Engine - Misses During All Driving Conditions

91saturn04

NO.: 91-T-42

DATE: November, 1991

GROUP: Engine

CORP. NO.: 186405


SUBJECT: Engine Misses During All Driving Conditions (Install New Spark Plug Wire Clips)

MODELS
AFFECTED: 1991 and 1992 SL2 and SC Saturn vehicles with DOHC (LLO) engines

CONDITION: Engine misses during all driving conditions.

CAUSE: The number one spark plug wire may contact the hood insulator and/or the spark plug wire harness may contact the camshaft cover, damaging the insulation on the spark plug wire(s). If this insulation becomes damaged, a short to ground can result causing an engine miss.

CORRECTIVE
ACTION: Inspect the number one spark plug wire and hood insulator for signs of contact. Also, inspect the spark plug wire harness at the camshaft cover for signs of contact. If there is indication of rubbing damage to any spark plug wire, replace the damaged wire(s) and install new spark plug holding clips according to the following procedure.

NOTE: The 4-way spark plug wire clip (P/N 12034561) is designed so that it can be cut in half and used to retain two spark plug wires instead of four.

If there is no evidence of spark plug damage, refer to the "Electronic Engine Controls Service Manual" for diagnostic procedures to correct the concern.





PROCEDURE:
1. Inspect the # 1 spark plug wire for evidence of damage or contact with the hood insulator. If there is any evidence of damage or contact, install a 4-way spark plug wire clip (P/N 12034561). Before installing the clip, cut it into two equal parts and smooth out the cut end. Horizontally install this half of the clip approximately 50 mm (2 in.) from # 2 spark plug boot (refer to Figure). Replace spark plug wire if there is evidence of damage to the wire.

2. Inspect the spark plug wire harness for evidence of damage or contact with the camshaft cover. If there is any exidence of damage or contact, install a 4-way spark plug wire clip (P/N 12034561). Replace any damaged spark plug wires. Refer to the following Figure for correct clip location and spark plug wire routing.

IMPORTANT: The hose clamp tab should be at a 12 o'clock position as shown in Figure.


PARTS
REQUIREMENTS: 12034561 4-Way Spark Plug Wire Clip
21020652 Spark Plug Wire # 1
21020655 Spark Plug Wire # 4
CLAIM
INFORMATION: To receive credit for this repair, submit a claim through the Saturn Dealer System as follows:

Labor
Case Operation
Type Description Code Time

VW Inspect Wires and Install Clips T9561 0.4 hrs