2000 Saturn L-Series Vehicles

Caution: FOR VEHICLES INVOLVED IN THIS CAMPAIGN, DO NOT FOLLOW THE NORMAL PROCEDURE OF DEPLOYING REPLACED INFLATOR MODULES. DEPLOYMENT OF AN INFLATOR MODULE REPLACED UNDER THIS CAMPAIGN COULD CAUSE THE INFLATOR MODULE TO EXPLODE, AND COULD RESULT IN SEVERE INJURY FROM METAL AND PLASTIC DEBRIS.

To prevent the possibility of this condition occurring, Saturn Retailers will replace the intermediate fuel rail fitting and seals.

Saturn has decided that a defect which relates to motor vehicle exits in certain 2000 Saturn L-Series model vehicles. The passenger side inflator module in some of these vehicles may have been built with incorrect generant. In the event of a crash that would trigger a passenger side inflator module deployment, a module with a double load of generant can cause the inflator module to explode. If an inflator module explodes, metal and/or plastic debris could cause the inflator module to explode. If an inflator module explodes, metal and/or plastic debris could cause severe injury to vehicle occupants. A module with no generant would not inflate the airbag, and occupants may receive more severe injuries.

Only selected 2000 model year L-Series Saturn vehicles within the following VIN numbers will require this campaign.

YY663916 -YY664698-YY663601

You must verify campaign involvement through your AS400 system, or with the listing attached to this bulletin. It is important to note that campaign claims will only be paid on involved vehicles.

Owners of all involved vehicles will be notified of this campaign by Saturn. (Refer to the owner letter included in this bulletin.)

A list of vehicles assigned to you (Facility VIN Listing) , which our records indicate were sold by or shipped to you, (or are located in close proximity to your facility) is enclosed.

This listing contains:

The Facility VIN Listing (with owner information) is furnished to involved Retailers with the Product Campaign Bulletin. Although these vehicles are assigned to your facility, it is important to note that owners may elect to have their vehicle serviced at the Saturn Retail Facility of their choice.

Those Retailers not involved initially in this campaign will receive a message at the top of a blank Facility VIN Listing that states: NO VEHICLES ASSIGNED AT THIS TIME FOR CAMPAIGN 01C05.

All unsold vehicles in Retailers' possession and subject to this campaign must be held at the retail facility and repaired per the service procedure of this campaign bulletin before owners take possession of these vehicles.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your retail facility for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

Saturn vehicles that have been sold by you, which may be closer in proximity to another Saturn Retailer, may still appear on your Facility VIN Listing. If either you or the vehicle owner determines that it is more desirable for a vehicle on your Facility VIN Listing to be serviced by another Saturn Retailer, or if the customer's address has recently changed, campaign responsibility may be transferred by completing the following:

A copy of the Campaign Vehicle Action Report is included for your reference. Additional copies can be ordered from Saturn Publications (1-800-828-2112, prompt 3, Item #S0397050 ). All changes to campaign responsibility will be reflected in your next Unfixed VIN Report.

All other changes in vehicle status (e.g., scrapped, stolen, etc.) are to be made in accordance with section 4.4.3 of the Retailer Service Reference Guide, "Notifying Saturn of Vehicle Status Change."

1. A 100% pre-shipment of module assemblies required to perform this campaign has been automatically sent by Saturn to affected Retailers. These initial shipments are to aid Retailers in campaign preparation.
2. Should additional parts be required, please order from Saturn Service Parts Operation (SSPO) as needed.
3. Required Parts.

Caution: FAILURE TO FOLLOW THE CORRECT PROCEDURES COULD CAUSE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR UNNECESSARY SIR SYSTEM REPAIRS.

Caution: WHEN YOU ARE CARRYING AN UNDEPLOYED INFLATOR MODULE:

•	DO NOT CARRY THE INFLATOR MODULE BY THE WIRES OR CONNECTOR ON THE INFLATOR MODULE.

•	MAKE SURE THE BAG OPENING POINTS AWAY FROM YOU.

WHEN YOU ARE STORING AN UNDEPLOYED INFLATOR MODULE, MAKE SIRE THE BAG OPENING POINTS AWAY FROM THE SURFACE ON WHICH THE INFLATOR MODULE RESTS. WHEN YOU ARE STORING A STEERING COLUMN, DO NOT REST THE COLUMN WITH THE BAG OPENING FACING DOWN AND THE COLUMN VERTICAL. PROVIDE FREE SPACE FOR THE AIR BAG TO EXPAND IN CASE OF AN ACCIDENT DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT.

1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead.
2. Turn ignition switch to the OFF position and remove key.
3. Remove IGNI mini-fuse from underhood fuse block.
4. Remove lower left I/P closeout panel.



5. Push out clips that secure the driver and passenger inflator module yellow 2-way connectors to I/P panel brace.
6. Remove CPA retainers and disconnect both yellow 2-way connectors.



7. Open glove compartment door.
8. Remove love compartment lamp wiring harness from glove compartment lamp.
9. Disconnect glove compartment lamp wiring harness from glove compartment lamp.



10. Remove right side I/P lower closeout panel (hush panel) retainers.
11. Pull closeout panel (hush panel) rearward to detach from forward retainers.



12. Remove right side heater outlet assembly retainer and remove outlet.



13. Remove glove compartment door.



14. Remove glove compartment bin fasteners.



15. Slowly remove glove compartment bin tilting bin downward to expose BCM residing on glove box.
16. Remove BCM module from glove compartment by sliding module out of attaching slots. Check system for leaks.
17. Remove glove compartment bin.

Important: The harness on the passenger inflator module should not be removed.

18. Disconnect inflator module from vehicle wire harness at yellow 2-way connector.
19. Remove pigtail connection rosebud from I/P support beam.



20. Remove fasteners securing inflator module to I/P support beam.
21. Push inflator module rearward and rotate round end downward.
22. Remove inflator module from vehicle through glove compartment opening.
23. Obtain replacement passenger inflator module P/N 24431683.

Important: The harness exits the inflator module on the right side of vehicle.

24. Insert inflator module through I/P opening with vinyl edge UP and harness on right side of vehicle.




Important: The harness connected to the inflator module (1) must be routed between the round guide pin and the inflator module mounting ear.

25. Insert inflator module guide pins in I/P brace slots and rotate round edge upward to align bolt holes.
26. Install fasteners securing inflator module to I/P support beam.

Tighten
Tighten Passenger Inflator Module (Air Bag) bolts to 10 N·m (89 in lbs).

27. Connect yellow 2-way connector to the vehicle wiring harness and install CPA retainer.
28. Install pigtail connection rosebud to I/P support beam.



29. Install glove compartment bin partially into opening.
30. Secure BCM to glove compartment bin slots.



31. Route glove box lamp wiring harness through lamp opening and connect glove compartment lamp wiring harness to glove compartment lamp.
32. Snap lamp into glove compartment bin.



33. Install glove compartment bin to I/P with fasteners.

Tighten
Tighten Glove Compartment Bin-to-I/P Fasteners to 2 N·m (18 in lbs).




34. Install heater outlet with retainer to glove compartment bin.



35. Install right side lower I/P closeout panel (hush panel) with retainers.



36. Install glove compartment door with fasteners.
37. Function glove compartment lamp and glove compartment door to ensure proper operation.



38. Turn the steering wheel so that the vehicle's wheels are pointed straight ahead.
39. Turn ignition switch to OFF position and remove key.
40. Connect both the driver and passenger inflator module yellow 2-way connectors and install CPA retainers.
41. Fasten clips on yellow 2-way connectors to I/P panel brace.
42. Install IGNI mini-fuse in underhood fuse block.



43. Turn ignition On and verify AIR BAG telltale flashes seven times and then goes OFF. (If AIR BAG telltale does not go OFF, refer to the "SIR Diagnostic System Check" procedure in the SIR section of the 2000/20001 L-Series Restraints Service Manual.)
44. Install lower left I/P closeout panel.

Important: Do not cover existing underhood labels when affixing Campaign Completion Label.

45. Affix Campaign Completion Label on a clean and dry surface of radiator core support, in an area clearly visible when hood is raised. (For more information, refer to "Campaign Completion Label" in this bulletin.)

Upon completion of the campaign, a Campaign Identification Label and a Clear Protective Cover should be affixed on a clean, dry surface of the radiator core support in an area clearly visible when the hood is raised. Each label provides a space to print in ink (or type) the campaign number (01C05) and the five (5) digit facility code of the Retailer performing the campaign service.

As a reminder, additional labels may be ordered from Saturn publications (1-800-828-2112, prompt 3, Item #S03 00013A for the Campaign Completion Label and Item #S03 00013B for the Clear Protective Cover ).

1. To receive credit for replacing the cooling fan control module, submit a claim with the information below:

2. To receive credit for loaner/rental car costs incurred while owner awaits campaign repair or other goodwill expenses, submit a claim with the information below:

3. Retailers are empowered to use good judgement regarding loaner/rental cars or any other goodwill expenses deemed necessary. It will not be necessary to call the Saturn Customer Assistance Center for authorization of goodwill. The Goodwill Worksheet (printed towards the back of this bulletin) must be used to document goodwill expenses. The completed Goodwill Worksheet must be attached to the hard copy of the CSO. Retailers are to make sufficient copies of the blank Goodwill Worksheet to document goodwill expenses.

4. Check your Saturn SERVICELINE.XL Claim Memorandum daily. Remember to code the claim as a WC sale type and VC case type. Contact your field representative if you need assistance.

5. All labor operations claimed in this bulletin must be submitted on individual (unrelated) CSO lines. Refer to the Customer Service Order Preparation Manual for details on Product Campaign Claim Submission.

* This is the intermediate fuel line fitting part allowance. Claim using net item code "M"

** Campaign administrative allowance.

*** Net amount must be submitted as a miscellaneous sale...Loaner reimbursement not to exceed $30/day.

**** Enter number of days vehicle was rented...Not to exceed 1 day.

As stated in the "Credit" section of this bulletin, Retailers are empowered to use good judgement regarding loaner/rental cars or other goodwill expenses that might become necessary for customer satisfaction.

Complete this worksheet and attach it to the hard copy of the Customer Service Order (CSO) to document all campaign goodwill claims submitted to Saturn.

VIN #

Dear Saturn Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Saturn has decided that a defect which relates to motor vehicle safety exits in certain 2000 Saturn L-Series model vehicles. The passenger side inflator module in some of these vehicles may have been built incorrect generant loads; some may have been built with a double load of generant and some may have been built with no generant. In the event of a crash that would trigger a passenger side inflator module deployment, a module with a double load of generant can cause the inflator module to explode. If an air bag inflator module explodes, metal and/or plastic debris could cause severe injury to vehicle occupants. A module with no generant would not inflate the air bag, and occupants may receive more severe injuries.

To remedy this condition, Retailers will replace the passenger side inflator module.

We will replace the passenger side inflator module at no charge to you. It will take less than half an hour to perform the replacement, although some additional time am be required for paperwork and processing.

Contact your Saturn Retailer to arrange to have this service performed.

Your Retailer is prepared to perform this service promptly and with minimal inconvenience to you. However, if your car is provided to the retailer on the agreed service date and the condition is not remedied on that date, or within five days, please contact Saturn Customer Assistance Center at 1-800-553-6000 prompt 3, or for the hearing impaired, 1-800-833-6000. We will assist you and the Retailer in getting your car serviced.

If, after contacting your Saturn Retailer and the Saturn Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh St., SW, Washington, DC 20590, or call 1-800-424-9393

Again, we sincerely regret any inconvenience or concern this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your Saturn provides you may miles of enjoyable driving.

Sincerely,

Saturn Corporation

01-C-05