Subject: | Engine Runs Rough, Surges at Idle, Stalls after Start and/or MIL On and PCM/EC
DTC 45 (1995 Vehicles) or DTC P0172 (1996 Vehicles) (Replace O2S Wire) This bulletin
is being revised to add a part number for the replacement wire and supercedes bulletin
96-t-32, which should be discarded. |
Models: | 1995 Saturns built between and including VINs SZ352000 and SZ403344, and 1996
Saturns built between VINs TZ100181 and TZ143882. |
Condition
Engine may run rough or surge at idle, or the engine may start then stall. In
some cases, the malfunction indicator lamp (MIL) (SERVICE ENGINE SOON telltale lamp)
may be On with PCM/EC diagnostic trouble code (DTC) 45 (1995 vehicles) or DTC P0172
(1996 vehicles) stored in the memory. DTC 45 (Rich Oxygen Sensor Signal) or DTC P0172
(learned Fuel Control Fuel System Too Rich) indicates that the oxygen sensor is sensing
a rich fuel condition.
The conditions stated above may occur when:
• | Driving through precipitation containing road salts. |
• | Driving through standing water containing road salts. |
• | Driving through precipitation after the vehicle has been subjected to
road salts. |
• | During or after a car wash. |
Cause
The oxygen sensor (Purple) wire for circuit 412 may have perforations in the
insulation causing intermittent malfunction of the oxygen sensor signal. These perforations
are only visible with magnification.
Correction
Refer to Procedures in this bulletin to diagnose this condition.
Procedures
Diagnosis
The oxygen sensor (O2S) consists of a zirconia electrolyte between two platinum
plates. When the sensor reaches approximately 318°C (600°F) it becomes an
electrical source that responds to the oxygen content in the exhaust. The PCM produces
a bias voltage of approximately 450 millivolts on the oxygen sensor circuit. When
the sensor is cold, its internal resistance is extremely high, therefore, the PCM
recognizes the bias as an open circuit. As the sensor warms up, the internal resistance
decreases. When the sensor reaches approximately 318°C (600°F), it starts
producing a voltage based on the oxygen content in the exhaust stream. This voltage
is used by the PCM to determine a rich or lean oxygen sensor signal and adjusts the
fuel mixture accordingly.
DIAGNOSTIC AIDS
- Bias voltage of less than 600 mV should be observed with oxygen sensor
disconnected. If higher voltage is observed, the source must be diagnosed.
- Turning On cooling fans may provide the voltage source for oxygen sensor
short.
- Oxygen sensor wire perforation results in short to voltage through conductive
salt water. If harness was exposed to salt water in the past, wetting the harness
will "reactivate" the salt water short.
- If the voltage on oxygen sensor wire is less than 600 mV, refer to service
manual for appropriate symptom diagnosis.
Service Procedure
- Turn ignition Off.
- Disconnect negative battery cable.
- Open air cleaner clamp at throttle body by compressing tangs on the air
cleaner clamp. The air cleaner clamp will lock in the open position when the tangs
are compressed sufficiently to engage the locking tab.
- Disconnect fresh air hose at cam cover.
- Remove air cleaner assembly top and front air intake duct assembly.
- Disconnect electrical connector at the intake air temperature (IAT) sensor.
- Remove plastic air cleaner resonator retainer at top of air cleaner resonator
and remove air cleaner resonator.
- Remove three air cleaner assembly fastener and remove air cleaner assembly.
- Disconnect front oxygen sensor connector and
check oxygen sensor connector for corrosion.
• | If corrosion is present, replace front oxygen sensor (P/N 21022987) and
proceed to next step. |
• | If corrosion is not present, proceed to next step. |
- Disconnect PCM engine harness connectors.
- Raise vehicle on a hoist.
- Remove bolts attaching wheelhouse panel to front fascia.
- Remove inner plastic fasteners attaching wheelhouse panel to fender support
bracket, motor compartment side panels and inner wheelhouse panel.
- Remove plastic fasteners at outer edge of wheelhouse panel to fender attachment
location.
- Remove wheelhouse panel.
- Remove engine harness grommet, and carefully
pull PCM connectors through engine harness pass-through.
- At the PCM 32-way connector (cavity D9 1995 vehicles and C14 on 1996 vehicles),
cut purple wire (circuit 412), leaving a 51 mm (2 in.) length of wire from end of
connector.
- On the passenger compartment side of the grommet, unwrap the gray tape
from grommet to free up the grommet flange from the wiring harness.
Important: It is not necessary to unwrap the wiring harness any further than to allow access
to the grommet flange.
- Cut a 2.75 meter (9 ft.) piece of high-quality, stranded, 0.80 mm2
(18 gage) copper wire (P/N 12116140).
- Feed enough replacement wire through engine compartment side of the grommet
to reach the PCM connector.
- Feed replacement wire through engine harness
conduit located on the inboard side of the grommet, between the grommet and the PCM
connectors.
- Using the Packard Crimp and Seal splice (salmon/pin color, OTC P/N 217670,
found in the wire repair kit), and the Saturn recommended procedures, splice the replacement
wire to the remaining length of purple wire at the PCM connector. (For recommended
splicing procedures, refer to "Electrical Trouble Shooting" section in
the 1995 or 1996 "Electrical Service Manual.")
- Re-wrap inboard side of wiring harness with
the gray tape that will ensure that the grommet has been sealed.
Important: Properly wrap the grommet to eliminate any possibility of engine compartment
fumes and/or water from entering into the passenger compartment.
Important: If the original gray tape loses its tackiness, a high-quality electrical tape
may be used in its place.
- Route the replacement wire along the original path of the oxygen sensor
wire, from the grommet up to the first harness rosebud retainer location.
- Using high - quality electrical tape,
wrap the engine wiring harness from the outboard side of the grommet to the first
engine wiring harness rosebud retainer.
Important: The outboard side of the grommet must be taped securely to prevent water from
wicking along the replacement wire into the passenger compartment.
- Using a sealer such as Kent Industries High Tech Leak Check Seam Sealer
Black (P/N 10070) or equivalent, apply a bead around the entire diameter of the harness,
where it goes into the outboard side of the grommet.
- Install grommet into pass - through, making sure it is correctly
installed.
- Cut a 1.5 meter (5 ft.) section of 9 mm wiring
harness conduit (P/N 210023494).
Notice: To prevent damage to the replacement wire, fuel, oil and heat resistant conduit
must be used. Wiring harness conduit (P/N 210023494) or equivalent fuel, oil and heat
resistant conduit must be used.
- Insert the remaining length of the replacement wire into the conduit.
- At the first engine wiring harness rosebud retainer, secure the conduit
to the engine wiring with wiring harness straps (P/N 21020792).
- Using wiring harness straps (P/N 21020792), secure the new conduit from
coming in contact with any moving parts.
- Route wiring harness conduit along exact path
of the original engine wiring harness, up through access hole in front of the underhood
junction block (UHJB).
- Route wiring harness conduit up
to the oxygen sensor connector. Secure with wiring harness straps (P/N 21020792).
- Trim wiring harness conduit.
- Cut replacement wire and using the Packard Crimp and Seal splice (salmon/pink
color, OTC P/N 217670, found in the wire repair kit), and the Saturn recommended procedures,
spice the replacement wire to the new oxygen sensor connector kit (P/N 21022282).
(For recommended splicing procedures, refer to the "Electrical Trouble
Shooting" section in the 1995 or 1996 "Electrical Service Manual.")
- Cut the old oxygen sensor connector as close to the engine wiring harness
as possible. Discard the old oxygen sensor connector.
- Connector the oxygen sensor connector and the PCM connector.
Notice: Make sure the oxygen sensor connector and/or wiring will not come in contact
with the exhaust manifold or the engine cooling fan.
- Position wheelhouse panel into location.
- Install plastic fasteners and bolts at outer edge of wheelhouse panel.
Tighten
Tighten nut to 3.5N·m (31 in lbs)
- Install inner plastic fasteners.
- Install air cleaner assembly to vehicle and install
three fasteners.
Tighten
Tighten nut to 10N·m (89 in lbs)
- Connect intake air temperature (IAT) sensor electrical connector.
- Install air cleaner resonator to vehicle. Insert the end of the air cleaner
resonator into the air cleaner assembly opening.
- Install air cleaner resonator retainer.
- Install air cleaner assembly top, and front air intake duct assembly.
Attach clips at air cleaner assembly and air cleaner clamp to front air intake duct
assembly.
- Close air cleaner clamp striking the tab on the spring clamp with an object
such as a screwdriver. The locking tab will disengage and the clamp will spring into
the closed position.
- Connect fresh air hose at cam cover.
- Connect negative battery cable.
- Turn ignition On and using Scan tool, monitor oxygen sensor voltage. Voltage
should be approximately 450 millivolts.
- For 1995 vehicles, clear diagnostic trouble codes.
Parts Requirement
21022282
| Connector Kit - Oxygen Sensor (1 required)
|
21022987
| Sensor Asm - Exhaust Oxygen (1, if required)
|
21020792
| Strap - Wiring Harness (10 required)
|
21023494
| Conduit - Wiring Harness (1.5 meters [5 ft.] required.)
|
IMPORTANT: Conduit is packaged in a 3 meter (10 ft.) length package. One package
is to be used for two vehicles.
|
12116140
| 0.80mm2 (18 gage) stranded copper wire with
|
GXL insulation (2.75 meters [9 ft.] required)
|
Crimp and Seal Splice (Salmon/Pink)
|
OTC P/N 217670 (2 required)
|
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
| Replace Oxygen Sensor Wire
| T9704
| 1.2 hrs
|