Service Procedure
1. The required service procedure is determined by the model year of the vehicle.
^ 2000 or 2001: Perform steps 2, 4 and 5 (Replace spark plugs and ignition control module [ICM].)
^ 2002: Perform steps 2, 3, 4 and 5. (Update powertrain control module [PCM] calibration as needed; replace spark plugs and ICM.)
^ 2003: If vehicle identification number (VIN) is 3Y530041 or lower, perform steps 2, 3, 4 and 5. (Update PCM calibration as needed; replace spark plugs and [ICM].) If VIN is 3Y530042 or higher, determine repair steps required based on engine unit number (EUN) as follows:
- EUNs up to and including 211019999, perform steps 2, 4 and 5. (Replace spark plugs and ignition control module.)
- EUNs from 211020001-304220120, perform step 5. (Replace ICM.)
- EUNs greater than 304220121 are not involved in the recall. No action is required.
2. Remove ignition coil housing assembly.
2.1 Turn ignition Off.
2.2 Remove terminal position assurance (TPA) device from powertrain control module (PCM)/ignition coil module (ICM) connector.
2.3 Disconnect PCM/ICM electrical connector.
2.4 Remove ignition coil housing attachment bolts and remove ignition coil housing.
Important:
Step 3 applies only to 2002 and certain 2003 model year vehicles, as indicated in step 3. Using a portable scan tool, check current PCM calibration ID. Refer to 2002 or 2003 Model Year Calibration Table, as appropriate.
^ If calibration is listed in table, reprogram PCM with calibration available on the Saturn Service Stall CD, version TIS 04/2003 or later.
^ If the calibration is not listed in the table, reprogramming the PCM is not required. Proceed to step 4.
Notice:
This engine has an aluminum cylinder head. Do not remove the spark plugs from a hot engine. Removing spark plugs from a hot engine may cause cylinder head damage. Before spark plugs are removed, allow the engine to cool to below 49°C (120°F).
4. Replace spark plugs.
Important:
Ensure water and debris are blown out of spark plug holes before removing spark plugs.
4.1 Remove old spark plugs using a 5/8 in. spark plug socket.
Spark Plug Gap
1.1 mm (0.45 in.)
Notice:
Do NOT coat spark plug threads with anti-seize compound. If anti-seize compound is used and spark plugs are over-torqued, damage to the cylinder head threads may result.
4.2 Install new spark plugs (P/N 12569190).
Tighten
Spark plugs: 20 Nm (15 ft-lbs)
4.3 Apply dielectric compound to spark plug boots and make sure no corrosion is present.
5. Replace ignition control module (ICM) (P/N 12580215).
5.1 Remove attachment screws from ICM and remove ICM. Ensure that old ICM electrical connector and seal are removed from ignition coil housing.
5.2 Apply dielectric grease to all terminals on both ends of the new ICM electrical connector.
5.3 Install new seal onto the new ICM electrical connector.
5.4 Install ICM electrical connector into the new ICM prior to installing the ICM onto the coil housing assembly.
5.5 Install ICM to ignition coil housing assembly.
5.6 Install ICM attachment screws.
Tighten
ICM-to-Ignition Coil Housing Screws: 1.5 Nm (13 in-lbs)
Important:
Perform steps 5.7 - 5.8 only if coil housing has been removed.
5.7 Install ignition coil housing with spark plug boots to camshaft cover.
5.8 Install ignition coil housing attachment bolts.
Tighten
Ignition Coil Housing Bolts: 10 Nm (89 in-lbs)
5.9 Connect PCM/ICM electrical connector. Push in connector until a click is heard to confirm positive engagement.
5.10 Install TPA device into PCM/ICM connector.
6. Test drive vehicle to verify no ignition-related conditions are present.
7. Affix Recall Identification Label on a clean and dry surface of radiator core support, in an area clearly visible when hood is raised. (For more information, refer to "RECALL IDENTIFICATION LABEL" in this bulletin).