For 1990-2009 cars

# RKE or Security System Inoperative and/or Engine Will Not Crank, Power Door Locks Inoperative or Intermittently Inoperative, Power Windows Inoperative, Power Mirror Inoperative, Door Speaker Volume

Subject: | Remote Keyless Entry (RKE) or Security System Inoperative and/or Engine Will Not Crank, Power Door Locks Inoperative or Intermittently Inoperative, Power Windows Inoperative, Power Mirror Inoperative, Door Speaker Volume Cutting Out, 10A BODY Fuse Open or 10A CHIME Fuse Open -- Repair Body Wiring Harness.

Models: | 1996-1999 Saturn S-Series Sedans and Wagons

### Condition:

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

• | Remote keyless entry (RKE) or security system inoperative, and/or the engine will not crank. Must be equipped with RPO code AU0.

• | Power door locks inoperative or intermittently inoperative. Must be equipped with RPO code AU0.

• | Power windows inoperative, Must be equipped with RPO code A31.

• | Power mirror inoperative. Must be equipped with RPO code D35.

• | Front door speaker volume cuts in and out intermittently.

### Cause:

The cause of the above conditions may be the main body to front door wire harness coming into contact with the front door hinge reinforcement bracket. Refer to the illustration on the following page.

The harness is routed into the front doors through a grommet as it enters the outer door structure. It is then routed across the front door hinge reinforcement, about 51 mm (2 in), from the end of the grommet, before it is anchored by a rosebud.Depending on variation in either the manufacturing or routing of the wire harness, there is a chance that the wire harness can come into contact with the hinge reinforcement bracket and chafe, causing a short to ground on one or more of the circuits listed on the following page.

Important: On 1996 model year vehicles, circuit 294 from RKE and security system module may be affected, but will not cause an engine no crank condition.

• | Circuit 294/TAN Drivers door unlock output from RKE and security system module. Engine will not crank and RKE and security system inoperative. A short to ground on this circuit may cause internal damage to the RKE and security system module. On 1997 vehicles, up to and including VIN VZ264043, the 10A BODY fuse may be open. ON 1997 vehicles, after VIN VZ264043., 1998, and 1999 model year vehicles, the 10 A CHIME fuse may be open.

• | Circuit 294/TAN Right front door lock motor, and Circuit 295/GRA Right and left front door lock motors -- Power door locks may be inoperative due to an open on the 20 A LOCKS fuse.

• | Circuit 340/ORN, 194/WHT, 195/LT BLU -- Power door lock switch circuit -- Power door locks may be inoperable due to an open on the 10 A BODY fuse.

• | Circuit 164/DK BLU, 165/BRN Left front power window motor or Circuit 166/LT BLU, 167/TAN Right front power window motor -- Power windows may be inoperative due to an open on the 30 A CONVCE fuse.

• | Circuit 81/WHT. 82/LT BLU, 89/GRN Passenger side power mirror. -- Power mirror may be inoperative due to an open on the 10 A BODY fuse.

• | Circuit 200/LT GRN, 1Must be equipped with RPO code AU0.17/DK GRN Right front speaker and/or Circuit 201/TAN, 118/GRA Left front speakers -- Door speaker volume cutting out.

### Correction:

After all appropriate diagnostic steps have been followed and the condition is not resolved, proceed with the procedure in this bulletin.

### Procedure:

1. Remove the front door outer panel on the side of the vehicle that is affected. Refer to Front Door Outer Panel -- Sedan/Wagon removal procedure in the Doors section of the appropriate model year Body/Repair service manual.
2. Inspect the door wiring harness for signs of damage. If water deflector is obstructing the wiring harness inspection, carefully peel it out of the way.

• | If damage has occurred to any wires continue to step 3.

• | If no damage has occurred refer to the appropriate model year Electrical service manual for further diagnostic information.

3. Cut the damaged wire at the location of the chafe.
4. Remove the insulation from both ends of the cut wire, recommended wire strip length is 9.5 mm (3/8 in 0. Caution must be used when stripping wire to prevent cutting the wire strands. Locate the 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 Sleeves, or equivalent, be used

5. Using a Saturn approved crimp and seal sleeve, found in special tools kit SA9138Z position stripped ends of wires in the sleeve until the wires hit stop.
6. Hand crimp the sleeve using the appropriate crimping tool. Gently tug on the wires to ensure they are secure before applying heat to seal the sleeve.

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

7. Apply heat using the Ultratorch® or some other device, heating to 175°C (347°F) until the glue flows around the edges of the sleeve.
8. Check for continuity in the wire and verify repair.
9. If electrical tape was removed to perform the wire harness inspection or repair, re-tape the wires and harness to the original condition.
10. Install one Sealer Patch P/N 21124362 to the sharp metal edges of the hinge support under the wire harness to protect against further wire harness damage.
11. Install the front door outer panel. Refer to Front Door Outer Panel -- Sedan/Wagon installation procedure in the Doors section of the appropriate model year Body/Repair service manual.

| Salmon | Blue | Yellow
--- | --- | --- | ---
Wire Size | 0.35, 0.50, 0.80 | 1.0, 2.0 | 3.0, 5.0
Gage | 22, 20, 18 | 16, 14 | 12, 10
Packard P/N* | 12089189 | 12089190 | 12089190
Special Tools P/N** | 217670 | 217671 | 271672
*Order through Packard at 1-800-PACKARD (1-800-722-5273) **Order through Saturn special Tool Catalog. Included with Terminal Repair Kit (SA9138Z).

### Parts Requirements:

Part Number | Description
--- | ---
21124362 | Sealer Patch

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 Chaffed Wires in Door Wiring Harness INC: Time to check continuity of repaired wires. | Z4036 | 0.8 hrs
-- | Add: | A. To repair each additional chaffed wire | -- | 0.1 hrs