MALFUNCTION INDICATOR LAMP. Saturn Saturn 1992

For 1990-2009 cars

# MALFUNCTION INDICATOR LAMP

#### SUBJECT: Malfunction Indicator Lamp (SERVICE ENGINE SOON Telltale Lamp) Illuminated with PCM/TC Diagnostic Trouble Codes 45, 46 and/or 49, and/or Harsh Transaxle Engagement or 2nd Gear Start MP6/MP7 Automatic Transaxles (Repair Wiring and Install Conduit)

#### MODELS AFFECTED: 1991-1995 Saturns equipped with MP6 or MP7 automatic transaxles built up to and including VIN SZ173488

CONDITION: The malfunction indicator lamp (MIL) (SERVICE ENGINE SOON telltale lamp) is illuminated and PCM/TC diagnostic trouble codes (DTCs) 45, 46 and/or 49 are set, and/or transaxle exhibits harsh engagement into any gear or starts out in 2nd gear.

CAUSE: The park neutral position switch assembly wiring harness may be contacting the automatic transaxle valvebody cover flange, causing wiring harness insulation to chafe. The chafed wires could ground against the automatic transaxle valvebody cover or short to each other and set PCM/TC DTCs 46 and/or 49. Also, the wires could be cut causing an open circuit, setting DTC 45.

CORRECTION: Inspect the park neutral position switch assembly wiring harness, and if necessary, repair according to the procedures in this bulletin.

#### PROCEDURE

1. Remove front air intake duct assembly and air hose.

2. Disconnect park neutral position switch assembly connector and inspect all wires of the park neutral position switch assembly wiring harness for chafed insulation.

o If any wires in the park neutral position switch assembly wiring harness are found to be chafed or open, proceed to step 3.

o If there is no indication of chafing of any wires in the park neutral position switch assembly wiring harness, install a 64 mm (2.5 in.) length of flexible conduit (P/N 21023494) over wiring harness to prevent possible chafing of the wiring harness wires. Place flexible conduit so that there is an approximate 6.35 mm (1/4 in.) gap between the end of the flexible conduit and the park neutral position switch assembly wiring connector.

o Tape flexible conduit with electrical tape at both ends to secure flexible conduit in place. Connect park neutral position switch assembly electrical connector.

o Once flexible conduit is installed, refer to the appropriate diagnostic trouble code in the "Automatic Transaxle Service Manual" to diagnose the diagnostic trouble codes.

3. If any wire is chafed or open, cut at the point of chafing or at point of break in wire.

4. Remove 9.5 mm (3/8 in.) of insulation from both ends of the cut wire(s).

5. Visually inspect wire strands for corrosion. If corrosion is present, cut wire back further and re-strip as necessary until clean, non-corroded wire strands are obtained. Care must be used to prevent cutting of wire strands.

#### NOTICE: If wire length is not long enough to prevent straining the wiring harness, install a 0.5 sq. mm (20 gage) length of wire with additional salmon colored crimp and seal sleeve to lengthen wire, as necessary.

6. Position stripped ends of wire from wiring harness into salmon colored crimp and seal sleeve (P/N 12029189).

#### IMPORTANT: If repairing more than one wire, make sure crimp and seal sleeves are staggered in the wiring harness.

7. Hand crimp using the approved crimping tool. Gently tug on wires to make sure they are secure before applying heat.

8. Apply heat using butane torch (included with special tool SA9138Z), heating to 175 degrees Celsius ( 347 degrees Fahrenheit), working from the center to the ends, until glue flows around both edges of crimp and seal sleeve.

#### CAUTION:

DO NOT USE MATCH OR OPEN FLAME TO APPLY HEAT TO SEAL.

9. Install a 64 mm (2.5 in.) length of flexible conduit (P/N 21023494) over harness. Place flexible conduit so that there is an approximate 6.35 mm (1/4 in.) gap between the end of the flexible conduit and the park neutral position switch assembly wiring connector.

10. Tape flexible conduit with electrical tape at both ends to secure flexible conduit in place.

11. Connect park neutral position switch assembly electrical connector.

12. Install front air intake duct assembly and air hose.

13. Verify condition has been repaired.

PARTS REQUIREMENTS: 21023494 Flexible Conduit

12029189 Crimp and Seal Sleeve Splice (Salmon) Available from OTC Division of SPX Corporation at 1 (800) 533-5338, or from Packard Electric at 1 800-PACKARD (with a minimum total order of $25.00 for any combination of parts.)

CLAIM INFORMATION: To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:

Labor Case Operation Type Description Code ------------------------------------------------ VW Repair Park Neutral Position N6045 Switch Wiring and Install Flexible Conduit

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.