For 1990-2009 cars

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

Subject: | Saturn Field Product Reminder -- Vehicle "Fix It Right the First Time" Issues, Parts Restriction Information and Technical Bulletins Released in August 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
--- | --- | --- | --- | ---
2002-2003 | VUE Vehicles with 2.2L 4-Cylinder Engine - Check Engine Light on with P0440 or P0442 Stored | Verify no EVAP leaks using the service manual procedure. If no leaks are identified, reprogram the ECM with the calibration available on Saturn Service Stall data release TIS 8.0 2004 or later. | Don’t replace EVAP components. | 04-06-04-033A
2002 | VUE Vehicles with 2.2L 4-Cylinder Engine - Check Engine Light On with P0606 after ECM programming | Reprogram the ECM again with the calibration available on Saturn Service Stall data release TIS 8.0 2004 or later. | Don't replace the ECM. | Saturn Service Stall release notes for data release TIS 8.0 2004
2003-2004 | ION Built Up To and Including VIN Breakpoint 4Z211388 - Temperature/Mode Control Knobs May Not Rotate, Air Flow Restricted, or HVAC Mode Door Gasket or Temperature Door Gasket Foam Comes Off | Replace A/C Evaporator Case/Heater Case Assembly. | Don’t replace or attempt to reattach the foam gasket. | 04-01-38-011
2002-2004 | VUE with All Wheel Drive (RPO GQ1) Built Prior to VIN Breakpoint 4S853184 - Vibration Felt in Seatback or Armrest at Vehicle Speeds Between 30 to 55 mph | Replace Propeller Shaft Center Support Bearing. | Don’t replace the propeller shaft. | 04-04-17-002
2004 | ION Red Line Coupe with 2.0 L LSJ Engine - Engine Cranks With No Start or Engine has Extended Crank (Greater than 3 Seconds) Before Starting | Verify the timing of the camshaft position trigger and adjust if necessary. | Don’t replace fuel pump or other ignition related components. | 04-06-01-026
2004 | ION and VUE with Single-Disc CD Player (RPO U1C) - Popping/Crackling Noise or Distorted Sound from Speakers at Low Volume When a CD Is Played. This information also applies to any Saturn vehicle with service CD player (P/N 22711669) installed. | Replace CD player/radio with P/N 21997420. | Don’t replace CD player/radio with any other radio part number. | 04-08-44-016
2004 | VUE AWD with 3.5 L L66 Engine - Moan/Growl Noise/Vibration from Rear of Vehicle when Turning at Low Speeds | Replace Rear Drive Module Differential Clutch Drum with P/N 15235314. | Don’t replace RDM clutch drum with any other part number. | Reference parts catalog.
2002-2003 | VUE - Air Conditioning (A/C) Compressor Inoperative withVehicle Speed | Disconnect and inspect instrument panel/body inline connector (black 40-pin electrical connector) and replace damaged terminals and/or apply dielectric grease to connector. | Don’t replace compressor, HVAC control head or other a/c components. | 03-08-45-003A
1991-2005 | All Saturn Vehicles - Pinstripe/Vinyl Graphic Installation Tips and Techniques | Follow tips and techniques as outlined in bulletin 04-08-51-004. | Don't use any aromatic solvents such as acetone, M.E.K., toluene, paint thinner, lacquer thinner on the pinstripes/vinyl graphics. Don't overcoat the pinstripes/vinyl graphics with clear paint. Don't apply wax over pinstripes/vinyl graphics. | 04-08-51-004
2003-2004 | ION Coupes - Gap Is Present Between the Front Fascia and Headlamp Assembly During Times of High Ambient Temperatures and Maximum Thermal Growth | Replace fascia with P/N 15207535. | Don't attempt other repair. | Reference ESI "Preliminary Information" PIC3105.

#### Saturn Technical Bulletins Released in August 2004

Category Type | Subject | Model(s) | Model Year(s) | Bulletin Number
--- | --- | --- | --- | ---
Body & Accessories | Reduced Power, Stuck in High Gear, Service Engine Soon (SES) Light On, DTCs P0223, P0504, P0700, P1228, P1271, P1280, P1599, P1779, P1791, P2119, P2101, P2128, P2135, or P2138 Set, Buzz Noise from Door Speakers or Door Speakers Inoperative, Heating-Ventilation-Air Conditioning (HVAC) Blower Motor Inoperative and/or Air Conditioning (A/C) Compressor Inoperative with Vehicle Speed (Inspect/Replace Corroded or Bent Terminals) | VUE | 2002-2003 | 03-08-45-003A
Body & Accessories | Headliner Material (Fabric) Sagging or Separating from Substrate (Replace Headliner) | ION Quad Coupe | 2004 | 04-08-110-006
Body & Accessories | Popping/Crackling Noise or Distorted Sound from Speakers at Low Volume When a Compact Disc (CD) Is Played (Replace RPO U1C CD Player/Radio with New Design CD Player/Radio) | VUE & ION This bulletin also applies to any Saturn vehicle with service CD player, P/N 22711669, installed | 2004 | 04-08-44-016
Body & Accessories | Squeak/Itch Noise from Rear Seat When Driving on Rough Surfaces (Apply Squeak Reduction Tape to Striker) | ION | 2003-3005 | 04-08-50-013
Body & Accessories | Pinstripe/Vinyl Graphic Installation Tips and Techniques | All Saturn vehicles | 1991-2005 | 04-08-51-004
Body & Accessories | Fuel Gauge Displays an Erratic or False Reading or No Start Condition after Vehicle is Shut Off with Low Fuel Level (Diagnose Fuel Gauge and Fuel Sender and/or Adjust/Replace Fuel Sender) | L-Series | 2000-2005 | 03-08-49-022A
Body & Accessories | Wind Noise at Highway Speeds from Base of Driver Side (Left) A-Pillar Near VIN Plate Area (Seal Area with Seam Sealer) | VUE | 2003-2004 | 03-08-58-05A
Driveline Axle | Vibration Felt in Seatback or Armrest at Vehicle Speeds Between 48 to 89 km/h (30 to 55 mph) (Replace Propeller Shaft Center Support Bearing) | VUE w/ RPO GQ1 and VIN Break | 2002-2004 | 04-04-17-002
Engine /Propulsion System | Engine Cranks With No Start or Engine has Extended Crank (Greater than 3 Seconds) Before Starting (Verify the Timing of the Camshaft Position Trigger and Adjust if Necessary) | ION Red Line Coupe | 2004 | 04-06-01-026
HVAC | Water Leaks into Passenger Compartment Through HVAC Module Condensate Drain Tube When Parked on Incline/Uphill Position (Install Auxiliary Drain Tube Extension) | ION Sedans and Coupes | 2003-2004 | 03-01-39-011A
HVAC | Temperature/Mode Control Knobs May Not Rotate, Air Flow Restricted, or HVAC Mode Door gasket or Temperature Door Gasket Foam Comes Off (Replace A/C Evaporator Case/Heater Case Assembly) | ION w/ VIN Break | 2003-2004 | 04-01-38-011
Suspension | Steering Wheel Shake or Vibration at 100 to 109 km/h (62 to 69 mph) (Follow Vibration Complaint Flow Chart/Replace Hub Assembly, If Necessary) | S-Series | 2000-2002 | 04-03-10-008
Suspension | Creaking/Squeaking Noise From the Front Suspension When Turning the Steering Wheel (Replace Front Strut Bumper) | ION | 2003-2004 | 04-03-08-013
Suspension | Vehicle Vibrations at Highway Speeds 72 to 110 km/h (45 to 79 mph) (Road Test Vehicle/Perform Diagnostic Procedures, If Necessary) | ION | 2004-2005 | 04-03-10-006
Transmission/ Transaxle | Grind/Rattle Noise from Transaxle in Park or Neutral After an Extended Cold Soak Following Case Cover Replacement or Other Internal Transaxle Overhaul (Replace VT25E Transaxle Assembly) | ION and VUE | 2003-2004 | 04-07-30-032

#### Parts on Restriction at TAC (as of August 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)