Procedure

1. Remove left side hinge pillar garnish molding by gently prying at clip locations.

(Right side shown, left side similar.)








2. Inspect I/P wiring harness at wire chafe location shown in illustrations.

^ If damage has occurred to any wire(s), continue with step 3.

^ If no damage is observed, refer to the appropriate service manual for further diagnostic information.

3. Cut damaged wire at location of chafe.

4. Remove insulation from both ends of cut wire, recommended wire strip length is 4.8 mm (3/16 in.) for 12-20 gauge wires and 9.5 mm (3/8 in) for 22 gauge wire so it can be folded in half. 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:
For the wiring used in Saturn vehicles, it is recommended that only approved Packard Electric Crimp and Seal Splice Sleeves (or equivalent) be used.





5. Using a Saturn approved crimp and seal splice sleeve (found in terminal repair kit J44020), position stripped ends of wires in sleeve until wires hit stop.

6. Hand crimp splice sleeve using correct jaws in Packard crimper (P/N 12085115) or 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.





7. Apply heat using Ultratorch(R) or heat gun. Heat to 175°C (347°F) until glue flows around edges of sleeve.

8. Check for continuity in the wire and verify repair.

9. If electrical tape was removed to perform wire harness inspection or repair, tape wires and harness to original condition.





10. Install one Sealer Patch (P/N 21124362) to metal edge(s) of cockpit support under wire harness to protect against farther wire harness damage.





11. Install left side hinge pillar garnish molding by aligning and pushing at clip locations. (Right side shown, left side similar.)