Service Manual Update Regarding the Cruise Control Inoperative/Malfunctioning Diagnostic Table. Saturn ION 2004

Subject:

Service Manual Update Regarding the Cruise Control Inoperative/Malfunctioning Diagnostic Table

Models:

2003-2004 Saturn ION

with 2.2L Engine (VIN F -- RPO L61)

Attention:

Technician

Purpose

The Cruise Control Inoperative/Malfunction diagnostic table in the Cruise Control section of the 2003 and 2004 Saturn ION Service Manuals should be replaced with the Cruise Control Inoperative/Malfunction diagnostic table in this bulletin. The new table uses resistance values instead of voltage readings or a test lamp when checking the proper operation of the cruise control function switches.

The SI website will be updated immediately and future Service Stall System SI CD releases will include this and other Service Manual updates.

Diagnostic Aids

Caution: Refer to SIR Caution in Cautions and Notices.

Important: Perform the following in order to avoid misdiagnosis.

Inspect for proper operation of brake lamps.
Inspect throttle linkage for mechanical binding which could cause the system to malfunction.
Inspect cruise control cable adjustment, should have minimum slack.
When testing vehicles equipped with steering wheel controls, the steering wheel must be rotated to each stop position while testing the cruise control switch signal circuits. This will ensure the integrity of the SIR coil.

Disable the inflatable restraint steering wheel module when performing this diagnostic table.

Refer to SIR Disabling and Enabling Zone 3 in SIR in the appropriate service manual.

•	Ensure that the following cruise control switches are not stuck in the engaged position:

•	o On/off switch

•	o Set/coast switch

•	o Resume/accel switch

•

With a scan tool, observe the associated cruise control switch parameter in the ECM Cruise Control Data list, while rotating the steering wheel to both steering stops and separately activating each cruise control switch. This will help eliminate the possibility of an internally shorted inflatable restraint steering wheel module coil.

•	EMI on the speed sensor signal circuit may cause erratic cruise control operation.

•	For an intermittent condition, refer to "Testing for Intermittent and Poor Connections" in Wiring Systems.

Conditions for Enabling Cruise Control

•	When vehicle speed is more than 40 km/h (25 mph)

•	When PARK, REVERSE, NEUTRAL, or 1st gear is not indicated

•	When an over/undercharged battery condition does not exist

•	With normal engine RPM

•	Without high engine RPM fuel cut-off

Step

Action

Values

Yes

Schematic Reference: Cruise Control Schematics

Connector End View Reference: Cruise Control Connector End Views or Engine Control Module (ECM) Connector End Views in Engine Controls - 2.2L (L61)

Did you perform the Diagnostic System Check - Cruise Control?

Go to Step 2

Go to Diagnostic System Check - Cruise Control

Install a scan tool.
Turn ON the ignition, with the engine OFF.
Turn the cruise control On/Off switch OFF.
With the scan tool, observe the following cruise control parameters in the engine control module (ECM) Data list:

•	Cruise On/Off Switch

•	Cruise Resume/Accel Switch

•	Cruise Set/Coast Switch

Do all of the parameters listed above display Off?

Go to Step 3

Go to Step 6

With the scan tool, observe the Cruise On/Off Switch parameter.
Turn the cruise On/Off switch ON.

Does the Cruise On/Off Switch parameter display On?

Go to Step 4

Go to Step 7

With the scan tool, observe the Cruise Set/Coast Switch parameter.
Press and hold the set/coast switch.

Does the Cruise Set/Coast Switch parameter display On?

Go to Step 5

Go to Step 8

With the scan tool, observe the Cruise Resume/Accel Switch parameter.
Press and hold the resume/accel switch.

Does the Cruise Resume/Accel Switch parameter display On?

Go to Diagnostic Aids

Go to Step 8

Turn OFF the ignition.
Remove the inflatable steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement in SIR.
Disconnect the cruise control switch.
Turn ON the ignition, with the engine OFF.
Observe the Cruise On/Off Switch parameter in the Cruise Control Data list.

Does the Cruise On/Off Switch parameter display Off?

Go to Step 12

Go to Step 10

Turn OFF the ignition.
Remove the inflatable steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement in SIR.
Disconnect the cruise control switch.
Turn ON the ignition, with the engine OFF.
Connect a test lamp between the ignition 1 voltage circuit and a good ground.

Does the test lamp illuminate?

Go to Step 9

Go to Step 14

Important: The cruise control on/off switch must be turned ON in order to correctly view the set/coast switch and the resume/accel switch resistance values with the Digital Multimeter (DMM) Tester. (SA91114NE)

Turn OFF the ignition.
Remove the inflatable steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement in SIR.
Disconnect the cruise control switch.
With a DMM, measure the resistance of the cruise control switch between the ignition 1 voltage circuit and the cruise control set/coast and resume/accelerate switch signal circuit.
Individually activate and hold the cruise control function switches while measuring the resistance values of each switch.

Do the resistance values measure at the specified values?

Off = O.L.

On = 7.8K - 8.6Kohms

S/C - 1.2K - 1.3K ohms

R/A - 2.7K - 3K ohms

Go to Step 11

Go to Step 12

Important: The cruise control on/off switch must be turned ON in order to correctly view the set/coast switch and the resume/accel switch resistance values with the DMM.

With a DMM, measure the resistance of the cruise control switch between the ignition 1 voltage circuit and the cruise control set/coast and resume/accelerate switch signal circuit.
Individually activate and hold the cruise control function switches while measuring the resistance values of switch.

Do the resistance values measure at the specified values?

Off = O.L.

On = 7.8K - 8.6Kohms

S/C - 1.2K - 1.3K ohms

R/A - 2.7K - 3K ohms

Go to Step 13

Go to Step 12

Test the cruise control set/coast and resume/accelerate switch signal circuit for a short to voltage. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems.

Did you find and correct the condition?

Go to Step 17

Go to Step 13

Test the cruise control set/coast and resume/accelerate switch signal circuit for an open, for a short to voltage, for a short to ground, or for a high resistance. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems.

Did you find and correct the condition?

Go to Step 17

Go to Step 13

Inspect for poor connections at the harness connector of the cruise control switch. Refer to Testing for Intermittent and Poor Connections and to Connector Repair in Wiring Systems.

Did you find and correct the condition?

Go to Step 17

Go to Step 15

Inspect for poor connections at the harness connector of the ECM. Refer to Testing for Intermittent and Poor Connections and to Connector Repair in Wiring Systems.

Did you find and correct the condition?

Go to Step 17

Go to Step 16

Repair the open, the short to ground, or the high resistance in the ignition 1 voltage circuit. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems.

Did you complete the repair?

Go to Step 17

Replace the cruise control switch. Refer to Cruise Control Switch Replacement in Steering Wheel and Column.

Did you complete the replacement?

Go to Step 17

Important: Program the replacement Engine Control Module (ECM).

Replace the ECM. Refer to ECM Replacement in Engine Controls - 2.2L (L61).

Did you complete the replacement?

Go to Step 17

Install the inflatable steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement in SIR.
Enable the inflatable restraint steering wheel module. Refer to SIR Disabling and Enabling Zone 3 in SIR.
Operate the vehicle with in the conditions for cruise control operation.

Does the cruise control system operate properly?

System OK

Go to Step 2