For 1990-2009 cars

# ENGINE CRANKS BUT WILL NOT START, OR ENGINE STALLS

#### SUBJECT: Engine Cranks but will not Start, or Engine Stalls Immediately After Start Followed by Extended Engine Cranking, and/or Ignition Misfire Resulting in DTCs P0300, P0301, P0302, P0303, P0304 (Replace Spark Plugs and Install New Emissions Label)

#### MODELS AFFECTED: 1996 Saturns equipped with spark plugs (AC 41-607 [L24] or AC41-608 [LLO]) set at 1.5 mm (0.060 inches) gap. IMPORTANT: To identify the gap of the spark plug installed in the engine, refer to "Vehicle Emissions Control Information Label" (identified on the vehicle as the "Saturn Power Module" label), located on the radiator core support.

* If the "Spark Plug Gap" specification on the label is 0.060 inches, the engine does not have the new spark plugs installed, and you should proceed with this bulletin.

* If the "Spark Plug Gap" specification on the label is 0.040 inches, new spark plugs and a new vehicle emissions control information label have been installed. Refer to the "1996 Revised Powertrain Controls Service Manual" for diagnostic information.

#### CONDITION

The vehicle may exhibit one or more of the following conditions:

No start until "clear flood" is performed

Stall after a start, followed by extended engine cranking

Engine misfire and diagnostic trouble codes (DTCS) P0300, P0301, P0302, P0303 and/or P0304 in PCM memory.

Exhaust valves sticking (popping noise heard through exhaust) and DTCs P0300, P0301, P0302, P0303 and/or P0304 in PCM memory.

#### CAUSE

Secondary coil output voltage may be exceeded with spark plug gaps at 0.060 inch or greater.

#### CORRECTION

Refer to Procedures in this bulletin to locate and correct the condition.

#### PROCEDURE

1. Install new spark plugs (P/N 21024004 [AC 41-617]- L24, P/N 21024005 [AC 41-618]- LLO). Make sure to check and if necessary, adjust gap to 1.0 mm (0.040 inches).

#### NOTICE: Do not reduce the air gap on the original spark plugs (P/N 21021526 - L24, P/N 21021527. - LLO) from 1.5 mm (0.060 inches) to 1.0 mm (0.040 inches), because life expectancy of the spark plugs may be reduced and cold driveability issues may result. New spark plugs (P/N 21024004 - L24, P/N 21024005 - LLO) must be used with the air gap set to 1.0 mm (0.040 inches).

2. If vehicles does not have DTCs P0300, P0301, P0302, P0303 and/or P0304 in PCM memory, and there is no exhaust valves sticking (popping noise heard through exhaust), proceed to step 7.

If vehicle has DTCs P0300, P0301, P0302, P0303 and/or P0304 in PCM memory, and has cylinder head exhaust valves sticking (popping noise heard through exhaust), proceed to the next step.

3. Add one bottle of Saturn Fuel Injector Cleaner (P/N 21007313) or equivalent to a full tank of fuel.

IMPORTANT- Fuel injector cleaner must be added to a full tank of fuel to prevent over treatment of fuel. Adding fuel injector cleaner to a partially filled tank of fuel may cause the fuel to create deposit formations on the cylinder head valves and in the combustion chambers.

4. Start engine and bring up to normal operating temperature.

5. Drive vehicle in D2 (automatic transaxle) or 3rd gear (manual transaxle) for 10 minutes at 80 km/h (50 mph) to clean cylinder head exhaust valves.

6. Clear diagnostic trouble codes from PCM memory.

#### NOTICE: After new spark plugs are installed, a new vehicle emissions control information label must be applied over existing emissions control information label.

7. Apply new vehicle emissions control information label ("Saturn Power Module") over the existing vehicle emissions control information label.

a. Use a clean dry cloth to wipe dirt, oil, etc., from the vehicle emissions control information label currently on the vehicle.

b. Remove backing from the new vehicle emissions control information label.

c. Apply the new vehicle emissions control information label over the existing vehicle emissions control information label.

#### VEHICLE EMISSIONS CONTROL INFORMATION LABELS

ENGINE APPLICATION PART NUMBER

L24 Federal Emissions 21008376

LL0 Federal Automatic & Manual Transaxle Emissions 21008377 California Automatic Transaxle Emissions

L24 California Emissions 21008378

LL0 California Manual Transaxle Emissions 21008379

L24 Canada/Taiwan Export 21008380

LL0 Canada/Taiwan Export 21008381

d. Using a clean dry cloth, smooth the label by starting at the center of the label and working outward on both sides. (Air bubbles can be removed by puncturing the air bubble with a pin and then smoothing the air bubble over with the clean dry cloth.)

#### IMPORTANT: Do not attempt to remove or loosen the new vehicle emissions control information label once it has been installed, or this will damage the new vehicle emissions control information label.

PARTS REQUIREMENTS: 21024004 Spark Plug Asm - L24 21024005 Spark Plug Asm - LLO 21007313 Cleaner Pkg-F/Injector

One of the following vehicle emissions control information labels:

21008376 L24 Federal Emissions 21008377 LL0 (Auto/Man Trans.), California Auto Trans Emissions 21008378 L24 California Emissions 21008379 LLO California Manual Transaxle Emissions 21008380 L24 Export 21008381 LLO Export

CLAIM INFORMATION: To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:

Labor Case Operation Type Description Code Time ---- ------------ ---------- -----

VW Replace Spark Plugs and Install T9712 0.4 hrs New Emissions Label VW Remove Carbon Deposits From T9713 0.7 hrs Exhaust Valves, Replace Spark Plugs and Install New Emissions Label

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.