For 1990-2009 cars

# Harsh or Erratic Transaxle Shifting and/or Service Engine Soon Lamp Illuminated with One or More DTCs set in PCM, ECM or TCM History

Subject: | Various Driveability Concerns Including: Harsh or Erratic Transaxle Shifting and/or Service Engine Soon Lamp Illuminated with One or More DTCs set in PCM (L61), ECM (L81), or TCM (L81) History (Repair Damaged Wire(s) in Engine Harness)

Models: | 2000 and 2001 Saturn L-Series vehicles

### Condition

Customers may comment the Service Engine Soon Lamp is illuminated and/or the transaxle shifts are harsh or erratic.

### Cause

This condition may be caused by the engine harness wires to the PCM (L61) or TCM (L81) being pinched by the harness boot.

(Refer to illustration on page 3 of this bulletin.)

### Correction

Repair damaged wires within harness boot. Refer to service procedure outlined in this bulletin.

### SERVICE PROCEDURE

1. Remove rear hood seal.
2. Raise right side front corner of air inlet grill in order to access 4 connector boot attachment nuts.
3. Remove connector boot attachment nuts.
4. Remove boot.
5. Inspect engine wiring harness at PCM (L61) or TCM (L81) for damaged wires that may have been pinched between the boot and cowl panel.

• | If any wire(s) are damaged, proceed to step 6.

• | If no wire(s) are damaged, refer to appropriate service manual and perform additional diagnostics as needed.

6. Disconnect negative battery cable.
7. Disconnect PCM/TCM connector.
8. Cut damaged wire at location of chafe.
9. 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 905 mm (3/8 in.) for 22 gauge wires. 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: For the wiring used in Saturn vehicles, it is recommended that only approved Packard Electric Crimp and Seal Splice Sleeves (or equivalent) be used.

10. Determine proper sleeve for gage of wire. Refer to PARTS REQUIREMENTS section in this bulletin for sleeve identification.
11. Position stripped ends in sleeve until wires hit the stop in the center of the splice.
12. Hand crimp using the approved crimping tool. Gently tug on wires to make sure they are secure before applying heat to them.

Caution: DO NOT USE MATCH OR OPEN FLAME TO APPLY HEAT TO SEAL.

13. Apply heat using the Heat Gun (for equivalent heating device), to 175°C (347°F) until glue flows around edges of sleeve.
14. Check repaired wire continuity and verify proper repair.
15. Connect PCM/TCM connector.
16. Tape wiring harness with electrical tape prior to installing it into conduit to prevent the possibility of future chafing.
17. Install wire(s) into conduit and wrap conduit seem to original condition with electrical tape.
18. Reinstall connector boot.

Tighten
PCM Harness connector Boot Attachment Nuts: 2.5N·m (22 in lbs)

19. Ensure air inlet grill is positioned correctly and harness grommet is positioned in the front of dash cutout.
20. Install rear hood seal.
21. Connect negative battery cable.

Tighten
Battery Terminal Bolts: 17N·m (13 lb ft)

22. Road test vehicle to verify repair and service engine soon (SES) lamp is not illuminated.

### 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).

### 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 Code | Time
VW | Inspect for Chafed Wire at | Z4079 | 0.2 hrs
PCM/TCM Connector
ADD: | A. To Repair One Wire | 0.6 hrs
B. To repair Each Additional Wire | 0.1 hrs