For 1990-2009 cars

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

Subject: | Saturn Field Product Reminder -- Vehicle "Fix It Right the First Time" Issues, Parts Restriction Information and Technical Bulletins Released in October 2004

Models: | 2005 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.

#### 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
--- | --- | --- | --- | ---
2004-2005 | All Cars and Trucks - State-of-Charge Upon Delivery of New Vehicle | Check and record battery’s state-of-charge per revised PDI procedure. | Don’t remove and replace battery. | New PDI and Bulletin 04-SE-03 (in Canada, HOL # 2004-208)
2003-2004 | ION- Squeak, Rattle, Pop or Clunk Noise From Front of Vehicle During Suspension Movement | Replace Front Stabilizer Shaft Insulators with correct part depending on suspension type (FE1 use P/N 10370615, FE2 use P/N 10370616.) | Don’t replace with incorrect Front Stabilizer Shaft Insulators, which may lead to a noise concern. | 04-03-08-003A
2005 | ION and VUE equipped with 6- disc CD player RPO US9 - An instruction label has been added to the face of radio (CD loading and operation information) | Leave label on face plate of radio, to be removed by customer only. | Don’t remove label on faceplate of radio which contains customer operating instructions. | 04-I-12 (in Canada, TT # SSI 109)
2004-2005 | ION and VUE with 6-Disc CD Player (RPO US9) - Compact Disc (CD) Will Not Eject/Load or CD Function Inoperative in 6-Disc CD MP3 Player/Radio | Reset CD player and complete questionnaire. | Don’t replace radio if it functions correctly after it has been reset. | 04-08-44-018
2004-2005 | ION with Power Mirrors - Outside Power Mirror Inoperative | Follow diagnostics in service manual/SI. | Don’t simply replace outside rearview mirror switch. | Reference appropriate service information in manual/SI.
2003-2004 | ION Sedans with Sunroof (RPO CF5) Built Up To and Including VIN Breakpoint 4Z200281- Sunroof Drain Hose Rattle | Install mastic patch on the upper rail of the space frame directly above sunroof drain tube connector. | Don’t replace sunroof module or drain tubes. | 04-08-67-007
2002-2003 | VUE with 2.2L 4-Cylinder Engine (RPO L61) - Check Engine Light On with P0440 or P0442 Stored | Diagnose Evaporative Emission [EVAP] System and if no leak is detected, reprogram Engine Control Module [ECM]. | Don’t replace EVAP system components if no leak is detected. | 04-06-04-033A
2002-2004 | VUE - Crank No Start, Hard Start, Stalling, or Front Lamps Intermittently Inoperative Setting Any of the Following Diagnostic Trouble Codes (DTCs) - P0629, B2752, B3722, B3717, B2717, B2600, B2722 | Tighten or replace the left forward lamp ground splice pack (G101) nut, which may be loose or missing. | Don’t replace BCM or other related components. | 04-06-03-007
2004-2005 | Saturn ION Red Line Coupe with 2.0 L LSJ Engine - Service Engine Soon (SES) Light On, Engine Starts but Runs Rough and Stalls Repeatedly, Diagnostic Trouble Codes (DTCs) P0443, P0102, P0135, P0141, P0023A | Inspect for open 15 amp emission fuse and if found, replace fuse and coolant pump charge air cooler. | Don’t simply replace the fuse. | 04-06-02-009
1992-2002 | S-Series - Cruise Control is Inoperative or Will Not Set/Engage After the Manual Transaxle Has Been Replaced | Inspect to determine if correct transaxle (MP2 vs MP3) is installed in the vehicle. | Don’t replace or adjust cruise control components. | ESI PIP3178
1992-2002 | S-Series - Delay and Harsh Engagement into Drive and/or Harsh Engagement Into Reverse, 2nd, 3rd, or 4th Gears After Repairs in which the Clutch Spring Packs were Removed/Replaced | Inspect the 1st clutch spring pack to verify that the 1st clutch spring pack is located in 1st clutch. | Don’t replace valve body or other transaxle components. | ESI PIP3175

#### Saturn Technical Bulletins Released in October 2004

Category Type | Subject | Model(s) | Model Year(s) | Bulletin Number
--- | --- | --- | --- | ---
Body and Accessories | Aftermarket Window Tinting Scratched or Torn (Replace Side Door Window Inner Sealing Strips) | ION w/ VIN Break | 2003-2004 | 03-08-64-038A
Body and Accessories | Compact Disc (CD) Will Not Eject/Load or CD Function Inoperative in 6-Disc CD MP3 Player/Radio (Reset CD Player and Complete Questionnaire) | ION VUE | 2004-2005 | 04-08-44-018
Body and Accessories | Sunroof Drain Hose Rattle (Install Mastic Patch) | ION Sedans | 2003-2004 | 04-08-67-007
Body and Accessories | Cruise Control Inoperative and/or Service Engine Soon (SES) Telltale Illuminated with Diagnostic Trouble Code (DTC) P0571 Stored in Powertrain Control Module (PCM) (Reprogram PCM) | VUE w/ VIN 4 - RPO L66 | 2004 | 04-08-68-004
Engine / Propulsion System | Service Engine Soon (SES) Light On, Engine Starts but Runs Rough and Stalls Repeatedly, Diagnostic Trouble Code (DTCs) P0443, P0102, P0135, P0141, P023A are Set (Replace Coolant Pump Charge Air Cooler and 15-amp Emission Fuse) | ION Red Line Coupe | 2004-2005 | 04-06-02-009
Engine / Propulsion System | Service Engine Soon (SES) Lamp Illuminated with DTC P0135 "HO2S Heater Circuit Performance Bank 1 Sensor 1" and/or DTC P0155 "HO2S Heater Performance Bank 2 Sensor 1" (Perform Oxygen Sensor Conditioning Drive Cycle) | L-Series vehicles equipped with V6 engine (VIN R - RPO L81) VUE vehicles equipped with V6 engine (VIN - RPO L81) | 2000-2005 2002-2003 | 04-06-04-008A
Engine / Propulsion System | Service Engine Soon (SES) and/or Reduced Power Lamp Illuminated, Limited Throttle Response Following Cold Engine Start Up, Diagnostic Trouble Code (DTC) P0638 (Re-locate Primary Positive Crankcase Ventilation (PCV) Hose, Re-route Secondary PCV Hose) | VUE w/ VIN 8 - RPO L81 | 2002-2003 | 04-06-04-074
Engine / Propulsion System | Service Procedure for Replacement of Resonator and Intermediate Pipe | S-Series SC2 Coupe w/ RPO LL0 | 1998-2000 2001 | 04-06-05-010
General Information | Steering Wheel Shake or Vibration at Highway Speeds (Balance Tire/Wheel Assemblies, Replace Front Lower Control Arm Rear Bushings, Replace Steering Gear Preload Spring, and Replace Tires If Necessary) | L-Series | 2000-2005 | 99-00-91-002E
HVAC | Air Conditioning (A/C) Condensation Collecting Causing a Water Leak onto the Vehicle Floor During Times of A/C Usage (Remove Obstruction From Evaporator Drain Hole) | ION | 2003-2005 | 03-01-38-020A
Suspension | New Measuring Wheel Alignment Procedure For Labor Operation Numbers E2020 and E2000 | All Saturn vehicles | 2005 and prior | 04-03-07-003
Transmission / Transaxle | Service Manual Update for Manual Shift Control Assembly Replacement and Shift Control Cable Replacement | ION Red Line vehicles w/ RPO MU3 | 2004-2005 | 04-07-29-002
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) | VUE vehicles w/ RPO M75/M16 | 2003-2005 | 03-07-30-051A

#### Parts on Restriction at TAC (as of October 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 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 # 04-08-44-009 Saturn Technical Assistance Center 1-800-828-2112, prompt * (The prompt for XM radio callers is combined with the OnStar prompt.)
2004 | Saturn ION Supercharged 2.0L LSJ Ecotec Engine | Bulletin #04-06-01-014 Saturn Technical Assistance Center 1-800-828-2112, prompt 1, (Canada English 1-800-263-7740, Canada French 1-800-263-7960)