Engine Stalls, No Start, Hard Start (Repair Fuel Pump Feed Circuit)

Some customers may comment that the vehicle starts then stalls or does not start at all. These symptoms may be intermittent and after several start attempts, the vehicle may stay running.

This condition may be caused by intermittent fuel pump operation due to a poor electrical connection within the 23-way connector (C210) located behind the glove box. Suspect circuit 120, PIN J, is a gray wire that serves as the fuel pump motor feed between the relay and pump.

Remove the glove box and separate the 23-way connector (C210). Inspect the terminal connection at PIN J. Perform a pin drag test. Inspect for a good solid connection and for any evidence of excessive heat that may also indicate a poor connection.

If the connection is suspect, use the procedure listed below to repair the fuel pump feed circuit.

1. Reconnect the 23-way connector (C210).
2. Cut the gray wires (circuit 120) on both sides of the 23-way connector at PIN J. Cut the wires as close to the connector as possible.
3. Strip approximately 7.5 mm (5/16 in) of insulation from each wire end.
4. Install a 51 mm (2 in) piece of shrink tubing over one wire end.
5. Overlap the 2 stripped wire ends and hold them between your thumb and forefinger.
6. Center the splice clip, P/N 05297428, over the stripped wires and hold the clip in place.

•	Ensure that the wires extend beyond the clip in each direction.

•	Ensure that no insulation is caught under the clip.

7. Center the crimp tool over the splice clip and wires.
8. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut.
9. Crimp the splice on each end.
10. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment.
11. Heat shrink the entire splice area.
12. Reinstall the glove box.

The splice clip is included in Packard Terminal Repair Kit J 38125-A or is available from GMSPO.

For vehicles repaired under warranty, use: