2004 Saturn Ion technical service bulletins
525 technical service bulletins and manufacturer communications cover the 2004 Saturn Ion.
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
- Unknown or other
- Electrical system
- Unknown or other
- Unknown or other
- Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles
- This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as...
- This service bulletin provides information for dealers/technicians on Service Programming System (SPS)...
- This Warranty Administration bulletin provides retail and wholesale service personnel with the...
- This bulletin provides information for electrical ground repairs using new General Motors replacement...
- This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake...
- This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil...
- This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License...
- This PI bulletin advises the technician on the proper way to install the pistons in an engine.
- Equipment: other: owners/service/other manual
- This service bulletin provides a vibration analysis worksheet the technician can use in conjunction with...
- This service bulletin provides information about the Hunter wheel Road Force balancers that should be...
- This service bulletin provides information for dealers on how to submit a product information report (PIR)...
- This informational bulletin provides information for the IPC odometer programming method quick reference...
- This service bulletin provides graphics, information and guidelines for engine component wear to assist...
- Engine
- This diagnostic tip bulletin provides additional information on how to diagnose a possible valve, lifter...
- This service bulletin provides service information on new torque specification and installation procedure...
- This warranty administration bulletin provides information regarding the field action courtesy...
- This service bulletin provides information for dealers/technicians on Exterior Lamp Condensation and Water...
- Visibility: defroster/defogger/HVAC system: rear window: electrical heating element
- Unknown or other
- This service bulletin provides information on OEM and Remanufactured Engine and Automatic...
- Power train
- This service bulletin provides policy information on warranty administration guidelines for multiple...
- This service bulletin provides a vibration analysis worksheet the technician can use in conjunction with...
- Equipment
- Fuel system, gasoline
- Equipment
- This informational bulletin provides guidelines and diagnostic/repair information to technicians regarding...
- Equipment
- This informational bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake...
- This informational bulletin provides information on key code security rules and information on GM keycode...
- This informational bulletin provides information for dealers/technicians on Exterior Lamp Condensation and...
- This informational bulletin provides information for dealers how to submit a product information report...
- This informational bulletin provides information on key code security and information on GM key code look...
- This informational bulletin provides information for the GM of Canada OnStar Cellular Communication...
- Equipment
- This bulletin explains the labor operation numbers used for submitting warranty claims for module...
- This informational bulletin advises of a new fuel injection kit used for decarbonizing the intake valves,...
- This bulletin provides information for electrical ground repairs using new replacement fasteners with...
- This informational bulletin explains the wheel Road Force balancers and what they can do for customer...
- Engine and engine cooling: exhaust system: emission control
- Equipment: electrical: radio/tape deck/cd etc.
- Equipment
- Engine
- Equipment
- Electrical system
- Engine
- Equipment
- Engine and engine cooling
- Electrical system: instrument cluster/panel
- IPC Odometer Programming Method Quick Reference Guide
- Information Regarding the Differences Between Fluid Leakage and Seepage
- Essential Tools that Include Consumable Parts (U.S. Only)
- Equipment: electrical
- This informational bulletin explains the Road Force balancers and what they can do for customer concerns.
- Electrical system: software
- Equipment: other: owners/service/other manual
- This informational bulletin explains how to update the older Onstar module software to new software over GSA.
- This warranty administration bulletin provides policy information with the field action courtesy...
- This information bulletin explains the labor operation numbers used for submitting warranty claims and how...
- This informational bulletin provides information for dealers how to submit a product information report.
- Electrical system: software
- This informational bulletin provides explanation on how to take snapshot data with a Tech 2 and upload it...
- Steering
- Electrical system: software
- Engine
- This informational bulletin provides information on OnStar® VCIM is currently restricted parts
- Electrical system
- This warranty administration bulletin provide policy information for GM dealer empowerment program and...
- Equipment adaptive/mobility
- Electrical system
- 14632C
- This Warranty Admin bulletin provides retail and wholesale service personnel with the policies/procedures...
- This informational bulletin explains the programming method quick reference guide for the IPC Odometer.
- This preliminary information communication provides information to the technician about vehicles that have...
- This informational bulletin provides additional information on how to install pistons and suggest what...
- This technical bulletin provides a procedure to reprogram the media disc player with the latest...
- This informational bulletin provides information to gm dealers on the correct cleaning methods when...
- This informational bulletin explains the use of diesel fuel additives in an engine, are not required...
- This informational bulletin provodes information on the gm of canada onstar cellular communication upgrade.
- This preliminary information communication advises the technician that ,when testing any circuit for open...
- This preliminary information communication advises the technician if unable to place an onstar call in the...
- This preliminary information communication advises the technician on the steps to diagnose and repair the...
- This preliminary information communication advises the technician the steps on repairing the concern
- This preliminary information communication provides information to help the dealership technicians perform...
- This preliminary information communication advises the technician on the steps for diagnosing the concern
- This preliminary information communication advises the technician, if unable to place an onstar call in...
- Equipment: electrical
- This informational bulletin provides information on vehicles may rock or move slightly forward or rearward...
- Engine and engine cooling: exhaust system: emission control: catalytic convertor
- Equipment: other: owners/service/other manual
- Equipment: electrical
- This informational bulletin provides an out line on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp...
- This informational bulletin provides information on Clarification of Use
- This preliminary information communication provides information to the technician about finding needle...
- This informational bulletin provides information on exterior lamp condinsation and replacement guidelines
- This informational bulletin provides information on Behavior of Non-Upgraded OnStar Equipped Vehicles...
- This informational bulletin provides information on Part Restriction and Ordering Process Information for...
- Equipment: electrical: radio/tape deck/cd etc.
- Fuel system, gasoline
- OEM and Remanufactured Engine and Automatic Transmission/Transaxle Identification
- OnStar® Voice Fallback Number Update Some customers may have received a letter from OnStar® stating that...
- Engine and engine cooling: exhaust system: emission control: catalytic convertor
- Equipment: electrical: navigational system(global positioning system)
- Electrical system
- This informational bulletin provides information on a GM of Canada OnStar cellular communication upgrade.
- Electrical system
- Fuel system, gasoline
- This informational bulletin provides information to advise dealers about seat belt buckles not operating...
- Electrical system
- This informational bulletin provides information on a GM of Canada OnStar® cellular communication upgrade.
- Equipment adaptive/mobility
- Electrical system
- This informational bulletin provides technicians with information regarding automatic transmission oil...
- This informational bulletin provides dealership personnel with information on flexible fuel vehicles...
- This informational bulletin provides information to assist dealership personnel with the identification of...
- This informational bulletin provides information to dealership personnel on upgrading certain OnStar...
- This informational bulletin provides information on communication with OnStar® module after Canadian...
- This TSB contains owner notification letter
- Equipment: electrical
- This warranty administration bulletin provides information to clarify proper transaction administration of...
- Special Coverage (part name revised)
- General motors 2005-2011 chevrolet cobalt, hhr 2006-2010 pontiac solstice, G5,G4,2007-2010 saturn sky ,...
- This informational bulletin provides information on control module diagnostics and configuration,...
- This informational bulletin updates information on electrical ground repairs using new replacement...
- Engine and engine cooling
- Equipment: electrical
- This informational bulletin provides a vibration analysis worksheet the technician can use in conjunction...
- Special coverage (q&a)
- Special coverage. on some vehicles equipped with an automatic transmission, the vehicles transmission...
- This informational bulletin provide information for the technicians to repair the rear window defroster...
- This information provides the proper way to install the floor mats .
- Summary to be provided on a future date.
- Special Coverage Adjustment ? Unable to Remove Ignition Key
- Ignition Switch Replacement
- Replace Ignition Key
- This warranty bulletin clarifies the use of dealer empowerment to satisfy the customer.
- This informational bulletin helps the technician quick reference repairs to bulletins as opposed to...
- Canadian Customers Unable To Place Calls And Turn By Turn Inoperative In The United States.
- XM Audio Traffic And Travel Link Availability And Operation.
- This informational bulletin provides a quick guide to updating which model vehicle after replacing the IPC.
- Equipment: electrical: radio/tape deck/cd etc.
- Fuel system, gasoline
- This informational bulletin provides information on how to use floor mats.
- This information bulletin provides the dealers on how to submit a product information report.
- This information bulletin provides the technician the information on how to properly clean a metal surface...
- This informational bulletin provides information on what products GM has to aid in the eliminating...
- Electric Power Steering Assist
- Vehicle Recalls
- Equipment: electrical: radio/tape deck/cd etc.
- Equipment: electrical: radio/tape deck/cd etc.
- Programming And Activation Of Replacement OnStar Modules.
- This informational bulletin advises the technician to update the Onstar from an analog system to a digital...
- This informational bulletin provides the technician with information on what E85 fuel may due to a non E85...
- Replace Ignition Lock Cylinder and Ignition Key
- This informational bulletin is to assist with the identification of issues that are not considered...
- This informational bulletin explains condensation in exterior lights and replacment guidelines for...
- This information bulletin provides the technician with additional information on fixing the vehicle right...
- Equipment: electrical: radio/tape deck/cd etc.
- Electrical system: software
- Canadian Customers Unable To Place Calls In The United States
- Information On Requests To Add OnStar Bluetooth Option.
- Electrical system: software
- Refinishing Aluminum Wheels
- Equipment
- Underbody Component Corrosion The following information may be helpful when addressing underbody component...
- This informational bulletin provides directions on submitting different PIRs
- Equipment: other: owners/service/other manual
- This informational bulletin provides information on how to save fuel and proper maintenance without using...
- This informational bulletin provides an update for 13-00-89-004C to include updated information.
- This informational bulletin provides a revision for 04-06-04-047 to add the 2014 model year.
- This informational bulletin provides a revision for 04-06-04-047K to add the 2014 model year.
- This informational Bulletin provides a revision for 10-08-110-001 to add the 2012-2014 model years.
- Equipment
- Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
- Electrical system
- This warranty administration bulletin provide policy information new tire warranty program and global...
- This informational bulletin provides information on key codes security rules and information on GM key...
- This technical service bulletin provides a revision for 07-08-49-020G to add the 2014 model year and...
- This informational bulletin provides information for Automatic Transmission Oil Cooler Flow Test Essential...
- This informational bulletin provides information for Engine Squealing Type Noise on Start-up or Vibration...
- This informational bulletin provides a revision for 11-00-89-005D to add additional Mandatory Minimum...
- This informational bulletin provides a revision for 02-08-98-002C to add the 2010-2013 model years and...
- This informational bulletin provides a revision for 09-00-89-008 to add model years, update the Labor...
- This informational bulletin provides a revision for 05-08-48-001B to add 2010-2014 model years and update...
- This informational bulletin provides a revision for 13-00-89-004A to include updated information.
- Electrical system: instrument cluster/panel
- This technical bulletin provides Warranty Administration
- This technical bulletin provides a revision of 13-00-89-004 to update car issues information for reference...
- This technical bulletin provides a revision of 99-04-20-002G to add 2013-2014 model years.
- This technical bulletin provides a revision of 10-00-89-017Z to include updated information.
- This warranty administration bulletin provide policy information on clarification of use-dealer...
- This informational bulletin provides information on fix it right for first time issues.
- This informational bulletin provides information on the appearance of chromed aluminum wheels due to...
- Electrical system
- This warranty administration bulletin provides information on the Clarification of Use for Dealer...
- Electrical system
- Engine and engine cooling
- This informational bulletin provides a list off all the issues revolving around new vehicles for a one...
- This informational bulletin provides information regarding the aftermarket device interference with onstar...
- This informational bulletin provides a step by step procedure on how to properly use the GM chemicals to...
- This warranty administration bulletin provides information regarding customer concerns not duplicated and...
- This informational bulletin provides information and rules for GM keycode look up applicationa dn the key...
- This informational bulletin provides a list of newly released PI and Bulletins in regards to recent...
- This informational bulletin provides a single point reference and strategy document to aid in reducing...
- Service brakes
- Electrical system
- Equipment adaptive/mobility
- This warranty administrational bulletin provides information on Clarification of Use
- This informational bulletin provides information on newly release bulletins used to fi the vehicles in the...
- Saturn service campaign: special coverage adjustment-power steering assist
- Special Coverage Adjustment ? Power Steering Assist
- Gm: there are seat belt problems: difficulty latching and unlatching buckle
- Saturn: low brake fluid warning and/or red brake light on due to possible brake fluid reservoir or fluid...
- Gm: there may be noise coming from the cylinder head, because of low oil pressure which is caused by debris
- Cluck, thump or rattle noise from front suspension while driving over rough road conditions or when...
- Normal operating characteristics of electric power steering (EPS) system during extended lock-to-lock...
- Saturn chevrolet service campaign: some 2004-07 saturn ion red line and 2005-07 chevrolet cobalt ss...
- Saturn service campaign: new special reimbursement policy for vehicles equipped with variable transmission...
- Diagnostic tips for power steering inoperative/steering wheel hard to turn, power steering message...
- Chevrolet/pontiac/saturn: blocked shift, gear hop out 1ST, 3RD, 5TH gear or difficulty shifting
- Power steering inoperative/steering wheel hard to turn, pwr str displayed on driver information center (DIC)
- Information on tire radial force variation (RFV)
- General motors corp: special coverage adjustment; analog onstar deactivation.
- Buick cadillac chevrolet gmc hummer oldsmobile pontiac saab saturn service campaign: special coverage...
- Trailer, recreational and disabled vehicle towing information
- General motors: information on tire radial force variation
- Intermittent ses light due to dtc's P060E, P2135, and/or P2138
- Clunk noise in steering system at slow speeds while turning and/or driving over bumps
- MG3, M86 transaxle grinding/whining noise in 3RD or 4TH gear, excessive engagement or disengagement effort...
- Floor plan corrosion (RUST) perforation in battery compartment
- Parts update - timing chain tensioner design change
- Low oil pressure - inspect oil filter for damage
- Information on inadvertent turning of key cylinder, loss of electrical system and no dtc's
- Engine malfunction indicator lamp (MIL)/service engine soon (SES) lamp illuminated with DTC P0171
- BCM service part not available for TSB 04-08-45-005C
- No crank, no start when ambient temperatures is cold - diagnostic trouble codes (DTCS) B2960 and or B3033...
- M86/M94 transmission information to disassemble third fourth and fifth gear
- Service engine soon light due to P0300 - inspect fuel system for rust contamination
- Hesitation on acceleration after internal engine repairs - check injector harness orientation
- Fuel tank is slow to fill and/or DTC P0446 - inspect evap vent pipe
- Remanufactured VT25E transmission quality issues
- Incorrect mileage displayed after programming a new BCM
- Momentary sag on light to moderate accel when cold - valve deposits
- Water leaks into passenger compartment with vehicle in incline/uphill position
- No movement in drive or reverse with or without diagnostic trouble codes (DTCS) P1758, P1758, P1882,...
- Identifying correct design level of rear axle assembly
- Manual transaxle gear rattle noise heard during cold ambient temperatures with clutch pedal released (UP)...
- Transaxle slips, no third gear, engine flare during shift after transaxle service
- Sulfur odor from exhaust
- Service engine soon (SES) light at highway speeds due to a P0171 diagnostic trouble code (DTC)
- Service engine soon (SES) light and severe engine misfire on cylinders 1 and 4 or cylinders 2 and 3
- Clunk noise from front of vehicle during turning maneuver
- Power steering inoperative/steering wheel hard to turn, pwr str message displayed on driver information...
- Supplement to 05-06-01-003A - wrong throttle gasket part number
- Shift control knob loose or detached from shift control lever
- Crank no start, hard start, or service engine soon (SES) light after campaign 05522
- Service engine soon (SES) light due to a P1182 diagnostic trouble code - potential causes and issues
- Trailer, recreational and disabled vehicle towing information
- XM digital radio receiver ordering process
- Rear defogger grid inoperative or incomplete defogging of rear glass
- Oil life system reset procedures - cars
- Premature and/or irregular tire wear
- Engine stalls, loss of electrical systems, and no diagnostic trouble code (DTC)
- Engine flare during 2-3 shift, most noticeable during light to moderate acceleration
- Service information regarding saturn rear drum wheel cylinder inspections
- Turn signal indicator flashing faster than normal and corresponding front turn signal bulb inoperative
- Engine lacks power hesitates and or stumbles on hard acceleration and or loses some power after high RPM...
- Intermittent no movement in drive or reverse with or without diagnostic trouble codes
- Low speed grind noise and or hesitation while driving
- Service engine soon telltale illuminated with diagnostic trouble code P0742
- Intermittent hesitation during vehicle launch
- Engine runs rough after extended crank, and/or engine hesitation on acceleration after initial cold start...
- Recreational and disabled vehicle towing information
- Vehicle does not shift or move after running for a period of time and/or check engine light is on and DTC...
- UPDATE-2003-2004 ion sedan turn signal lamp/drl saturn letter to owners
- Daytime running lights (DRL) / turn signal bulb
- Generation 5 onstar steering wheel control function
- Low speed coast grinding noise and/or hesitation at vehicle launch - technical service bulletin
- Air conditioning (a/c) condensation leaking onto the vehicle floor during times of a/c usage
- Aftermarket window tinting scratched or torn
- Service engine soon (SES) light on, engine starts but runs rough and stalls repeatedly, diagnostic codes...
- Service manual update for manual shift control assembly replacement and shift control cable replacement
- Compact disc (CD) will not eject/load or cd function inoperative in 6-DISC cd MP3 player/radio
- Sunroof drain hose rattle
- Engine flare during 2-3 shift, most noticeable during light to moderate acceleration
- Erratic engine speed control at closed throttle
- Revised VT25E (VTI) spacer plate available
- Heater-ventilation-air conditioning (HVAC) blower motor click/tick or chirping noise
- Service manual update for 2004 and 2005 MU3 manual transmission backup lamp switch installation procedure
- Engine cranks with no start or engine has extended crank (greater than 3 seconds) before starting
- Temperature/mode control knobs may not rotate, air flow restricted, or HVAC mode door gasket or...
- Squeak/itch noise from rear seat when driving on rough surfaces
- Headliner material (fabric) sagging or separating from substrate
- Grind/rattle noise from transaxle in park and neutral after an extended cold soak following case cover...
- Vehicle vibrations at highway speeds 72-110 km/h (45-70 mph)
- Creaking/squeaking noise from the front suspension when turning the steering wheel
- Popping/crackling noise or distorted sound from speakers at low volume when a compact disc (CD) is played
- Oil life system reset procedures - cars
- Return form for compact discs (CDS) or digital versatile discs (DVDS) that are stuck in cd player when...
- Additional power distribution information for body control module electrical (BCM elect) fuse in the...
- One or both daytime running lamps (DRL) are inoperative, diagnostic trouble code (DTC) B3948 and/or B3949...
- Sunroof inoperative and/or inside rearview mirror electrical functions inoperative
- Itch/squeak type noise coming from the sunroof area
- Squeak, rattle, pop or clunk noise from front of vehicle during suspension movement
- On-board diagnostic (OBD) system software update - improved purge flow diagnostics
- Service manual update regarding tightening procedure and specification for the ball joint-to-steering...
- Diagnostic trouble code (DTC) PO132, P0138, or P0172 diagnostic enhancements
- Engine exchange program for supercharged 2.0L ecotec engine
- Anaerobic sealant application requirements for VT25E transaxle
- Rattle noise from steering column
- Saturn field product reminder- vehicle fix it right the first time issues, parts restriction information...
- Service information regarding installation of a saturn radio with tape player into a 2004 or 2005 model...
- Malfunction indicator lamp (MIL) service engine soon telltale illuminated, diagnostic trouble code (DTC)...
- Service manual update - hood opening procedure for inoperative hood latch
- Service manual update regarding the cruise control inoperative/malfunctioning diagnostic table
- 1-2 and/or 2-3 upshift delay, harsh tip-in downshift, erratic engagement of down slope mode
- Special policy adjustment - extended transmission warranty coverage for the variable transmission with...
- Service support and technical assistance for onstar and/or XM radio
- Service manual updated - body control module (BCM) connector C3 and C4 illustrations
- Hiss/chirp noise in park or neutral
- Service information regarding radio upgrade/downgrade procedures
- On wheel movement in snow or slippery surfaces
- Speedometer fluctuation
- 2003-2004 generation 5 onstar steering wheel control function explanation
- No reverse after case cover assembly replaced
- 02-05 onstar equipped vehicles emitting beeping noise before connecting to onstar
- No forward or reverse gears or line pressure after a valve body replacement on a VT25E transaxle
- Delay into reverse or no reverse after valvebody replacement
- No selection fir saturn when programming a saturn vehilcle
- Onstar center unable to perform remote diagnostic
- Gap is present between the front fascia and headlamp assembly
- XM radio was working prior to july 26, 2004 and it is inoperative now
- Poor or loss of FM radio reception
- Owner manual update regarding filter change to the automatic and vti transaxles
- Water enters passenger compartment, creaking noise from door while driving and/or rear door header seal...
- Fluid dripping on driver's floormat
- Service manual update for headlamp wiring harness replacement
- Slight loss of coolant or low coolant light coming on with no signs of external leaks. also the engine may...
- Installation of remote keyless entry (RKE) to ION2 vehicles
- Service information regarding transaxle poor performance after case cover replacement, diagnostic trouble...
- Changes to the AM/FM stereo and audio disc player radio on-board diagnostic modes and cd load operation
- Oil filter cap assembly and oil filter element design change
- Clarification of labor codes used for reprogramming vehicle controllers
- Spark plug inspect/replace - product emission recall
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