For 1990-2009 cars

# Inoperative or Intermittent Operation of Many Circuits

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.

*

• | Rear washer pump

• | Speaker(s) Cutting Out

• | 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)

• | Rear Wiper

• | RKE Horn Function

• | 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

1. 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.

2. Cut damaged wire at location of chafe.
3. 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.

4. 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.
5. 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.
6. Apply heat using Ultratorch® or heat gun, heating to 175°C (347°F) until glue flows around edges of sleeve.
7. Check for continuity in the wire and verify repair.
8. If electrical tape was removed to perform wire harness inspection or repair, tape wires and harness to original condition.
9. Install Sealer Patch (P/N 21124362) to sharp metal edge(s) of cockpit support under wire harness to protect against further wire harness damage.
10. 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