Body - Liftgate Lock Cylinder Connector Incompatibility
BULLETIN NO.: 01-T-48ISSUE DATE: October, 2001
CATEGORY TYPE: Electrical - 10
CATEGORY: Locks and Security
CORPORATION NO.: 01-08-64-013
SUBJECT:
New Design Liftgate Lock Cylinder Case Connector Does Not Mate With Existing Liftgate Wiring Harness Connector (Replace Liftgate Wiring Harness Connector with New Design Connector Replacement Pack)
MODELS AFFECTED:
2000 L-Series Wagons
CONDITION:
New design wagon liftgate lock cylinder case P/N 22689998, will not mate with the existing liftgate wiring harness connector.
CAUSE:
This condition is caused by an introduction of a new design connector between the liftgate wiring harness and the micro-switch located in the liftgate lock cylinder case.
CORRECTION:
Replace liftgate wiring harness connector with new design connector replacement pack P/N 21022284.
PROCEDURE:
1. Remove liftgate lock cylinder case. Refer to "Liftgate Lock Assembly" removal procedure in the Locks and Security of the 2000 Body/Electrical Volume II Service Manual.
2. Locate and cut existing liftgate lock connector (BLK 2-way) from liftgate wiring harness.
3. Cut replacement connector (GRA 2-way) wires to length.
IMPORTANT:
Saturn recommends that approved Packard Electric Crimp and Seal Splice Sleeves (or equivalent) be used.
4. Splice wires into liftgate wiring harness.
4.1 Remove insulation from both ends, recommended 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 (1-1/2 in.) from an outlet or other splice.
IMPORTANT:
When using the salmon splice sleeve with 0.35 mm (22 gage) 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.
4.2 Determine proper sleeve for gage of wire. Position stripped ends in sleeve until wires hit stop.
IMPORTANT:
When splicing three wire ends into one splice sleeve, insert both wires into one end; one cut wire end from vehicle harness and new splice wire end into one side of the splice sleeve until wires hit stop. Hand crimp using approved crimping tool. Insert remaining cut wire end from vehicle harness into other side of splice sleeve and crimp.
4.3 Hand crimp sleeve using the approved crimping tool. Gently tug on wires to make sure they are secure before applying heat for shrinking to them.
4.4 Check for continuity in the wire.
CAUTION:
DO NOT USE A MATCH OR OPEN FLAME TO APPLY HEAT TO SPLICE SLEEVE.
4.5 Apply heat using U1tratorch(R) (or equivalent), heating splice sleeve to 175° C (347° F). Heat until glue flows around edges of splice sleeve.
5. Install new liftgate lock cylinder case. Refer to "Liftgate Lock Assembly" Installation procedure in the Locks and Security of the 2000 Body/Electrical Volume II Service Manual
PARTS REQUIREMENTS
CLAIM INFORMATION:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for B5810 (Cylinder, Tailgate Lock - R&R or Replace), or if another procedure is performed, refer to the appropriate Electronic Labor Time Guide for the correct Labor Operation Code and Time.
DISCLAIMER