Service Information Regarding Rear Seat Entertainment System (DVD) Diagnostics and Service Procedures

This bulletin (04-08-44-008A) is identical to Saturn bulletin 02-I-01A previously published. This bulletin is being issued for electronic purpose only and the paper bulletin (02-I-01A) should not be discarded.

The purpose of this bulletin is to provide the following information to diagnose and service the 2002-2003 Saturn L-Series rear seat entertainment system.

1. Digital Video Disc (DVD) Player Harness
2. Advanced Audio Jumper
3. Left Instrument Panel Fuse Block (LIPFB)
4. AVI Module to Radio 12-Way Harness
5. AVI Module
6. AVI Module to Radio 24-Way Harness
7. Underhood Fuse Block (UHFB)
8. Right Instrument Panel Fuse Block (RIPFB)
9. Roof Console Harness
10. Radio
11. Digital Video Disc (DVD) Player
12. Dome Lamp Jumper Harness
13. Roof Console

DVD Players

Remote Controls

DVD PLAYER

The DVD player is designed to be compatible with Digital Video Discs (DVD) authorized for use in the United States and Canada. Regular audio Compact Discs (CD) can also be played by the DVD Player. Home-recorded CDs (CD-R) or home-recorded DVDs may not play in this player.

On power-up, the DVD player is in Auxiliary (AUX) mode. When a DVD begins playing, it switches to DVD mode. Pressing the PWR/AUX or SOURCE button returns the player to AUX mode. Pressing Play from AUX mode puts the player in DVD mode.

Auxiliary input jacks are provided to connect video and audio from other devices. For example, video games or cameras can be connected to use the video display and vehicle speakers. Or, a portable CD or digital media player can be connected to the audio inputs to use the vehicle speakers.

The DVD player sends the video signal to the roof console for video display. Video sound is output to the AVI module where it is sent to the radio for vehicle speaker sound and the roof console for headphone sound.

The DVD player can be controlled by the front panel controls or by the remote control. Remote control commands are transmitted by infrared (IR) signal to the roof console IR transceiver. The roof console IR transceiver sends the IR signal to the DVD player through the wire harness and AVI module.

Power and grounds for the DVD player are the same as the Radio. Connections in the AVI module splice the DVD player power and ground into the radio power and ground. The DVD player provides power to the roof console through the wire harness and AVI module.

ROOF CONSOLE

The roof console houses the video display screen, infrared (IR) transceiver and video/audio electronics. Video signals from the DVD player are processed and displayed on the video display screen. Audio from the DVD player is converted to infrared (IR) output signal to the headphones. only DVD player audio is available through the IR headphones.

IR signals from the remote control are sent by the roof console IR transceiver to the DVD player through the wire harness and AVI module.

The video display screen activates when it is un-latched and pulled down. Pushing up and latching the video display screen turns the screen off, but leaves the audio headphones and remote control features on.

Power and ground to the roof console is provided by the DVD player through the wire harness and AVI module.

RADIO

The radio receives audio input from the entertainment system AVI module. Audio from the DVD player is selectable at the radio like other radio media (CD or Cassette Tape) by pressing the AUX button. The radio makes the video AUX mode available when IGN #2 and IGN #3 are high (battery voltage). In video AUX mode, the radio display shows AUX and fade, balance and tone control are available.

ONSTAR®

If the vehicle is also equipped with OnStar®, DVD audio will be interrupted during an OnStar® call. During an OnStar® call, the mute line is low (ground) and the AVI module relay switches to connect the OnStar® audio to the radio audio inputs. In OnStar® AUX mode, the radio displays AUX and the fade is fixed at full-front, balance control is fixed at center, and the tone control is fixed at a pre-set equalization.

AUDIO VIDEO INTERFACE (AVI) MODULE

The Audio Video Interface (AVI) module connects between the vehicle harness and the radio. The AVI module connects the entertainment system to the audio inputs of the radio and splices the entertainment system power and grounds into the radio power and ground. The AVI module also overrides the video sound input to the radio during an OnStar® call. For the vehicle speaker outputs, amp sense and park lamps input circuits, the AVI Module functions as a junction block, with no other connections to these circuits inside the module.

During DVD player operation, the DVD player audio enable circuit is low (grounded). The AVI module logic turns on the audio relay to connect the DVD audio outputs to the radio audio inputs, and causes IGN #2 and IGN #3 circuits to be high (battery voltage). When IGN #2 and IGN #3 are high, the radio mode switches to video AUX mode.

DVD player audio is interrupted when OnStar® is in use. During an OnStar® call, the OnStar® mute circuit is low and the AVI module logic turns off the audio relay. This disconnects the DVD player audio outputs and connects OnStar® audio outputs to the radio audio inputs. The AVI module turns Off IGN #2 and IGN #3 and the radio switches to OnStar® AUX mode.

HEADPHONES

The wireless headphones receive audio from infrared (IR) signals sent by the roof console IR transceiver. The headphones only receive audio from the DVD player. The radio does not need to be On or in video AUX mode for the headphones to work.

Strong sunlight may interfere with the IR signal and headphone sound operation.

REMOTE CONTROL

The remote control sends infrared (IR) signals to the roof console IR transceiver. These command signals are converted and sent to the DVD player through the wire harness and AVI module.

Removal

Important: You do not need to disconnect the left heated seat/fog switch, hazard switch, or traction/right heated seat switch electrical connectors.

1. Grab center trim plate at A/C vent area and pull gently to disengage attaching clips.



2. Remove radio fasteners.
3. Pull radio out slightly to access rear of radio.
4. Disconnect electrical connector(s), antenna, and radio ground strap spade terminal from rear of radio.
5. Remove radio.



6. Pull up on AVI module until vehicle harness connectors can be accessed.
7. Disconnect vehicle harness connector(s) from AVI module.
8. Remove AVI module.

Installation

Important: If the AVI module is being replaced, transfer the AVI module to radio harnesses (12-way and 24-way) to new AVI module prior to installation.

1. Connect vehicle harness connector(s) to the AVI module.
2. Position AVI module and push down into place.



3. Connect electrical connector(s), antenna, and radio ground strap spade terminal to radio.
4. Install radio, making sure all electrical harnesses fit into place without pinching.
5. Install radio fasteners.

Tighten
Radio-to-I/P Fasteners: 2.5 N·m (22 in-lbs)




6. Install center trim plate into I/P by gently engaging attachment clips.

Removal

1. Lower roof console display screen to access four mounting screws.
2. Remove four mounting screws.



3. At left-hand side of dome lamp lens, place small flat head screwdriver into indentation and pry lens loose.

Important: Support rear of roof console while performing next step.

4. Remove two screws inside dome lamp.



5. Gently lower roof console to expose locking tabs located in front left-hand corner.
6. Pinch locking tabs together and lower roof console.



7. Disconnect dome lamp wire harness at connector.
8. Disconnect roof console wire harness from circuit board.
9. Remove roof console.

Installation

1. Connect roof console wire harness to circuit board.
2. Connect dome lamp wire harness.



3. Line-up roof console locking tabs with roof bracket.
4. Push-up on roof console to engage locking tabs.



5. Support rear of roof console.
6. Install two screws inside dome lamp.

Tighten
Roof Console to Bracket: 2.0 N·m (18 in-lbs)

7. Snap dome lamp lens into place.



8. Install four screws above roof console display.

Tighten
Roof Console to Bracket: 2.0 N·m (18 in-lbs)

Removal

1. Remove roof console.
2. Push-down on two locking tabs on the latch.



3. Push latch rearward and un-hook spring.

Installation

1. Align latch and spring into latch opening.
2. Hook spring onto roof console housing.
3. Push latch into roof console housing until locking tabs engage.
4. Install roof console.

Important: New replacement headliners must be modified prior to installation on vehicles equipped with the optional rear seat entertainment system. Use the following procedure to make needed modifications when replacing a headliner.

1. Remove roof console.
2. Partially remove headliner to allow access to the roof console wiring harness. Refer to "Headliner" removal procedure in the Body Electrical Service Manual.
3. Remove roof console wiring harness from headliner by cutting through the retaining glue.
4. Remove headliner from vehicle.



5. Cut through the glue retaining the dome lamp harness and place out of the way.
6. Place new headliner on a flat surface with the fabric side up.
7. Place old headliner on new headliner and align together, using front visor holes and rear high mount stop lamp cutouts as alignment reference points.




Important: Markers may bleed into fabric and therefore are not recommended.

8. Using the old headliner as a template, mark a pencil line 1/4 inch inside the roof console opening on the new headliner.

Important: Fabric may tear if cut from the fiberglass side of the new headliner.

Important: Be sure that all wires on the back of the headliner are out of the way before cutting.

9. Using a sharp utility knife, cut along the pencil line on the fabric side of the new headliner.



10. Partially install headliner into vehicle, placing the front edge of the headliner first.
11. Locate roof console wire harness next to headliner wiring harness.
12. Secure roof console wiring harness to headliner with retaining tape.

Important: Trim headliner opening if headliner material interferes with roof console bracket.

13. Install headliner to roof.
14. Finish installing headliner. Refer to "Headliner" installation procedure in the Body Electrical Service Manual.

Removal

Important: A Torx T8 or T10 driver is required to remove the DVD player. For 2002 L-Series vehicles with a VIN up to and including 1G8JS54F12Y576087, use a T8 driver. For 2002 L-Series vehicles with a VIN break of 1G8JS54F12Y576088 or higher, use a T10 driver. For 2003 L-Series vehicles, use a T10 driver.

1. Remove two screws from the rear underside of DVD player console upper cover.
2. Slide upper cover to the rear and lift-up to remove.
3. Remove bracket to DVD player screw on the left side.
4. Remove bracket to lower console screw on right side.
5. Remove nut at rear of DVD player.



6. Lift up DVD player and disconnect wiring harness and ground strap.

Installation

Important: If the DVD player is being replaced, transfer the right-side bracket from the old player to the replacement player prior to installation.

Tighten
Right Bracket to DVD Player: 1 N·m (9 in-lbs)

1. Connect DVD player wiring harness and ground strap.
2. Align a stud at rear of DVD player to the slot in the lower console.



3. Install bracket to lower console screw on right side.

Tighten
Right Bracket to Lower Console: 1 N·m (9 in-lbs)

4. Install bracket to DVD player screw on the left side.

Tighten
Left Bracket to DVD Player: 1 N·m (9 in-lbs)

5. Install nut at rear of DVD player.

Tighten
DVD Player Nut: 1 N·m (9 in-lbs)

6. Position console upper cover slightly rearward of the DVD player faceplate.
7. Slide console upper cover forward into DVD player faceplate.
8. Install screws into rear underside of center console.

Tighten
Center Console Upper Cover Screw: 1 N·m (9 in-lbs)

Removal

1. Remove DVD player.
2. Remove screw at bottom of storage bin under rubber pad.
3. Remove two screws in rear of lower center console.
4. Remove lower console, feeding DVD player wiring harness through opening.

Installation

1. Position DVD player lower console into the console, feeding DVD player harness through the opening.
2. Install two screws in the rear of the lower center console.

Tighten
DVD Player Lower Console Screw: 2.5 N·m (22 in-lbs)

3. Install screw into bottom of storage bin.

Tighten
DVD Player Lower Console Screw: 2.5 N·m (22 in-lbs)

4. Install DVD player.

Important: 2002 model year vehicles with Rear Seat Entertainment utilize 1st design AVI module and 1st or 2nd design DVD Player and Remote control. 2003 model year vehicles with Rear Seat Entertainment without OnStar® utilize 1st design AVI Module and 2nd design DVD Player and Remote control. 2003 model year vehicles with Rear Seat Entertainment and OnStar® utilize 2nd design parts throughout.

Important: Second design parts are compatible with vehicles built with 1st design components and should be used for replacement parts when servicing 1st design systems.