Wire Splicing - General Information For C60 & C68 HVAC Systems

(for both C60 and C68 HVAC Systems)

With the wiring used in the Saturn vehicles, it is recommended that approved Packard Electric Crimp and Seal Splice Sleeves (or equivalent) be used. The information in this section applies to wire splicing performed in the subsequent sections for both Delayed Blower Kit Installation (manual HVAC, RPO C60) and Delayed Blower Motor Control Activation (automatic climate control, RPO C68) procedures.

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 (1.5 in.) from an outlet or other splice.





2. Determine proper sleeve for gage of wire.

3. Position stripped ends in sleeve until wires hit the stop in the center of the splice.

Important:
When using the salmon splice sleeve with .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.

Important:
When splicing three wire ends into one splice sleeve, insert 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. Hand crimp sleeve using the approved crimping tool. Gently tug on wires to make sure they are secure before applying heat to them.





6. Apply heat using Ultratorch (or equivalent), heating splice sleeve to 175° C (347° F). Heat until glue flows around edges of splice sleeve.

Caution:
Do not use a match or open flame to apply heat to splice sleeve.

Delayed Blower Kit Installation and Testing Procedure (for C60 manual HVAC systems only)

Important:
This procedure is for vehicles equipped with manual HVAC systems (RPO C60) only. If vehicle is equipped with automatic climate control (RPO C68), go to "Delayed Blower Motor Control Activation" section in this bulletin.

Before starting the following procedure, obtain the following parts:

^ 3 Wire Splice Connector, P/N 22709318

^ Delayed Blower Control Module Kit, P/N 22679784

^ Relay Kit, P/N 22688666

^ Splice Sleeves - Salmon, P/N 12089189 (need 5 sleeves)

^ Splice Sleeves - Yellow, P/N 12089191 (need 5 sleeves) Splice Sleeves - Blue, P/N 12089190