Extended Engine Crank Time Before Engine Starts (Replace Primary Fuel Pump)

Some customers may comment on extended engine cranking time of 3-5 seconds before engine will start after the engine has been shut off longer than 30 seconds.

This condition may be caused by inadequate fuel pressure due to excessive fuel pressure bleed down with engine off.

Determine if fuel pressure bleed down is outside specification and, if necessary, replace primary fuel pump. Refer to service procedure in this bulletin.

Caution: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Install the fuel pressure gauge. Refer to "Fuel Pressure Gage Installation and Removal" procedure in the Engine Controls - 2.2L (L61) or Engine Controls - 3.5L (L66) section of the 2004 Saturn VUE Service Manual, Vol. 1 (SI Document ID #783543 [L61] or 1243335 [L66]).
2. Run engine to stabilize fuel pressure and then turn engine OFF.
3. Complete Step 4 of "Fuel System Diagnosis" by monitoring fuel pressure for five minutes. Refer to "Fuel System Diagnosis" in the Engine Controls - 2.2L (L61) or Engine Controls - 3.5L (L66) section of the 2004 Saturn VUE Service Manual, Vol. 1 (SI Document ID #1344573 [L61] or 1360601 [L66]).

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If fuel pressure decreases by more than 100 kPa (14.5 psi) in five minutes, replace the primary fuel pump. Refer to "Fuel Tank Module Replacement - Primary" in the Engine Controls - 2.2L (L61) or Engine Controls - 3.5L (L66) section of the 2004 Saturn VUE Service Manual, Vol. 1 (SI Document ID #1353537 [L61] or 1275645 [L66]).

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If vehicle was built up to and including VIN breakpoint 4S802436, fuel feed hose must also be replaced. Use P/N 22730899 for vehicles with 2.2L 4-cyl. (L61) engine or P/N 22730901 for vehicles with 3.5L V-6 (L66) engine. Refer to "Fuel Hose/Pipes Replacement - Chassis" in the Engine Controls - 2.2L (L61) or Engine Controls - 3.5L (L66) section of the 2004 Saturn VUE Service Manual, Vol. 1 (SI Document ID #1275739 for both L61 and L66).

-	If vehicle was built after VIN breakpoint 4S802436, the fuel feed hose does not need to be replaced.

•	If fuel pressure does not decrease by more than 100 kPa (14.5 psi) in five minutes, continue with "Fuel System Diagnosis" procedure.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for J5590 (Pump, Fuel [In Tank] - R&R or Replace).