Engine will Not Crank, MIL and ABS Light On, Park Lamps Inoperative, Fuel Gage Inoperative, and/or Radio Speaker Inoperative

The customer may comment that on occasion, one or more of the following conditions may have occurred:

Important: 

The cause of the above conditions may be the instrument panel wire harness coming in contact with the clutch pedal pivot bolt/clip causing a short to ground on the following circuits:

From the driver side footwell area, inspect the instrument panel wire harness at the location directly above the clutch pedal pivot bolt/clip. If any wire is found to be chaffed on the clutch pedal pivot bolt/clip, refer to the following repair procedures. If no wire damage is observed, refer to the appropriate Service Manual for diagnostic information.

1. Disable the SIR system. Refer to Disabling the SIR System procedure in the SIR Service Manual.
2. Remove the connectors from the powertrain control module (PCM).
3. Remove the PCM from the vehicle.

Cut the existing wire harness tie strap rose bud clip off, so the harness is loose from the spaceframe. The rose bud clip is located directly above the clutch pedal.

4. Loosen the harness clamp. Located 76 mm (3 in) away from the rose bud clip.
5. Remove the I/P harness tape from the starter relay to the branch that goes down to the IPJB.
6. Separate the harness until the damaged wire is exposed. Cut the damaged wire at the location of the chafe, if the harness is not chaffed, refer to the appropriate Service Manual section for diagnostic information.

Important: With the wiring used in Saturn vehicles, it is recommended that the approved Packard Electric Crimp and Seal Splice Sleeves, or equivalent, be used.

7. Remove the insulation from both ends of the cut wire, recommended wire strip length is 9.5 mm (3/8 in). Caution must be used to prevent cutting the wire strands. Locate the new splice a minimum of 40 mm (1.5 in) from other splices. If necessary add a 51 mm (2 in) length of stranded copper wire, the same size, and same gage as the existing wire.
8. Using the Saturn approved crimp and seal sleeve found in special tools kit SA9138Z, position the stripped ends of the wires in the sleeve until the wires hit stop.

Important: When using the salmon splice sleeve with 0.35 (22 gage) wire. remove 19 mm (3/4 in) of insulation. Bend the stripped portion in half to double the thickness of the wire going into the splice sleeve. twist the stripped, doubled wire and insert it into the splice sleeve.

9. INSERT TABLE SHOWING WIRE SIZE AND GAGES



10. Hand crimp the sleeve using the appropriate crimping tool. Gently tug on the wires to ensure they are secure before applying heat to them.

Caution: Do not use a match or open flame to apply heat to the splice sleeve.




11. Apply heat using Ultratorch® or some other device, heating to 175°C (347°F) until the glue flows around the edges of the sleeve.
12. Inspect for continuity in the wire.
13. Install 101 mm (4 in) of conduit P/N  1023495 to the I/P harness. Make sure to position the conduit over the clutch pedal pivot clip.
14. Tape the conduit and fasten the wire harness clip to the harness and spaceframe.
15. Using Saturn P/N 08905262, wiring harness clip, install the clip on the harness and insert the rose bud into the hole that the previous strap was removed from.
16. Enable the SIR system. Refer to enabling the SIR System procedure in the SIR Service Manual.
17. Clear any DTCs that may have been set.