Procedure

1. Disable SIR system. (Refer to "Disabling the SIR System" procedure in the "SIR Service Manual.")

2. Remove connectors from powertrain control module (PCM).

3. Remove PCM from vehicle.

4. Cut existing wire harness tie strap rose bud clip off, so harness is loose from spaceframe. (Rose bud clip is located directly above clutch pedal)

5. Loosen harness clamp. (Located 76 mm [3 inches] away from rose bud clip.)

6. Remove I/P harness tape from starter relay to branch that goes down to the IPJB.

7. Separate harness until damaged wire is exposed. Cut damaged wire at location of chafe (if harness is not chafed. refer to the appropriate Service Manual section for diagnostic information).

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

8. Remove insulation from both ends of cut wire, recommended wire strip length is 9.5 mm (3/8 in). Caution must be used to prevent cutting the wire strands. Locate new splice a minimum of 40 mm (1.5 in.) from other splices. If necessary add a 51 mm (2 in.) length of stranded copper wire, same size, same gage as existing wire.

9. Using the Saturn approved crimp and seal sleeve found in special tools kit 5A9138Z, position stripped ends of wires in sleeve until wires hit stop.





IMPORTANT:
When using the salmon splice sleeve with .35 (22 gauge) wire, remove 19 mm (3/4 in.) of insulation. Bend the stripped portion in half to double the thickness of the wire going into the splice sleeve. Twist the stripped, doubled wire and insert into the splice sleeve.





10. Hand crimp sleeve using the appropriate crimping tool. Gently tug on wires to make sure they are secure before applying heat to them.

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





11. Apply heat using Ultratorch(R) or some other device, heating to 175°C (347°F) until glue flows around edges of sleeve.

12. Check for continuity in the wire.

13. Install 101 mm (4 in.) of conduit (P/N 21023495) to I/P harness. Make sure to position conduit over clutch pedal pivot clip.

14. Tape conduit and fasten wire harness clip to harness and spaceframe

15. Using Saturn P/N 08905262, wiring harness clip, install clip on harness and insert rose bud into hole that the previous strap was removed from.

16. Enable SIR system. (Refer to "Enabling the SIR System" procedure in the "SIR Service Manual.")

17. Clear any DTCs that may have been set.