On-Board Diagnostic (OBD) System Software Upgrade-Improved Purge Flow Diagnostics (Install Updated Engine Control Module (ECM) Calibration)

This bulletin provides information about installing a new engine control module (ECM) calibration on certain 2004 Saturn ION vehicles intended for registration in California (RPO YF5). The revised calibration includes improvements to the P0496 evaporative emission purge flow diagnostic. Install the new calibration on all affected vehicles identified in this bulletin, including new vehicles in retailer inventory and any vehicles that return for service during the applicable 8-year/80,000 mile (130,000 km) emission controller warranty coverage period . Refer to the following procedure in this bulletin.

Verifying Calibration ID Number

Important: You must view calibration numbers using the TECH 2 Scan Tool and NOT the Saturn Service Stall System (SSS).

1. Connect Scan Tool to the vehicle.
2. Navigate to the 2.2L (VIN F) Powertrain Menu.
3. Select ID INFORMATION.
4. Select ENGINE INFORMATION.
5. Read CALIBRATION ID.

•	If the current ECM calibration ID is the same or later than the calibration listed in the "Calibration Information Table," do not reprogram the ECM. The updated calibration is already installed and reprogramming is not required.

•	If calibration ID number is not the same or later than the calibration listed in the "Calibration Information Table," then reprogram ECM with latest available service calibration.

Reprogramming ECM

Important: Before installing new ECM calibration, make sure the Saturn Service Stall System (SSS) version is TIS 3.0 2004 or later.

Important: While ignition is OFF, apply parking brake to disable daytime running lights (DRLs) prior to starting reprogramming procedure.

Important: Technician must select "Replace and Reprogram" option in order to reprogram the ECM.

Reprogram the engine control module (ECM) with the appropriate updated calibration listed in this bulletin. Refer to the "Calibration Information Table" to select the correct calibration for the vehicle being serviced. (If newer calibrations than those listed in the "Calibration Information Table" are available, install the latest available service calibration.) Use Saturn Service Stall System (SSS) software version TIS 3.0 2004 or later data CD. Refer to "Service Programming System (SPS)" in the SSS User Guide and "Service Programming System (SPS)" in the Vehicle Control Systems section of the 2004 Saturn ION Service Manual, Vol. 3, for reprogramming procedures.

To receive credit for this repair during the applicable 8-year/80,000 mile (130,000 km) emission controller warranty coverage period, submit a claim through the Saturn Dealer System for the following: