SATURN Field Product Reminder - Vehicle Fix It Right The First Time Issues, Parts Restriction Information And Technical Bulletins Released In May, 2004 (04-00-89-023)

Publication date: 2004-06-15
Reference number: 04-00-89-023

SATURN FIELD PRODUCT REMINDER - VEHICLE FIX IT RIGHT THE FIRST TIME ISSUES, PARTS RESTRICTION INFORMATION AND TECHNICAL BULLETINS RELEASED IN MAY, 2004

TECHNICAL SERVICE BULLETIN

Reference Number(s): 04-00-89-023, Date of Issue: June 15, 2004

SATURN:	2004 and Prior Model Year Vehicles
SECTION:	00 - General Information

SERVICE INFORMATION

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
2004	ION Equipped with 2.0 LSJ Engine	Use Mobil 1(R) motor oil or oil meeting GM Standard GM4718M when performing an oil change.	Don't use any motor oil that does not meet standard GM4718M.	See Owner's Manual and/or oil fill cap on engine.
2000-2004	All Saturn Vehicles with SDIN Single CD (U1C) Radio - CD Skip	Reference bulletin 03-08-44-016A for radio part number that contains CD buffer.	Don't install radio other than the one contained in the bulletin.	03-08-44-016A
2002-2003	VUE, L-Series, and ION with 6-Disc (UR9 or UB2) Radio - CD Player is Inoperative, Low Volume Tick, Clock Will Not Keep Correct Time	Reference bulletins 03-08-44-010 & 03-08-44-019A for fixes.	Don't use radio P/N 22661247.	03-08-44-010 & 03-08-44-019A
2004	VUE AWD with 3.5 L L66 Engine - Grind Noise After RDM Clutch Drum Replacement	For 3.5 L AWD L66, use RDM clutch drum P/N 22730517	Don't use P/N 22714938. This P/N should not be used for the 3.5L AWD L66.	See Parts Catalog.
1996-2002	Multiple Transaxle DTC's After Reman Transaxle Replacement	Inspect for loose buss plate to actuator connections and check actuator resistance. Replace buss plate and/or actuator as required.	Don't replace transaxle assembly or complete valve body assembly.	Reference appropriate model year transaxle service manual.
2003-2004	ION Built Prior to VIN Breakpoint 4Z210712 - No Crank, No Start With DTCs B2960 and/or B3033 Set In BCM	Replace ignition switch, which contains passlock sensor.	Don't replace starter, BCM, or ignition housing, which doesn't contain passlock sensor.	04-08-45-005
2003-2004	ION - Turn Signal Indicator Flashes Faster Than Normal And Corresponding Front Turn Signal Bulb is Inoperative with B3948 and/or B3949 (Turn Signals Operate Correctly When Key Cycled)	Install capacitor per bulletin 03-08-42-009.	Don't replace bulb or BCM.	03-08-42-009
2003-2004	ION Sedans - Turn Signal Indicator Flashes Faster Than Normal and Corresponding Front Turn Signal Bulb is Inoperative (Turn Signals Bulbs Will Not Illuminate/Operate Correctly Due To Bulb Being Burnt Out, When Key Is Cycled)	Install Harness Kit.	Don't simply replace the bulb or install capacitor as outlined in bulletin 03-08-42-009.	04-08-42-002
1998-2002	S-Series Vehicles With MP6/MP7 Automatic Transaxles- P0731 and No Movement in Drive During Cold Ambient Temperatures	Replace 1st Gear Sprag Clutch Assembly or Oil Pump.	Don't replace 1st Driven Gear Assembly, which is no longer included in the parts requirement.	03-07-30-008A
2002-2004	VUE - Hiss Noise When the Air Conditioning (A/C) Compressor Is Turned OFF. The Noise May Also Be Heard if the Cooling Fan Comes On in the High-Speed Mode with A/C Compressor ON.	Replace Low Speed Engine Cooling Fan Resistor.	Don't replace TXV or compressor.	04-01-37-006
2002-2004	VUE and ION Vehicles with VT25E Transaxles - New Service Procedures for Torque Converter, Differential Housing, and Case Cover Assembly	Apply 1-2 mm (0.04-0.08 in.) bead P/N 22722716 to surface.	Don't apply bead larger than 2 mm (0.08 in.), which could lead to subsequent transaxle noise and damage.	04-07-30-011A
2000-2005	L-Series with A/C - Chatter or Clicking Noise that Is Produced In the Engine Compartment During Engine Start With the A/C or Defrost Mode Selected or During Initial A/C or Defrost Activation After the Engine Is Running	Show customer bulletin 04-01-37-005.	Don't replace A/C compressor.	04-01-37-005
2000-2004	L-Series- Clunk Noise Coming From the Front of the Vehicle During a Turning Maneuver	Lubricate intermediate shaft.	Don't replace intermediate shaft.	04-02-35-008
2003-2004	ION - Windshield Wiper Arms Difficult to Remove From Vehicle	Use J39637 or equivalent to remove the wiper arm from the wiper pivot stud.	Don't rock wiper arm on pivot stud in an attempt to remove. Doing this my result in breakage of the wiper module.	Reference appropriate model year service manual

Saturn Technical Bulletins Released in May 2004

Category Type	Subject	Model(s)	Model Year(s)	Bulletin Number
Body & Accessories	Left Side (Driver's Side) Outside Rearview Mirror Cracking (Replace Outside Rearview Mirror Glass Assembly)	VUE	2003-2004	04-08-64-008
Body & Accessories	XM Digital Radio Receiver Ordering Process	ION & VUE w/ RPO U2K	2004	04-08-44-009
Engine/ Propulsion System	Service Manual Update for Engine Block Clearance, Cylinder Head Clearance and Fastener Torque Specifications	L-Series & VUE w/ RPO L81	2000-2004 2002-2003	04-06-01-011
Engine/ Propulsion System	Engine Exchange Program for Supercharged 2.0L Ecotec Engine (VIN P - RPO LSJ)	ION Quad Coupe w/ VIN P -RPO LSJ	2004	04-06-01-014
Engine/ Propulsion System	Check Engine Light on with P0440 or P0442 Stored (Diagnose EVAP System and/or Reprogram ECM)	VUE w/ VIN D -RPO L61	2002-2003	04-06-04-033
Engine/ Propulsion System	Diagnostic Trouble Code (DTC) P0132 (H02S Circuit High Voltage Sensor 1), P0138 (H02S Circuit High Voltage Sensor 2), or P0172 (Fuel Trim System Rich) Diagnostic Enhancements	ION w/ VIN Break	2003-2004	04-06-04-035
HVAC	Information Regarding Air Conditioning (A/C) Compressor Noise at Engine Start (A/C or Defrost Mode Selected) or at A/C or Defrost Activation (After Engine Start)	L-Series w/ RPO C60/C68	2000-2005	04-01-37-005
HVAC	Heater-Ventilation-Air Conditioning (HVAC) Hiss-Type Noise (Replace Low Speed Engine Cooling Fan Resistor)	VUE	2002-2004	04-01-37-006
Suspension	Squeak, Rattle, Pop or Clunk Noise From Front of Vehicle During Suspension Movement (Replace Front Stabilizer Shaft Insulators)	ION	2003-2004	04-03-08-003A
Suspension	Service Manual Update Regarding Tightening Procedure and Specification for the Ball Joint-to-Steering Knuckle Nut	ION	2003-2004	04-03-08-005
Suspension	Clunk, Thump or Rattle Noise from Front Suspension while Driving Over Rough Road Conditions or when Braking (Replace Front Lower Control Arm Rear Bushing)	ION	2003	04-03-08-006
Steering	Clunk Noise from Front of Vehicle During Turning Maneuver/Steering Wheel Rotation (Lubricate Intermediate Shaft)	L-Series	2000-2004	04-02-35-008
Transmission/Transaxle	Service Engine Soon (SES) Light On with Diagnostic Trouble Code (DTC) P0731, No Movement in Drive During Cold Ambient Temperatures (Replace Oil Pump or 1st Gear Sprag Clutch Assembly)	S-Series w/ RPO MP6/MP7	1998-2002	03-07-30-008A
Transmission/ Transaxle	No Movement in Drive or Reverse With or Without DTCs P1758, P1756, P1882, P0841, P0741, P0742 (Replace VT25E Transaxle Assembly)	VUE & ION w/ RPO M16/M75	2003-2004	04-07-30-024

MAY 2004 SYSTEM SOFTWARE UPGRADE BULLETIN

Category Type	Subject	Model(s)	Model Year(s)	Bulletin Number
Engine/ Propulsion System	On-Board Diagnostic (OBD) System Software Upgrade - Improved Purge Flow Diagnostics (Install Updated Engine Control Module [ECM] Calibration)	ION w/ RPO YF5 w/ VIN Break	Certain 2004 intended for CA registration	4026

PARTS ON RESTRICTION AT TAC (AS OF MAY 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
2004	Saturn ION Supercharged 2.0L LSJ Ecotec Engine	Bulletin #04-06-01-014