Any Of The Following Components Or Circuits Are Inoperative Or Intermittently Inoperative - Rear Washer Pump, Rear Wiper, Speakers Cutting Out, Vehicle Cranks But May Not Start, Mil SES Light On (00-T-43A)

ANY OF THE FOLLOWING COMPONENTS OR CIRCUITS ARE INOPERATIVE OR INTERMITTENTLY INOPERATIVE - REAR WASHER PUMP, REAR WIPER, SPEAKERS CUTTING OUT, VEHICLE CRANKS BUT MAY NOT START, MIL SES LIGHT ON

TECHNICAL SERVICE BULLETIN

SUBJECT

Any of the Following Components or Circuits are Inoperative or Intermittently Inoperative: Rear Washer Pump, Rear Wiper, Speakers Cutting Out, Vehicle Cranks but May not Start, MIL SES Light On with DTCs P0447, P0452, P462, or P1635 - Due to a revision of the VIN breakpoint under MODELS AFFECTED, this bulletin has been revised and supersedes bulletin 00-T-43, which should be discarded.

MODELS AFFECTED

2000-2001 Saturn S-Series vehicles built up to and including VIN IZ252292.

CONDITION

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

• The rear washer pump is inoperative - wagon only.
• The rear wiper motor is inoperative - wagon only.
• The speaker volume cuts out intermittently.
• The vehicle cranks but may not start - DTC P1635 will set.
• The MIL SES light is ON with DTCs P0447, P0452, P0462 or P1635.

CAUSE

The cause of the above conditions may be the instrument panel (I/P) wire harness coming into contact with a left side I/P bracket at the left side footwell area. At that location, the I/P harness connects to a body-to-I/P inline connector. The I/P harness is attached to the left side I/P bracket by as rosebud clip. Between the rosebud clip and the I/P connector, the harness may come into contact with the left side I/P bracket. Chafing the wiring harness may cause a short to ground on one or more of the following circuits.

• The rear washer pump is inoperative (15A SUNROOF fuse open) -Circuit 392 (Dk Grn)- Rear washer pump switch (SW only).
• The rear wiper motor is inoperative (15A SUNROOF fuse open)-Circuit 393 (Wht)- Rear washer pump switch (SW only).
• The speaker volume cuts out intermittently.
  • Circuit 200 (Lt Grn) RF speaker, Circuit 117 (Dk Grn) RF speaker.
  • Circuit 201 (Tan) LF speaker, Circuit 118 (GRA) LF speaker.
  • Circuit 199 (BRN) LR speaker, Circuit 116 (Yel) Lr speaker.
  • Circuit 46 (Dk Blu) RR speaker, Circuit 115 (Lt Blu) RR speaker.
• DTC P0447 EVAP Vent Solenoid Control Circuit Low Voltage (CKT 1310).
• DTC P0452 Fuel Tank Pressure Sensor Circuit Low Voltage (CKT 890).
• DTC P0462 Fuel Tank Level Sensor Circuit Low Voltage (CKT 30).
• DTC P1635 5-Volt Reference Circuit (CKT 416). Also, vehicle will crank but may not start.

CORRECTION

Refer to the procedure in this bulletin to diagnose and repair this condition.

PROCEDURE

1. Remove the left side hinge pillar garnish molding by gently prying at the clip locations. (Right side shown, left side similar). See Fig 1 .
   Fig 1: Hinge Pillar Garnish

   
2. Inspect the I/P wiring harness at the wire chafe location shown in the illustrations.
   • If damage has occurred to any wires, continue with step 3.
   • If no damage is observed, refer to the appropriate service manual for further diagnostic information.
3. Cut the damaged wire at the location of the chafe. See Fig 2 .
   Fig 2: Location of I/P Harness

   
4. Remove the insulation from both ends of the cut wire, recommended wire strip length is 4.8 mm (3/16 in) for 12-20 gage wires and 9.5 mm (3/8 in) for 22 gage wire so it can be folded in half. 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. See Fig 3 .
   Fig 3: Wire Chafe Location

   
   IMPORTANT: For the wiring used in Saturn vehicles, it is recommended that only approved Packard Electric Crimp and Seal Splice Sleeves, or equivalent, be used.
5. Using a Saturn approved crimp and seal splice sleeve, found in the terminal repair kit J 44020, position stripped ends of the wire in the sleeve until the wire hit stop.
   Fig 4: Stripping Wire

   
6. Hand crimp the splice sleeve using the correct jaws in the Packard crimper P/N 12085115 or 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 an Ultratorch(R) or heat gun. Heat to 175°C (347°F) until the glue flows around the edges of the sleeve. See Fig 5 .
   Fig 5: Crimp and Seal Splice Sleeve

   
8. Check for continuity in the wire and verify the repair.
9. If electrical tape was removed to perform the wire harness inspection or repair, tape the wires and harness to the original condition.
10. Install one Sealer Patch (Fig 6 )P/N 21124362 to the metal edges of cockpit support under the wire harness to protect against further wire harness damage.
    Fig 6: Mastic Patch Location

    
11. Install the left side hinge pillar garnish molding by aligning and pushing at the clip locations (right side shown left side similar). See Fig 1 .

PARTS REQUIREMENTS

Part Number	Description
21124362	Sealer - Rkr Inr Pnl

---	Salmon	Blue	Yellow
Wire Size in Millimeters	0.35, 0.50, 0.80	1.0, 2.0	3.0, 5.0
Wire Gage	22, 20, 18	16, 14	12, 10
Packard P/P*	12089189	12089190	12089191
Special Tool P/N**	217670	217671	217672
* Order through Packard at 1-800-PACKARD (1-800-722-5273)
** Order through Saturn Special Tools Catalog. Included with Terminal Repair Kit J 44020.

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 Chafed Wires At Left Footwell Area	Z4053	0.5 hrs
--	Add: To repair each additional wire	--	0.1 hrs