INFORMATION ON INSTRUMENT CLUSTER ASSEMBLY REPLACEMENT. Saturn Saturn 1994

For 1990-2009 cars

# INFORMATION ON INSTRUMENT CLUSTER ASSEMBLY REPLACEMENT

#### SUBJECT: Service Information on Instrument Cluster Assembly Replacement

#### MODELS AFFECTED: 1991-1994 Saturns

PURPOSE: When servicing an instrument cluster assembly, the following guidelines must be followed in order to ensure an efficient and cost effective repair.

#### SERVICE PROCEDURES

Removal and installation procedures can be found in the "Instrument Panel and Console" section of the "Body/Collision Repair Service Manual."

#### IMPORTANT: Failure to remove power when removing or installing an instrument cluster assembly may cause the fusible link on the back of the instrument cluster assembly to open.

Diagnostic procedures can be found in the "Power Distribution" section of the "Electrical Service Manual."

#### Instrument Cluster Assembly Technical Tips

Following is a list of normal performance characteristics of the Saturn instrument cluster assembly that have prompted unnecessary instrument cluster assembly replacements:

1. Odometer steps, instead of a smooth continuous movement.

2. Odometer makes a slight ticking noise.

3. Main odometer and the trip odometer may not synchronize when they turn over. The roll over point of the trip odometer versus the main odometer is determined by when the reset button is pushed in, during the main odometer cycle.

4. Speedometer may not start to move until the vehicle has reached 13 km/h (8 mph).

5. Perception of a large gap between the white metal wheel and the first black wheel on the trip odometer is similar on all instrument cluster assemblies.

6. Fuel gauges on 1991 and 1992 vehicles retum to zero when the ignition is turned Off. On 1993 and 1994 vehicles, fuel gauges will stay within five angular degrees (about 2.5 tick marks) of actual level when the ignition is turned Off.

#### SERVICEABLE COMPONENTS

The instrument cluster assembly is serviced only by replacement. The only authorized retailer repair is bulb replacement. The following bulbs are available through Saturn Service Parts:

Part Number Description ----------- ----------- 21020635 I/P Cluster Telltale Lamp 21020634 I/P Cluster Back Light

#### PART NUMBER IDENTIFICATION

To identify the correct part number for the replacement instrument cluster assembly, obtain the full vehicle identification number (VIN) and record VIN positions four, five, six and ten. Match these VIN position numbers to the "Instrument Cluster Assembly-Part Number Reference Chart" shown on the last page of this bulletin.

#### MILEAGE DETERMINATION

The replacement instrument cluster assembly mileage must match exactly with the mileage of the instrument cluster assembly being replaced. Since the instrument cluster assembly cannot be repaired, the mileage must be stated when ordering the replacement part. Sublet repairs to speedometer shops for mileage changes are not authorized.

In order to ensure an exact mileage match, the vehicle must not be driven after the replacement part is ordered. If the customer requires alternate transportation, obtain prior approval from your area team leader at the Saturn Assistance Center. If prior approval is obtained, submit a claim for reimbursement from the Saturn Dealer Systems as follows:

Labor Case Operation Type Description Code ---- ----------- --------- GW Instrument Cluster R & R N4180

#### REPLACEMENT PART ORDERING

To order a service replacement instrument cluster assembly, call the Parts Assistance Center at 1 (800) 828-2112, Prompt 2, with the following information:

o Part number (determined using the attached "Instrument Cluster Assembly-Part Number Reference Chart")

o Vehicle identification number (VIN)

o Customer service order number

o Mileage

Description of problem with instrument cluster assembly being replaced. NOTE: When describing the problem with the instrument cluster assembly being replaced, please include the following:

- Which gauge or telltale is malfunctioning

- Describe the malfunction (completely inoperative, inaccurate, etc.)

- Conditions when malfunction occurs (hot, cold, always, high rpm, etc.)

An instrument cluster assembly is shipped directly from the supplier using overnight express shipment. Orders received prior to 11:00 a.m. (CST) will be shipped the same day. If a replacement instrument cluster assembly is defective or damaged at the time of installation, call the Parts Assistance Center.

#### FAILED PARTS RETURN PROCEDURE

If a packing slip is generated for repair, the instrument cluster assembly should be returned in the box that the replacement instrument cluster assembly was shipped in. The following information must be included with the part being returned.

1. Completed "Orange Failed Part Tag" (including description of the problem with the instrument cluster assembly).

2. Completed "VDO-YAZAKI Saturn Cluster Return Instructions" sheet (included with each replacement instrument cluster assembly). (An example of the "VDO-YAZAKI Saturn Cluster Return Instruction" sheet is shown on the next page.)

3. Copy of the service invoice.

Return the failed part within 10 business days to the following address:

VDO Yazaki Corp. 188 Brooke Road Winchester, VA 22603 Attn: Returns Warehouse

#### MATERIAL RETURN PROCEDURE

If an instrument cluster assembly was ordered in error by your facility, contact the Parts Assistance Center. The only authorized material return will be for an instrument cluster assembly that has never been installed in a vehicle.

Return the part to Saturn Service Parts Operations (SSPO) using the guidelines outlined in Parts and Accessories Bulletin 92-PA-07, "Saturn Service Parts Operations (SSPO) Material Return Program."

Any instrument cluster assembly shipped to SSPO will be inspected. If the instrument cluster assembly is found to have previously been installed in a vehicle, the retailer will be charged for the instrument cluster assembly and it will be returned to the retailer.

#### VDO-YAZAKI SATURN CLUSTER RETURN INSTRUCTIONS

o COMPLETE QUESTIONS 1-6, ATTACH THIS FORM TO YOUR INVOICE AND RETURN IT WITH THE REMOVED CLUSTER.

RETURN TO: Control No: 40800 VDO-Yazaki Corp. Contact Date: 3/21/94 188 Brooke Road Dealer No: 00011 Winchester, VA 22603 Name: SATURN OF ANYWHERE Attn: Returns Warehouse Address: 11011 SATURN HIGHWAY SPRING HILL, TN

Order No CSO No: ___________________ CSO Date: _____________________ VDO Part No: 1 812 501 426S Cluster No: Vehicle ID: 1G8ZH1572RZ000111 Mileage: 1234

1. WHAT WAS THE CUSTOMER COMPLAINT? __________________________________

___________________________________________________________________

___________________________________________________________________

2. CAN THE TECHNICIAN DUPLICATE THE COMPLAINT? YES_____ NO_____

3. WHAT PART OF THE CLUSTER WAS THE ACTUAL COMPLAINT? GAUGES LISTED BELOW, PLEASE CHECK ONE OF THE FOLLOWING.

_____ Speedometer _____ Tachometer _____ Odometer

_____Trip Odometer _____ Fuel _____ Temperature

_____Oil Pressure _____ Telltales _____ Other

_____Illumination Display

4. WHEN DOES THE CUSTOMER NOTICE THE OCCURRENCE OF THE COMPLAINT? PLEASE CHECK ONE OR MORE OF THE FOLLOWING.

_____ Cold _____ Hot _____ Engine Off

_____ Engine On _____ Stopped _____ Moving

_____ Under 55 MPH _____ Over 55 MPH _____ At Night

_____ Daytime _____ Intermittently _____ Always

5. DIAGNOSTIC TESTS PERFORMED AND COMMENTS.

6. CLAIM TYPE: WARRANTY________ CUSTOMER ________ OTHER ____

VDO Technician: __________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

Return Date__________ Part #__________ Date Code __________

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.