Service Information on 2nd Design Battery Positive Cable Assembly and A/C Compressor Suction Hose Assembly. Saturn Saturn 1995

For 1990-2009 cars

# Service Information on 2nd Design Battery Positive Cable Assembly and A/C Compressor Suction Hose Assembly

Subject: | Service Information on Second Design Battery Positive Cable Assembly and A/C Compressor Suction Hose Assembly

Models: | 1995 Saturns built after and including VIN SZ209189

### Purpose:

This bulletin provides information on a design change to the battery positive cable assembly and A/C compressor suction hose assembly including VIN breakpoints, part numbers and service procedures for the battery positive cable assembly routing.

The battery positive cable assembly and A/C compressor suction hose assembly have been changed as of VIN SZ248610. In addition some vehicles between VINs SZ209189 and SZ210432 and between SZ245214 and SZ248610 also were built with the second design battery positive cable assembly and A/C compressor suction hose assembly.

The second design battery positive cable assembly is shorter, uses no clip attachments, and has a revised routing. The second design A/C compressor suction hose assembly has additional conduit to prevent it from being rubbed by the second design battery positive cable assembly. The routing of the second design A/C compressor suction hose assembly is the same as for the first design A/C compressor suction hose assembly.

When servicing 1995 Saturns, it is important to note the VIN to determine the proper part numbers and cable routing.

The second design A/C compressor suction hose assembly supersedes the first design A/C compressor suction hose assembly and can be used on all 1995 Saturns with air conditioning.

Regardless of what design the vehicle was built with, service all vehicles built before and including VIN SZ248609 with the first design battery positive cable assembly. All mounting location points will still be located on the vehicle, and first design service parts will continue to be available from Saturn Service Parts.

Vehicles built after and including VIN SZ248610 should be serviced with second design battery positive cable assembly.

### Procedures: Battery Positive Cable Assembly -- Removal Procedure

1. Disconnect the negative terminal from the battery.
2. Disconnect the positive terminal from the battery.
3. Raise the vehicle and remove the starter motor splash shield, if equipped, later design starter motors do not require a separate starter shield.
4. Remove the 13 mm nut at the starter motor solenoid and remove the battery positive cable assembly from the stud.
5. Remove the battery positive cable assembly from the retainer at the cylinder block, required only for first design. Remove the electrical tape securing the battery positive cable assembly to the engine wiring harness.
6. Lower the vehicle on the hoist.
7. Remove the battery positive cable assembly from the retainer at the brake booster. Required only for first design.
8. Remove the cover from the underhood junction block and remove the bolt attaching the battery positive cable assembly to the underhood junction block.
9. Remove the battery positive cable assembly from the vehicle. Note the routing of the battery positive able assembly for installation of the new battery positive cable assembly.

### Installation Procedure:

Notice: Make sure the battery positive cable assembly is correctly routed and there are no points of contact between the cable and any other engine compartment components. Failure to correctly route the cable could cause it to rub through and short.

Important: The second design battery positive cable assembly requires a second design A/C compressor suction hose with increased conduit length to prevent the hose being rubbed through by the battery positive cable assembly.

1. Position the battery positive cable assembly into the vehicle.
2. Connect the battery positive cable assembly to the battery -- the negative battery cable should still be disconnected.

Tighten
Tighten the cable assembly to 17 N·m (151 lb in).

3. Route the battery positive cable assembly according to the appropriate illustration for either the first design or second design cables being installed.
4. Connect the battery positive cable assembly to the underhood junction block and install the bolt.

Tighten
Tighten the bolt to 5 N·m (44 lb in).

5. Install the underhood junction block cover.
6. Position the battery positive cable assembly into the retainer at the brake booster. Required only for first design.
7. Raise the vehicle on the hoist.
8. Position the battery cable assembly into the retainer at the cylinder block, required only for first design. Secure the battery positive cable assembly to the engine wiring harness with electrical tape.
9. Connect the battery positive cable assembly to the starter motor solenoid and tighten.

Tighten
Tighten the battery positive cable assembly to 10 N·m (89 lb in).

10. On 1991-1993 vehicles, use feeler gages stacked to 2 mm (0.080 in) to verify the distance between the rubber insulator on the battery positive cable assembly and the metal housing on the starter motor solenoid is greater than 2 mm (0.080 in) and less than 6 mm (0.240 in).

Tighten
Tighten to 10 N·m (89 lb in).

11. Install the starter motor splash shield and retainer, if equipped, later design starter motors do not require a separate shield.
12. Lower the vehicle on the hoist.
13. Connect the battery negative cable.

Tighten
Tighten to 17 N·m (151 lb in).

### Parts Requirements:

Part Number | Description
--- | ---
1995 built before and including VIN SZ248609 -- service with the first design cable and new hose:
21022775 | Cable Assembly -- Battery Positive
21031069 | Hose Assembly -- A/C Compressor Suction
1995 Interim forward built after and including VIN SZ248610 -- service with second design parts
21023226 | Cable Assembly -- Battery Positive
21031069 | Hose Assembly -- A/C Compressor Suction