Electrical Concerns - Intermittent/Inoperative Components, DTC B1327, B1330 Set, ABS and T/C Lamps On, Wiring Chafed/Shorted at Transaxle Mount, Below Underhood Fuse Block and/or Left Wheelhouse

This bulletin is being revised to include additional concerns for the Epica model. Please discard Corporate Bulletin Number 05-08-45-003D (Section 08 - Body and Accessories).

Some customers may comment on one or more of the following effects (symptoms) and/or driver notifications:

Important: Not all of the effects or driver notifications listed above have been or will be experienced. However, the different effects and driver notifications may be caused by one of the wires in the floor wire harness being chafed, cut or damaged. Components on different lines in the list above are in different circuits. Due to the cause of this condition, and the positions of the wires in the wire harness, it is unlikely that more than one circuit will be affected by the condition.

2004-2007 Chevrolet Optra Built Prior to VIN Breakpoint 7K492368

This condition may be caused by one of the wires in the floor wiring harness being chafed, cut, shorted/melted, or damaged near the transmission mounts or underneath the underhood fuse block. The images above show some of the types and locations of floor wiring harness damage, indicated by the arrows.

2004-2005 Chevrolet Epica Built Prior to VIN Breakpoint 5B174211 or 2004-2005 Chevrolet Optra Built Prior to VIN Breakpoint 5K205703

This condition may be caused by one of the wires in the floor wiring harness being chafed, cut (1), shorted (2) or damaged around the rear of the left side front wheelhouse splash shield (driver's side) near where the harness exits from the passenger compartment.

Carefully inspect wires in floor wiring harness for any damage and repair as necessary. If no damage is found, refer also to individual component diagnostics in SI.

2004-2007 Chevrolet Optra Built Prior to VIN Breakpoint 7K492368

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

Notice: Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.

1. Disconnect negative battery cable.
2. inspect the wires in the floor wiring harness at the transmission mount and underneath the underhood fuse block.

Tip
Use the special labor code N9563 for any repairs performed on the floor wiring harness at the transmission mount or underneath the underhood fuse block.

3. Repair any affected wires. Refer to Wiring Repair in the Wiring System subsection of SI for information on appropriate repair procedures.
4. Wrap the repaired wire and harness with 3M® Electrical Moisture Sealant Tape, P/N 06147, or equivalent, to prevent future damage.
5. Re-route the floor wiring harness so that it does not to contact the transmission mount.
6. Replace any fuses, if necessary.
7. Connect the negative battery cable.
8. If the condition is still present (2004-2005 MY vehicles only) refer to procedure below to inspect for and repair left wheelhouse wiring concerns.

2004-2005 Chevrolet Epica Built Prior to VIN Breakpoint 5B174211 or 2004-2005 Chevrolet Optra Built Prior to VIN Breakpoint 5K205703

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

Notice: Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.

1. Disconnect the negative battery cable.
2. Remove the left side front wheelhouse splash shield. Refer to Splash Shield Replacement - Wheelhouse in SI.
3. Inspect wires in the floor wiring harness at the rear of the wheelhouse.
4. Repair any affected wires. Refer to Wiring Repair in the Wiring System subsection of SI for information on appropriate repair procedures.
5. Wrap the repaired wire and harness with 3M® Electrical Moisture Sealant Tape, P/N 06147, or equivalent, to prevent future damage.
6. Install the left side front wheelhouse splash shield. Refer to Splash Shield Replacement - Wheelhouse in SI.
7. Replace any fuses, if necessary.
8. Connect the negative battery cable.

For vehicles repaired under warranty, use: