Procedure

1. Remove left side hinge pillar garnish molding and inspect I/P wiring harness. (Refer to "Moldings-All Models" in the Vehicle Interior Systems section of the appropriate model year Body/Repair service manual.)

^ If damage has occurred to any wire, continue with step 2.

^ If no damage is observed, go to the appropriate section of the electrical service manual for further diagnostic assistance.

2. Cut damaged wire at location of chafe.





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

4. Using a Saturn approved crimp and seal sleeve (found in special tools kit 5A9138Z) position stripped ends of wires in sleeve until wires hit stop.





5. 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.





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

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

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





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

10. Install left side hinge pillar garnish molding. (Refer to "Moldings-All Models" in the Vehicle Interior Systems section of the appropriate model year Body/Repair service manual.)