Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0443, P0102, P0135, P0141, P023A, Engine Starts, Runs Rough, Stalls Repeatedly (Replace Coolant Pump Charge Air Cooler, 15 amp Fuse)

Some customers may comment on the engine running rough, stalling repeatedly, and the SES light is on. DTCs P0443, P0102, P0135, P0141, P023 set.

The coolant pump charge air cooler rubber insulator may not be positioned correctly causing the pump motor to bind and open the emission fuse (15-amp #10 Under Hood Junction Box [UHJB]). The open emission fuse will result in the DTCs being set and the SES light coming on.

Verify the coolant pump charge air cooler is causing the 15-amp #10 emissions fuse to open by following the procedures outlined in this bulletin.

1. Turn ignition key OFF.
2. Replace the 15-amp #10 emissions fuse in the UHJB.
3. Turn ignition key ON (RUN position), but do not start engine.
4. Using the TECH 2®, Special Function, turn the coolant pump charge air cooler ON.

Important: The position of the charge air cooler pump motor insulator is critical to the operation of the pump. A small gap (5 mm, 0.20 in.) between the ends of the insulator is required for proper charge air cooler pump operation. The insulator should NOT overlap once installed.

Important: Re-use the Coolant Pump Charge Air Cooler insulator.

5. If the 15-amp #10 emissions fuse opens, replace the charge air cooler pump. (Refer to "Coolant Pump Replacement - Charge Air Cooler" procedures (SI Document ID #1389541) in the appropriate Saturn ION Engine Service Manual.
6. If the fuse does not open, continue with the diagnosis of the DTCs stored in the Powertrain Control Module (PCM).
7. Start engine and verify repair.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for J5776 (Transfer Pump, Charge Air Cooler Radiator - Replace).