| Subject: | Inoperative or Intermittent Operation of Any of the Following Circuits: * |
| Models: | 1995-1999 Saturn S-Series vehicle built up to and including VIN XZ336032.
Vehicles built after VIN XZ336032 have a larger rosebud clip to help protect
affected wiring harness from making contact with cockpit bracket. |
*
| • | RKE Decklid/Liftgate Function |
| • | Fuel Gauge Pegged on Full or Empty |
| • | Vehicle Starts in Theft Deterrent Mode |
| • | Vehicle Cranks but Will Not Start (Repair Wire Harness) |
| • | Decklid/Liftgate Telltale On |
Condition
The customer may comment that on occasion, one or more of the following conditions
may have occurred:
| • | Rear washer pump inoperative (Wagon only) |
| • | Rear wiper motor inoperative (Wagon only) |
| • | Speaker volume cuts out intermittently |
| • | Horn intermittently On without horn switch input |
| • | Decklid/Liftgate release operates with vehicle speed (RPO AU0 only) |
| • | Liftgate Ajar telltale On (Wagon only) |
| • | Fuel gauge pegged on FULL (1995 & 1996) |
| • | Fuel gauge pegged on EMPTY (1997) |
| • | Vehicle will start even in Theft Deterrent Mode |
| • | Vehicle cranks but will not start (DTC P1635 will set) (1998 &
1999) |
| • | Horn Chirps intermittently/FOB disabled for 30 seconds |
Cause
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 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 connector, the harness may come into contact with
the left side I/P bracket chafing the wiring harness causing a short to ground on
one or more of the following circuits:
1998-1999 Vehicles
| • | Rear washer pump inoperative (15A SUNROOF fuse open) -- Circuit 392
(Dk Grn) -- Rear washer pump switch (SW only) |
| • | Rear wiper motor inoperative (15A SUNROOF fuse open) -- Circuit 393
(Wht) -- Rear wiper switch (SW only) |
| • | Speaker volume cuts out intermittently |
| • | Circuit 200 (Lt Grn) RF speaker, Circuit 117 (Dk Grn) RF
speaker |
| • | Circuit 201 (Tan) LF speaker, Circuit 118 (Gra) LF speaker |
| • | Circuit 199 (Brn) LR speaker, Circuit 116 (Yel) LR speaker |
| • | Circuit 46 (Dk Blu) RR speaker, Circuit 115 (Lt Blu) RR
speaker |
| • | Horn intermittently comes On without horn switch input -- Circuit 28
(Blk) RKE horn function Horn will come on without horn switch input |
| • | Decklid/Liftgate release operative with vehicle speed -- Circuit 1344
(Lt Blu) |
| • | Liftgate Ajar telltale On -- Circuit 146 (Drk Grn) (Wagon
only) |
| • | Vehicle will start in Theft Deterrent Mode -- Circuit 625
(Yel/Blk) Crank Enable (Not used on Right Hand Drive Domestic) |
| • | Vehicle will crank but will not start -- Circuit 416 (Gra)
5V reference fuel pressure sensor |
| • | Horn Chirps intermittently/FOB disabled for 30 seconds --
Circuit 1455 (Blk/Wht) RKE Program Function |
1995-1997 Vehicles
| • | Rear washer pump inoperative (15A SUNROOF fuse open) -- Circuit 392
(Dk Grn) -- Rear washer pump switch (Wagon only) |
| • | Rear wiper motor inoperative (15A SUNROOF fuse open) -- Circuit 393
(Wht) -- Rear wiper switch (Wagon only) |
| • | Speaker volume cuts out intermittently |
| • | Circuit 200 (Lt Grn) RF speaker, Circuit 117 (Dk Grn) RF
speaker |
| • | Circuit 201 (Tan) LF speaker, Circuit 118 (Gra) LF speaker |
| • | Circuit 199 (Brn) LR speaker, Circuit 116 (Yel) LR speaker |
| • | Circuit 46 (Dk Blu) RR speaker, Circuit 115 (Lt Blu) RR
speaker |
| • | Horn intermittently comes On without horn switch input -- Circuit 28
(Blk) RKE horn function Horn will come on without horn switch input |
| • | Decklid release operative with vehicle speed -- Circuit 1344
(Lt Blu) |
| • | Liftgate Ajar telltale On -- Circuit 146 (Drk Grn) (Wagon
only) |
| • | Fuel Gauge pegged on FULL -- Circuit 30 (Ppl) (1995 &
1996) |
| • | Fuel Gauge pegged on EMPTY -- Circuit 30 (Ppl) (1997) |
| • | Horn Chirps intermittently/FOB disabled for 30 seconds --
Circuit 1455 (Blk/Wht) RKE Program Function |
Correction
After all appropriate diagnostic steps have been followed and the issue has
not been resolved, proceed with repair procedure in this bulletin.
Procedure
- Remove left side hinge pillar garnish molding
and inspect I/P wiring harness. Refer to Moldings -- All Models in the appropriate
model year Body/Repair service manual.
| • | If damage has occurred to any wire, continue with step 2. |
| • | If no damage is observed, go to the appropriate section of the electrical
service manual for further diagnostic assistance. |
- Cut damaged wire at location of chafe.
- Remove insulation from both ends of cut wire, recommended wire strip length
is 4.8 mm (3/16 in) for 12-20 gauge wires and 9.5 mm (3/8 in)
for 22 gauge wire so it can be folded in half. Caution must be used when stripping
wire to prevent cutting wire strands. Locate 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 Sleeve (or equivalent) be used.
- Using a Saturn approved crimp and seal sleeve (found in special tools kit SA9138Z)
position stripped ends of wires in sleeve until wires hit stop.
- Hand crimp splice sleeve using correct jaws in
Packard crimper (P/N 12085115) or appropriate crimper (P/N 12085115)
or appropriate crimping tool. Gently tug on wires to ensure they are secure before
applying heat to seal sleeve.
- Apply heat using Ultratorch® or heat gun,
heating to 175°C (347°F) until glue flows around edges of sleeve.
- Check for continuity in the wire and verify repair.
- If electrical tape was removed to perform wire harness inspection or repair,
tape wires and harness to original condition.
- Install Sealer Patch (P/N 21124362) to
sharp metal edge(s) of cockpit support under wire harness to protect against further
wire harness damage.
- Install left side hinge pillar garnish molding. Refer to Moldings --
All Models in the Vehicle Interior Systems section of the appropriate model year Body/Repair
service manual.
Parts Requirements
21124362 Sealer - Rkr Inr Pnl
WIRE SIZE
GAGE
| 0.35
22
| 0.50
20
| 0.80
18
| 1.0
16
| 2.0
14
| 3.0
12
| 5.0
10
|
Packard P/N*
| Special Tools P/N**
| | | |
12089189
| (217670)
| -- Salmon --
| | |
12089190
| (217671)
| | -- Blue --
| |
12089191
| (217672)
| | | -- Yellow --
|
* Order through Packard at 1-800-PACKARD (1-800-722-5273)
** Order through Saturn Special Tool Catalog. Included with Terminal Repair
Kit (SA9138Z).
Claim Information
To receive credit for this repair during the warranty coverage period, submit
a claim through the Saturn Dealer System as follows:
Case Type
| Description
| Labor Operation
| Labor Time
|
VW
| Repair Chafed Wire(s) at Left Footwell Area
| Z4053
| 0.5 hrs
|
Add:
| To repair each additional wire
|
| 0.1 hrs
|
