INFO. ON REPLACEMENT OF POWER DOOR LOCKS CIRCUIT WIRING. Saturn Saturn 1994

For 1990-2009 cars

# INFO. ON REPLACEMENT OF POWER DOOR LOCKS CIRCUIT WIRING

#### SUBJECT: Service Information on Replacement of Power Door Locks Circuit Wiring Insulation Displacement Connectors

#### MODELS AFFECTED: 1991-1994 Saturns equipped with power door locks.

PURPOSE: The insulation displacement connectors (IDCS) used on the power door lock circuits 194, 195, 294 and 295 have not been repairable. This bulletin provides a moisture-resistant repair procedure for the insulation displacement connectors.

PROCEDURE: When diagnosing power door lock concerns, it is important to check for moisture and/or corrosion in the insulation displacement connectors used on the LOCK and UNLOCK circuits. The insulation displacement connectors are taped within the body wiring harness, located under the front seats as indicated in the following circuit location chart.

Model Body Circuit Number Wire Seat IDC Year Style No. of Wires Color Located Under -------------------------------------------------------------- 91-93 Sedan 194 2 Blk Left 195 2 Lt Blu Left 294 3 Tan Right 295 3 Gra Left 91-93 Coupe 194 2 Blk Left 195 2 Lt Blu Left 94 Sedan/Wagon 195 2 Lt Blu Left 294 3 Tan Right 295 3 Gra Left 94 Coupe 195 2 Lt Blu Left

#### IMPORTANT: On insulation displacement connectors having three wires, one end of one wire has no connection in harness. This leaves only five wire ends to be spliced, using the service splice connector.

#### Repairing Insulation Displacement Connectors

1. Disconnect negative battery terminal.

2. Remove appropriate front seat (refer to above chart for location according to circuit being worked on.) Refer to "Vehicle Interior Systems" section of the "Body/Collision Repair Service Manual" for seat removal procedures.

3. Remove liner in rear storage tray of center console and remove two screws under liner.

4. Remove two screws on the front end of the center console.

5. Lift center console slightly to gain access to carpet under center console.

6. Lift carpet to expose wiring harness.

7. Locate insulation displacement connectors in body wiring harness and remove approximately 152 mm (6 in.) of electrical tape.

8. Cut wiring approximately 51 mm (2 in.) back from insulation displacement connector.

9. Strip ends of wires back 9.5 mm (3/8 in.).

10. Inspect for corrosion on exposed wires. Cut back all wires evenly as necessary to remove all corroded wire. Cut and strip as much wire as necessary to allow only non-corroded wire to be exposed.

11. Cut one piece of 1.0 sq. mm (16 gage) wire to length necessary to connect wire ends previously cut from body wiring harness. Use a minimum of 305 mm (12 in.).

12. Place two shrink tubing lengths onto new wire.

13. Position stripped ends of wire harness and one end of new wire into splice clip, making sure to overlap wire.

14. Hand crimp with pliers, using just enough pressure to secure wires in splice clip without damaging them.

15. Repeat steps 13 and 14 for remaining wire ends.

16. Solder wire into splice clips using 60/40 tin/lead solder. (Butane torch/soldering iron is included with special tool SA9138Z.)

#### IMPORTANT: When soldering, apply heat to one side of splice clip for several seconds, then apply solder to hole in splice clip. Watch for solder flow to be visible on wires where they emerge from the splice clip.

17. Position one shrink tubing length over each splice clip and shrink, using Butane torch with heat shrink heat deflector attachment. Be careful not to scorch wires or tubing. Shrink from center, working to ends of tubing to make sure of proper flow of adhesive.

18. Repeat step 17 for other shrink tubing length.

19. Use electrical tape to replace tape removed in step 7.

20. Install carpet and position carpet under center console. (The console may have to be slightly lifted to position the carpeting under the center console edge.)

21. Position center console and install two screws on the front end of the center console.

22. Install two screws in the rear storage tray of the center console and install rear storage tray liner.

23. Install front seat. Refer to "Vehicle Interior Systems" section of the "Body/Collision Repair Service Manual" for seat installation procedures.

24. Connect negative battery terminal.

PARTS REQUIREMENTS: 21023101 Splice Connector (2 per splice required) 1.0 sq. mm (16 gage) wire

CLAIM INFORMATION: To receive credit for this repair, submit a claim through the Saturn Dealer System as follows:

Labor Case Operation Type Description Code Time ------------------------------------------------- VW Power Door Lock Wiring T9674 1.5 hrs Repair

#### Add:

A. To R&R opposite seat and partially remove carpeting to replace all IDCs (if necessary) 0.5 hrs

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.