Driveability
bowtiebandit
02-02-2003, 12:54 AM
Bear with me on this. I don't know much about the difference in Saturns but I've read alot of concerns with driveability so I'm putting them up here.
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ECT Sensor Related DTCs and/or the Following Condtions - Hard Start, Erratic Idle, Rough Running, Engine Overheating, Low and/or Leaking Coolant, and/or Service Engine Soon Lamp Illuminated #010604005 - (01/07/2003)
Engine Coolant Temperature Sensor Related Diagnostic Trouble Code(s) and/or the Following Conditions: Hard Start, Erratic Idle, Rough Running, Engine Overheating, LOW and/or Leaking Coolant, and/or Service Engine Soon Lamp Illuminated. (Replace Engine Coolant Temperature Sensor with new Design Sensor - P/N 21025106)
1991 - 2001 Saturn S-Series vehicles
Condition
Customers may comment about various driveability and/or engine operating concerns including: hard start, erratic idle, rough running, engine overheating, low and/or leaking coolant, and/or Service Engine Soon lamp illuminated.
Cause
This condition may be caused by a cracked engine coolant temperature sensor.
Correction
Replace engine coolant temperature sensor, inspect and if necessary replace sensor harness connector. Refer to procedure in this bulletin to replace engine coolant temperature sensor and Parts Requirements for specific parts information.
PROCEDURE
Disconnect engine coolant temperature sensor electrical connector and inspect sensor connector terminals for corrosion and/or evidence of engine coolant
If terminals are corroded or if there is evidence of engine coolant, proceed to step 4.
If terminals are not corroded and there is no evidence of engine coolant, reconnect the electrical connector and continue to next step.
Caution
TO AVOID THE DANGER OF BEING BURNED, DO NOT REMOVE THE CAP WHILE THE ENGINE, RADIATOR, AND SURGE TANK ARE STILL HOT. SCALDING FLUID AND STEAM CAN BE BLOWN OUT UNDER PRESSURE.
Perform one or both of the following checks to determine whether the engine coolant temperature sensor is providing the correct temperature indication.
If engine is at ambient temperature (vehicle has been sitting overnight or not started for several hours), use a Scan tool to compare the inlet air temperature (IAT) to the engine coolant temperature (ECT). These two readings should be within 2° C (4°F) of each other.
If engine is at operating temperature, install a thermometer in the coolant recovery reservoir. With the engine running and A/C off, use a Scan tool to compare the engine coolant temperature sensor reading to the thermometer reading. These two readings should be within 8° C (15° F) of each other. If engine coolant temperature sensor reading does not pass either of the above tests, continue with next step. If engine coolant temperature sensor reading passes both of the tests above, refer to appropriate symptom diagnostic chart in the Engine/Emissions Control Section of applicable Engine Service Manual.
Turn ignition Off.
Remove coolant surge tank cap.
Caution
DO NOT REMOVE CAP OR OPEN COOLING SYSTEM DRAINS FROM A HOT SYSTEM. ALLOW SYSTEM TO COOL FIRST.
Drain at least 1.9L (2 Qt.) of engine coolant from the cooling system by opening radiator drain valve or removing engine drain plug. Collect
Disconnect engine coolant temperature sensor electrical connector.
Remove engine coolant temperature sensor from cylinder head.
Obtain replacement engine coolant temperature sensor (P/N 21025106).
Use appropriate tap to clean sensor mounting hole of any thread sealant residue.
Install engine coolant temperature sensor in cylinder head. Tighten
Engine Coolant Temperature Sensor: 8N·m (71 in lbs)
Inspect harness connector terminals for corrosion and/or evidence of engine coolant. If harness connector terminals are corroded or there is evidence of engine coolant. The harness connector must be replaced with new connector (P/N 12117087- includes : connector, terminals, wires, and splice sleeves).
Connect engine coolant temperature sensor connector.
Transfer engine coolant drained in step 5 into coolant surge tank. If necessary fill coolant surge tank to the FULL COLD range with 50/50 solution of correct type of antifreeze and clean water.
Start engine and check for leaks.
Run engine until upper radiator hose is hot, then add additional coolant if needed, to bring the level to the FULL COLD level (1991 -early 1997) or within the Min./Max. cold range (late 1997-2001).
Install coolant surge tank cap.
PARTS REQUIREMENTS
21025106
Sensor-Coolant Temperature
12117087
Connector-Engine Coolant Temperature Sensor
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ECT Sensor Related DTCs and/or the Following Condtions - Hard Start, Erratic Idle, Rough Running, Engine Overheating, Low and/or Leaking Coolant, and/or Service Engine Soon Lamp Illuminated #010604005 - (01/07/2003)
Engine Coolant Temperature Sensor Related Diagnostic Trouble Code(s) and/or the Following Conditions: Hard Start, Erratic Idle, Rough Running, Engine Overheating, LOW and/or Leaking Coolant, and/or Service Engine Soon Lamp Illuminated. (Replace Engine Coolant Temperature Sensor with new Design Sensor - P/N 21025106)
1991 - 2001 Saturn S-Series vehicles
Condition
Customers may comment about various driveability and/or engine operating concerns including: hard start, erratic idle, rough running, engine overheating, low and/or leaking coolant, and/or Service Engine Soon lamp illuminated.
Cause
This condition may be caused by a cracked engine coolant temperature sensor.
Correction
Replace engine coolant temperature sensor, inspect and if necessary replace sensor harness connector. Refer to procedure in this bulletin to replace engine coolant temperature sensor and Parts Requirements for specific parts information.
PROCEDURE
Disconnect engine coolant temperature sensor electrical connector and inspect sensor connector terminals for corrosion and/or evidence of engine coolant
If terminals are corroded or if there is evidence of engine coolant, proceed to step 4.
If terminals are not corroded and there is no evidence of engine coolant, reconnect the electrical connector and continue to next step.
Caution
TO AVOID THE DANGER OF BEING BURNED, DO NOT REMOVE THE CAP WHILE THE ENGINE, RADIATOR, AND SURGE TANK ARE STILL HOT. SCALDING FLUID AND STEAM CAN BE BLOWN OUT UNDER PRESSURE.
Perform one or both of the following checks to determine whether the engine coolant temperature sensor is providing the correct temperature indication.
If engine is at ambient temperature (vehicle has been sitting overnight or not started for several hours), use a Scan tool to compare the inlet air temperature (IAT) to the engine coolant temperature (ECT). These two readings should be within 2° C (4°F) of each other.
If engine is at operating temperature, install a thermometer in the coolant recovery reservoir. With the engine running and A/C off, use a Scan tool to compare the engine coolant temperature sensor reading to the thermometer reading. These two readings should be within 8° C (15° F) of each other. If engine coolant temperature sensor reading does not pass either of the above tests, continue with next step. If engine coolant temperature sensor reading passes both of the tests above, refer to appropriate symptom diagnostic chart in the Engine/Emissions Control Section of applicable Engine Service Manual.
Turn ignition Off.
Remove coolant surge tank cap.
Caution
DO NOT REMOVE CAP OR OPEN COOLING SYSTEM DRAINS FROM A HOT SYSTEM. ALLOW SYSTEM TO COOL FIRST.
Drain at least 1.9L (2 Qt.) of engine coolant from the cooling system by opening radiator drain valve or removing engine drain plug. Collect
Disconnect engine coolant temperature sensor electrical connector.
Remove engine coolant temperature sensor from cylinder head.
Obtain replacement engine coolant temperature sensor (P/N 21025106).
Use appropriate tap to clean sensor mounting hole of any thread sealant residue.
Install engine coolant temperature sensor in cylinder head. Tighten
Engine Coolant Temperature Sensor: 8N·m (71 in lbs)
Inspect harness connector terminals for corrosion and/or evidence of engine coolant. If harness connector terminals are corroded or there is evidence of engine coolant. The harness connector must be replaced with new connector (P/N 12117087- includes : connector, terminals, wires, and splice sleeves).
Connect engine coolant temperature sensor connector.
Transfer engine coolant drained in step 5 into coolant surge tank. If necessary fill coolant surge tank to the FULL COLD range with 50/50 solution of correct type of antifreeze and clean water.
Start engine and check for leaks.
Run engine until upper radiator hose is hot, then add additional coolant if needed, to bring the level to the FULL COLD level (1991 -early 1997) or within the Min./Max. cold range (late 1997-2001).
Install coolant surge tank cap.
PARTS REQUIREMENTS
21025106
Sensor-Coolant Temperature
12117087
Connector-Engine Coolant Temperature Sensor
bowtiebandit
02-02-2003, 12:55 AM
Engine Stalls After Initial Start, or During Warm Up and May Restart with increased Idle #286502 - (01/07/2003)
Engine Stalls After Initial Start, or During Warm - Up and May Restart with increased Idle, SOHC (LKO) Engines (Install New PCM Calibration)
All 1992 Saturns with SOHC (LKO) engines
Condition
Some customers of 1992 Saturns, equipped with SOHC (L/KO) engines may comment that the engine stalls after the vehicle is initially started, or stalls when first shifted into gear or during engine warm-up. Customers may also comment of increased-idle conditions after a stall on initial start while vehicle is out of gear.
Cause
Due to engine sensitivity to variations in cool ambient temperatures along with new 1992 Federal regulations that address Spring and Summer fuel grade volatility, initial start - up and warm - up driveability has been impacted, especially on new engines.
Correction
Verify that the start/stall condition occurs during initial start or engine warm-up, then proceed with the Steps listed under "Procedures", on the next page.
Important
On all vehicles built before January 1, 1992, refer to Technical information Bulletin 91-T-35A (Corporate Bulletin # 106301R) and completely follow the instructions. After following procedures in bulletin 91-T-35A (Corporate Bulletin #106301R), install new PCM calibration (refer to page 2 of this bulletin for correct calibration number). The manufacture's label on the driver's door provides vehicle build date.
On vehicles built after January 1, 1992, proceed to Steps 1 through 30 of this bulletin. If the condition still exists after following the procedures in this bulletin and the new calibration has been installed, refer to Technical Information Bulletin 91-T-35A and completely follow the bulletin instructions.
Using the Scan tool, check for PCM EC/TC codes and flags. If codes or flags are present, refer to the applicable diagnostic charts in the "Electronic Engine Controls Service Manual" and repair the condition. After verifying that condition has been repaired, download the new calibration according to Step 3.
If no codes or flags are present, monitor Scan tool data and verify all parameters are within specification. Refer to "Electronic Engine Controls Service Manual." If parameters are not within specification, repair the condition. After verifying that condition has been repaired, download the new calibration according to Step 3.
If no codes or flags are present and Scan tool data is within specification, download new calibration using the Saturn Service Stall System or refer to the "Electronic Engine Controls Service Manual."
Important
Before installing a new calibration, make a note of the transaxle calibration installed, and download the same transaxle calibration with the correct engine calibration.
1992 New Calibration - SOHC (LKO) Engines
TCM
ECM
0749
3184
Automatic Transaxles before VIN NZ200001 through NZ200100
8518
3184
All Other Automatic Transaxles
--
3182
Manual Transaxles
Important
After the new calibration has been installed, vehicle must be driven until opening temperature is reached. This allows the PCM to relearn variations in the fuel system electronic controls that improve driveability and engine idle.
Engine Stalls After Initial Start, or During Warm - Up and May Restart with increased Idle, SOHC (LKO) Engines (Install New PCM Calibration)
All 1992 Saturns with SOHC (LKO) engines
Condition
Some customers of 1992 Saturns, equipped with SOHC (L/KO) engines may comment that the engine stalls after the vehicle is initially started, or stalls when first shifted into gear or during engine warm-up. Customers may also comment of increased-idle conditions after a stall on initial start while vehicle is out of gear.
Cause
Due to engine sensitivity to variations in cool ambient temperatures along with new 1992 Federal regulations that address Spring and Summer fuel grade volatility, initial start - up and warm - up driveability has been impacted, especially on new engines.
Correction
Verify that the start/stall condition occurs during initial start or engine warm-up, then proceed with the Steps listed under "Procedures", on the next page.
Important
On all vehicles built before January 1, 1992, refer to Technical information Bulletin 91-T-35A (Corporate Bulletin # 106301R) and completely follow the instructions. After following procedures in bulletin 91-T-35A (Corporate Bulletin #106301R), install new PCM calibration (refer to page 2 of this bulletin for correct calibration number). The manufacture's label on the driver's door provides vehicle build date.
On vehicles built after January 1, 1992, proceed to Steps 1 through 30 of this bulletin. If the condition still exists after following the procedures in this bulletin and the new calibration has been installed, refer to Technical Information Bulletin 91-T-35A and completely follow the bulletin instructions.
Using the Scan tool, check for PCM EC/TC codes and flags. If codes or flags are present, refer to the applicable diagnostic charts in the "Electronic Engine Controls Service Manual" and repair the condition. After verifying that condition has been repaired, download the new calibration according to Step 3.
If no codes or flags are present, monitor Scan tool data and verify all parameters are within specification. Refer to "Electronic Engine Controls Service Manual." If parameters are not within specification, repair the condition. After verifying that condition has been repaired, download the new calibration according to Step 3.
If no codes or flags are present and Scan tool data is within specification, download new calibration using the Saturn Service Stall System or refer to the "Electronic Engine Controls Service Manual."
Important
Before installing a new calibration, make a note of the transaxle calibration installed, and download the same transaxle calibration with the correct engine calibration.
1992 New Calibration - SOHC (LKO) Engines
TCM
ECM
0749
3184
Automatic Transaxles before VIN NZ200001 through NZ200100
8518
3184
All Other Automatic Transaxles
--
3182
Manual Transaxles
Important
After the new calibration has been installed, vehicle must be driven until opening temperature is reached. This allows the PCM to relearn variations in the fuel system electronic controls that improve driveability and engine idle.
bowtiebandit
02-02-2003, 12:56 AM
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Engine Stalls After Initial Start/Hesitates During Launch/Surges During Light Acceleration, or Has Increased, and/or Fluctuating Idle that is More Pronounced with A/C On #486001 - (01/08/2003)
Engine Stalls After Initial Start /Hesitates During Launch/Surge During Light Acceleration, or Has Increased, and/or Fluctuating Idle that is More Pronounced with A/C On (install New PCM Calibration) Due to additional subject information and a revised procedures, this bulletin cancels and supercedes (with a new bulletin number) bulletin 92-T-35 (Corporation No. 286503), which should be discarded.
1992 Saturns with DOHC (LLO) engines.
Condition
Some customers of 1992 Saturn, equipped with DOHC (LLO) engines may comment that the engine exhibits one or more of the following conditions:
Engine stalls after initial start.
Hesitates during launch.
Surges during light acceleration
Increased and/or fluctuating idle that is more pronounced with the A/C On.
Cause
Due to engine sensitivity to variations in cool ambient temperatures along with the 1992 Federal regulations addressing Spring and Summer fuel grade volatility, initial start- up and warm -- up driveability has been impacted.
Correction
Verify that one or more of the conditions listed above exist.
If any of these conditions exit, proceed with the steps listed under "PROCEDURE," on the next page.
Procedure
Use the Scan tool, to check for PCM/EC or PCM/TC diagnostic trouble codes and information flags. If no diagnostic trouble codes or information flags are present go to step 2. If diagnostic trouble codes or information flags are present, refer to the appropriate chart in the "Electronic Engine Controls" or "Automatic Transaxle" Service Manuals, and repair the condition. After verifying that all diagnostic trouble codes and/or information flags have been repaired to step 2.
If no diagnostic trouble codes for information flags are present or have been repaired, monitor Scan tool data and verify that all parameters are within specification. (Refer to "Scan Tool General Information Table" in the "Electronic Engine Controls Service Manual.") If parameters are not within specification, repair the condition. After verifying that all parameters are within specification, refer to step 3.
Download the new calibration, using the service stall system (SSS). (Refer to "Service Stall System User Guide" or Electronic Engine Controls Service Manual" for download instructions.)
Important
Before installing a new calibration with the correct engine calibration,
1992 CALIBRATIONS - DOHC (LLO) ENGINES
ECM
TCM
Application
2303
2548
Automatic transaxles. Vehicles built before VIN NZ205625 (excluding NZ200001 through NZ20010)
2303
8520
All other automatic transaxle
2302
Manual transaxle
Important
Verify that the concern has been repaired. If problem still exits, refer to diagnostic procedures in the "Fuel/Air Intake/Exhaust Service Manual," and/or "Electronic Engine Controls Service Manual."
Engine Stalls After Initial Start/Hesitates During Launch/Surges During Light Acceleration, or Has Increased, and/or Fluctuating Idle that is More Pronounced with A/C On #486001 - (01/08/2003)
Engine Stalls After Initial Start /Hesitates During Launch/Surge During Light Acceleration, or Has Increased, and/or Fluctuating Idle that is More Pronounced with A/C On (install New PCM Calibration) Due to additional subject information and a revised procedures, this bulletin cancels and supercedes (with a new bulletin number) bulletin 92-T-35 (Corporation No. 286503), which should be discarded.
1992 Saturns with DOHC (LLO) engines.
Condition
Some customers of 1992 Saturn, equipped with DOHC (LLO) engines may comment that the engine exhibits one or more of the following conditions:
Engine stalls after initial start.
Hesitates during launch.
Surges during light acceleration
Increased and/or fluctuating idle that is more pronounced with the A/C On.
Cause
Due to engine sensitivity to variations in cool ambient temperatures along with the 1992 Federal regulations addressing Spring and Summer fuel grade volatility, initial start- up and warm -- up driveability has been impacted.
Correction
Verify that one or more of the conditions listed above exist.
If any of these conditions exit, proceed with the steps listed under "PROCEDURE," on the next page.
Procedure
Use the Scan tool, to check for PCM/EC or PCM/TC diagnostic trouble codes and information flags. If no diagnostic trouble codes or information flags are present go to step 2. If diagnostic trouble codes or information flags are present, refer to the appropriate chart in the "Electronic Engine Controls" or "Automatic Transaxle" Service Manuals, and repair the condition. After verifying that all diagnostic trouble codes and/or information flags have been repaired to step 2.
If no diagnostic trouble codes for information flags are present or have been repaired, monitor Scan tool data and verify that all parameters are within specification. (Refer to "Scan Tool General Information Table" in the "Electronic Engine Controls Service Manual.") If parameters are not within specification, repair the condition. After verifying that all parameters are within specification, refer to step 3.
Download the new calibration, using the service stall system (SSS). (Refer to "Service Stall System User Guide" or Electronic Engine Controls Service Manual" for download instructions.)
Important
Before installing a new calibration with the correct engine calibration,
1992 CALIBRATIONS - DOHC (LLO) ENGINES
ECM
TCM
Application
2303
2548
Automatic transaxles. Vehicles built before VIN NZ205625 (excluding NZ200001 through NZ20010)
2303
8520
All other automatic transaxle
2302
Manual transaxle
Important
Verify that the concern has been repaired. If problem still exits, refer to diagnostic procedures in the "Fuel/Air Intake/Exhaust Service Manual," and/or "Electronic Engine Controls Service Manual."
bowtiebandit
02-02-2003, 12:58 AM
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MIL (SES LAMP) ON, ENGINE RUNS ROUGH/STALLS AT IDLE #94-T-13 - (04/07/1994)
SUBJECT: Malfunction Indicator Lamp (SERVICE ENGINE SOON telltale Lamp) On, Engine Runs Rough and/or Stalls at Idle, Diagnostic Trouble Codes 45 and/or 49 May Set-SOHC (LKO) Engines (Replace TBI Tube Module)
MODELS AFFECTED: 1991-1994 Saturns with SOHC (LKO) engines, equipped with plastic TBI tube module assembly.
CONDITION: The malfunction indicator lamp (MIL) (SERVICE ENGINE SOON telltale lamp) may be On, engine may run rough and/or engine may stall at idle. PCM diagnostic trouble codes 45 and/or 49 may also be present.
CAUSE: The gasket on the plastic TBI tube module on the TBI assembly and/or the connectors of the vacuum harnesses from the vacuum tube module to the MAP sensor, EGR solenoid/valve and the EVAP canister purge solenoid may be damaged, producing a vacuum leak.
CORRECTION: Inspect the gasket of the plastic TBI tube module and vacuum harness connectors according to the procedure in this bulletin.
PROCEDURE:
--------- 1. Remove vacuum source harness assemblies, connecting the TBI tube module to the EVAP canister purge and EGR solenoids, EGR valve and MAP sensor, from the TBI tube module.
2. Remove the vacuum source harness assembly from the MAP sensor and the vacuum source harness assembly from the EGR valve and EVAP canister purge solenoid.
3. Inspect the vacuum source harness assemblies for any deterioration or splitting. If either of the vacuum source harness assemblies show signs of deterioration or splitting, replace with a new vacuum source harness assembly, using the appropriate part number given under "PARTS REQUIREMENTS" in this bulletin.
4. If the vacuum source harness assemblies do not show signs of deterioration or splitting, remove the two bolts securing the TBI tube module to the throttle body assembly.
5. Remove the TBI tube module and inspect the gasket for deterioration and/or splitting.
6. If the gasket shows signs of deterioration or splitting, replace the TBI tube module kit with a new metal TBI tube module kit (P/N 21007009).
IMPORTANT: The new metal TBI tube module kit requires a paper gasket, which is included with the TBI tube module kit (P/N 21007009).
7. If the gasket of the plastic TBI tube module does not show signs of deterioration or splitting, refer to diagnostic trouble code charts in the "Electronic Engine Controls Service Manual" for the diagnostic trouble code(s) set. If no diagnostic trouble code is set, refer to the "Cause- Complaint-Condition" charts in the "Engine Mechanical Service Manual."
PARTS REQUIREMENTS: 21007009 TBI Tube Module Kit (Metal) 21006243 Harness Asm-Vac Sce (MAP) 21000843 Harness Asm-Vac Sce (EGR/EVAP)
MIL (SES LAMP) ON, ENGINE RUNS ROUGH/STALLS AT IDLE #94-T-13 - (04/07/1994)
SUBJECT: Malfunction Indicator Lamp (SERVICE ENGINE SOON telltale Lamp) On, Engine Runs Rough and/or Stalls at Idle, Diagnostic Trouble Codes 45 and/or 49 May Set-SOHC (LKO) Engines (Replace TBI Tube Module)
MODELS AFFECTED: 1991-1994 Saturns with SOHC (LKO) engines, equipped with plastic TBI tube module assembly.
CONDITION: The malfunction indicator lamp (MIL) (SERVICE ENGINE SOON telltale lamp) may be On, engine may run rough and/or engine may stall at idle. PCM diagnostic trouble codes 45 and/or 49 may also be present.
CAUSE: The gasket on the plastic TBI tube module on the TBI assembly and/or the connectors of the vacuum harnesses from the vacuum tube module to the MAP sensor, EGR solenoid/valve and the EVAP canister purge solenoid may be damaged, producing a vacuum leak.
CORRECTION: Inspect the gasket of the plastic TBI tube module and vacuum harness connectors according to the procedure in this bulletin.
PROCEDURE:
--------- 1. Remove vacuum source harness assemblies, connecting the TBI tube module to the EVAP canister purge and EGR solenoids, EGR valve and MAP sensor, from the TBI tube module.
2. Remove the vacuum source harness assembly from the MAP sensor and the vacuum source harness assembly from the EGR valve and EVAP canister purge solenoid.
3. Inspect the vacuum source harness assemblies for any deterioration or splitting. If either of the vacuum source harness assemblies show signs of deterioration or splitting, replace with a new vacuum source harness assembly, using the appropriate part number given under "PARTS REQUIREMENTS" in this bulletin.
4. If the vacuum source harness assemblies do not show signs of deterioration or splitting, remove the two bolts securing the TBI tube module to the throttle body assembly.
5. Remove the TBI tube module and inspect the gasket for deterioration and/or splitting.
6. If the gasket shows signs of deterioration or splitting, replace the TBI tube module kit with a new metal TBI tube module kit (P/N 21007009).
IMPORTANT: The new metal TBI tube module kit requires a paper gasket, which is included with the TBI tube module kit (P/N 21007009).
7. If the gasket of the plastic TBI tube module does not show signs of deterioration or splitting, refer to diagnostic trouble code charts in the "Electronic Engine Controls Service Manual" for the diagnostic trouble code(s) set. If no diagnostic trouble code is set, refer to the "Cause- Complaint-Condition" charts in the "Engine Mechanical Service Manual."
PARTS REQUIREMENTS: 21007009 TBI Tube Module Kit (Metal) 21006243 Harness Asm-Vac Sce (MAP) 21000843 Harness Asm-Vac Sce (EGR/EVAP)
bowtiebandit
02-02-2003, 12:59 AM
MIL IS ON AND/OR VEH. HARD TO START HES., ROUGH OR IDLE #93-T-30-SATURN - (12/07/1993)
SUBJECT: Malfunction Indicator Lamp (SERVICE ENGINE SOON Telltale Lamp) is On and/or Vehicle Hard to Start, No Start, Hesitation, or Rough or Surging Idle (Repair and Route Wires)
MODELS AFFECTED: 1991-1992 Saturns and 1993 Saturns built before and including VIN PZ144581 equipped with DOHC (LLO) engines.
CONDITION: Some owners may experience the malfunction indicator lamp (SERVICE ENGINE SOON telltale lamp) is On, or the vehicle is hard to start, no start, hesitates, has a rough idle or surges during idle. Also, when performing PCM diagnostics, the following PCM diagnostic trouble codes or PCM information flags may be present:
o PCM diagnostic trouble codes 35, 22 or 49
o PCM information flags 52, 54, 67 or 76
CAUSE: There are two potential areas that could cause these conditions:
o The number 4 injector wire may be rubbing through at the throttle bracket and shorting to ground, or
o Idle air control (IAC) or throttle position (TP) sensor wires are rubbing through at brass coolant fitting on intake manifold.
CORRECTIVE ACTION: Inspect wires at both locations. (Refer to Figures on the following page for locations to inspect.) If any of the wires are damaged, repair according to procedure given in this bulletin on page 3.
If wires are not damaged and PCM diagnostic trouble codes or information flags are present, refer to PCM diagnostic trouble code and/or information flag charts in the "Electronic Engine Controls Service Manual." If no diagnostic trouble codes or information flags are present, refer to complaint/cause charts in the "Electronic Engine Controls Service Manual."
PROCEDURE:
--------- If individual wire strands are broken, replace the damaged portion of the wire and re-route the harness to prevent damage. (Refer to "Wire Repair" in the "Electrical Trouble Shooting" section of the "Electrical Service Manual" for procedures on repairing broken wires.)
If just the insulation is worn away, and no damage has been done to the individual wire strands, tape the damaged area and re-route the wiring harness to prevent damage.
Clear diagnostic trouble codes and verify that condition is repaired.
SUBJECT: Malfunction Indicator Lamp (SERVICE ENGINE SOON Telltale Lamp) is On and/or Vehicle Hard to Start, No Start, Hesitation, or Rough or Surging Idle (Repair and Route Wires)
MODELS AFFECTED: 1991-1992 Saturns and 1993 Saturns built before and including VIN PZ144581 equipped with DOHC (LLO) engines.
CONDITION: Some owners may experience the malfunction indicator lamp (SERVICE ENGINE SOON telltale lamp) is On, or the vehicle is hard to start, no start, hesitates, has a rough idle or surges during idle. Also, when performing PCM diagnostics, the following PCM diagnostic trouble codes or PCM information flags may be present:
o PCM diagnostic trouble codes 35, 22 or 49
o PCM information flags 52, 54, 67 or 76
CAUSE: There are two potential areas that could cause these conditions:
o The number 4 injector wire may be rubbing through at the throttle bracket and shorting to ground, or
o Idle air control (IAC) or throttle position (TP) sensor wires are rubbing through at brass coolant fitting on intake manifold.
CORRECTIVE ACTION: Inspect wires at both locations. (Refer to Figures on the following page for locations to inspect.) If any of the wires are damaged, repair according to procedure given in this bulletin on page 3.
If wires are not damaged and PCM diagnostic trouble codes or information flags are present, refer to PCM diagnostic trouble code and/or information flag charts in the "Electronic Engine Controls Service Manual." If no diagnostic trouble codes or information flags are present, refer to complaint/cause charts in the "Electronic Engine Controls Service Manual."
PROCEDURE:
--------- If individual wire strands are broken, replace the damaged portion of the wire and re-route the harness to prevent damage. (Refer to "Wire Repair" in the "Electrical Trouble Shooting" section of the "Electrical Service Manual" for procedures on repairing broken wires.)
If just the insulation is worn away, and no damage has been done to the individual wire strands, tape the damaged area and re-route the wiring harness to prevent damage.
Clear diagnostic trouble codes and verify that condition is repaired.
bowtiebandit
02-02-2003, 01:00 AM
ENGINE STALLS AFTER INITIAL START OR RESTART-HIGH IDLE #92-T-33-SATURN - (06/01/1992)
SUBJECT: Engine Stalls After Initial Start, or During Warm-Up and May Restart with Increased Idle, SOHC (LKO) Engines (Install New PCM Calibration)
MODELS AFFECTED: All 1992 Saturns with SOHC (LKO) engines
CONDITION:
Some customers of 1992 Saturns, equipped with SOHC (LKO) engines may comment that the engine stalls after the vehicle is initially started, or stalls when first shifted into gear or during engine warm-up. Customers may also comment of increased-idle conditions after a stall on initial start while vehicle is out of gear.
CAUSE:
Due to engine sensitivity to variations in cool ambient temperatures along with the new 1992 Federal regulations that address Spring and Summer fuel grade volatility, initial start-up and warm-up driveability has been impacted, especially on new engines.
CORRECTIVE ACTION: Verify that the start/stall condition occurs during initial start or engine warm-up, then proceed with the Steps listed under "Procedures," on the next page.
IMPORTANT: On all vehicles built before January 1, 1992, refer to Technical Information Bulletin 91-T-35A (Corporate Bulletin # 106301 R) and completely follow the instructions. After following procedures in bulletin 91-T-35A (Corporate Bulletin #106301R), install new PCM calibration (refer to page 2 of this bulletin for correct calibration number). The manufacturer's label on the driver's door provides vehicle build date.
On vehicles built after January 1, 1992, proceed to Steps 1 through 3 of this bulletin. If the condition still exists after following the procedures in this bulletin and the new calibration has been installed, refer to Technical Information Bulletin 91-T-35A and completely follow the bulletin instructions.
PROCEDURE:
1. Using the Scan tool, check for PCM EC/TC codes and flags. If codes or flags are present, refer to the applicable diagnostic charts in the "Electronic Engine Controls Service Manual" and repair the condition. After verifying that condition has been repaired, download the new calibration according to Step 3.
2. If no codes or flags are present, monitor Scan tool data and verify all parameters are within specification. Refer to "Electronic Engine Controls Service Manual." If parameters are not within specification, repair the condition. After verifying that condition has been repaired, download the new calibration according to Step 3.
3. If no codes or flags are present and Scan tool data is within specification, download new calibration using the Saturn Service Stall System or refer to the "Electronic Engine Controls Service Manual."
IMPORTANT: Before installing a new calibration, make a note of the transaxle calibration installed, and download the same transaxle calibration with the correct engine calibration.
1992 New Calibration - SOHC (LKO) Engines
TCM ECM
0749 3184 Automatic Transaxles before VIN NZ205625, excluding NZ200001 through NZ200100
8518 3184 All Other Automatic Transaxles 3182 Manual Transaxles
SUBJECT: Engine Stalls After Initial Start, or During Warm-Up and May Restart with Increased Idle, SOHC (LKO) Engines (Install New PCM Calibration)
MODELS AFFECTED: All 1992 Saturns with SOHC (LKO) engines
CONDITION:
Some customers of 1992 Saturns, equipped with SOHC (LKO) engines may comment that the engine stalls after the vehicle is initially started, or stalls when first shifted into gear or during engine warm-up. Customers may also comment of increased-idle conditions after a stall on initial start while vehicle is out of gear.
CAUSE:
Due to engine sensitivity to variations in cool ambient temperatures along with the new 1992 Federal regulations that address Spring and Summer fuel grade volatility, initial start-up and warm-up driveability has been impacted, especially on new engines.
CORRECTIVE ACTION: Verify that the start/stall condition occurs during initial start or engine warm-up, then proceed with the Steps listed under "Procedures," on the next page.
IMPORTANT: On all vehicles built before January 1, 1992, refer to Technical Information Bulletin 91-T-35A (Corporate Bulletin # 106301 R) and completely follow the instructions. After following procedures in bulletin 91-T-35A (Corporate Bulletin #106301R), install new PCM calibration (refer to page 2 of this bulletin for correct calibration number). The manufacturer's label on the driver's door provides vehicle build date.
On vehicles built after January 1, 1992, proceed to Steps 1 through 3 of this bulletin. If the condition still exists after following the procedures in this bulletin and the new calibration has been installed, refer to Technical Information Bulletin 91-T-35A and completely follow the bulletin instructions.
PROCEDURE:
1. Using the Scan tool, check for PCM EC/TC codes and flags. If codes or flags are present, refer to the applicable diagnostic charts in the "Electronic Engine Controls Service Manual" and repair the condition. After verifying that condition has been repaired, download the new calibration according to Step 3.
2. If no codes or flags are present, monitor Scan tool data and verify all parameters are within specification. Refer to "Electronic Engine Controls Service Manual." If parameters are not within specification, repair the condition. After verifying that condition has been repaired, download the new calibration according to Step 3.
3. If no codes or flags are present and Scan tool data is within specification, download new calibration using the Saturn Service Stall System or refer to the "Electronic Engine Controls Service Manual."
IMPORTANT: Before installing a new calibration, make a note of the transaxle calibration installed, and download the same transaxle calibration with the correct engine calibration.
1992 New Calibration - SOHC (LKO) Engines
TCM ECM
0749 3184 Automatic Transaxles before VIN NZ205625, excluding NZ200001 through NZ200100
8518 3184 All Other Automatic Transaxles 3182 Manual Transaxles
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