GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 Engine 🢒 Engine Electrical 🢒 Accessory Wiring Junction Block Replacement

Removal Procedure
  1. Open the rear compartment.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  3. Open the hood.

    4. Object Number: 894911 Size: SH
  4. Remove the fuse block cover (1).

    5. Object Number: 893222 Size: SH
  5. Disconnect the remote battery terminal and cables (1).

    6. Object Number: 893223 Size: SH
  6. Disconnect the EPS cable (1).

    7. Object Number: 891604 Size: SH

    Important: Do not lift up on the locking tabs. Use one hand to release the locking tab while lifting up on the junction block with the other hand. Use a flat-bladed tool to access the outboard tab.

  7. Release the 3 locking tabs on the edges of the junction block.
  8. Loosen the connector bolts in order to back out the connectors from the junction block.
  9. Remove the engine wiring harness connector (1), the body wiring harness connector (2), and the forward lamp harness connector (3) from the base of the junction block and the junction block base.
  10. Remove the junction block base bolt.
  11. Remove the junction block base.

Installation Procedure

    Object Number: 891604 Size: SH
  1. Position the junction block base into the engine compartment.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the junction block base bolt.

    3. Tighten
    Tighten the bolt to 10 N·m (89 lb in).

  3. Route the engine wiring harness (1), body wiring harness (2), and forward lamp harness (3) into the junction block base.

    4. Tighten
    Tighten the connector bolts to 4 N·m (35 lb in).

  4. Install the junction block into the base.

    5. Object Number: 893223 Size: SH
  5. Install the EPS cable and nut (1).

    6. Tighten
    Tighten the nut to 10 N·m (89 lb in).


    Object Number: 893222 Size: SH
  6. Install the battery cables and the remote terminal (1).

    7. Tighten
    Tighten the terminal to 15 N·m (11 lb ft).


    Object Number: 894911 Size: SH
  7. Install the junction block cover (1).
  8. Close the hood.
  9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  10. Close the rear compartment.