For 1990-2009 cars

# Field Product Reminder - Vehicle Fix It Right the First Time Issues, Parts Restriction Information and Bulletins Released in December 2004 and January 2005

Subject: | Saturn Field Product Reminder -- Vehicle "Fix It Right the First Time" Issues, Parts Restriction Information and Bulletins Released in December 2004 and January 2005

Models: | 2005 and Prior Model Year Saturn Vehicles

In order to access this bulletin electronically, go to the Service Information (SI) Home Page 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
2000 - 2005 | L-Series - Clunk Noise from Front of Vehicle During Turning Maneuver/Steering Wheel Rotation | Lubricate intermediate shaft with lubrication kit P/N 26098237. | Don’t replace the intermediate shaft or steering column. | 04-02-35-008A
2002 - 2005 | L-Series with 3.0L L81 Engine - Insufficient Heat, Service Engine Soon (SES) Light On, DTC P0128 Set | Replace thermostat (P/N 24420653) and O-ring seals. | Don’t replace the thermostat and housing as an assembly. | 03-06-02-002A (Bulletin in approval process.)
2002 - 2003 | VUE with 3.0L L81 Engine - Insufficient Heat, Service Engine Soon (SES) Light On, DTC P0128 Set | Replace thermostat (P/N 24420653) and O-ring seals. | Don’t replace the thermostat and housing as an assembly. | 03-06-02-002A (Bulletin in approval process.)
2005 | Relay - Power Sliding Door Motor Replacement Procedure | Remove 15 amp PSD fuse from the instrument panel fuse block and adjust cables prior to installing new motor. | Don’t plug in and power up new motor without removing 15 amp PSD fuse and adjusting cables. | SI Document ID# 1541213 for left hand door and/or or SI Document ID# 1501361 for right hand door.
2005 | ION with 2.2L 4-Cylinder L61 Engine Built Up to and Including VIN Breakpoint 5Z135349 Service Engine Soon Lamp Illuminated with Diagnostic Trouble Codes (DTC) P0300, Misfire Detected and/or P0315 Crankshaft Variation Position Not Learned and/or P0507 - Idle Speed Too High and/or P1574 Stop Lamp Switch Circuit and/or P1621 Control Module Long Term Memory Performance Set and/or Cruise Control is Inoperative | Reprogram Engine Control Module (ECM) with Saturn Service Stall System (SSS) software version 12.0 (2004 or later data CD). | Don’t replace any other engine or cruise components. | 05-06-04-005
2004 - 2005 | ION Red Line with 2.0L Engine (VIN P - RPO LSJ) - Engine Runs Rough After Extended Crank and/or Engine Hesitation on Acceleration after Initial Cold Start During Ambient Temperatures Below 10° C (50° F) | Reprogram Engine Control Module (ECM) with Saturn Service Stall System (SSS) software version 1.0 (2005 or later data CD). | Don’t replace any engine components. | 05-06-04-006
2005 | ION - Fuel Gauge May Intermittently Drop to Empty Even with Nearly a Full Tank of Fuel and/or Speedometer May Drop to Zero and/or Security Telltale May Come On with U1064 Stored in the ECM. | Reference SI PI PIC3328 and clear DTC if applicable. | Don’t replace Instrument Panel (I/P) cluster, fuel level sender, or Body Control Module (BCM). | SI PI PIC3328
2004 - 2005 | VUE Vehicles with 3.5L V-6 Engine - Cruise Control Inoperative and/or Service Engine Soon (SES) Telltale Illuminated with Diagnostic Trouble Code (DTC) P0571 Stored in Powertrain Control Module (PCM) | Clear DTC with Tech 2 and wait for future field communication. | Don’t replace any cruise control components. | 04-08-68-004A
2004 | VUE with 3.5L V-6 Engine (VIN 4 - RPO L66) - B1372 as well as Various U-Codes (e.g. U2105, U2106, etc.) | Clear DTC with Tech 2 and wait for future field communication. | Don’t replace controllers/modules. | SI PI PIC3258
2005 | The Following RPAs are Ship Direct Parts from Supplier to Retailer (Not Shipped with Vehicle): RELAY - VDJ - Toy Box, VEH - Overhead Console, AQW - Sit & Lift Mobility Chair ION - D81 - Aero Wing Rear Spoiler VUE - R1V - BVE running boards and T43 Spoiler | Consult with parts department for location of RPA components. | Don’t submit missing RPA components under warranty. | Parts and Accessories bulletin 04-PA-05
2003 - 2004 | ION Sedans - Instruction on When or If to Install Headlamp Harness on Vehicles Involved in Campaign 04095 | Follow campaign instructions and install 2 new bulbs (and resistor kit 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. | Campaign 04095
2003 - 2005 | ION - Premature and/or Irregular Tire Wear | Verify the concern and adjust the front total toe as necessary to the new preferred setting of (+0.20° ± 0.05°) for tire wear issues. Reference this bulletin and SI for new alignment specifications. | Don’t follow alignment specs in the printed manual, as they have been changed. | 05-03-07-001
2005 | Relay - Speedometer Drops to Zero Intermittently While on an OnStar® Call | Inform customer that Saturn is aware of the concern and working on a resolution. | Don’t replace the OnStar® VCIM. | SI PI PIT3333

#### Saturn Bulletins Released in December 2004

Category Type | Subject | Model(s) | Model Year(s) | Bulletin Number
--- | --- | --- | --- | ---
Body and Accessories | Sunroof Drain Hose Rattle (Install Mastic Patch) | ION w/ RPO CF5 w/ VIN Break | 2003 - 2004 | 04-08-67-007A
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) (Clear DTC P0571) | VUE w/ RPO L66 | 2004 - 2005 | 04-08-68-004A
Driveline Axle | Moan/Growl Noise/Vibration from Rear of Vehicle when Turning at Low Speeds (Replace Rear Drive Module Differential Clutch Drum) | VUE w/ AWD | 2003 - 2004 | 03-04-20-003B
Engine / Propulsion System | Service Engine Soon (SES) Telltale Illuminated with Diagnostic Trouble Code (DTC) P0171, P0174 and/or P0175 (Refer to Diagnostic Procedure in this Bulletin and Replace Mass Air Flow [MAF] Sensor, if Necessary) | L-Series w/ RPO L81 | 2000 - 2003 | 01-06-04-016A
Engine / Propulsion System | Service Manual Update - Diagnostic Trouble Code (DTC) P0601, P0602, P0603, P064, P0605, P0606, P0607, P1600, P1621, P1627, P1680, P1681, P1683, or P2610 | L-Series w/ RPO L81 | 2004 and 2005 | 04-06-04-026A
Engine / Propulsion System | Service Engine Soon (SES) and/or Reduced Power Lamp Illuminating Following Cold Engine Start Up In Subfreezing Temperatures, Diagnostic Trouble Codes (DTC) P0638, P1510 and/or P1516 Stored in Engine Control Module (ECM) (Re-locate Small Primary Positive Crankcase Ventilation [PCV] Hose) | L-Series w/ RPO L81 | 2000 - 2005 | 04-06-04-085
General Information | Trailer, Recreational and Disabled Vehicle Towing Information for 2000 - 2005 Saturn Vehicles | L-Series VUE ION Relay | 2000 - 2005 2002 - 2005 2003 - 2005 2005 | 03-00-89-033A
Transmission / Transaxle | Vehicle Does Not Shift or Move After Running for a Period of Time and/or Check Engine Light is ON and DTC P0741 is Set (Replace Torque Converter, Valve Body, Clean Out Transaxle and Install New Flex Plate Bolts and Washers) | VUE w/ AF33-5 ION w/ AF23-5 | 2002 - 2003 2003 - 2004 | 03-07-30-023B
Transmission / Transaxle | Service Manual Update - Liquid Polyacrylate (PA) Sealant Application Requirements | VUE and ION w/ VT25E RPO M75/M16 | 2002 - 2005 2003 - 2004 | 04-07-30-011B

#### Saturn Bulletins Released in January 2005

Body and Accessories | Compact Disc (CD) or DVD Player Skipping, Inoperative, Sluggish, and/or Long Search Times | All Saturn Vehicles | 2005 and Prior | 05-08-44-001
Body and Accessories | OnStar® Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar® Fuse and Replace Vehicle Communication Interface Module [VCIM] or Follow SI Diagnostics) | ION, VUE, and Relay | 2005 | 05-08-46-001
Body and Accessories | Unable to Connect to OnStar® or OnStar® Personal Calling Inoperative in Alaska Only (Change Transceiver ID) | Saturn Vehicles with Analog OnStar® System (RPO UE1) | 2002 - 2005 | 05-08-46-002
Body and Accessories | Erratic Fuel Gauge Readings (Install Updated Engine Control Module [ECM]) | ION Vehicles with 2.2L Engine (VIN F - RPO L61) | 2005 | 05-08-49-004
Engine / Propulsion System | Service Engine Soon Lamp Illuminated with Diagnostic Trouble Codes (DTC) P0300 "Misfire Detected" and/or P0315 "Crankshaft Variation Position Not Learned" and/or P0507 "Idle Speed Too High" and/or P1574 "Stop Lamp Switch Circuit" and/or P1621 "Control Module Long Term Memory Performance" Set and/or Cruise Control is Inoperative (Reprogram Engine Control Module [ECM] with Updated Calibration) | ION Vehicles With 2.2L 4-Cylinder Engine (VIN F - RPO L61) with VIN Break | 2005 | 05-06-04-005
Engine / Propulsion System | Engine Runs Rough After Extended Crank, and/or Engine Hesitation on Acceleration after Initial Cold Start During Ambient Temperatures Below 10°C (50°F) (Reprogram Powertrain Control Module [PCM]) | ION Red Line with 2.0L Engine (VIN P - RPO LSJ) | 2004 - 2005 | 05-06-04-006
General Information | Rear Seat Operation - Instruction for Removal and Installation | Relay | 2005 | 05-00-89-002
Suspension | Premature and/or Irregular Tire Wear (Set Front Sum Toe and Rotate Tires as Necessary) | ION | 2003 - 2005 | 05-03-07-001
Transmission / Transaxle | Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) LIght On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter | All Saturn Vehicles | 2005 and Prior | 04-07-30-013A

#### Parts on Restriction at TAC (as of Jan 2005)

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.)