For 1990-2009 cars

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

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

#### 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
2004 | ION Equipped with 2.0 LSJ Engine | Use Mobil 1® motor oil or oil meeting GM Standard GM4718M when performing an oil change. | Don’t use any motor oil that does not meet standard GM4718M. | See Owner’s Manual and/or oil fill cap on engine.
2000-2004 | All Saturn Vehicles with SDIN Single CD (U1C) Radio - CD Skip | Reference bulletin 03-08-44-016A for radio part number that contains CD buffer. | Don’t install radio other than the one contained in the bulletin. | 03-08-44-016A
2002-2003 | VUE, L-Series, and ION with 6-Disc (UR9 or UB2) Radio - CD Player is Inoperative, Low Volume Tick, Clock Will Not Keep Correct Time | Reference bulletins 03-08-44-010 & 03-08-44-019A for fixes. | Don’t use radio P/N 22661247. | 03-08-44-010 &03-08-44-019A
2004 | VUE AWD with 3.5 L L66 Engine - Grind Noise After RDM Clutch Drum Replacement | For 3.5 L AWD L66, use RDM clutch drum P/N 22730517 | Don’t use P/N 22714938. This P/N should not be used for the 3.5L AWD L66. | See Parts Catalog.
1996-2002 | Multiple Transaxle DTC’s After Reman Transaxle Replacement | Inspect for loose buss plate to actuator connections and check actuator resistance. Replace buss plate and/or actuator as required. | Don’t replace transaxle assembly or complete valve body assembly. | Reference appropriate model year transaxle service manual.
2003-2004 | ION Built Prior to VIN Breakpoint 4Z210712 - No Crank, No Start With DTCs B2960 and/or B3033 Set In BCM | Replace ignition switch, which contains passlock sensor. | Don’t replace starter, BCM, or ignition housing, which doesn’t contain passlock sensor. | 04-08-45-005
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 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
1998-2002 | S-Series Vehicles With MP6/MP7 Automatic Transaxles- P0731 and No Movement in Drive During Cold Ambient Temperatures | Replace 1st Gear Sprag Clutch Assembly or Oil Pump. | Don’t replace 1st Driven Gear Assembly, which is no longer included in the parts requirement. | 03-07-30-008A
2002-2004 | VUE - Hiss Noise When the Air Conditioning (A/C) Compressor Is Turned OFF. The Noise May Also Be Heard if the Cooling Fan Comes On in the High-Speed Mode with A/C Compressor ON. | Replace Low Speed Engine Cooling Fan Resistor. | Don’t replace TXV or compressor. | 04-01-37-006
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 (0.04-0.08 in.) bead P/N 22722716 to surface. | Don’t apply bead larger than 2 mm (0.08 in.), which could lead to subsequent transaxle noise and damage. | 04-07-30-011A
2000-2005 | L-Series with A/C - Chatter or Clicking Noise that Is Produced Inthe Engine Compartment During Engine Start With the A/C or Defrost Mode Selected or During Initial A/C or Defrost Activation After the Engine Is Running | Show customer bulletin 04-01-37-005. | Don’t replace A/C compressor. | 04-01-37-005
2000-2004 | L-Series- Clunk Noise Coming From the Front of the Vehicle During a Turning Maneuver | Lubricate intermediate shaft. | Don’t replace intermediate shaft. | 04-02-35-008
2003-2004 | ION - Windshield Wiper Arms Difficult to Remove From Vehicle | Use J39637 or equivalent to remove the wiper arm from the wiper pivot stud. | Don’t rock wiper arm on pivot stud in an attempt to remove. Doing this my result in breakage of the wiper module. | Reference appropriate model year service manual.

#### Saturn Technical Bulletins Released in May 2004

Category Type | Subject | Model(s) | Model Year(s) | Bulletin Number
--- | --- | --- | --- | ---
Body & Accessories | Left Side (Driver’s Side) Outside Rearview Mirror Cracking (Replace Outside Rearview Mirror Glass Assembly) | VUE | 2003-2004 | 04-08-64-008
Body & Accessories | XM Digital Radio Receiver Ordering Process | ION & VUE w/ RPO U2K | 2004 | 04-08-44-009
Engine/ Propulsion System | Service Manual Update for Engine Block Clearance, Cylinder Head Clearance and Fastener Torque Specifications | L-Series & VUE w/ RPO L81 | 2000-2004 2002-2003 | 04-06-01-011
Engine/ Propulsion System | Engine Exchange Program for Supercharged 2.0L Ecotec Engine (VIN P - RPO LSJ) | ION Quad Coupe w/ VIN P -RPO LSJ | 2004 | 04-06-01-014
Engine/ Propulsion System | Check Engine Light on with P0440 or P0442 Stored (Diagnose EVAP System and/or Reprogram ECM) | VUE w/ VIN D -RPO L61 | 2002-2003 | 04-06-04-033
Engine/ Propulsion System | Diagnostic Trouble Code (DTC) P0132 (H02S Circuit High Voltage Sensor 1), P0138 (H02S Circuit High Voltage Sensor 2), or P0172 (Fuel Trim System Rich) Diagnostic Enhancements | ION w/ VIN Break | 2003-2004 | 04-06-04-035
HVAC | Information Regarding Air Conditioning (A/C) Compressor Noise at Engine Start (A/C or Defrost Mode Selected) or at A/C or Defrost Activation (After Engine Start) | L-Series w/ RPO C60/C68 | 2000-2005 | 04-01-37-005
HVAC | Heater-Ventilation-Air Conditioning (HVAC) Hiss-Type Noise (Replace Low Speed Engine Cooling Fan Resistor) | VUE | 2002-2004 | 04-01-37-006
Suspension | Squeak, Rattle, Pop or Clunk Noise From Front of Vehicle During Suspension Movement (Replace Front Stabilizer Shaft Insulators) | ION | 2003-2004 | 04-03-08-003A
Suspension | Service Manual Update Regarding Tightening Procedure and Specification for the Ball Joint-to-Steering Knuckle Nut | ION | 2003-2004 | 04-03-08-005
Suspension | Clunk, Thump or Rattle Noise from Front Suspension while Driving Over Rough Road Conditions or when Braking (Replace Front Lower Control Arm Rear Bushing) | ION | 2003 | 04-03-08-006
Steering | Clunk Noise from Front of Vehicle During Turning Maneuver/Steering Wheel Rotation (Lubricate Intermediate Shaft) | L-Series | 2000-2004 | 04-02-35-008
Transmission/Transaxle | Service Engine Soon (SES) Light On with Diagnostic Trouble Code (DTC) P0731, No Movement in Drive During Cold Ambient Temperatures (Replace Oil Pump or 1st Gear Sprag Clutch Assembly) | S-Series w/ RPO MP6/MP7 | 1998-2002 | 03-07-30-008A
Transmission/ Transaxle | No Movement in Drive or Reverse With or Without DTCs P1758, P1756, P1882, P0841, P0741, P0742 (Replace VT25E Transaxle Assembly) | VUE & ION w/ RPO M16/M75 | 2003-2004 | 04-07-30-024
MAY 2004 SYSTEM SOFTWARE UPGRADE BULLETIN
Engine/ Propulsion System | On-Board Diagnostic (OBD) System Software Upgrade - Improved Purge Flow Diagnostics (Install Updated Engine Control Module [ECM] Calibration) | ION w/ RPO YF5 w/ VIN Break | Certain 2004 intended for CA registration | 04026

#### Parts on Restriction at TAC (as of May 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 | 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)