Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSSATURN1998SC1 L4-1.9L SOHC VIN 8REPAIR AND DIAGNOSISSTARTING AND CHARGINGSTARTING SYSTEMDIAGRAMSDIAGNOSTIC AIDSWIRE REPAIR PROCEDURESCONNECTOR REPAIRSPUSH-TO-SEAT CONNECTORS
1998 Saturn SC1 L4-1.9L SOHC VIN 8
Push-to-Seat Connectors
1998 Saturn SC1 L4-1.9L SOHC VIN 8SECTION Push-to-Seat Connectors
IMPORTANT: Cut leads with terminals are available from Saturn Service Parts for terminal replacement.
TERMINAL REMOVAL
1. Remove any Terminal Position Assurance (TPA) locks.
2. Insert the terminal lock release tool into the front of the connector cavity. Pull the wires and terminal out of the back of the connector.
CUT LEAD INSTALLATION
1. Put connector seal (if equipped) on wire and strip approximately 9.5 mm (3/8 in.) of insulation off the wire.
2. Remove insulation from the end of the cut lead and the harness. Recommend strip length is 9.5 mm (3/8 in.). Caution must be used to prevent cutting the wire strands.
3. Determine proper sleeve for gage of wire.
4. Position stripped ends in sleeve until wires hit the stop in the center of the splice.
5. Hand crimp using the approved crimping tool. Gently tug on wires to make sure they are secure before applying heat to them.
CAUTION: Do not use match or open flame to apply heat to seal.
6. Apply heat using Ultratorch(R) or some other device, heating to 175°C (347°F) until glue flows around edge of sleeve.
7. Check for continuity.
8. Insert the terminal into the connector. Check to make sure the terminal lock tab is engaged by gently tugging on the wire.
9. Replace any terminal position assurance (TPA) devices.
IMPORTANT: The salmon splice can be used on the 0.35 (22 gage) wire if the following additional steps are taken:
10. Remove 19 mm (3/4 in.) of insulation.
11. Bend the stripped portion in half to double the thickness.
12. Twist the stripped, doubled wire and insert into the splice sleeve.
TERMINAL REMOVAL
Push-To-Seat Connectors: Terminal Removal:
1. Remove any Terminal Position Assurance (TPA) locks.
2. Insert the terminal lock release tool into the front of the connector cavity. Pull the wires and terminal out of the back of the connector.
CUT LEAD INSTALLATION
Push-To-Seat Connectors: Cut Lead Installation:
1. Put connector seal (if equipped) on wire and strip approximately 9.5 mm (3/8 in.) of insulation off the wire.
2. Remove insulation from the end of the cut lead and the harness. Recommend strip length is 9.5 mm (3/8 in.). Caution must be used to prevent cutting the wire strands.
Push-To-Seat Connectors: Wire Size:
3. Determine proper sleeve for gage of wire.
Push-To-Seat Connectors: Cut Lead Installation:
4. Position stripped ends in sleeve until wires hit the stop in the center of the splice.
5. Hand crimp using the approved crimping tool. Gently tug on wires to make sure they are secure before applying heat to them.
CAUTION: Do not use match or open flame to apply heat to seal.
6. Apply heat using Ultratorch(R) or some other device, heating to 175°C (347°F) until glue flows around edge of sleeve.
7. Check for continuity.
8. Insert the terminal into the connector. Check to make sure the terminal lock tab is engaged by gently tugging on the wire.
9. Replace any terminal position assurance (TPA) devices.
IMPORTANT: The salmon splice can be used on the 0.35 (22 gage) wire if the following additional steps are taken:
10. Remove 19 mm (3/4 in.) of insulation.
11. Bend the stripped portion in half to double the thickness.
12. Twist the stripped, doubled wire and insert into the splice sleeve.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.