Emissions - Design Changes to Air Pump Isolation System
BULLETIN NO.: 99-T-30ISSUE DATE: July, 1999
GROUP/SEQ. NO.: Engine-08
CORPORATION NO.: 99-06-05-003
SUBJECT:
Service Information on Design Changes to Air Pump Isolation System
MODELS AFFECTED:
1999 Saturn S-Series vehicles built before and including VIN XZ315309 equipped with air pump system (RPO NC1)
PURPOSE:
This bulletin provides back service information about design changes to the air pump system. Vehicles equipped with an air pump system and produced after VIN XZ315309 are built using the second design air pump isolation system.
IMPORTANT:
The new air pump isolation system will be referred to as the second design air pump isolation system in this bulletin. The previous design of the air pump isolation system will be referred to as the first design.
The second design air pump isolation system will back service all 1999 vehicles built with the first design air pump isolation system after the parts supply of first design air pump isolation systems have been depleted from Saturn Service Parts Operations' inventory. To install the second design air pump isolation system on a vehicle originally equipped with the first design system, the air pump bracket, mounting bolts, grommets, and grommet bushings must be replaced according to the procedure provided in this bulletin. Below are some of the changes to the air pump isolation system:
^ Second design air pump mounting bolts are smaller in diameter than the first design air pump-to-air pump bracket mounting bolts.
^ Second design air pump mounting bolts have a captured washer.
^ Inside diameter of second design rubber grommets is different than diameter of first design rubber grommets. Inside diameter of second design rubber grommet is 5.6 mm (7/32 in.).
^ Second design rubber grommet bushing is smaller in diameter than first design rubber grommet bushing. Second design rubber grommet bushing is now directional.
^ Second design air pump bracket has smaller threaded holes for the air pump mounting bolts.
PROCEDURE
1. Disconnect air pump wiring harness connector.
2. Remove air pump wiring harness connector from bracket.
3. Remove air pump outlet air hose from combination valve.
4. Remove air pump bracket bolts.
5. Remove air pump bracket assembly from vehicle.
6. Remove air pump mounting bolt.
7. Remove air pump from bracket.
8. Install three second design rubber grommets (02) (P/N 21015225) onto air pump.
IMPORTANT:
Grommet bushings (3) are directional. Grommet bushing must be installed with the flared end of the grommet bushing facing the air pump bracket.
9. Install three grommet bushings (03) (P/N 21015226) into grommets (02).
10. Install air pump into second design air pump bracket (P/N 21005057).
11. Install and torque three second design air pump mounting bolts (01) (P/N 21015058).
Torque: 5.5 N.m (49 in-lbs)
12. Install air pump bracket pump assembly into vehicle.
13. Install and torque air pump bracket bolts.
Torque: 25 N.m (18 ft-lbs)
14. Install air pump outlet air hose to combination valve.
15. Connect air pump wiring harness connector.
16. Install air pump wiring harness connector on air pump bracket.
PARTS REQUIREMENTS:
21015057 Bracket-Secd Air Injn Pump
21015058 Bolt/Screw-Secd Air Injn Pump
21015225 Grommet-Secd Air Injn Pump
21015226 Bushing-Seed Air Injn Pump
CLAIM INFORMATION:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System using the appropriate Electronic Labor Time Guide and Labor Operation Code J6057 (Secondary Air Injector Pump Bracket Replace.)