For 1990-2009 cars

# Engine will Not Crank, MIL and ABS Light On, Park Lamps Inoperative, Fuel Gage Inoperative, and/or Radio Speaker Inoperative

Subject: | Engine will not Crank, MIL and ABS Light On, Park Lamps Inoperative, Fuel Gage Inoperative, and/or Radio Speaker Inoperative -- Repair Wire Harness

Models: | 1996-1998 Saturn equipped with MP2/MP3 manual transaxles

### Condition:

The customer may comment that on occasion, one or more of the following conditions may have occurred:

• | The engine will not crank.

• | The malfunction indicator lamp (MIL) (SERVICE ENGINE SOON lamp) is ON with or without inoperative fuel gage.

• | The anti-lock brake system (ABS) light is ON.

• | The park lamps are inoperative.

• | One or more of the radio speakers is inoperative.

### Cause:

Important:

• | The I/P harness contains approximately 100 circuits that are routed above the clutch pedal. It would be difficult to list all circuits contained in the harness and their respective failure modes associated with a short to ground. Based on the manufacturing process of the I/P harness, and the location of certain circuits in the harness, the circuits listed in this bulletin have the highest probability of potentially coming into contact with the clutch pedal pivot bolt/clip.

• | If the vehicle is equipped with an MP2/MP3 transaxle, and a difficult to diagnose electrical condition exists, inspect the harness above the clutch pedal pivot.

The cause of the above conditions may be the instrument panel wire harness coming in contact with the clutch pedal pivot bolt/clip causing a short to ground on the following circuits:

• | The engine will not crank -- May be caused by an open #2 Maxifuse (ignition 3) due to circuit #5 (yellow wire) shorting on the clutch pedal pivot bolt/clip or an open #5 Maxifuse (ignition 40 due to circuit #3C (pink wire) shorting on the clutch pedal pivot bolt/clip.

• | The MIL (SERVICE ENGINE SOON LIGHT) ON with diagnostic trouble codes (DTC)s P1640 or P1641 (low fuel circuit fault) -- May be caused by circuit 1885 (purple wire). circuit 35 (dk. green wire), or circuit 172 (yellow wire) shorting on the clutch pedal pivot bolt/clip.

• | The MIL (SERVICE ENGINE SOON LIGHT) ON with DTCs P1650 or P1651 (quad driver B output fault) -- May be caused by circuit 419 (brown/white wire) or circuit 456 (tan/black wire) shorting on the clutch pedal pivot bolt/clip.

• | The ABS light ON with ABS DTC P0572 (Brake Switch Stuck Open -- Voltage Low) -- May be caused by circuits 341F (brown wire) or 86A (brown wire) shorting on the clutch pedal pivot bolt/clip.

• | The park lamps inoperative -- May be caused by the 10-amp park fuse being open. Circuits 240 (orange wire) or circuit 9K (brown wire) shorting on the clutch pedal pivot bolt/clip.

• | One or more radio speakers inoperative -- This may be caused by circuits 199A (brown wire), 116A (yellow wire), 46A (dk. blue wire), and/or 115A (lt. blue wire) shorting on the clutch pedal pivot bolt/clip.

### Correction:

From the driver side footwell area, inspect the instrument panel wire harness at the location directly above the clutch pedal pivot bolt/clip. If any wire is found to be chaffed on the clutch pedal pivot bolt/clip, refer to the following repair procedures. If no wire damage is observed, refer to the appropriate Service Manual for diagnostic information.

### Procedure:

1. Disable the SIR system. Refer to Disabling the SIR System procedure in the SIR Service Manual.
2. Remove the connectors from the powertrain control module (PCM).
3. Remove the PCM from the vehicle.

Cut the existing wire harness tie strap rose bud clip off, so the harness is loose from the spaceframe. The rose bud clip is located directly above the clutch pedal.

4. Loosen the harness clamp. Located 76 mm (3 in) away from the rose bud clip.
5. Remove the I/P harness tape from the starter relay to the branch that goes down to the IPJB.
6. Separate the harness until the damaged wire is exposed. Cut the damaged wire at the location of the chafe, if the harness is not chaffed, refer to the appropriate Service Manual section for diagnostic information.

Important: With the wiring used in Saturn vehicles, it is recommended that the approved Packard Electric Crimp and Seal Splice Sleeves, or equivalent, be used.

7. Remove the insulation from both ends of the cut wire, recommended wire strip length is 9.5 mm (3/8 in). Caution must be used to prevent cutting the wire strands. Locate the new splice a minimum of 40 mm (1.5 in) from other splices. If necessary add a 51 mm (2 in) length of stranded copper wire, the same size, and same gage as the existing wire.
8. Using the Saturn approved crimp and seal sleeve found in special tools kit SA9138Z, position the stripped ends of the wires in the sleeve until the wires hit stop.

Important: When using the salmon splice sleeve with 0.35 (22 gage) wire. remove 19 mm (3/4 in) of insulation. Bend the stripped portion in half to double the thickness of the wire going into the splice sleeve. twist the stripped, doubled wire and insert it into the splice sleeve.

9. INSERT TABLE SHOWING WIRE SIZE AND GAGES
10. Hand crimp the sleeve using the appropriate crimping tool. Gently tug on the wires to ensure they are secure before applying heat to them.

Caution: Do not use a match or open flame to apply heat to the splice sleeve.

11. Apply heat using Ultratorch® or some other device, heating to 175°C (347°F) until the glue flows around the edges of the sleeve.
12. Inspect for continuity in the wire.
13. Install 101 mm (4 in) of conduit P/N 1023495 to the I/P harness. Make sure to position the conduit over the clutch pedal pivot clip.
14. Tape the conduit and fasten the wire harness clip to the harness and spaceframe.
15. Using Saturn P/N 08905262, wiring harness clip, install the clip on the harness and insert the rose bud into the hole that the previous strap was removed from.
16. Enable the SIR system. Refer to enabling the SIR System procedure in the SIR Service Manual.
17. Clear any DTCs that may have been set.

### Parts Requirements:

Part Number | Description
--- | ---
08905262 | Clip -- Wire Harness
12089189* or (21760**) | Splice Sleeve -- Salmon (Pink) -- 6 Required
21023495 | Conduit
*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 Code | Time
-- | VW | Repair Wire Harness | T7991 | 1.1 hrs
-- | ADD: | To repair each additional wire | -- | 0.30 hrs