Info - Engine Control Module (ECM)/Transmission Control Module (TCM)/Ignition Module Ground Location Change (03-06-03-005A)

Publication date: 2004-03-26
Reference number: 03-06-03-005A
Supersedes refnos: 03-06-03-005

INFO - ENGINE CONTROL MODULE (ECM)/TRANSMISSION CONTROL MODULE (TCM)/IGNITION MODULE GROUND LOCATION CHANGE

TECHNICAL SERVICE BULLETIN

Reference Number(s): 03-06-03-005A, Date of Issue: March 26, 2004

SATURN:	2003 ION Vehicles
SECTION:	06 - Engine/Propulsion

Superceded Bulletin(s): 03-06-03-005

NOTE: This bulletin is being revised to update information regarding a new ground location. Please discard Corporate Bulletin Number 03-06-03-005 (Section 06 - Engine).

PURPOSE

The purpose of this bulletin is to inform Saturn Retailers of changes to the engine ground location. For 2003 Saturn ION vehicles, there are three possible locations for the ECM/TCM/ignition module ground location:

VEHICLES BUILT PRIOR TO VIN 3Z118970

Vehicles built prior to VIN 3Z118970 utilize the lower stud on the intake cam end cover plate. Refer to the Service Procedure in this bulletin for instructions to relocate the ground to the rear cam cover. While it is not necessary to relocate this ground terminal, it is suggested that whenever the intake cam cover stud is being serviced, the ring terminal ground connection be moved to the updated location.

VEHICLES BUILT BETWEEN AND INCLUDING VINS 3Z118970 AND 3Z176922

Vehicles built between and including VINs 3Z118970 and 3Z176922 utilize the ground stud toward the rear of the cam cover.

VEHICLES BUILT AFTER AND INCLUDING VIN 3Z176923

Vehicles built after and including VIN breakpoint 3Z176923 have the ground located at G105. The G105 ground placement is located in the lower left front side of the engine, above the starter. Refer to the following illustration for location.

Fig 1: Ground Location G105

SERVICE PROCEDURE

IMPORTANT: This procedure should be performed only on vehicles built prior to VIN 3Z118970.

REMOVAL

Remove nut from intake cam end cover plate lower stud.

Fig 2: End Cover Lower Stud

IMPORTANT: To avoid loosening end cover plate and/or damaging wiring harness, hold end cover stud with suitable 13 mm (0.5 in) thin wrench such as Saturn special tool SA9401C (Generator Output Stud Wrench).

Remove ground harness ring terminal and discard nut removed in Step 1. Tighten the end cover stud to 25 N.m (18 ft-lb).

INSTALLATION

Remove the ground strap retaining stud from the camshaft cover.

Fig 3: Ground Strap Retaining Stud
Install the ECM/TCM/ignition module ground harness ring terminal ON TOP of the braided ground strap.
Install the ground strap retaining stud to the camshaft cover to secure the ground harness ring terminal and braided ground strap. Tighten the ground strap stud to 10 N.m (89 in-lb).