For 1990-2009 cars

# Engine Cranks But Will Not Start, Engine Stalls and Will Not Restart and/or Engine Runs Rough with MIL Service Engine Soon Telltale Lamp On with PCM DTC P0300, and/or P1599 Present

Subject: | Engine Cranks But Will Not Start, Engine Stalls and Will Not Restart and/or Engine Runs Rough with (MIL) SERVICE ENGINE SOON Telltale Lamp On with PCM DTC P0300, and/or P0201, P0202, P0203, P0204, and/or P1599 present (Repair Chafed Wire(s) At Fuel Injector Harness)

Models: | 2001 - 2002 Saturn S-Series vehicles equipped with DOHC engines (RPO LLO)

### Condition

Engine cranks but will not start, or engine runs rough with the following DTCs that may be present P0300, and/or P0201, P0202, P0203, P0204, and/or P1599.

### Cause

This condition may be caused by wire chafes on one or more of the fuel injector harness wires rubbing on the fuel rail and/or the #1 injector harness rubbing on the power steering pump housing. For the particular condition refer below.

• | Engine cranks but will not start - The injector B+ circuit may have a chafe in the insulation causing a short to ground. In some cases the short to ground could result in the injector fuse opening. In this case DTCs P0201, P0202, P0203, P0204 and/or P1599 may be present.

• | Engine runs rough and/or Fuel Injector DTCs present - the fuel injector ground circuits may have a chafe in the insulation causing a short to ground. This short to ground may cause the fuel injector to deliver fuel to the engine when not required. In this case DTCs P0300 and/or P0201, P0202, P0203, P0204 may be present.

### Correction

Refer to "Service Procedure" in this bulletin and repair as necessary.

### Service Procedure

#### Wire chafing against power steering pump housing

1. Inspect fuel injector harness wires for chafes at either the power steering pump housing or fuel rail location as shown in the illustrations.

#### Wire chafing against fuel rail

2. Is chafing of fuel injector harness present?

• | If chafing is evident, proceed to step 3.

• | If chafing is not evident, refer to appropriate DTC information or other diagnostic charts in the Engine/Emissions Control section of the 2000/2002 S-Series Engine Service Manual.

### Wire Repair Procedure

3. Cut damaged wire(s) at location of chafe or pinch.

4. Remove insulation from both ends of cut wire. Recommended strip length is 9.5 mm (3/8 in.). 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 Crimp and Seal Splice Sleeves (or equivalent) be used.

5. Using Saturn approved crimp and seal splice sleeve (found in special tools kit J44020), position stripped ends of wires in sleeve until wires hit stop.

6. Hand crimp splice sleeve using appropriate crimping tool. Gently tug on wires after crimping to ensure they are secure.

Caution: DO NOT USE A MATCH OR OPEN FLAME TO APPLY HEAT TO SPLICE SLEEVE.

7. Apply heat using Ultratourch®(or equivalent) device, heating to 175° C (347° F) until glue flows around edges of sleeve.

8. Check repaired wire(s) continuity and verify proper repair.

9. Tape wiring harness with electrical tape to prevent the possibility of future chafing.

Important: Due to contamination with fuel, the engine oil and filter must be changed.

10. After the wire(s) have been repaired, change engine oil and filter.

11. Perform exhaust system pressure test. Refer to "Restricted Exhaust System Check" procedure in the Exhaust System section of the 2000 - 2002 S-Series Engine Service Manual.

• | If exhaust system pressure is out of specification, the catalytic converter is plugged and must be replaced. Refer to "Catalytic Converter and Intermediate Pipe Heat Shields" procedure in the Exhaust System section of the 2000 - 2002 S-Series Engine Service Manual

• | If exhaust system pressure is within specifications, no further repairs are necessary. Continue to next step.

12. Start engine and verify all DTCs are cleared and engine runs smoothly.

### Parts Information

Wire Size (In millimeters) Wire Gage | .35 - .50 - .80 22 - 20 - 18 | 1.0 - 2.0 16 - 14 | 3.0 - 5.0 12 - 10
--- | --- | --- | ---
Packard P/N * | Special Tools P/N ** | -- | -- | --
12089189 | (217670) | Salmon | -- | --
12089190 | (217671) | -- | Blue | --
12089191 | (217672) | -- | -- | Yellow

### Warranty Information

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for N6278 (Wiring and/or Connector, Fuel Injection - Repair), or if another procedure is performed, refer to the appropriate Electronic Labor Time Guide for the correct Labor Operation Code and Time.

Notice: All labor operations claimed in this bulletin must be submitted on individual (unrelated) CSO lines with the exception of Labor Op J0950 - Filter, Oil Replace which must be related to Labor Op N6278.

Important: Installation of the crimps require the use of Packard P/N's 12089189,12089190 & 12089191. Claims received in the amount of Retailer cost plus 40% parts allowance will be accepted for the material required to perform the repair. It will be necessary to sell these parts to the CSO as "Material", using net item code "M". Claims amount of $0.94 each (cost $0.67 each x 1.4 part allowance) for part numbers 12089189 & 12089190 and $1.85 each (cost $1.32 each x 1.4 part allowance) for part number 12089191.