RKE or Security System Inoperative and/or Engine Will Not Crank, Power Door Locks Inoperative or Intermittently Inoperative, Power Windows Inoperative, Power Mirror Inoperative, Door Speaker Volume

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

The cause of the above conditions may be the main body to front door wire harness coming into contact with the front door hinge reinforcement bracket. Refer to the illustration on the following page.

The harness is routed into the front doors through a grommet as it enters the outer door structure. It is then routed across the front door hinge reinforcement, about 51 mm (2 in), from the end of the grommet, before it is anchored by a rosebud.Depending on variation in either the manufacturing or routing of the wire harness, there is a chance that the wire harness can come into contact with the hinge reinforcement bracket and chafe, causing a short to ground on one or more of the circuits listed on the following page.

Important: On 1996 model year vehicles, circuit 294 from RKE and security system module may be affected, but will not cause an engine no crank condition.

After all appropriate diagnostic steps have been followed and the condition is not resolved, proceed with the procedure in this bulletin.

1. Remove the front door outer panel on the side of the vehicle that is affected. Refer to Front Door Outer Panel -- Sedan/Wagon removal procedure in the Doors section of the appropriate model year Body/Repair service manual.



2. Inspect the door wiring harness for signs of damage. If water deflector is obstructing the wiring harness inspection, carefully peel it out of the way.

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

•	If no damage has occurred refer to the appropriate model year Electrical 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 9.5 mm (3/8 in 0. 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: With wiring used in Saturn vehicles, it is recommended that approved Packard Electric Crimp and Seal Splice Sleeves, or equivalent, be used

5. Using a Saturn approved crimp and seal sleeve, found in special tools kit SA9138Z position stripped ends of wires in the sleeve until the wires hit stop.



6. Hand crimp the sleeve using the 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 the Ultratorch® or some other device, heating to 175°C (347°F) until the glue flows around the edges of the sleeve.
8. Check for continuity in the wire and verify repair.
9. If electrical tape was removed to perform the wire harness inspection or repair, re-tape the wires and harness to the original condition.
10. Install one Sealer Patch P/N 21124362 to the sharp metal edges of the hinge support under the wire harness to protect against further wire harness damage.
11. Install the front door outer panel. Refer to Front Door Outer Panel -- Sedan/Wagon installation procedure in the Doors section of the appropriate model year Body/Repair service manual.