Service Procedure

Wire chafing against power steering pump housing





1. Inspect fuel injector harness wires for chafes at either the power steering pump housing or fuel rail location as shown in the illustrations.

Wire chafing against fuel rail





2. Is chafing of fuel injector harness present?

^ If chafing is evident, proceed to step 3. If chafing is not evident, refer to appropriate DTC information or other diagnostic charts in the Engine/Emissions Control section of the 2000/2002 S-Series Engine Service Manual.

Wire Repair Procedure:





3. Cut damaged wire(s) at location of chafe or pinch.

4. Remove insulation from both ends of cut wire. Recommended 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 Crimp and Seal Splice Sleeves (or equivalent) be used.

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

6. Hand crimp splice sleeve using appropriate crimping tool. Gently tug on wires after crimping to ensure they are secure.

CAUTION:
DO NOT USE A MATCH OR OPEN FLAME TO APPLY HEAT TO SPLICE SLEEVE.





7. Apply heat using Ultratourch (or equivalent) device, heating to 175°C (347° F) until glue flows around edges of sleeve.

8. Check repaired wire(s) continuity and verify proper repair.

9. Tape wiring harness with electrical tape to prevent the possibility of future chafing.

IMPORTANT:
Due to contamination with fuel, the engine oil and filter must be changed.

10. After the wire(s) have been repaired, change engine oil and filter.

11. Perform exhaust system pressure test. Refer to "Restricted Exhaust System Check" procedure in the Exhaust System section of the 2000 - 2002 S-Series Engine Service Manual.

If exhaust system pressure is out of specification, the catalytic converter is plugged and must be replaced. Refer to "Catalytic Converter and Intermediate Pipe Heat Shields" procedure in the Exhaust System section of the 2000 - 2002 S-Series Engine Service Manual

^ If exhaust system pressure is within specifications, no further repairs are necessary. Continue to next step.

12. Start engine and verify all DTCs are cleared and engine runs smoothly.