For 1990-2009 cars

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

Subject: | Saturn Field Product Reminder -- Vehicle "Fix It Right the First Time" Issues, Parts Restriction Information and Technical Bulletins Released in June and July 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 | VUE with 3.5L V-6 Engine - Service Engine Soon (SES) Telltale with Diagnostic Trouble Code (DTC) P0453 | Select the "Replace and Reprogram" option on the service stall and recalibrate the PCM with Calibration I.D. number 12594438 or later. | Don’t replace the fuel tank pressure sensor. | 04-06-04-052
2002-2004 | VUE - Pop/Clunk Noise From the Rear of the Vehicle on Initial Cold Start and/or During the Warm-Up Drive Cycle | Refer customer to bulletin 04-06-05-009 and/or demonstrate noise using Tech 2. | Don’t replace the vent solenoid. | 04-06-05-009
2004 | ION Redline w/ 5-speed Manual Trans - Manual Transaxle Fluid Information | If it is necessary to perform manual transaxle fluid change, install Saturn P/N 21018899. | Don’t substitute any other fluid. | Reference Parts Catalog
2000-2005 | All Vehicles with Compact Discs (CD) or Digital Versatile Discs (DVD) Player - CD or DVD Stuck in CD Player When Returned as a Core Return | Complete return form as called out in bulletin 04-08-44-015. | Don’t attempt to disassemble the radio to remove CDs. | 04-08-44-015
2003-2004 | ION Sedans Built Up To VIN 4Z190767 and Coupes Built Up To VIN 4Z191744 - Sunroof Inoperative and/or Inside Rearview Mirror Electrical Functions Inoperative | Replace fuse and install new sunroof switch P/N 22687360. | Don’t replace sunroof module. | 04-08-45-006
2004 | VUE - Extended Engine Crank Time Before Engine Starts | Determine if fuel pressure bleed down is outside specification. If so, replace primary fuel pump. | Don’t replace other fuel system components. | 04-06-04-048
2004 | VUE w/ 3.5L V-6 Engine - Service Engine Soon (SES) Lamp Illuminated with Diagnostic Trouble Code (DTC) P0496 Set and/or Hard Start or Extended Crank After Adding Fuel | Determine if fuel pressure bleed down is within specification. If so, replace EVAP Canister Purge Solenoid Valve. | Don’t replace fuel pump. | 04-06-04-046
2004 | ION - Headliner Sags Near Center High Mounted Stop Lamp (CHMSL) | Replace headliner. | Don’t attempt to re-attach headliner. | Reference service manual for replacement procedure.
2003 - 2004 | VUE Built After VIN 3S844189 - A/C Compressor On In Floor Mode | Normal condition to reduce window moisture. Refer customer to bulletin 04-01-38-007. | Don’t replace HVAC control head. | 04-01-38-007
2004 | ION Redline w/ 2.0L LSJ Engine - Engine Cranks But Will Not Start and/or Engine Has Extended Crank Before Starting | Contact technical assistance to verify the timing of the Camshaft Position Trigger. | Don’t replace fuel pump or other ignition components. | Contact Saturn Technical Assistance Center 1-800-828-2112, prompt 1, (Canada English 1-800-263-7740, Canada French 1-800-263-7960)
2000 - 2004 | L-Series w/ 3.0L L81 Engine - Service Engine Soon (SES) Lamp Illuminated with DTC P0135 "HO2S Heater Circuit Performance Bank 1 Sensor 1" and/or DTC P0155 "HO2S Heater Performance Bank 2 Sensor 1" | Perform Oxygen Sensor Conditioning Drive Cycle procedure in bulletin. | Don’t replace heated oxygen sensor(s). | 04-06-04-008
2002-2003 | VUE w/ 3.0L L81 Engine - Service Engine Soon (SES) Lamp Illuminated with DTC P0135 "HO2S Heater Circuit Performance Bank 1 Sensor 1" and/or DTC P0155 "HO2S Heater Performance Bank 2 Sensor 1" | Perform Oxygen Sensor Conditioning Drive Cycle procedure in bulletin. | Don’t replace heated oxygen sensor(s). | 04-06-04-008
2004 | L-Series w/ 3.0L L81 Engine - Service Engine Soon (SES) Lamp Illuminated with Diagnostic Trouble Code (DTC) P0606 Set | Reprogram Engine Control Module (ECM). | Don’t replace ECM. | 04-06-04-026

#### Saturn Technical Bulletins Released in June and July 2004

Category Type | Subject | Model(s) | Model Year(s) | Bulletin Number
--- | --- | --- | --- | ---
Technical Bulletins for June 2004
Body & Accessories | Erratic Front Turn Signal Operation When Using a Cell Phone Charger in Either Accessory Power Outlet (Install Capacitor In Accessory Outlet Wiring) | ION | 2003-2004 | 03-08-42-009A
Body & Accessories | Service Manual Update - Rear Seat Entertainment System (DVD) Diagnostics and Service Procedures | VUE w/ RPO U32 | 2004 | 04-08-44-012
Body & Accessories | Theft Deterrent Feature Will Not Set On Cassette Single CD Player Radio (Replace Radio) | Various Models w/ RPO UP0 | Various Model Years | 04-08-44-013
Body & Accessories | No Crank, No Start When Ambient Temperature Is Cold - DTCs B2960 and/or B3033 Are Set (Replace Ignition Switch) | ION w/ VIN Break | 2003 & 2004 | 04-08-45-005
Body & Accessories | Sunroof Inoperative and/or Inside Rearview Mirror Electrical Functions Inoperative (Replace Fuse and Install New Sunroof Switch) | ION Coupe & Sedan w/ VIN Break | 2003 - 2004 | 04-08-45-006
Body & Accessories | Squeak Noise from Front Inner Door Armrest/Pull Handle (Replace Front Inner Door Pull Handle Pushnuts) | VUE | 2002-2004 | 02-08-64-019A
Body & Accessories | Itch/Squeak Type Noise Coming From the Sunroof Area (Trim Sunroof Reinforcement Flange Tabs) | ION Coupe w/ RPO CF5 | 2004 | 04-08-67-004
Engine /Propulsion System | Service Engine Soon (SES) Lamp Illuminated with Diagnostic Trouble Code (DTC) P0496 Set and/or Hard Start or Extended Crank After Adding Fuel (Replace EVAP Canister Purge Solenoid Valve) | VUE w/ VIN 4 - RPO L66 | 2004 | 04-06-04-046
Engine /Propulsion System | Extended Engine Crank Time Before Engine Starts (Replace Primary Fuel Pump) | VUE | 2004 | 04-06-04-048
HVAC | Information on Proper Mode Switch Setting (Between Defrost and Heater/Defrost) to Prevent Window Moisture and HVAC Controller Assembly Logic Revision | VUE | 2002 - 2003 | 04-01-38-007
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/ RPO M09/M45 ION w/ RPO M43 | 2002 - 2003 2003 | 03-07-30-023A
Transmission/ Transaxle | Remanufactured Transmission and Remanufactured Valve Body Information Requirements | S-Series | 1991 - 2002 | 04-07-30-026
Technical Bulletins for July 2004
Body & Accessories | Return Form for Compact Discs (CDs) or digital Versatile Discs (DVDs) That Are Stuck in CD Player When Returned as a Core Return | S-Series L-Series VUE ION | 2000 - 2002 2000 - 2005 2002 - 2005 2003 - 2005 | 04-08-44-015
Body & Accessories | Additional Power Distribution Information for Body Control Module Electrical ("BCM ELECT") Fuse in the Instrument Panel Fuse Block (IPFB) | ION | 2003 - 2005 | 04-08-45-007
Engine/ Propulsion System | Engine Squeak/Chirp Noise from Bank 2 (Front Bank) Camshaft Sprockets/Behind Timing Belt Cover with Engine Speeds of 600-3500 RPM (Replace Bank 2 [Front Belt] Timing Belt Sprockets) | L-Series w/ VIN R - RPO L81 w/ VIN Break | 2005 | 04-06-01-024
Engine/ Propulsion System | Extended Engine Crank Time Before Engine Starts (Replace Primary Fuel Pump) | VUE | 2004 | 04-06-04-048
Engine/ Propulsion System | Service Engine Soon (SES) Telltale with Diagnostic Trouble Code (DTC) P0453 Stored in the Powertrain Control Module (PCM) (Recalibrate PCM) | VUE w/ VIN 4 - RPO L66 | 2004 | 04-06-04-052
Engine/ Propulsion System | Service Information Regarding a Pop/Clunk Noise From the Rear of the Vehicle on Initial Cold Start and/or During the Warm-Up Drive Cycle | VUE | 2002 - 2004 | 04-06-05-009

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