For 1990-2009 cars

# Crank No Start with DTCs U1000, U1064 set in BCM History and/or P1599, and P1632 set in PCM History, Including Inoperative Decklid Release

Subject: | Crank No Start with DTCs U1000, U1064 set in BCM History and/or P1599, and P1632 set in PCM History, Including Inoperative Decklid Release (Repair Wire Chafe or Pinch at Lower Left Rear Carpet Retainer Trim Panel)

Models: | 2001 Saturn L-Series Sedans

### Condition

Some customers may comment the engine cranks but will not start and/or decklid release is inoperative.

### Cause

This condition may be caused by a wire chafe or pinch condition to the rear main body harness, due to a retaining clip located under the left rear carpet retainer. The decklid release and/or other circuits could be affected.

### Correction

Remove left rear carpet retainer retaining clip from retainer, repair wiring harness and re-route.

### Procedure

1. Move driver's seat to forward most position.
2. Starting at front of vehicle, remove carpet retainer by gently pulling on retainer at attaching clip locations.

(Right Side Shown, Left Side Similar)

3. Remove the rear-most retainer clip on the carpet retainer and discard. The retainer clip will not be used during installation.
4. Cut damaged wire(s) at location of chafe or pinch.
5. 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.

6. 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.
7. 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.

8. Apply heat using Ultratorch® (or equivalent) device, heating to 175° C (347° F) until glue flows around edges of sleeve.
9. Check repaired wire(s) continuity and verify proper repair.
10. Tape wiring harness with electrical tape to prevent the possibility of future chafing.
11. Re-route harness away from retainer clip to ensure chaffing or pinching will not occur.
12. Position carpet retainer into vehicle.

(Right Side Shown, Left Side Similar)

13. Starting at rear of vehicle, slide carpet retainer under rear seat cushion.
14. Position carpet retainer over remaining attaching clip locations.
15. Gently push on attaching clips to install carpet retainer.
16. Install weatherstrip over carpet retainer using a flat blade tool.
17. Verify vehicle starts and decklid release operates as designed.

• | If vehicle does not start check for an open BCM/CLUSTER fuse located in the Underhood Fuse Block (UHFB). If fuse is Ok, refer to "Diagnostics" in the Engine /Emission Controls section of the 2001 L-Series (L61) or (L81) Engine Service Manual.

• | If decklid release is inoperative, refer to "Diagnostics" in the Locks and Security section of the 2001 Body/Electrical Volume II Service Manual.

• | If vehicle starts and decklid release operates as designed, vehicle is repaired and no further repairs are necessary.

### 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 -

* Order through Packard at 1-800-PACKARD (1-800-722-5273)

** Order through Saturn Special Tool Catalog. Included with Terminal Repair Kit (J44020)

### Warranty Information

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:

CaseType | Description | Labor Operation Code | Time
--- | --- | --- | ---
VW | Repair Wire and Modify Trim Panel | Z4171 | 0.4 hrs.
ADD: | To Repair Each Additional Wire | -- | 0.2 hrs.