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Engine Controls - SES Lamp ON/Driveability Issues

Bulletin No.: 06-06-03-005

Date: June 19, 2006

TECHNICAL

Subject:
Service Engine Soon (SES)/Malfunction Indicator Lamp (MIL) On and/or Engine Driveability Concerns (Wiggle ECM/PCM Connector and Replace Connector, If Necessary)

Models:
2004-2006 Saturn VUE with 3.5L V6 Engine (VIN 4 - RPO L66)
2005-2006 Saturn ION with 2.2L 4-Cylinder Engine (VIN F - RPO L61)

Condition

Some customers may comment on the SES/MIL light coming on and/or engine driveability concerns. If the customer concern cannot be duplicated or eliminated, wiggling the ECM/PCM connector on the affected vehicles may cause the symptoms to manifest.

Cause

This condition may be caused by damage to the retention feature on the connector body. This allows the connector to lose clamp load to the control module, which may cause intermittent connections between the control module and wiring harness.

Correction

Do NOT replace the complete engine wiring harness if the condition can be duplicated by wiggling the 73-way ECM/PCM connector.

If this condition can be duplicated by wiggling the 73-way ECM/PCM connector, replace the connector following the procedure below:

Connector Replacement

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI.

2. For the Saturn VUE only, remove the upper air cleaner housing lid and the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement in SI.

3. Disconnect both the body and the engine harness connector at the ECM/PCM.

Note:
Do not rotate or turn the J 35616-64A or J 35616-64B when it is inserted into a terminal. The square cross-section of the tool may loosen the terminal if the tool is rotated.

4. Perform a terminal tightness check on all terminals using the J 35616-64A or J 35616-64B. If there are any loose terminals, replace the terminals and retest prior to performing Step 5. Refer to Delphi Connectors (Micro .64 Connectors) in SI.

5. Rotate the engine harness connector cam lock forward to the released position. Remove the connector top cover and then cut and remove the cable tie strap that retains the wire to the body of the connector.





6. On the connector face, remove the blue protective sleeve for the ground wire (at pin 73). Remove the ground wire (pin 73) by moving the tab away from the terminal on the connector face and pulling on the wire from the backside.

Note:
Do NOT damage the gray retaining tabs. The gray retaining tabs must be released before removing the gray housing. Damaged tabs may not secure to the connector body.

7. Remove the green TPA from the rear of the connector first, then carefully pry up the four retaining tabs on the gray housing where the wires go into the housing.

8. Remove the gray housing (along with the wires) from the connector body.

Note:
Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM.

Important:
Do NOT rotate the cam lock on connector body unless the connector is positioned on the ECM/PCM.

9. Remove the ECM/PCM by unsnapping it from the bracket.

Tip:

Before placing the new connector on the ECM/PCM, disengage both rear retaining tabs on the gray housing. After placing the new connector on the ECM/PCM, disengage the remaining two tabs in order to remove the gray cover.

10. Place the new connector on the ECM/PCM and rotate the cam lock to the secured position. Remove and discard the gray cover.

11. Remove the connector from the ECM/PCM. Remove and discard the white TPA housing from the new connector.

Important:
Prior to installing the new connector body, make sure all terminal ends are at approximately the same length and in the correct position (none at odd angles).

12. Slowly install the original gray housing with the terminal ends into the new connector body. Verify that all terminal ends are at the same depth. If not, find the corresponding wire at the top of the gray connector and pull up on the wire. Reinstall the wire and seat the terminal.

Important:
The green TPA should insert easily. If any resistance is encountered, check for an out-of-position terminal.

13. When all terminal ends are at the same length, insert the new green TPA. Verify again that all terminal ends are at the same depth.

14. Install the ground wire through the gray connector and click into place into the connector body.

15. Install the new blue protective sleeve at the ground wire terminal (pin 73). Use a new cable tie strap to attach the connector body to the wiring harness, then install the cover to the connector body.

16. Reinstall the ECM/PCM and reconnect the engine and the body harness connectors to the ECM/PCM.

17. For the Saturn VUE only, reinstall the upper air cleaner housing lid and the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement in SI.

18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI.

19. Start the vehicle and verify that the concern has been corrected.





Parts Information

Warranty Information





For vehicles repaired under warranty, use the table.





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