Engine Lacks Power, Hesitates, Stumbles on Hard Acceleration, Loses Some Power After High RPM Cruising in High Temperatures (Inspect Coolant Charge Pump Electrical Connector Terminal Location, Adjust)

Some customers may comment that the engine lacks power, hesitates, and/or stumbles on hard acceleration and/or loses some power after extended high speed (high revolutions per minute [RPM]) cruising in high ambient temperatures.

The condition may be caused by a wiring variation in the coolant charge pump wire connector that may reduce coolant flow from the pump.

Inspect the coolant pump/air cooler charger electrical connector for correct wire terminal location, and adjust if necessary. Refer to the Service Procedure section of this bulletin.

Tools Required

GM 12094429 Terminal Release Tool (Terminal Repair Kit J44020)

1. Disconnect the negative battery cable. Refer to "Battery Negative Cable Disconnect/Connect" procedure in the Engine Electrical subsection of the 2004 or 2005 Saturn ION Service Manual, Vol. 1 (2004) or 2 (2005) (SI Document ID #877687 [2004] or #1479587 [2005]).

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.

Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack.

2. Raise vehicle on hoist. Refer to "Lifting and Jacking the Vehicle" in the General Information section of the 2004 or 2005 Saturn ION Service Manual, Vol. 1 (SI Document ID #878849).
3. Disconnect the electrical connector on the supercharger coolant pump.



4. The connector cavities are identified by a number (1 and 2) that is cast into the side of the connector body. The negative (-) wire terminal (black with a white stripe) should be in cavity number 1. The positive (+) wire terminal (black wire) should be in cavity number 2.

•	If the wire terminals are in the correct location, no additional wiring repairs are necessary. Refer to "Diagnostic Starting Point - Engine Mechanical" in the Engine Mechanical 2.0L (LSJ) section of the 2005 Saturn ION Service Manual, Vol. 2 (SI Document ID #1407510) to diagnose customer concern.

•	If the wire terminals are NOT in the correct location, proceed to step 5 in these procedures.

Important: There are two terminal lock slots for each terminal pin (above and below the terminal pin) but there is only one locking mechanism on the wire terminal pin. If you cannot feel the lock when inserting the tool, move to the opposite lock slot for that terminal pin.

5. Use terminal release tool GM 12094429 (green handle). Insert the flat blade of the release tool into the terminal lock slot located in the connector face to release the terminal.
6. Gently pull the wire and terminal pin out of the back of the connector.
7. Repeat the same steps for the next cavity.
8. Reform the locking device on each terminal pin.



9. Insert the negative (-) wire terminal (black with a white stripe) in connector cavity number 1. Listen for the terminal lock to engage, a soft click can be heard when the lock engages. Ensure the terminal lock engages by gently pulling on the wire terminal.
10. Insert the positive (+) wire terminal (black) in connector cavity number 2. Listen for the terminal lock to engage. A soft click can be heard when the lock engages. Ensure the terminal lock engages by gently pulling on the wire terminal.
11. Connect the electrical connector to the supercharger to the coolant pump.
12. Lower vehicle. Refer to "Lifting and Jacking the Vehicle" in the General Information section of the 2004 or 2005 Saturn ION Service Manual, Vol. 1 (SI Document ID #878849).
13. Connect the negative battery cable. Refer to "Battery Negative Cable Disconnect/Connect" procedure in the Engine Electrical subsection of the 2004 or 2005 Saturn ION Service Manual, Vol. 1 (2004) or 2 (2005) (SI Document ID #877687 [2004] or #1479587 [2005]).
14. Verify the coolant charge air cooler pump operates by using the TECH 2®. Navigate to the "Special Function" screen and select "Engine Output Controls," then select "Intercooler Pump."
15. If the pump turns on when selected, no additional repairs are required.
16. If pump does not turn on, check the electrical connector and make sure the connector is fully seated and the terminal pins are locked in the connector.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for N6610 (Wiring and/or Connector, Engine Wiring, Coolant Charge Pump - Repair or Replace).