINES

### All Saturn Retailers and Authorized Service Providers

Saturn has decided that certain 2001 L-Series vehicles equipped with 2.2L (L61 4-cylinder) engine have a risk increased evaporative emissions. These vehicles were produced with an intermediate fitting and seals between the fuel feed pipe and the fuel assembly that could result in fuel seepage.

To prevent the possibility of this condition occurring, Saturn Retailers will replace the intermediate fuel rail fitting and seals.

### Vehicles Involved

Only selected 2001 model year L-Series Saturn vehicles equipped with 4-cylinder (L61) engines within the following VIN range will require this campaign:

1Y543314 - 1Y577420

A VIN listing of the vehicles is included in this bulletin for your reference.

You must verify campaign involvement through your AS400 system, or with the listing attached to this bulletin. It is important to note that campaign claims will only be paid on involved vehicles.

### Owner Notification

Owners of all involved vehicles will be notified of this campaign by Saturn. (Refer to the owner letter included in this bulletin.)

### Facility VIN Listing

A list of vehicles assigned to you (Facility VIN Listing) , which our records indicate were sold by or shipped to you, (or are located in close proximity to your facility) is enclosed.

This listing contains:

• | Owner's name with address and telephone number;

• | Complete vehicle identification number (VIN); and

• | VINs of vehicles which according to Saturn records are in retail stock.

The Facility VIN Listing (with owner information) is furnished to involved Retailers with the Product Campaign Bulletin. Although these vehicles are assigned to your facility, it is important to note that owners may elect to have their vehicle serviced at the Saturn Retail Facility of their choice.

Those Retailers not involved initially in this campaign will receive a message at the top of a blank Facility VIN Listing that states: NO VEHICLES ASSIGNED AT THIS TIME FOR CAMPAIGN 01E01.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Those records updated with California DMV registration information will have the following message printed adjacent to the appropriate VIN: "OWNER INFORMATION UPDATED BY CALIFORNIA DMV; PUBLICATION PROHIBITED."

### Retailer Responsibility

All unsold vehicles in Retailers' possession and subject to this campaign must be held at the retail facility and repaired per the service procedure of this campaign bulletin before owners take possession of these vehicles.

Retailers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your vehicle inventory are to be contacted by the Retailer and arrangements made to make the required correction according to the procedure contained in this bulletin.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your retail facility for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

### Transfer of Campaign Responsibility

Saturn vehicles that have been sold by you, which may be closer in proximity to another Saturn Retailer, may still appear on your Facility VIN Listing. If either you or the vehicle owner determines that it is more desirable for a vehicle on your Facility VIN Listing to be serviced by another Saturn Retailer, or if the customer's address has recently changed, campaign responsibility may be transferred by completing the following:

• | Submit a Campaign Vehicle Action Report to your Customer Assistance Manager (CAM) at the Saturn Customer Assistance Center; OR

• | Submit an update in owner information to the Saturn Owner of Record system, via SERVICELINE XL, for Saturn Customer Assistance Center review and approval.

A copy of the Campaign Vehicle Action Report is included for your reference. Additional copies can be ordered from Saturn Publications (1-800-828-2112, prompt 3, Item #S0397050 ). All changes to campaign responsibility will be reflected in your next Unfixed VIN Report.

All other changes in vehicle status (e.g., scrapped, stolen, etc.) are to be made in accordance with section 4.4.3 of the Retailer Service Reference Guide, "Notifying Saturn of Vehicle Status Change."

### Parts Information

1. A pre-shipment of all parts required to perform this campaign has been shipped at no charge to you from Saturn..
2. Should additional parts be required, please contact Technical Assistance at (800) 828-2112, prompt 1.

Part Number | Description | Quantity Required Per Vehicle
--- | --- | ---
NA* | Fitting Fuel ASM-Fuel Feed Pipe | 1

### Disposition of Replaced Parts

Retailers will scrap all replaced parts in a manner that ensures that they cannot be reused, remanufactured, or otherwise entered into the stream of commerce in the future.

### Suggestions for Ensuring Customer Satisfaction

As you know, Saturn's success hinges upon our ability to execute superior customer support throughout the ownership experience, especially when important corrective actions such as this are required.

It is imperative that every effort is made to accommodate the affected owners. Additionally, priority should be given to customer vehicles over retail inventory vehicles. If you have any questions, please coordinate with the Saturn Customer Assistance Center to help ensure customer satisfaction.

#### Cooling Fan Control Module Replacement Procedure

1. Connect the scan tool and start vehicle.
2. Turn scan tool On, and enter vehicle information (model year, engine, and transaxle)..
3. Select POWERTRAIN.
4. Select SPECIAL FUNCTIONS, then select FUEL SYSTEM.
5. Select FUEL PUMP, then command fuel pump Off.
6. Engine will still in 3-15 seconds, turn key Off, and process with intermediate fuel fitting replacement.

Caution: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE. ANY TIME WORK IS BEING DONE ON THE FUEL SYSTEM. DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR TEST WHERE BATTERY VOLTAGE IS REQUIRED.

Important: The PCM will set a P1599 DTC (Engine Stall or Near Stall Detected) when the engine stalls. It will be necessary to clear the codes after completing the following repair.

7. Disconnect negative battery cable.
8. Place a shop towel around the fuel feed pipe fitting at fuel rail to catch any residual fuel that will leak out when the fitting is removed.
9. Loosen 24 mm nut on fuel feed pipe at fuel rail, and remove pipe from fuel rail fitting. Position pipe up and away from fuel rail.
10. Remove black intermediate fuel fitting from fuel rail assembly and discard.
11. Apply a light coating of engine oil to upper and lower O-rings of new black intermediate fuel fitting.
12. Hand start and install new black intermediate fuel fitting.

Tighten
Tighten Fuel Fitting-to-Fuel Rail to 20 N·m (15 ft lbs).

13. Insert fuel feed pipe into black intermediate fuel fitting. Hand start fuel feed pipe nut and tighten.

Tighten
Tighten Feed Pipe Nut to 10 N·m (88 in lbs).

14. Ensure fuel pipe and canister purge solenoid vacuum line are in retaining clip, and cap is on fuel pressure test port.
15. Connect negative battery cable.

Tighten
Tighten Battery Terminal bolts to 17 N·m (13 ft lbs).

16. Turn ignition key to On position, and use scan tool to energize fuel pump.
17. Check system for leaks.
18. Use scan tool and clear all DTCs that have been set.
19. Affix Campaign Completion Label on a clean and dry surface of radiator core support, in an area clearly visible when hood is raised. (For more information, refer to "CAMPAIGN COMPLETION Label." in this bulletin.)

### Campaign Completion Label

Upon completion of the campaign, a Campaign Identification Label and a Clear Protective Cover should be affixed on a clean, dry surface of the radiator core support in an area clearly visible when the hood is raised. Each label provides a space to print in ink (or type) the campaign number (01E01) and the five (5) digit facility code of the Retailer performing the campaign service.

As a reminder, additional labels may be ordered from Saturn publications (1-800-828-2112, prompt 3, Item #S03 00013A for the Campaign Completion Label and Item #S03 00013B for the Clear Protective Cover ).

### Credit

1. To receive credit for replacing the cooling fan control module, submit a claim with the information below:

Repair Performed | Net Item* | Sale Type | Case Type | Labor Op | Labor Hours | Admin. Hours**
--- | --- | --- | --- | --- | --- | ---
To Replace Intermediate Fuel Line Fitting | $1.50 | WC | VC | V0736 | 0.3 | 0.1

2. To receive credit for loaner/rental car costs incurred while owner awaits campaign repair or other goodwill expenses, submit a claim with the information below:

Repair Performed | Sale Type | Case Type | Labor Op | Net Item Amount | Net Item Code | # Days Rental
--- | --- | --- | --- | --- | --- | ---
Loaner Reimbursement | WC | VC | Z4157 | *** | C | ****
Other Goodwill | WC | VC | Z4158 | *** | R | N/A

3. Retailers are empowered to use good judgement regarding loaner/rental cars or any other goodwill expenses deemed necessary. It will not be necessary to call the Saturn Customer Assistance Center for authorization of goodwill. The Goodwill Worksheet (printed towards the back of this bulletin) must be used to document goodwill expenses. The completed Goodwill Worksheet must be attached to the hard copy of the CSO. Retailers are to make sufficient copies of the blank Goodwill Worksheet to document goodwill expenses.

4. Check your Saturn SERVICELINE.XL Claim Memorandum daily. Remember to code the claim as a WC sale type and VC case type. Contact your field representative if you need assistance.

5. All labor operations claimed in this bulletin must be submitted on individual (unrelated) CSO lines. Refer to the Customer Service Order Preparation Manual for details on Product Campaign Claim Submission.

* This is the intermediate fuel line fitting part allowance. Claim using net item code "M"

** Campaign administrative allowance.

*** Net amount must be submitted as a miscellaneous sale...Loaner reimbursement not to exceed $30/day.

**** Enter number of days vehicle was rented...Not to exceed 1 day.

### List of Involved Vehicles Within VIN Range for 01-E-01

### 01-E-01 GOODWILL WORKSHEET

As stated in the "Credit" section of this bulletin, Retailers are empowered to use good judgement regarding loaner/rental cars or other goodwill expenses that might become necessary for customer satisfaction.

Complete this worksheet and attach it to the hard copy of the Customer Service Order (CSO) to document all campaign goodwill claims submitted to Saturn.

VIN #

A. Vehicle Loaner/Rental Allowance Explanation: | $
Repair Performed | Sale Type | Case Type | Labor OP | Net Item Code | # Days Rental
Loaner Reimbursement | WC | VC | Z4042 | C | *
* Not to exceed $30/day for 1 day
B. Other/Goodwill Allowance Explanation (Specify what was done and why): | $
Repair Performed | Sale Type | Case Type | Labor OP | Net Item Code | # Days Rental
Other Goodwill | WC | VC | Z4043 | R | N/A
Authorized Retailer Signature
(Please copy this form as necessary)

May 2001

Dear Saturn Owner:

This notice is sent to inform you that Saturn is conducting a voluntary emission recall campaign that affects certain 2001 Saturn L-Series vehicles.

Saturn has decided that certain 200 L-Series vehicles equipped with 2.2L (L61 4-cylinder) engine have a risk of increased evaporative emissions. These vehicles were produced with an intermediate fitting and seals between the fuel feed pipe and the fuel rail assembly that could result in fuel seepage.

### What Saturn will do

To prevent the possibility of this condition occurring, your Saturn Retailer will replace the engine cooling fan module at no charge to you. The repairs should take less than one hour, but additional time may be required for paperwork and processing.

### What you should do

Please contact your Saturn Retailer to arrange to have this service performed.

The enclosed Campaign Reply card identifies your vehicle, and will facilitate completion of the repairs when presented to your Saturn retail facility. If your address has changed, please provide the new information in the space provided. This will assist us in ensuring that all affected vehicles are corrected.

Your Retailer is prepared to perform this service promptly and with minimal inconvenience to you. However, if your car is provided to the Retailer on the agreed service date and the condition is not remedied within a reasonable amount of time, please contact the Saturn Customer Assistance Center at 1-800-553-6000 prompt 3, or for the hearing impaired, 1-800-833-6000. We will assist you and the Retailer in getting your car serviced. If your Retailer and the Saturn Assistance Center are unable to remedy this condition within reasonable time, you may wish to advise the Environmental Protection Agency as the following address: Director, Manufacturer's Operations Division (6405J), United States Environmental Protection Agency, 401 M Street, SW, Washington, D.C. 24060.

Again, we sincerely regret any inconvenience or concern this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your Saturn provides you may miles of enjoyable driving.

Sincerely,

Saturn Corporation

01-E-01