Crank/No Start/Extended Crank, Delay into Reverse, Inop/Intermittent Components w/DTC P0112, P0300-P0306, P0571, P0621, P0629, P0693, U1088, U1095, U2105 and/or U2108 Set (Replace PCM, PCM Terminals)

This bulletin is being revised with new special tool and special tool kit numbers and a new labor operation code. Please discard Corporate Bulletin Number 04-06-04-061 (Section 06 - Engine/Propulsion System).

Some customers may comment on a crank, no start or extended crank (3 seconds or greater) prior to vehicle starting or delayed engagement when shifting into "REVERSE" (no DTCs or noise, could be 3-4 second delay or longer). One or more of the following diagnostic trouble codes (DTCs) may also be set:

Specific terminals on the 73-way (C1) connector and 56-way (C2) connector may be damaged as a result of a deformed (misshapen) male pin at the PCM. In the event that the male pin of the PCM does not provide the correct shape, installation of the connector to PCM may potentially damage the female terminals of the connectors.

Replace PCM, P/N 12583698, and damaged PCM terminals using Wire Lead Kit, P/N 22692904.

1. Verify that crank, no start, or extended crank comments are not related to fuel delivery concerns. (Refer to Corporate Bulletin Number 04-06-04-048.)
2. Verify that the vehicle identification number (VIN) is within the range. If vehicle is outside the VIN range, please refer to the Engine section of the 2004 Saturn VUE Service Manual, Vol. 1 for diagnostic assistance.
3. Remove the PCM C1 and C2 connectors.
4. Using probe tool J 35616-64A (0.64 mm) from kit J35616-C, carefully check terminal retention on suspect circuits.

Important: For intermittent conditions, try to duplicate the symptoms or display the DTCs referenced in this bulletin while performing a wiring harness PCM connector tug test. To perform the PCM connector tug test, securely grasp the wiring harness (wires) nearest the coupler connector and pull/tug on the wiring harness.

Powertrain Control Module (PCM) Replacement

Removal

1. Disconnect the battery negative cable. (Refer to Battery Negative Cable Disconnect/Connect procedure in the Engine Electrical section of the 2004 Saturn VUE Service Manual, Vol. 1 [SI Document ID# 1252679].)
2. Disconnect the wiring harness.
3. Depress the retaining tab and remove the PCM.
4. Remove the PCM from the housing.

Installation

1. Install the new PCM into the housing bracket.
2. Connect the wiring harness.
3. Connect the battery negative cable. (Refer to Battery Negative Cable Disconnect/Connect procedure in the Engine Electrical section of the 2004 Saturn VUE Service Manual, Vol. 1 [SI Document ID# 1252679].)
4. Program the PCM. Use Saturn Service Stall (SSS) software release TIS 5/2004 or higher data CD. (Refer to Service Programming System (SPS) in the SSS User's Guide.)
5. Perform the Idle Learn procedure. (Refer to the "Idle Learn" procedure in the Engine Controls - 3.5L [L66] section of the 2004 Saturn VUE Service Manual, Vol. 1 [SI Document ID# 1291973].)

Terminal Removal/Replacement Repair Procedure

Tools Required

J 38125-800 Terminal Repair Kit

Removal

1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock.
2. Disconnect the connector from the component.



3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool, push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the two front locks are unlocked, lift the front of the dress cover and pull it forward.



5. If the connector has a nosepiece, use a small flat-blade tool to remove the nosepiece by inserting the blade into the slot on the front of the connector and prying up on the nosepiece.




Notice: Always use care when removing a terminal position assurance (TPA) retainer in order to avoid damaging it.

6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA retainer and pushing down until the TPA retainer releases. Gently pry the TPA retainer out of the connector.




Notice: Do not angle or rock the J 38125-21 tool when inserting it into the connector to avoid tool or connector damage.

7. Insert the J 38125-21 tool (Delphi 15381651-2, into the round canal between the terminal cavities at the front of the connector. (See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used.)




Notice: Never use force to pull a terminal out of a connector to avoid damaging the terminal or connector.

8. While holding the J 38125-21 removal tool in place, gently pull the wire out of the back of the connector.

Terminal Replacement

Installing New Electrical Lead Kit

Important: Use only Saturn/GM splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection.

1. Open the harness.

•	If the harness is taped, remove the tape.

•	To avoid wiring insulation damage, use a sewing ripper, or equivalent, to cut open the harness.

•	If the harness has a black plastic conduit, pull out the desired wire.

2. Cut the wire.

•	Cut no more than 25 mm (1 in) off the harness.

•	Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage.

•	Trim new cut lead wire, P/N 22692904, to same length as damaged wire removed from connector.




3. Strip the insulation. Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
4. Place the provided splice sleeve in the 12085115 crimp tool nest, or equivalent, so that the crimp falls at point 1 on the splice.
5. Close the handles of 12085115 crimp tool, or equivalent, slightly to hold the splice sleeve firmly in the proper crimp tool nest.
6. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel to prevent the wire from passing through the splice (3).
7. Close the handles of the 12085115 crimp tool, or equivalent, until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. (Repeat for other half of splice sleeve.)

Caution: Do not use match or open flame to apply heat to seal.

8. Shrink the insulation around the splice. Seal splice sleeve by applying heat using Ultra Torch® J 38125-5A, or equivalent. Heat splice sleeve to 175°C (347°F) until glue flows around edges of splice sleeve.

Important: Verify terminal is completely seated in connector prior to putting connector back together.

9. Reinstall new cut lead(s) into correct connector cavity.
10. Rebuild electrical connector with reverse procedures of Steps 3 through 6. Make sure TPA retainer is seated prior to installing connector to the PCM.
11. If electrical tape was removed to perform wire harness inspection or repair, tape wires and harness to original condition.
12. Verify repair by driving vehicle to ensure condition has been corrected.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for J7905 (Module, Engine Control [PCM/ECM], V6 [L66] - Replace). An Add Time has been added to repair the damaged PCM terminals.