Any of the Following Components or Circuits are Inoperative or Intermittently Inoperative - Rear Washer Pump, Rear Wiper, Speakers Cutting Out, Vehicle Cranks but May Not Start, MIL SES Light On

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

The cause of the above conditions may be the instrument panel (I/P) wire harness coming into contact with a left side I/P bracket at the left side footwell area. At that location, the I/P harness connects to a body-to-I/P inline connector. The I/P harness is attached to the left side I/P bracket by as rosebud clip. Between the rosebud clip and the I/P connector, the harness may come into contact with the left side I/P bracket. Chafing the wiring harness may cause a short to ground on one or more of the following circuits.

Refer to the procedure in this bulletin to diagnose and repair this condition.

1. Remove the left side hinge pillar garnish molding by gently prying at the clip locations. (Right side shown, left side similar).



2. Inspect the I/P wiring harness at the wire chafe location shown in the illustrations.

•	If damage has occurred to any wires, continue with step 3.

•	If no damage is observed, refer to the appropriate service manual for further diagnostic information.




3. Cut the damaged wire at the location of the chafe.
4. Remove the insulation from both ends of the cut wire, recommended wire strip length is 4.8 mm (3/16 in) for 12-20 gage wires and 9.5 mm (3/8 in)

for 22 gage wire so it can be folded in half. Caution must be used when stripping wire to prevent cutting the wire strands. Locate the new splice a minimum of 40 mm (1.5 in) from other splices.





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

5. Using a Saturn approved crimp and seal splice sleeve, found in the terminal repair kit J 44020, position stripped ends of the wire in the sleeve until the wire hit stop.
6. Hand crimp the splice sleeve using the correct jaws in the Packard crimper P/N 12085115 or appropriate crimping tool. Gently tug on the wires to ensure they are secure before applying heat to seal the sleeve.




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

7. Apply heat using an Ultratorch® or heat gun. Heat to 175°C (347°F) until the glue flows around the edges of the sleeve.
8. Check for continuity in the wire and verify the repair.
9. If electrical tape was removed to perform the wire harness inspection or repair, tape the wires and harness to the original condition.



10. Install one Sealer Patch P/N 21124362 to the metal edges of cockpit support under the wire harness to protect against further wire harness damage.



11. Install the left side hinge pillar garnish molding by aligning and pushing at the clip locations (right side shown left side similar).