ION L4-2.2L VIN F (2004)
The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive
nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components,
such as connectors and terminals.
SIR/SRS CONNECTOR (PLASTIC BODY AND TERMINAL METAL PIN) REPAIR
Use the connector and wire repair assembly packs, available through Saturn Service Parts, to repair the damaged SIR/SRS wire harness connectors
and the terminals. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and
terminals to the harness. The splice crimping tool is color keyed in order to match the splices from J 44020 . You must use the splice crimping tool in
order to apply these splices.
If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order
to replace the SDM harness connector:
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The SDM harness connector pigtail assembly
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The SDM harness connector replacement kit
If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the
entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity.
SIR/SRS WIRE PIGTAIL REPAIR
IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire
component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component.
SIR/SRS WIRE REPAIR
IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in
order to ensure circuit integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire. Use the sealed splices and splice crimping tool from the
J 44020 . Use the shown wiring repair procedures in order to ensure the integrity of the sealed splice.
1. Open the harness by removing any tape:
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Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage.
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Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial.
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Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together.
IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must
obtain a clean strip with all of the wire strands intact.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice
locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors.
3. Strip the insulation:
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Perform one of the following items in order to find the correct wire size:
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Find the wire on the schematic and convert the metric size to the equivalent AWG size.
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Use an AWG wire gage.
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If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the
insulation.
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Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
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Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
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If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color
coding of the splice sleeves and the crimp tool nests.
