CAMPAIGN:GENERATOR WIRING HARNESS REPLACEMENT. Saturn Saturn 1992

For 1990-2009 cars

# CAMPAIGN:GENERATOR WIRING HARNESS REPLACEMENT

#### SUBJECT: GENERATOR WIRING HARNESS REPLACEMENT

YEAR and MODEL: 1991,1992, and 1993 SATURNS (ALL MODELS)

#### TO: ALL SATURN RETAILERS and AUTHORIZED SERVICE PROVIDERS

The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a product campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to adequately repair within sixty (60) days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge, or a refund of the purchase price, less a reasonable allowance for depreciation.

To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the owner letter, owners are being instructed to contact the Saturn Assistance Center if their Retailer does not remedy the condition within five (5) days of the service date. If the condition is not remedied within a reasonable time, owners are instructed how to contact the National Highway Traffic Safety Administration.

#### DEFECT INVOLVED

Saturn has determined that a defect which relates to motor vehicle safety exists in 1991, 1992 and 1993 Saturn vehicles produced prior to April 14, 1993. Should a vehicle have an electrical short circuit in the generator, the generator wiring harness may experience excessive current flow. Under certain conditions, enough heat could be generated to ignite surrounding materials. If this occurs, an underhood fire could result, with or without the engine running and without prior warning. Saturn will replace the vehicle's generator wiring harness with one that will open, as a fuse would under these conditions, to eliminate the potential for an underhood fire.

Some of the affected vehicles are in Retailer inventory and have not been delivered to customers. However, we are contacting owners of affected, delivered vehicles and asking them to make arrangements with a Saturn Retailer for service.

#### VEHICLES INVOLVED

The following Saturn vehicles will require this campaign:

All 1991 and 1992 Saturn vehicles.

All 1993 Saturn vehicles up to, and including PZ262277, except the two VIN's listed below:

PZ259583, PZ259644

Saturn vehicles produced after PZ262277 are not involved in this action. It is important to note that campaign claims will be aid on involved vehicles.

#### OWNER NOTIFICATION

Owners of vehicles involved will be notified of this campaign by Saturn. Also, because the potential consequences of this campaign are similar to those of the Battery Cable Campaign (93C04), owners previously affected by 93C04 will be sent letters to specifically address their concerns. Letters will be sent to these owners regardless of their involvement in campaign 93C05. (Refer to the owner letters included in this bulletin.)

#### FACILITY VIN LISTING

Two lists of vehicles assigned to you (Facility VIN Listing), which our records indicate were sold by or shipped to you, (or are located in close proximity to your facility) are enclosed.

The first list is a compilation of owners that were previously involved in 93C04 and are also involved in this campaign. The purpose of this list is to allow Retailers to be proactive in addressing the special concerns and needs of owners at a higher risk of dissatisfaction due to their recent involvement in two product recalls. The second list is a compilation of all non-93C04 owners involved in this campaign. These listings are furnished to Retailers to aid them in their campaign preparation and follow-up activities.

These listings contain:

0 Owner's name with address and telephone number;

0 Complete Vehicle Identification Number (VIN);

0 All other campaigns that are still outstanding for that VIN (e.g. 93C01 and 93C02) and;

0 VIN's of vehicles, which according to Saturn records are in retail stock.

The Facility VIN Listing (with owner information) is furnished to involved Retailers with the Product Campaign Bulletin. Although these vehicles are assigned to your facility, it is important to note that owners can take their vehicles to the Saturn Retail Facility of their choice to have this campaign performed.

Those Retailers not involved initially in this campaign will receive a message at the top of a blank Facility VIN Listing that states: NO VEHICLES ASSIGNED AT THIS TIME FOR CAMPAIGN 93C05.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of the law in several states. Accordingly, you are urged to limit the use of this listing to the follow up necessary to complete this campaign. Those records updated with California DMV registration information will have the following message printed adjacent to the appropriate VIN: "OWNER INFORMATION UPDATED BY CALIFORNIA DMV; PUBLICATION PROHIBITED."

#### REMOTE OWNER STRATEGY

In order to minimize customer inconvenience and ensure the highest level of customer satisfaction, owners who live in a remote location from an open Saturn Retail Facility will be contacted by Saturn to arrange to have their vehicles serviced in a manner convenient to them. Therefore, you may notice that not all vehicles which were sold by you are on your Facility VIN Listing.

#### RETAILER RESPONSIBILITY

All unsold new vehicles in Retailers' possession and subject to this campaign must be held at the retail facility and repaired per the service procedure of this campaign bulletin before owners take possession of these vehicles.

Retailers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the Retailer, and arrangements made to make the required correction according to instructions contained in this bulletin.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your retail facility for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

#### TRANSFER OF CAMPAIGN RESPONSIBILITY

Saturn vehicles that have been sold by you, which may be closer in proximity to another Saturn Retailer, may still appear on your Facility VIN Listing. If either you or the vehicle owner determines that it is more desirable for a vehicle on your Facility VIN Listing to be serviced by another Saturn Retailer, campaign responsibility may be transferred by 1) submitting a Campaign Vehicle Action Report to your field representative. A copy of the Campaign Vehicle Action Report can be found in your Service Support Activities Folder; or 2) submitting an update in owner information to the Saturn Owner of Record system, via SERVICELINE, for Field Organization review and approval. All changes to campaign responsibility will be reflected in your next monthly Unfixed VIN Report.

All other changes in vehicle status (e.g., scrapped, stolen, etc.) are to be made in accordance with section 4.4.3 of the Retailer Service Reference Guide (Notifying Saturn of Vehicle Status Change).

#### UPDATING SATURN OWNER INFORMATION

When reviewing the Unfixed VIN Report or entering claims into the SERVICELINE system, please compare your owner information to the Saturn owner information provided. If changes are required to the Saturn owner information, please make them promptly. Owner information changes by the Retailer should be made using the methods listed below:

A. Change in Current Owner Information

1. Select [CMD-3] key for "Change Customer Data" and access the Customer File Maintenance Screen. Make the appropriate changes.

2. Select [CMD-5] key to save the updated customer information and return to the Service Vehicle Master Maintenance Screen.

3. Enter vehicle mileage and select the [CMD-5] key to open a Customer Service Order (CSO).

B. New Owner Information

1. Choose vehicle by the VIN and not by the customer's name.

2. Select the [CMD - 2] key to access the Customer File and Maintenance Screen. Enter the new owner's name and address information, and enter "Y" in the "New Owner" field to prompt the update.

3. Select the [CMD - 5] key to save the updated information.

4. Enter vehicle mileage and select the [CMD -5] key to open a Customer Service Order (CSO).

#### PARTS INFORMATION

1. A pre-shipment of parts required this campaign has been automatically sent to you from Saturn Service Parts Operation (SSPO). The initial shipment will be followed up with recommended stocking policies ... so Retailers will not need to order parts.

2. Parts questions may be directed to your Saturn Parts Support Analyst.

3. Required Parts:

Quantity Required Part Number Description Per Vehicle ----------- ----------- ----------------- 21022755 Harness Assembly-Generator 1 Wiring

4. The following parts are not likely to be required. However, if lost or damaged during the repair, they must be replaced. Quantity Part Number Description Per Vehicle ----------- ----------- ----------- 21006316 Nut - Engine Wiring Harness 1 (At Generator) 11515535 Nut-Engine Wiring Harness 1 Starter Lead 14039420 Retainer-Starter Splash 1 or Shield 21030249 11515479 Bolt/Screw-Generator Splash 1 Shield

#### SUGGESTIONS FOR ENSURING CUSTOMER SATISFACTION

As you know, Saturn's success hinges upon our ability to execute superior customer support throughout the ownership experience, especially when important corrective actions such as this are required. The scope and magnitude of this field action will require extra planning to ensure effective execution. Retailers should have an "action plan" so that they can effectively complete the campaign ... and minimize customer inconvenience. Some thought starters include:

1) Develop a capacity- oriented plan to efficiently complete the campaign for vehicles assigned to your facility. Give consideration to leveraging additional available capacity outside of your Saturn facility (e.g. sublet work to non-Saturn facilities within your market area). Please remember that all customer interfaces should take place at the Saturn facility.

2) Dedicate an administrative "point person" in the Retail facility to facilitate Owner/Retailer/Saturn communication for this field action and consider the possibility of dedicated telephone lines.

3) Expand service staffing and dedicate technicians to this action.

4) Schedule appointments, so that this important service can be completed as quickly and conveniently as possible.

5) Utilize additional resources to minimize owner wait time and to reduce inconvenience (e.g., leveraged service capacity, extended service hours, weekend service, etc).

6) Coordinate with Saturn Roadside Assistance, as necessary, to pick-up and return vehicles for those owners who choose not to drive in.

7) Provide loaner or rental vehicles to owners, as required, until the repair can be performed.

Again, whatever "action plan" you choose, it is imperative that every effort is made to accommodate the owner. If you have any questions, please coordinate with the Saturn Assistance Center to help ensure customer satisfaction.

#### SERVICE PROCEDURE

GENERATOR WIRING HARNESS REPLACEMENT

#### CAUTION:

THE BATTERY NEGATIVE CABLE MUST BE DISCONNECTED FIRST TO PREVENT ARCING.

1. Disconnect the battery negative cable. (Record radio station presets.)

#### CAUTION:

MAKE SURE THE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED PRIOR TO LIFTING. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

2. Raise vehicle.

#### CAUTION:

BE CAREFUL NOT TO CONTACT HOT EXHAUST PIPE.

3. Remove starter motor splash shield retainer by pulling out center pin with pliers (first design) or inserting a small screwdriver in the flat and rotate screwdriver to remove the center pin (second design). (Refer to illustration.)

4. With center pin removed, remove outer portion of the starter motor splash shield retainer.

5. Remove starter motor splash shield, by lifting upward and pulling backward at the top of the shield to remove shield from the starter motor.

6. Remove the generator splash shield attachment bolt and unclip the generator splash shield from the generator. (Refer to illustration.)

7. Pull back protective cover (rubber boot) on the generator wiring harness at the generator B+ stud and remove generator wiring harness nut. (Refer to illustration View A)

#### NOTICE: Always spray the starter motor solenoid B+ stud and nut with penetrating oil prior to removing the nut. Use extreme care when loosening the nut to prevent cracking the solenoid's phenolic end cap. A cracked end cap will allow debris and moisture to corrode the solenoid contacts.

8. Remove nut from the B + stud on the starter motor solenoid, remove generator wiring harness (red wire) and discard harness. (Refer to illustration.)

#### Note: To effectively torque generator B+ stud nut and starter motor solenoid B+ stud nut, it may be necessary to utilize a 12 pt. socket with a click-type torque wrench with the appropriate scale.

#### NOTICE: Do not over-torque the starter motor solenoid's B+ stud nut. Over-torquing will crack the solenoid's phenolic end cap, allowing debris and moisture to corrode the electrical contacts.

9. Install new generator wiring harness assembly (orange wire) on the starter motor solenoid's B+ stud and tighten nut.

Torque: 10 N-m (89 in-lbs)

#### NOTICE: Make sure generator wiring harness terminal crimp, at generator B+ stud faces away from generator. (Refer to illustration View A.)

10. On DOHC (LLO) engines, route the generator wiring harness behind intake manifold support bracket to the generator B+ stud and position terminal between the 10 and 11 o'clock position and tighten nut. (Refer to illustration.)

11. On SOHC (LKO) engines, route the generator wiring harness to the generator B + stud and position terminal between the 10 and 11 o'clock position and tighten nut.

Torque: 10 N-m (89 in-lbs)

12. Install the protective cover (rubber boot) on the generator wiring harness assembly over the B+ terminal of the generator. The protective cover (rubber boot) must be properly installed to prevent moisture intrusion.

13. Install the generator splash shield by clipping shield to generator then install bolt and tighten. Make sure the EVO and generator wires are properly routed. (Refer to illustration.)

Torque: 10 N-m (89 in-lbs)

14. Install starter motor splash shield and retainer. Make sure the engine wiring harness is routed on the outside of the starter motor splash shield. (Refer to illustration.)

#### NOTICE: Inspect generator wiring harness (orange wire) and make sure it is not contacting starter motor or generator splash shields, or EVO and engine wiring harness conduit. (Refer to illustration.)

15. Lower vehicle.

16. Connect battery negative cable. (Reset clock and radio station presets, noted in step 1.)

Torque: 17 N-m (151 in-lbs)

17. Affix the campaign completion label as outlined on page 10 "CAMPAIGN COMPLETION LABEL."

#### CAMPAIGN COMPLETION LABEL

Upon completion of the campaign, a Campaign Completion Label should be affixed on a clean, dry surface of the radiator core support in an area clearly visible when the hood is raised. Each label provides a space to print in ink (or type) the campaign number (93C05) and the five (5) digit facility code of the Retailer performing the campaign service.

As a reminder, additional labels may be obtained from your Service Support Activities Folder (provided to each facility as part of their "start-up" package) or may be ordered from Saturn Publications (1 - 800 - 828 - 2112 prompt 3, Item # S03 00013).

#### CREDIT

1. To receive credit for replacing the generator wiring harness, submit a claim with the information below:

Failed Parts Sale Case Labor Labor Add Repair Performed Part # Allow Type Type Op Hours Hrs.* ---------------------------------------------------------------------------- Generator Wiring Harness 21022755 ** WC VC V8190 0.4 0.1 Replacement

2. To receive credit for loaner/rental car costs incurred while owner awaits campaign repair or other goodwill expenses, submit a claim with the information below: Sale Case Labor Net Item Net Item #Days Repair Performed Type Type Op Amount Code Rental ------------------------------------------------------------------------- Loaner Reimbursement WC VC T9957 *** C **** Other/Goodwill WC VC T9958 *** R ****

3. Retailers are empowered to use good judgement regarding loaner/rental cars or any other goodwill expenses deemed necessary. It will not be necessary to call the Saturn Assistance Center for authorization of goodwill. The Goodwill Worksheet (printed on the back of this bulletin) must be used to document goodwill expenses. The completed Goodwill Worksheet must be attached to the hard copy of the CSO. Retailers are to make sufficient copies of the blank Goodwill Worksheet to document goodwill expenses.

4. Check your Saturn SERVICELINE Claim Memorandum daily. Remember to code the claim as a WC sale type, and VC case type. Contact your field representative if you need assistance.

5. Refer to the Customer Service Order Preparation Manual for details on Product Campaign Claim Submission.

* Campaign administrative allowance

** The parts allowance should be the sum total of the current SSPO Retailer net price plus 30% of all parts required for the repair.

*** Net Item amounts must be submitted as a miscellaneous sale ... Loaner reimbursement not to exceed $30/day.

**** Enter number of days vehicle was rented ... Not to exceed 2 days.

Dear Saturn Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Saturn has determined that a defect which relates to motor vehicle safety exists in 1991, 1992 and 1993 Saturn vehicles produced prior to April 14, 1993. Should your vehicle have an electrical short circuit in the generator, the generator wiring harness may experience excessive current flow. Under certain conditions, enough heat could be generated to ignite surrounding materials. If this occurs, an underhood fire could result, with or without the engine running and without prior warning. To correct this condition we will replace your vehicle's generator wiring harness with one that will open, as a fuse would under these conditions, to eliminate the potential for an underhood fire.

As you know, we place the absolute highest priority on our owners safety and satisfaction and we sincerely regret any concern this situation may cause you. So, of course, we want to correct this condition as soon as possible. We will do our best to minimize any inconvenience to you and to provide you with the special care that all Saturn owners have come to expect.

What Saturn will do: We will replace your vehicle's generator wiring harness at no charge to you.

What you should do: Contact your Saturn Retailer to arrange a mutually convenient time to take your vehicle in to have this service performed. Just so you know, parts are already available and it will take about 25 minutes to replace the generator wiring harness. Some additional time may be needed for paperwork and processing.

Your Retailer is best equipped to perform this service promptly and with the least inconvenience to you. However, if your car is provided to the Retailer on the agreed service date and they do not remedy this condition on that date, or within five days, please contact the Saturn Assistance Center at 1-800-552-0008. Our advisors will assist you and the Retailer in getting your car serviced.

If after contacting your Saturn Retailer and the Assistance Center you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh St., S.W., Washington, DC 20590, or call 1-800-424-9393 (Washington, DC residents use 426-0123).

Again, we sincerely regret any inconvenience or concern this situation may cause you. We also want you to know that we will do our best, throughout your ownership experience, to ensure that your Saturn provides you many miles of safe and enjoyable driving.

Sincerely,

Saturn Corporation

Dear Saturn Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Saturn has determined that a defect which relates to motor vehicle safety exists in 1991, 1992 and 1993 Saturn vehicles produced prior to April 14, 1993. Should your vehicle have an electrical short circuit in the generator, the generator wiring harness may experience excessive current flow. Under certain conditions, enough heat could be generated to ignite surrounding materials. If this occurs, an underhood fire could result, with or without the engine running and without prior warning. To correct this condition we will replace your vehicle's generator wiring harness with one that will open, as a fuse would under these conditions, to eliminate the potential for an underhood fire.

Our records indicate that your vehicle previously required inspection and possible correction of the battery positive cable. Although you have already had that service performed, we are writing to advise you that your vehicle also requires replacement of the generator wiring harness for this second, unrelated condition. We sincerely regret the inconvenience and concern these two situations may cause you so early in your ownership experience. However, as we hope you know, we place the absolute highest priority on our owners safety and satisfaction. So, of course, we want to correct this condition as soon as possible and with minimal inconvenience to you.

What Saturn will do: We will replace your vehicle's generator wiring harness at no charge to you.

What you should do: Contact your Saturn Retailer to arrange a mutually convenient time to take your vehicle in to have this service performed. Just so you know, parts are already available and it will take about 25 minutes to replace the generator wiring harness. Some additional time may be needed for paperwork and processing.

Your Retailer is best equipped to perform this service promptly and with the least inconvenience to you. However, if your car is provided to the Retailer on the agreed service date and they do not remedy this condition on that date, or within five days, please contact the Saturn Assistance Center at 1-800-552-0008. Our advisors will assist you and the Retailer in getting your car serviced.

If, after contacting your Saturn Retailer and the Assistance Center you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh St., S.W., Washington, DC 20590, or call 1-800-424-9393 (Washington, DC residents use 426-0123).

Again, we sincerely regret any inconvenience or concern this situation may cause you. We also want you to know that we will do our best, throughout your ownership experience, to ensure that your Saturn provides you many miles of safe and enjoyable driving.

Sincerely,

Saturn Corporation

Dear Saturn Owner:

You may have heard about a Saturn 'recall' involving the generator wiring harness on 1991, 1992 and certain 1993 Saturn vehicles produced prior to April 14, 1993. We're writing to let you know what this is about ... and especially to let you know that your vehicle is not involved.

Should vehicles involved in this action have an electrical short circuit in the generator, the generator wiring harness may experience excessive current flow. Under certain conditions, enough heat might be generated to ignite surrounding materials. If this occurs, there is a potential for an underhood fire. As you know, we place the absolute highest priority on our owners' safety and satisfaction, and we sincerely regret any concern this situation may cause. Owners of these vehicles have already been notified and are having this condition corrected at no charge to them. As always, we will ensure that this condition is addressed promptly and with minimal inconvenience to affected owners.

Our records indicate that your vehicle was involved in a previous "recall" to address and correct another unrelated condition, involving the battery positive cable, that could have resulted in an underhood fire. Once again, we are writing to assure you that you are not affected by this current action. Also, we want you to know that we will always do our best to make sure you are completely satisfied with your Saturn.

Sincerely,

Saturn Corporation

93 - C - 05 GOODWILL WORKSHEET

As stated in the "Credit" section of this bulletin, Retailers are empowered to use good judgement regarding loaner/rental cars or other goodwill expenses that might become necessary for customer satisfaction.

Complete this worksheet and attach it to the hard copy of the Customer Service Order (CSO) to document all campaign goodwill claims submitted to Saturn ... you will not need to contact the Saturn Assistance Center for authorization of goodwill expenditures associated with this campaign.

VIN # ___________________________________

A. Vehicle Loaner/Rental Allowance $___________________ Explanation:

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

Repair Sale Case Labor Net Item # Days Performed Type Type OP Amount Rental ------------------------------------------------------------------------ Loaner Reimbursement WC VC T9957 C *

* Not to exceed $30 / day for 2 days

B. Other/Goodwill Allowance $____________________ Explanation (Specify what was done and why):

_________________________________________________________________________

_________________________________________________________________________

_________________________________________________________________________

Repair Sale Case Labor Net Item # Days Performed Type Type OP Amount Rental -------------------------------------------------------------------- Other/Goodwill WC VC T9958 R N/A

_____________________________ Authorized Retailer Signature

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.