Service Manual Update for ION Sedan Headlamp Wiring Harness Replacement

The purpose of this bulletin is to provide a service procedure for replacement of the headlamp wiring harness.

The ION Sedan has a wiring harness assembly that is integral to the headlamp assembly. During service diagnostics, if it is determined that there is a wiring harness/connector concern within the headlamp assembly, the wiring harness should be replaced instead of the complete headlamp assembly.

In the Body & Accessories section of the 2003 and 2004 Saturn ION Service Manual, Vol. 3, locate the "Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Sedan)" procedure (eSI Document ID #873984). Insert a copy of this bulletin in this location.

Removal Procedure

1. Remove headlamp assembly. Complete all steps in the "Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Sedan)" removal procedure (eSI Document ID #873984) in the Body & Accessories section of the 2003 and 2004 Saturn ION Service Manual, Vol. 3.
2. Remove 6-pin headlamp wiring harness connector from tab on headlamp housing.
3. Push rubber grommet into headlamp assembly and also push 6-pin connector through opening where grommet was previously located.

Important: Remove headlamp bulb and headlamp retaining nut from headlamp assembly/connector prior to wiring harness removal.

4. Carefully remove wiring harness through the park/turn bulb access opening.

Installation Procedure

1. Install wiring harness through park/turn bulb access opening starting with the headlamp connector.
2. Push headlamp connector up into headlamp opening.
3. Pull 6-pin connector through grommet opening in headlamp assembly and then pull grommet and seat it into the opening. Fasten the 6-pin connector to the tab on the headlamp housing.
4. Install headlamp assembly. Complete all steps in the "Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement (Sedan)" installation procedure (eSI Document ID #873984) in the Body & Accessories section of the 2003 and 2004 Saturn ION Service Manual, Vol. 3.