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

Subject: | Saturn Field Product Reminder -- Vehicle "Fix It Right the First Time" Issues, Parts Restriction Information and Technical Bulletins Released in November 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
--- | --- | --- | --- | ---
New Issues
2003 - 2004 | IONs Built Prior to VIN Breakpoint 4Z210712 - No Crank, No Start When Ambient Temperature is Cold - Diagnostic Trouble Codes (DTCs) B2960 and/or B3033 are Set in BCM History | Navigate to BCM history with TECH 2 and inspect for DTC(s). If found replace ignition switch with P/N 10392423. If an ignition switch was replaced prior to June 2004, replace ignition switch again. | Don’t replace the ignition housing, which does not contain the passlock sensor. | 04-08-45-005
2003 - 2005 | ION - Alignment Specifications | Reference the appropriate year service information in Electronic Service Information (ESI) for the most up to date and accurate alignment specifications. | Don’t rely on alignment specs that are resident within the alignment machine as some may be incorrect. | Reference the appropriate year service information in Electronic Service Information (ESI).
2004 | VUE with 3.5L V-6 Engine (VIN 4 - RPO L66) Cruise Control Inoperative and/or Service Engine Soon (SES) Telltale Illuminated with DTC P0571 Stored in Powertrain Control Module (PCM) | Clear DTC with Tech 2 and wait for future software updates and field communication. | Don’t reprogram PCM or replace other cruise control system components. | Service bulletin in process.
2004 | VUE with 5-speed Automatic Transaxle (RPO MJ7/MJ8) Service Engine Soon (SES) Telltale Illuminated with DTC P0873 Stored in Transaxle Control Module (TCM) | Replace 4th clutch pressure switch. | Don’t replace the 3rd clutch pressure switch. The Tech 2 software will incorrectly describe P0873 as a 3rd clutch pressure switch problem when, in fact, it is a 4th clutch pressure switch problem. | Reference the appropriate year service information in Electronic Service Information (ESI).
2005 | Relay - Interior Lights Flicker or Dim | Refer to PI for description of condition being "normal". | Don’t replace generator or any other electrical components. | PI PIT3246
2002 - 2003 | VUE Vehicles with 3.0L V-6 Engine (VIN B - RPO L81) - Service Engine Soon (SES) and/or Reduced Power Lamp Illuminated, Limited Throttle Response Following Cold Engine Start Up, DTC P0638 | Re-locate primary Positive Crankcase Ventilation (PCV) Hose and re-route secondary PCV hose per procedures in bulletin. | Don’t replace throttle body, PCM, or other related throttle control components. | 04-06-04-074
2000 - 2005 | L-Series with 3.0L V6 Engine (VIN R - RPO L81) Service Engine Soon Lamp Illuminated with DTCs P0130 "HO2S Circuit Bank 1Sensor 1", P0135 "HO2S Heater Circuit Performance Bank 1 Sensor 1", P0150"HO2S Circuit Bank 2 Sensor 1" and/or P0155 "HO2S Heater PerformanceBank 2 Sensor 1" | Perform oxygen sensor conditioning drive cycle. | Don’t replace oxygen sensor(s). | 04-06-04-008A
2003 - 2005 | ION Vehicles with Air Conditioning (RPO C60) - Moisture (Air Conditioning Condensation) Leaking onto Vehicle Floor when A/C Systemis Running | Remove obstruction from evaporator drain hole. | Don’t replace HVAC case half or any other A/C components. | 04-01-38-016
2003 - 2004 | ION - Squeak, Rattle, Pop or Clunk Noise from Front of Vehicle During Suspension Movement | Use chassis ears to verify the noise is coming from the sway bar bushing and replace if necessary. | Don’t replace steering rack, upper strut mounts, sway bar end links or lower control if chassis ears indicate noise is coming from sway bar bushing. | 04-03-08-003A
2003 | ION - Clunk, Thump or Rattle Noise from Front Suspension while Driving Over Rough Road Conditions or when Braking | Replace ION lower control arm bushings by pressing the old bushing out and pressing a new one in. | Don’t replace the complete lower control arm just for a lower control arm rear bushing concern. | 04-03-08-006
2004 | VUE with 3.5L V-6 Engine (VIN 4 - RPO L66) - B1372 along with various U-codes (i.e. U2105, U2106, etc.) | Clear DTC with Tech 2 and wait for future field communication. | Don’t replace controllers/modules. | ESI PI PIC3258
2004 | ION - Cruise Control Inoperative and/or Service Engine Soon (SES) TelltaleIlluminated with Diagnostic Trouble Code (DTC) P1574 Stored in PowertrainControl Module | Clear DTC with Tech 2 and wait for future field communication. | Don’t replace cruise switch, brake switch or other cruise control system components. | PI in process. Reference ESI for latest information.
2003 - 2004 | ION Sedans - Instruction On When or If To Install Headlamp Harness on Vehicles Involved in Safety Recall 04095 | Follow Safety Recall instructions and install 2 new bulbs (and resistance if needed). If after new bulb(s) is installed and new bulb(s) will not illuminate, then and only then install new headlamp harness. | Don’t replace the harness just because the socket appears deformed. | Safety Recall 04095
2002 - 2004 | VUE - with 5-speed AF33-5 Automatic Transaxle - No 3rd Gear (with or without p1719) After Trans Fluid Service | Remove trans fluid fill plug when adding transaxle fluid. | Don’t remove the 3rd gear anchor bolt, which can be mistaken for the trans fluid fill plug. Removing the incorrect bolt will dislocate internal components, cause a no 3rd gear concern and require transaxle removal to correct. | 03-07-30-018

#### Saturn Technical Bulletins Released in November 2004

Category Type | Subject | Model(s) | Model Year(s) | Bulletin Number
--- | --- | --- | --- | ---
Brakes | Brake Pedal Pulsation and/or Vehicle Vibration During Brake Application (Diagnosis/Service Procedures) | S-Series | 1991-1995 | 04-05-22-022
Engine/ Propulsion | Service Manual Update for Diagnostic Trouble Codes (DTC) P0033, P0068, P0101, P0102, P0171, P0172, P0230, P0335, P0507, P1101, P1182, P1516, P1682, P2125, P2176, and Fuel Injector Balance Test with Tech 2 | ION Red Line Coupe w/ VIN P - RPO LSJ | 2004-2005 | 04-06-04-084
General Information | Revised Pre-Delivery Inspection (PDI) Form | All Saturn vehicles | 2004-2005 | 04-00-89-054

#### Parts on Restriction at TAC (as of November 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.)