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 MANUALSSATURN2000LW2 V6-3.0L VIN RREPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTCOMPUTERS AND CONTROL SYSTEMSRELAYS AND MODULES - COMPUTERS AND CONTROL SYSTEMSENGINE CONTROL MODULETECHNICAL SERVICE BULLETINSCUSTOMER INTERESTENGINE CONTROLS - VARIOUS DRIVABILITY CONCERNS
2000 Saturn LW2 V6-3.0L VIN R
Engine Controls - Various Drivability Concerns
2000 Saturn LW2 V6-3.0L VIN RSECTION Engine Controls - Various Drivability Concerns
BULLETIN NO.: 99-T-68
ISSUE DATE December, 1999
GROUP/SEQ. NO.: Engine-13
CORPORATION NO.: 99-06-03-014
SUBJECT:
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)
MODELS 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(R) head
^ Intake runner support bracket bolt
^ Wiring harness support bracket bolt
(Refer to illustration)
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.
^ 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.
IMPORTANT:
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.
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(R) or equivalent device, heating to 175° C (347° F) until glue flows around edges of sleeve.
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.
PARTS REQUIREMENTS
CLAIM INFORMATION
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:
Labor
Case Operation
Type Description Code Time
VW Repair Chafed Engine Z4080 0.3 hrs
Harness Wire(s)
Add: A: To Repair Each Additional Wire 0.2 hrs
B: To Change Engine Oil and Filter 0.3 hrs
ISSUE DATE December, 1999
GROUP/SEQ. NO.: Engine-13
CORPORATION NO.: 99-06-03-014
SUBJECT:
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)
MODELS 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(R) head
^ Intake runner support bracket bolt
^ Wiring harness support bracket bolt
(Refer to illustration)
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.
^ 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.
IMPORTANT:
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.
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(R) or equivalent device, heating to 175° C (347° F) until glue flows around edges of sleeve.
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.
PARTS REQUIREMENTS
CLAIM INFORMATION
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:
Labor
Case Operation
Type Description Code Time
VW Repair Chafed Engine Z4080 0.3 hrs
Harness Wire(s)
Add: A: To Repair Each Additional Wire 0.2 hrs
B: To Change Engine Oil and Filter 0.3 hrs
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.