Subject: | Intermittent Battery Light due to DTC P0A4B - Install Service Jumper Harness |
Models: | 2007-2008 Saturn Aura Greenline Hybrid |
| with 2.4L Engine (VIN 5 - RPO LAT) |
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.
Condition/Concern:
On rare occasions, the SES and Battery Lights may illuminate with a DTC P0A4B. In some instances, a P0AA1 may also be stored with the P0A4B DTC. When the battery light is illuminated, the SGCM is not charging the 12 volt or 36 volt batteries. As a result,
the 12 volt battery could discharge if the vehicle is driven continuously with the battery light on. This condition may be a result of high resistance on one of the resolver circuits.
Recommendation/Instructions:
If a current or history DTC P0A4B is stored, install a service jumper harness (part number 25892536), which contains two new MGU connectors, a new lower SGCM C2 connector, revised terminals, and revised circuits. To install the harness, follow SI safety
precautions, and refer to the SGCM C2 connector end view (SI document # 1867441), and complete the following steps:
- Disconnect the lower SGCM C2 connector and remove the conduit/tape between the connector and the main portion of the engine wiring harness.
- Remove the clear connector cover from the original SGCM C2 connector and carefully remove terminals 1 (RD/WH) and 3 (PINK) by pulling up on the white "finger". Also remove the cavity plugs from cavities 8 & 21 on the old connector. These circuits/terminals
and cavity plugs will be installed in a new SGCM C2 connector, which is part of the service jumper harness, so do not damage them or cut them off.
- Cut the remaining circuits off the original SGCM C2 connector, discard the connector and tape the end of the remaining wires (stub end) with high temperature electrical tape, and tie strap it to the main portion of the engine harness.
- Remove the clear connector cover from the new SGCM C2 connector, which is part of the service jumper harness, and install terminals 1 (RD/WH) and 3 (PINK) in the correct connector cavities, and the cavity plugs in 8 & 21. Be careful not to bend
the terminals. After installing the circuits/terminals and plugs in the new connector, install the clear connector cover.
- Install conduit over the two circuits and tape it in place. Start the conduit at the main bundle to ensure all of the wiring is covered.
- Connect the service jumper harness and new SGCM C2 connector to the SGCM.
- Route the wiring harness jumper under the coolant hose and route it along the existing conduit to the MGU.
- Disconnect both of the original MGU connectors, remove the existing tie strap from the intake runner, and cut the original connectors off just to the right of the tie strap (being careful not to cut the throttle body circuits). Connect the new MGU
connectors and tie strap it in the original location.
- Tape the end of the remaining wires (stub end) with high temperature electrical tape, and tie strap back to the engine harness.
- Make sure nothing (i.e., forward lamp harness, shifter cable, etc.) is interfering with the service jumper harness routing and test drive the vehicle to confirm that the customer's concern has been corrected.
Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.