Various Driveability Concerns Including: Engine Cranks But Will Not Start, or MIL Service Engine Soon Telltale On with One or More ECM DTCs Stored

Customers may comment of engine cranking and not starting. Various engine control module (ECM) diagnostic trouble codes (DTCs) may be set with or without driveability concerns.

This condition may be caused by the ECM wiring harness becoming chafed at any of following points:

(Refer to illustration on page 2 of this bulletin.)

Repair damaged wires and wrap wiring harness conduit closed with electrical tape.

1. INSPECT ECM ENGINE WIRING CONDUIT AT LOCATIONS (1), (2), and (3) shown in illustration above.

•	If damage or protrusion of wiring conduit is evident, continue to step 2.

•	If damage or protrusion of wiring is not evident, refer to appropriate DTC information or other diagnostic charts in the Engine/Emissions Controls section of the 2000 L-Series (L81) Service Manual.

2. Disconnect negative battery cable.
3. Disconnect BLK 64-way connector J1 from ECM.
4. Remove tape from conduit and suspected area of wiring harness chafe.
5. Cut damaged wire at location of chafe.
6. Remove insulation from both ends of cut wire, recommended wire strip length is 9.5 mm (3/8 in). Caution must be used when stripping wire to prevent cutting wire strands. Locate new splice a minimum of 40 mm (1.5 in.) from other splices.




Important: With wiring used in Saturn vehicles, it is recommended that approved Packard Crimp and Seal Splice Sleeves (or equivalent) be used.

7. Using a Saturn approved crimp and seal sleeve (found in special tools kit SA9138Z) position stripped ends of wires in sleeve until wires hit stop.
8. Hand crimp sleeve using appropriate crimping tool. Gently tug on wires to ensure they are secure before applying heat to seal sleeve.




Caution: DO NOT USE A MATCH OR OPEN FLAME TO APPLY HEAT TO SPLICE SLEEVE.

9. Apply heat using Ultratorch or equivalent device, heating to 175° C (347° F) until glue flows around edges of sleeve.
10. Check repaired wire continuity and verify proper repair.
11. Tape wiring harness with electrical tape prior to installing it into conduit to prevent the possibility of future chafing.
12. Install wiring harness into conduit and wrap conduit seam to original condition with electrical tape.
13. Connect BLK 64-way connector J1 at ECM.
14. Connect negative battery cable.

Tighten
Tighten nut to 17 N m(13 lb ft)

15. If any chafed wire repaired was injector related, change engine oil filter because engine oil may be diluted with fuel.

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