DTCs P0201, P0202, P0204, P0443, P0449, P1691, P1693 with an Extended Cranking Time and/or Start then Stall #98-T-02 - (Jan 2, 2003)

1998 Saturns built up to and including VIN WZ174921

Condition:

Vehicle may have an extended cranking time and/or start then stall during cold ambient temperatures. Diagnostic trouble codes DTCs P0201, P0202, P0203, P0204, P0443, P0449, P1691, P1693 may set while the engine is being started. The condition is more likely to occur as the ambient temperature drops below 0°C (32°F).

Cause:

Ignition voltage on circuit 3C, from the ignition and start switch, may drop out momentarily when the engine is first started. Loss of voltage on this circuit for a certain duration will cause the above DTCs to be recorded in the PCM malfunction history. When the PCM detects a loss of voltage during start-up, the proper fuel delivery cannot be maintained, which could lead to the conditions mentioned.

Correction:

Refer to the malfunction history records to verify that the DTCs were stored during engine start-up. If DTCs were caused by the ignition and start switch dropout, the Eng. On Time will generally be less than 2 seconds. If verified, refer to the following procedure in this bulletin to replace the ignition and start switch.

If the Eng. On Time is greater than 2 seconds, refer to the 1998 Powertrain Controls Service Manual for diagnostic procedures.

If the vehicle condition is not related to the condition described in this bulletin and/or if additional DTCs have set, they must also be diagnosed and repaired before returning the vehicle to the customer. Refer to the appropriate service manual for diagnostic procedures.

Procedure:

Caution

When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR System. Use the following procedure to temporarily disable the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR System repairs.

Caution

The inflatable restraint sensing and diagnostic module maintains a reserve energy supply. When the vehicle power is insufficient to cause deployment of the air bags, the reserve energy supply provides the deployment power. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods:

1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead.
2. Turn the ignition key to the lock position and remove the key.




3. Remove the AIR BAG fuse from the I/P junction block.

Important

With the AIR BAG fuse removed and the ignition switch ON, the AIR BAG warning lamp will be ON. This is normal operation and does not indicate a SIR system malfunction.

4. Remove the connector position assurance (CPA) device and disconnect the yellow 2-way connector located near the base of the steering column.




5. Remove the upper trim panel screw caps by carefully prying with a small flat-head screwdriver.
6. Remove the upper trim panel screws.




7. Lift the upper trim panel at the clip locations on the rear edge to disengage the clips.
8. Disengage the forward edge of the upper trim panel by lifting upward at each outer corner, then pull rearward.

Important

Be careful not to damage the VIN plate when removing the upper trim panel.

Be careful when removing the upper trim panel, not to damage the upper trim panel seal.

9. Remove the upper trim panel.
10. Remove the upper trim panel insulator.




11. Remove the connector position assurance (CPA) device and disconnect the yellow two-way connector located on the pigtail from the passenger inflator module.




12. Remove the 2 screws holding the data link connector (DLC) to the filler
13. Remove the 5 steering column filler panel screws.




14. Remove the hood release cable from the lever by releasing the cable housing, then rotating the cable downward and out.
15. Remove the steering column filler panel.




16. Remove the 2 upper-to-lower steering column shroud screws and 3 lower steering column screws
17. Remove the upper steering column shroud.




18. Insert the ignition key into the ignition lock cylinder and rotate the ignition key to ACC position
19. Depress the square locking button on the top of the ignition lock cylinder module and slide the ignition lock cylinder assembly from the ignition lock cylinder.
20. With the ignition lock cylinder removed, remove the lower steering column shroud.
21. Disconnect the ignition and start switch electrical connector.




22. Remove the 2 screws holding the ignition module assembly, and remove the ignition and start switch.
23. Position the new ignition and start switch, P/N 21024682, to the ignition module assembly, install the 2 screws and tighten.
Tighten

Tighten the two screws to 2-3 N·m (18-27 lb in).

24. Connect the electrical connector to the ignition and start the switch.
25. Position the upper and lower steering column shrouds to the steering column and install 2 upper-to-lower steering column shroud screws and 3 lower steering column shroud-to-steering column screws.
26. Install the ignition lock cylinder into the ignition module.




27. Route the hood release cable through the I/P, then install the hood release cable to the lever.
28. Install the steering column filler panel and data link connector (DLC).
29. Install the and tighten 5 screws.
Tighten

Tighten the 5 screws to 2.2 N·m (20 lb in).





30. Turn the ignition switch to the LOCK position and remove the key.
31. Connect the yellow 2-way SIR connector at the base of the steering column and install the connector position assurance (CPA) device to the connector.




32. Install the upper trim panel insulator.

Important

• Make sure to tuck in all flaps.
• Be sure the upper trim panel seal is correctly seated on the forward edge before installing the upper trim panel.
• Be careful not to damage the VIN plate when replacing the upper trim panel.




33. Lower the panel, making sure the upper trim panel alignment tabs interlock with the windshield garnish slots.
34. Push down at the clip locations to secure.
35. Press down firmly at the forward corners to fully engage the retainers.




36. Install and tighten the screws.
37. Install the screw caps.
Tighten

Tighten the screw caps to 2.3 N·m 20 lb in).

38. Install the AIR BAG fuse to the junction block.
39. Turn the ignition switch to the run position and verify that the AIR BAG warning lamp flashes 7 times and then turns OFF. If it does not operate as described, perform the SIR Diagnostic System Check in the 1998 SIR Service Manual.

Parts Requirement:

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer".  They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle.  Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely.  If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition.  See your GM dealer for information on whether your vehicle may benefit from the information.

WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION

© Copyright General Motors Corporation.  All Rights Reserved.