Procedure

1. Remove front door outer panel on side of vehicle that is affected. (Refer to "Front Door Outer Panel - Sedan/Wagon" removal procedure in the Doors section of the appropriate model year Body/Repair service manual.)

2. Inspect door wiring harness for signs of damage. If water deflector is obstructing wiring harness inspection, carefully peel it out of the way.

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

^ If no damage has occurred, refer to the appropriate model year Electrical 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 9.5 mm (3/8 in). 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.

5. 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.





6. Hand crimp sleeve using 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 some other device, heating 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, re-tape wires and harness to original condition.

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

11. Install front door outer panel. (Refer to "Front Door Outer Panel - Sedan/Wagon" installation procedure in the Doors section of the appropriate model year Body/Repair service manual.)