Cranks But Will Not Start, Mil On - Chafed ECM Wire (99-T-68)

CRANKS BUT WILL NOT START, MIL ON - CHAFED ECM WIRE

TECHNICAL SERVICE BULLETIN

VARIOUS DRIVEABILITY CONCERNS INCLUDING: ENGINE CRANKS BUT WILL NOT START, OR (MIL) SERVICE ENGINE SOON TELLTALE ON WITH ONE OR MORE ECM DTCS STORED (REPAIR CHAFED WIRE(S) IN ENGINE HARNESS)

Model(s): 2000 Saturn L-Series

Group/Seq. No.: Engine-13

Corporation No.: 99-06-03-014

Bulletin No.: 99-T-68

Date: December, 1999

VEHICLES AFFECTED

2000 Saturn L-Series vehicles built before and including VIN YY607831 equipped with V-6 (RPO L81) engines.

CONDITION

Customers may comment of engine cranking and not starting. Various engine control module (ECM) diagnostic trouble codes (DTCs) may be set with or without driveability concerns.

CAUSE

This condition may be caused by the ECM wiring harness becoming chafed at any of the following points:

• Right rear ECM retaining bolt with Torx head
• Intake runner support bracket bolt
• Wiring harness support bracket bolt

See Fig 1 .

CORRECTION

Repair damaged wires and wrap wiring harness conduit closed with electrical tape.

PROCEDURE

1. Inspect ECM engine wiring conduit at locations (1), (2), and (3) shown in illustration above.
   • If damage or protrusion of wiring conduit is evident, continue to step 2.
   • If damage or protrusion of wiring conduit is not evident, refer to appropriate DTC information or other diagnostic charts in the Engine/Emissions Controls section of the 2000 L-Series (L81) Service Manual.
2. Disconnect negative battery cable.
3. Disconnect BLK 64-way connector J1 from ECM.
4. Remove tape from conduit and suspected area of wiring harness chafe.
5. Cut damaged wire at location of chafe.
6. 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.
   NOTE: With wiring used in Saturn vehicles, it is recommended that approved Packard Crimp and Seal Splice Sleeves (or equivalent) be used.
7. Using a Saturn approved crimp and seal sleeve (found in special tools kit SA9138Z) position stripped ends of wires in sleeve until wires hit stop. See Fig 2 .
8. 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.
9. Apply heat using Ultratorch or equivalent device, heating to 175°C (347°F) until glue flows around edges of sleeve. See Fig 3 .
10. Check repaired wire continuity and verify proper repair.
11. Tape wiring harness with electrical tape prior to installing it into conduit to prevent the possibility of future chafing.
12. Install wiring harness into conduit and wrap conduit seam to original condition with electrical tape.
13. Connect BLK 64-way connector J1 at ECM.
14. Connect negative battery cable. Torque: 17 N-m (13 ft-lbs)
15. If any chafed wire repaired was injector related, change engine oil and filter because engine oil may be diluted with fuel.