1996 Saturn Sc2 Repair Manual Pdf

1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

DESCRIPTION & OPERATION WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM procedures in appropriate AIR BAG RESTRAINT SYSTEM article.

DESCRIPTION Cruise control system is completely electronic, and does not require vacuum or a vacuum servo motor. To control throttle movement, a cable from cruise control module pulls on accelerator linkage at accelerator pedal.

Cruise control system consists of a cruise control module (located above accelerator pedal), control switches (located in center of steering wheel), brake release switch, and Powertrain Control Module (PCM). See Fig. 1 .

NOTE:

On M/T models, PCM interprets vehicle speed to calculate when clutch has been depressed. Separate clutch release switch has been eliminated.

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

Fig. 1: Cruise Control System Component Locations (All Models) Courtesy of GENERAL MOTORS CORP. ON/OFF SWITCH ON/OFF switch enables and disables cruise control system. With switch on, cruise control is active. With switch off, cruise control will be disabled.

SET/COAST SWITCH When cruise control switch is in ON position (engaged), pressing SET/COAST switch will engage cruise.

When cruise is engaged, holding SET/COAST switch will cause cruise to coast down until switch is released. In tap-down mode, set speed is adjusted down by momentarily depressing SET/COAST switch. Each press of SET/COAST switch will cause speed to be decreased by one MPH. RESUME/ACCEL SWITCH If cruise control has been in cruise engage mode and cruise has been disabled by pressing on brake switch and/or by PCM (M/T), cruise can return to previous speed by momentarily pressing RESUME/ACCEL switch one time. Holding RESUME/ACCEL switch will cause cruise to accelerate at a rate of one MPH per second until switch is released. In tap-up mode, set speed is adjusted up by momentarily depressing RESUME/ACCEL Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:25:40 PM

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

switch. Each press of RESUME/ACCEL switch will cause speed to be increased by one MPH. BRAKE RELEASE SWITCH An electrical release switch, part of stoplight switch on brake pedal bracket, disengages cruise when brake pedal is depressed.

CRUISE CONTROL MODULE Cruise control module interprets ignition power and PCM inputs. In response to these inputs, cruise control module controls cruise cable movement. Cruise control module is located on steering column support bracket, above accelerator pedal.

SIR COIL ASSEMBLY SIR coil assembly, mounted on steering column below steering wheel, is used to maintain electrical connection between harness and cruise control switches, horn switch and air bag module.

VEHICLE SPEED SENSOR (VSS) A Permanent Magnet (PM) generator, driven by transmission, generates vehicle speed information in form of a low AC voltage signal. This signal's frequency is proportional to vehicle speed for module to use as a comparison signal between vehicle speed and cruise set speed.

WARNING: Use extreme caution when servicing steering column on vehicles with SIR system; air bag could deploy at any time. Before servicing steering column, disable SIR system. See DISABLING & ACTIVATING AIR BAG SYSTEM . For additional safety precautions, see appropriate AIR BAG RESTRAINT SYSTEM article.

DISABLING & ACTIVATING DISABLING & ACTIVATING AIR BAG SYSTEM CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

Disabling Air Bag

1. To disable air bags, turn wheels to straight-ahead position and turn ignition off. Disconnect and shield negative battery cable. Remove AIR BAG fuse from fuse block. Remove Connector Position Assurance (CPA) clip from Yellow SIR connector at base of steering column. (All SIR system connectors use CPA clips to ensure connector retention.) Disconnect Yellow connector.

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

2. On Coupe models, start at rear above end cap and remove upper trim panel extension from clips. On all models, use small flat-blade screwdriver to remove upper trim panel screw caps. Remove upper trim panel screws. Remove upper trim panel from clips. On Sedan and Wagon models, DO NOT damage seal when removing upper trim panel.

3. On all models, remove upper trim panel insulator. Remove CPA clip. Disconnect Yellow connector from pigtail of passenger air bag. Wait 10 minutes before working on vehicle.

Activating Air Bag

1. To activate air bag system, turn ignition off. Connect Yellow SIR connector and CPA clip at base of steering column. Connect Yellow SIR connector and CPA clip to pigtail of passenger air bag.

2. Install AIR BAG fuse. Connect negative battery cable. Turn ignition switch to RUN position. Observe AIR BAG indicator light. Light should flash 7-9 times, and then go out.

ADJUSTMENTS BRAKE RELEASE SWITCH 1. Adjust brake switch by loosening switch bolt, and sliding switch toward or away from brake pedal. Install Brake Switch Adjustment Gauge (SA 9303BR) between brake switch and actuator pad on brake pedal arm. Ensure plunger protrudes through slot in gauge.

2. Using moderate force, pull brake pedal up and push brake switch forward against gauge. Holding brake switch perpendicular to actuator pad, tighten nut to 89 INCH lbs. (10 N.m). Release brake pedal.

3. Tap gauge side-to-side. If gauge does not swing freely, repeat steps 1) and 2). If gauge swings freely, go to next step.

4. Pull brake pedal up with about 2 lbs. of force. Tap gauge side-to-side. If gauge swings freely, repeat steps 1)-4). If gauge does not swing freely, go to next step.

5. Ensure 0.03-0.05" (0.8-1.2 mm) of plunger is visible between brake switch and actuator pad. Rounded crown of plunger is equal to 0.04" (1 mm). If 0.03-0.05" (0.8-1.2 mm) of plunger is not visible, repeat adjustment procedure.

CRUISE CONTROL CABLE NOTE:

Cruise control cable and adjuster assembly are not repairable or replaceable.

DO NOT attempt to remove cable and adjuster from cruise module. Damage to cruise module could result.

1. Remove air intake tube at throttle body. Observe position of throttle plate. Adjust cable by pulling forward and turning ring on adjuster until throttle blade is fully closed. Loosen ring 1/2 turn (2-3 clicks).

2. With throttle plate closed (throttle position sensor at 0 percent), adjust cruise control cable to .040.079" (1-2 mm) of cable free play. See Fig. 2 . Install air intake tube.

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

Fig. 2: Cruise Control Cable Adjustment (All Models) Courtesy of GENERAL MOTORS CORP.

TROUBLE SHOOTING Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:25:40 PM

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

Before beginning diagnosis, perform a visual inspection for disconnected or damaged wiring. Check fuses, and replace as necessary. Check for binding or misadjusted cruise control throttle linkage. If visual inspection shows no fault, check operation of electrical brake/clutch switches. See TESTING .

TESTING CRUISE CONTROL INOPERATIVE 1. Connect scan tool. Turn ignition switch to RUN position. Check for Diagnostic Trouble Codes (DTCs). If any DTC is present, see appropriate DTC. If no DTCs are present, go to next step.

2. Operate horn. If horn operates, go to next step. If horn does not operate, repair open in ground for cruise control and horn switches.

3. Check ON/OFF switch inputs on scan tool. If scan tool recognizes ON/OFF switch inputs, go to step 7).

If scan tool does not recognize ON/OFF switch inputs, go to next step.

4. Disable air bag system. See the DISABLING & ACTIVATING AIR BAG SYSTEM . Remove air bag module. See AIR BAG (INFLATOR) MODULE under REMOVAL & INSTALLATION. Disconnect cruise control switch. Using a 5-amp fused jumper wire, jumper Brown and Gray wires at cruise control switch. Turn ignition on, engine off. If DTC P0565 is not present, go to next step. If DTC P0565 is present, replace cruise switch.

5. Remove steering column cover. Disconnect 4-pin SIR roll connector. Using 5-amp jumper wire, jumper roll connector terminal "D" (Brown wire) to terminal "C" (Gray wire) on harness side. If DTC P0565 is not present, go to next step. If DTC P0565 is present, replace roll connector.

6. Using Digital Volt-Ohmmeter (DVOM), check voltage between Brown wire and ground. If battery voltage is not present, repair open in Brown wire. If battery voltage is present, check for open in Gray wire. If circuit is okay, replace PCM. 7. Check SET/COAST switch inputs on scan tool. If scan tool recognizes SET/COAST switch inputs, go to next step. If scan tool does not recognize SET/COAST switch inputs, replace cruise control switch.

8. Check RESUME/ACCEL switch inputs on scan tool. If scan tool recognizes RESUME/ACCEL switch inputs, go to next step. If scan tool does not recognize RESUME/ACCEL switch inputs, replace cruise control switch.

9. Using Digital Volt-Ohmmeter (DVOM), backprobe between cruise control module terminal No. 7 (Brown wire) and ground. If battery voltage is not present, repair open in Brown wire. If battery voltage is present, check for a poor connection in Brown wire. If circuit is okay, replace cruise control module.

Diagnostic Aids

1. If cruise control operates intermittently, see DTC P1584, CRUISE DISENGAGE . To verify system operation, use scan tool to operate cruise control cable from idle to 50 percent throttle angle.

2. If correct voltage level is not input from ON/OFF switch in circuit No. 1884 (Gray wire), cruise control system will not be enabled.

3. On A/T models, PCM requires a brake switch transition to occur or cruise will not be enabled. A rolling restart with no brake transition may result in an inoperative cruise control system.

DTC P0565, CRUISE SWITCH CIRCUIT MALFUNCTION Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:25:40 PM

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

Command state voltage levels are divided through a resistor network from ignition voltage through CRUISE fuse. Network consists of resistors in cruise control switch and PCM. If voltage level is within an acceptable window, PCM will decode the signal. Voltage level windows may vary due to battery calculations.

DTC P0565 will set if: z

z

z

When cruise control system is on, less than 0.5 volt or greater than one volt is present on circuit No. 1884 (Gray wire).

When RESUME/ACCEL switch is pressed, less than 1.2 volts or greater than 2.4 volts is present on circuit No. 1884 (Gray wire).

When SET/COAST switch is pressed, less than 3 volts or greater than 3.5 volts is present on circuit No. 1884 (Gray wire).

1. Turn ignition on, engine off. Connect scan tool. Turn cruise control system off. If DTC P0565 is present, go to step 5). If DTC P0565 is not present, go to next step.

2. Turn cruise control switch on. If DTC P0565 is present, replace cruise control switch. If DTC P0565 is not present, go to next step.

3. Press and hold SET/COAST switch. If DTC P0565 is present when SET/COAST switch is pressed, replace cruise control switch. If DTC P0565 is not present when SET/COAST switch is pressed, go to next step.

4. Press and hold RESUME/ACCEL switch. If DTC P0565 is present when RESUME/ACCEL switch is pressed, replace cruise control switch. If DTC P0565 is not present when RESUME/ACCEL is pressed, problem is intermittent. See DIAGNOSTIC AIDS. 5. Turn ignition off. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove air bag module. See AIR BAG (INFLATOR) MODULE . Disconnect cruise control switch connector. Turn ignition on. If DTC P0565 is present, go to next step. If DTC P0565 is not present, replace cruise control switch.

6. Turn ignition off. Remove steering column cover. Disconnect Black 4-pin SIR roll connector. Turn ignition on. If DTC P0565 is present, repair short to power in Gray wire or PCM. If DTC P0565 is not present, replace roll connector.

Diagnostic Aids

1. Check history of malfunction. Determine which portion of switch input was lost, and try to reproduce problem. Check for shorts in circuit No. 1884 (Gray wire) between cruise control switch and PCM. 2. If problem is intermittent, wiggle harnesses and connectors while observing parameters on scan tool.

Status changes on scan tool during test procedure indicate area of fault.

DTC P1580, CRUISE MOVE CIRCUIT - VOLTAGE LOW PCM provides battery voltage to control movement of cruise control module. PCM internally monitors feedback signal continuously using circuit No. 1886 (Pink wire) when cruise control system is turned on and off. DTC P1580 will set if less than 7 volts is present on circuit No. 1886 when cruise control system is turned on.

1) Turn ignition on, engine off. Connect scan tool. Check for Diagnostic Trouble Codes (DTCs). If DTC P1580 Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:25:40 PM

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

is present, go to next step. If DTC P1580 is not present, problem is intermittent. See DIAGNOSTIC AIDS. 2) Turn ignition off. Disconnect cruise control module connector. Turn ignition on, engine off. If DTC P1580 is present, check for short to ground in Pink wire between cruise control module and PCM. If circuit is okay, replace PCM. If DTC P1580 is not present, replace cruise control module.

Diagnostic Aids

Check history of malfunction. Determine which portion of switch input was lost, and try to reproduce problem.

If problem is intermittent, wiggle harnesses and connectors while observing parameters on scan tool. Status changes on scan tool during test procedure indicate area of fault.

DTC P1581, CRUISE MOVE CIRCUIT - VOLTAGE HIGH PCM provides battery voltage to control movement of cruise control module. PCM internally monitors feedback signal continuously using circuit No. 1886 (Pink wire) when cruise control system is turned on and off. DTC P1581 will set if more than 3 volts is present on circuit No. 1886 when cruise control system is turned off.

1) Turn ignition on, engine off. Connect scan tool. Check for Diagnostic Trouble Codes (DTCs). If DTC P1581 is present, go to next step. If DTC P1581 is not present, problem is intermittent. See DIAGNOSTIC AIDS. 2) Check scan tool for additional codes. If DTC P1583 is also present, repair open in Black wire between cruise control module and ground. If DTC P1583 is not present, go to next step.

3) Turn ignition off. Disconnect cruise control module connector. Using 5-amp fused jumper wire, jumper between circuit No. 1886 (Pink wire) and ground. Turn ignition on, engine off. If DTC P1581 is still present, check for open in Pink wire. If circuit is okay, replace PCM. If DTC P1581 is not present, go to next step.

4) If fused jumper wire did not blow, replace cruise control module. If fused jumper wire blew, repair short to power in Pink wire.

Diagnostic Aids

Check history of malfunction. Determine which portion of switch input was lost, and try to reproduce problem.

If problem is intermittent, wiggle harnesses and connectors while observing parameters on scan tool. Status changes on scan tool during test procedure indicate area of fault.

DTC P1584, CRUISE DISENGAGE DTC P1584 will set if PCM disengages the cruise control system due to abnormal parameters or driving maneuvers. This includes the following conditions: z z z

Ignition 1 voltage is less than 10 volts or greater than 16 volts.

Traction control is active or vehicle acceleration is greater than 10 MPH per second.

Deceleration is greater than 4 MPH per second.

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

z

z z z

Difference between set speed and actual vehicle speed is greater than 15 MPH for 10 seconds or greater that 20 MPH instantaneously. These speed errors may be caused by steep hills or engine lug(M/T).

Engine speed out of range (less than 950 RPM or greater than fuel cut-off RPM).

Gear out of range.

On A/T models, failure of park/neutral position switch.

Using scan tool, access MALF history parameters to determine whether problem was driver induced or caused by a system failure. Inspect "Disable" information at bottom of MALF table (i.e., Disable Volt Out Of Range, Disable PRNDL Fail). Determine if failed parameter has since passed, or if it has reset since ignition cycle cleared codes. Repair as necessary.

REMOVAL & INSTALLATION CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

AIR BAG (INFLATOR) MODULE Removal

1. Disable air bag. See DISABLING & ACTIVATING AIR BAG SYSTEM . Using small flat-blade screwdriver, pry screw caps from steering wheel. Remove and discard 4 air bag module screws from behind steering wheel.

2. Pull air bag module outward from steering wheel. Using flat-blade screwdriver, remove integral connector lock device. Disconnect electrical connectors from rear of module. Remove module and set aside with trim cover facing upward.

Installation

Connect electrical connectors to module. Install module using 4 NEW mounting screws. Tighten screws to 89 INCH lbs. (10 N.m). Activate SIR system. See DISABLING & ACTIVATING AIR BAG SYSTEM .

BRAKE RELEASE SWITCH Removal

Disconnect negative battery cable. Remove electrical connector from switch. Remove bolt from brake switch and remove brake switch.

NOTE:

Ensure tab on brake switch that keeps switch parallel to brake pedal is fitted into slotted hole. Ensure plunger is fully depressed with brake pedal released before tightening bolt.

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

Installation

To install, reverse removal procedure. Tighten bolt to 89 INCH lbs. (10 N.m). Adjust brake switch. See BRAKE RELEASE SWITCH under ADJUSTMENTS. CLUTCH RELEASE SWITCH Removal

Disconnect negative battery cable. Remove electrical connector from switch. Remove bolt from clutch switch and remove clutch switch.

Installation

To install, reverse removal procedure. Adjust clutch switch. See CLUTCH RELEASE SWITCH under ADJUSTMENTS. CRUISE CONTROL MODULE NOTE:

Adjust cruise control cable if cruise control module is removed or replaced.

Throttle operation could be affected.

Removal

Disconnect negative battery cable. Remove module connector retainer clip. Disconnect cruise control module electrical connector. Disconnect cruise cable from accelerator. Remove cruise module retaining nuts. Remove cruise control module.

Installation

To install, reverse removal procedure. Tighten module retaining bolt to 44 INCH lbs. (5 N.m).

CRUISE CONTROL SWITCH Removal & Installation

Remove air bag. See AIR BAG (INFLATOR) MODULE . Remove cruise switch mounting screws.

Disconnect cruise switch connector and remove switch. To install, reverse removal procedure. Tighten cruise switch mounting screws to 28 INCH lbs.(3.2 N.m).

SIR COIL ASSEMBLY CAUTION: To center coil assembly, set front wheels in straight-ahead position before removing or installing coil assembly. If an off-centered coil assembly is installed, ribbon in coil assembly will break when steering wheel is turned.

After coil removal, always keep ignition switch in LOCK position to Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:25:40 PM

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

prevent steering shaft from turning and causing coil assembly to be off centered.

Removal

1. Set front wheels in straight-ahead position, and turn ignition switch to LOCK position. Remove air bag module and steering wheel. See AIR BAG (INFLATOR) MODULE and STEERING WHEEL. 2. Remove upper steering column cover. Turn ignition switch to ACC position, depress lock button, and remove ignition lock bezel. Remove lower steering column cover. Disconnect SIR coil assembly electrical connectors. Disconnect horn and cruise switch connectors. To prevent coil assembly from rotating, insert Yellow tab (if available) into coil assembly, or securely tape coil assembly in present position. Remove coil assembly from shaft.

Installation

1. Route coil wiring down through column, and install coil to lever control switch. If installing original coil, remove tape from coil assembly before installing steering wheel.

2. New SIR coil assembly is pre-centered and held in center position by Yellow tab. Remove Yellow tab, after steering wheel is installed, by pulling tab out through opening in steering wheel. To complete installation, reverse removal procedure. Activate SIR system. See DISABLING & ACTIVATING AIR BAG SYSTEM .

STEERING WHEEL Removal

1. Set front wheels in straight-ahead position. Turn ignition switch to LOCK position. Remove air bag module. See AIR BAG (INFLATOR) MODULE . Disconnect horn switch connector and cruise control switch connector.

2. Remove and discard steering wheel nut. Using Steering Wheel Puller (J-1859-03), remove steering wheel.

DO NOT install puller bolts too deeply into center hub, as SIR coil assembly will be damaged.

3. After steering wheel is removed, prevent coil assembly from rotating by inserting Yellow tab (if available) into coil assembly, or tape coil assembly in place.

Installation

1. Ensure front wheels are straight ahead. Remove Yellow tab or tape from coil assembly. Install steering wheel to steering shaft. Steering wheel and steering shaft have locating notches or flats, allowing steering wheel to be installed in one position only.

2. Tighten NEW steering wheel nut to 30 ft. lbs. (41 N.m). To install remaining components, reverse removal procedure. Activate SIR system. See DISABLING & ACTIVATING AIR BAG SYSTEM .

VEHICLE SPEED SENSOR (VSS) Removal Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:25:40 PM

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

Disconnect negative battery cable. Raise vehicle on lift. Disconnect speed sensor electrical connector. Remove speed sensor. Inspect "O" ring for damage and replace if necessary.

Installation

To install, reverse removal procedure. Tighten speed sensor to 19 ft. lbs. (26 N.m). Lubricate fastener with transaxle fluid.

WIRING DIAGRAMS

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

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1996 Saturn SC2 CRUISE CONTROL SYSTEM 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Cruise Control System

Fig. 3: Cruise Control System Wiring Diagram (Saturn)

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1996 Saturn SC2 DEFOGGER - REAR WINDOW 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Rear Window Defogger

DEFOGGER - REAR WINDOW 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Rear Window Defogger

DESCRIPTION & OPERATION Heated rear window defogger system consists of a window with a series of grid lines baked on inside surface of glass. A break in an individual grid line would prevent current flow through that line. A control switch and relay control power to defogger grid.

Defogger grid circuit is protected by a 25-amp RR DFG (rear defogger) fuse, located in underhood junction block. Control switch and relay circuits are protected by a 7.5-amp IGN3 (ignition 3) fuse located in instrument panel junction block.

When control switch is moved to ON position, relay coil circuit is grounded, causing relay contacts to close.

Current is directed to defogger grid. An indicator light on control switch comes on to indicate system is on.

Chime module, located on instrument panel junction block, turns system off after 15 minutes (after 7 1/2 minutes if system has already operated through a 15-minute cycle).

ON-VEHICLE SERVICE GRID FILAMENT REPAIR 1. Clean area to be repaired with methylated spirits or window cleaner. Wipe using a clean dry towel to remove dust and grease. Place a strip of masking tape on each side of broken section of grid filament. See Fig. 1 . Apply repair compound to broken area. Overlap both broken ends of existing grid filament by about 3/4".

NOTE:

Allow 24 hours for complete cure of repair material.

2. Carefully remove masking tape from repaired filament. Allow repair compound to cure for 24 hours at room temperature or use a heat gun. Holding heat gun 2 inches from repaired area, apply 500-700°F (260371°C) heat for about 2 minutes. Check rear defogger operation.

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1996 Saturn SC2 DEFOGGER - REAR WINDOW 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Rear Window Defogger

Fig. 1: Repairing Rear Defogger Grid Element (Coupe, Sedan, Wagon)

TROUBLE SHOOTING Before performing following trouble shooting procedures, ensure circuit ground, circuit wiring harness and circuit fuses are okay. Also, ensure all circuit connections are clean and tight.

REAR DEFOGGER INOPERATIVE Check Defogger Relay

All relays on instrument panel junction block are interchangeable. Temporarily replace defogger relay with known-good relay and check to see if system operates.

Check (Rear Defogger) RR DEF 25-Amp Fuse

The 25-amp is located in underhood junction block. If fuse is blown, check circuit No. 1240A (Orange wire) for short to ground. Repair circuit and replace fuse as needed.

REAR DEFOGGER & INDICATOR LIGHT DOES NOT OPERATE Check Ignition Fuse No. 3 (Maxifuse)

The 30-amp maxifuse is located in underhood junction block. If A/C fan, power windows, Anti-Lock Brake System (ABS), alternator and cruise control are operating normally, fuse is most likely good. If fuse is blown, check circuit No. 102A (Red wire) for short to ground. Repair circuit and replace fuse as needed. If fuse is good, go to next item.

Check Ignition Fuse No. 3 (Minifuse) Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:27:47 PM

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1996 Saturn SC2 DEFOGGER - REAR WINDOW 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Rear Window Defogger

The 7.5-amp minifuse is located in instrument panel junction block. If alternator, chime and DRL system are operating normally, fuse is most likely good. If fuse is blown, check window relay. All junction block relays are interchangeable. Substitute a known-good relay from either junction block to check system. Repair as needed. If fuse is good, go to next item.

Check Instrument Panel Splice Pack

Instrument panel splice pack is taped to instrument panel harness, behind instrument panel cluster. Splice pack provides a ground path for instrument panel components. If instrument panel dimmer switch, cruise control, headlight switch, lighter and transaxle shift program switch are operating normally, ground circuit is most likely good. If instrument panel dimmer switch, cruise control, headlight switch, lighter and transaxle shift program switch are not operating normally, check ground circuit for poor connection or open. If okay, go to next item.

Check Circuit No. 102A (Red Wire)

Circuit No. 102A (Red wire) connects underhood junction block connector cavity "B" to ignition switch connector cavity "A". Circuit supplies battery voltage to ignition switch. Check for shorts and repair as needed.

If okay, go to next item.

Check Circuit No. 300 (Orange Wire)

Circuit No. 300 (Orange wire) connects ignition switch connector cavity "B" to instrument panel junction block connector cavity F9. Circuit supplies battery voltage to instrument panel junction block. Check for shorts and repair as needed. If okay, go to next item.

Check Defogger Switch

Turn defogger switch on. If resistance across defogger switch terminals is more than one ohm, replace defogger switch.

Check Chime Module

Chime module is not repairable. If other components in system operate, replace chime module with knowngood module. If problem is corrected, reinstall old chime module to verify problem is in chime module.

REAR DEFOGGER & INDICATOR LIGHT ARE STUCK ON Check Defogger Switch

Turn defogger switch on. If resistance across defogger switch terminals is more than one ohm, replace defogger switch.

Check Chime Module

Chime module is not repairable. If other components in system operate, replace chime module with knowngood module. If problem is corrected, reinstall old chime module to verify problem is in chime module.

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1996 Saturn SC2 DEFOGGER - REAR WINDOW 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Rear Window Defogger

TESTING SYSTEM OPERATION TEST Turn ignition switch to ON position. Turn defogger switch to ON position. Defogger relay should click and indicator light on switch should glow. Power should be available at defogger grid. System should stay on for 15 minutes (or 7 1/2 minutes if system has already operated through a 15-minute cycle).

GRID FILAMENT TEST NOTE:

Grid filament locations are on opposite sides for Wagon.

1. Turn ignition switch to ON position. Turn defogger switch to ON position. Using a voltmeter, measure voltage at driver's side "C" (Coupe and Sedan) of suspect grid filament. See Fig. 2 . Slowly move voltmeter lead toward passenger side "B" (Coupe and Sedan). If reading slowly drops as lead is moved, grid filament is okay.

2. If reading remains at battery voltage until it suddenly drops to zero volts, an open exists at point of voltage drop. Repair grid filament. See GRID FILAMENT REPAIR under ON-VEHICLE SERVICE.

Fig. 2: Testing Grid Line Voltage (Coupe & Sedan Shown; Wagon Sides Are Reversed) Courtesy of GENERAL MOTORS CORP.

REMOVAL & INSTALLATION DEFOGGER SWITCH Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:27:48 PM

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1996 Saturn SC2 DEFOGGER - REAR WINDOW 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Rear Window Defogger

Defogger switch is incorporated with fog lamp and traction control switch (POD switches) located at center of instrument panel. Removal and installation information is not available from manufacturer.

DEFOGGER RELAY Relay is located under instrument panel, to right of steering column, on instrument panel junction block.

WIRING DIAGRAM

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1996 Saturn SC2 DEFOGGER - REAR WINDOW 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Rear Window Defogger

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1996 Saturn SC2 DEFOGGER - REAR WINDOW 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Rear Window Defogger

Fig. 3: Rear Window Defogger System Wiring Diagram (All Models)

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1996 Saturn SC2 HEADLIGHT DOORS 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Headlight Doors

HEADLIGHT DOORS 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Headlight Doors

DESCRIPTION Automatic headlight doors are used on Saturn Coupe. Headlight door system consists of 2 fuses, headlight switch, right and left headlight door motors and headlight door module.

OPERATION Concealed headlights are raised and lowered by a reversible motor located near headlight doors. Headlight doors will open automatically when headlight switch is turned on. Headlight doors will remain open with headlights off when headlight switch is turned on, then to OPEN position. Headlight doors will automatically close when headlight switch is turned off.

MANUALLY OPERATING HEADLIGHT DOORS Manual headlight door opening knob is located under hood, next to headlight doors. To manually open headlight doors, remove Black boot at headlight assembly. Turn knob clockwise until doors are fully open. To close doors, turn knob counterclockwise. Install Black boot.

ADJUSTMENTS HEADLIGHT DOOR 1. Remove headlight trim bezel screws from headlight housing. See Fig. 1 . Manually lower headlight and detach trim bezel from lower inside corner of headlight assembly. Manually open headlight to fully open position and remove headlight trim bezel.

2. Make horizontal adjustment by loosening bracket-to-panel screws and positioning as necessary. Make vertical adjustment by loosening bracket-to-headlight housing screws and positioning as necessary.

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© 2004 Mitchell Repair Information Company, LLC.

1996 Saturn SC2 HEADLIGHT DOORS 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Headlight Doors

Fig. 1: Removing Headlight Trim Bezel (SC1 & SC2) Courtesy of GENERAL MOTORS CORP.

TROUBLE SHOOTING WARNING: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

HEADLIGHT DOORS FAIL TO OPERATE 1. Check for blown right or left headlight door fuse located in underhood junction block. Check for open or short in ground circuit located behind left headlight. Check for open or short in headlight door power circuit wiring between specified terminals. See HEADLIGHT DOOR WIRING CIRCUIT table. See Fig. 2.

HEADLIGHT DOOR WIRING CIRCUIT Wire Color

(1)

Between Terminals

Pink

(2)

"B" & (3) C12

Yellow

(4)

"B" & (2) "A"

(4)

Dark Green

"J" & (2) "D"

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1996 Saturn SC2 HEADLIGHT DOORS 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Headlight Doors

Orange

(2)

"C" & (3) D1

Orange

(2)

"E" & (3) B1

Light Green

(5)

"D" & (6) "C"

Dark Green

(5)

"C" & (6) "B"

Light Blue

(5)

"A" & (7) "C"

Dark Blue

(5)

"B" & (7) "B"

(1)

See Fig. 2 -5.

(2)

At headlight door module 6-pin connector.

(3)

At underhood junction block.

(4)

At headlight switch connector.

(5)

At headlight door module 4-pin connector.

(6)

At left headlight door motor connector.

(7)

At right headlight door motor connector.

2. Check resistance between headlight switch terminals. See HEADLIGHT SWITCH RESISTANCE table.

See Fig. 3 . Also check for open or short in headlight switch circuit.

HEADLIGHT SWITCH RESISTANCE Terminals Switch Position "A" To "B" Off "A" To "B" Door Open "A" To "B" Park "A" To "B" Headlights "A" To "B" High Beam "A" To "C" Off "A" To "C" Door Open "A" To "C" Park "A" To "C" Headlight "A" To "C" High Beam "B" To "C" Off "B" To "C" Door Open "B" To "C" Park "B" To "C" Headlight "B" To "C" High Beam "C" To "E" Off "C" To "E" Door Open

Resistance Less Than One Ohm Less Than One Ohm Less Than One Ohm Less Than One Ohm Open Open Open Open Less Than One Ohm Open Open Open Open Less Than One Ohm Less Than One Ohm Open Open

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1996 Saturn SC2 HEADLIGHT DOORS 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Headlight Doors

"C" To "E" "C" To "E" "C" To "E" "F" To "J" "F" To "J" "F" To "J" "F" To "J" "F" To "J" "F" To "K" "F" To "K" "F" To "K" "F" To "K" "F" To "K"

Park Headlight High Beam Off Door Open Park Headlight High Beam Off Door Open Park Headlight High Beam

Open Open Less Than One Ohm Less Than One Ohm Open Open Open Open Open Open Less Than One Ohm Less Than One Ohm Less Than One Ohm

3. Check continuity through headlight door right and left motor windings. Ensure all electrical connections are clean and tight. Check linkage for mechanical binding by manually operating headlight doors. Inspect body surrounding headlight doors for damage that may prevent doors from opening properly. Ensure battery is fully charged.

4. If one door motor is not working, cross-connect wiring between left and right motors. This will determine if problem is in motor, wiring or headlight module. Turn knob on top of motor. If output shaft does not turn, replace motor. Repair or replace components and/or wiring as necessary.

Fig. 2: Headlight Door Module Connector Terminal ID (SC1 & SC2) Courtesy of GENERAL MOTORS CORP.

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© 2004 Mitchell Repair Information Company, LLC.

1996 Saturn SC2 HEADLIGHT DOORS 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Headlight Doors

Fig. 3: Headlight Switch Connector Terminal ID (SC1 & SC2) Courtesy of GENERAL MOTORS CORP.

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© 2004 Mitchell Repair Information Company, LLC.

1996 Saturn SC2 HEADLIGHT DOORS 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Headlight Doors

Fig. 4: Headlight Door Motor Connector Terminal ID (SC1 & SC2) Courtesy of GENERAL MOTORS CORP.

Fig. 5: Underhood Junction Block Connector Terminal ID (SC1 & SC2) Courtesy of GENERAL MOTORS CORP.

TESTING Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:27:19 PM

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1996 Saturn SC2 HEADLIGHT DOORS 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Headlight Doors

Testing information is not available from manufacturer.

REMOVAL & INSTALLATION WARNING: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

HEADLIGHT ASSEMBLY Removal & Installation

1. Remove headlight trim bezel screws from headlight housing. See Fig. 1 and Fig. 6 . Manually lower headlight and detach trim bezel from lower inside corner of headlight assembly. Manually open headlight to fully open position and remove headlight trim bezel.

2. Remove headlight door panel screws from headlight housing. Manually lower headlight. Slide headlight door panel rearward, disengaging from bracket flange. Disconnect spring and disengage adjusters from headlight retainer. Remove headlight from housing and disconnect electrical connector.

3. Remove retaining screws and fasteners from lower front half of wheelwell liner. Remove nuts and reinforcement plate from fender-to-bumper fascia joint, and lower rear of bumper fascia. Remove bolts from parking light. Remove parking light and disconnect electrical connector.

4. Remove fender-to-upper motor rail bolts. Remove stud plate. Pull fender outward and remove headlight housing bolt. Remove remaining headlight housing bolts. Disconnect electrical connector and remove headlight assembly. To install, reverse removal procedure.

HEADLIGHT DOOR MOTOR Removal & Installation

1. Disconnect negative battery cable. Remove air duct plastic fasteners from upper tie bar. Remove air duct retaining screws from lower bumper fascia and air deflector. Remove air duct bolts from lower tie bar.

Carefully pull lower bumper fascia forward and remove air duct.

2. Disconnect headlight door motor electrical connectors. See Fig. 6 . Remove headlight trim bezel screws from headlight housing. Manually lower headlight and detach trim bezel from lower inside corner of headlight assembly. Manually open headlight to fully open position and remove headlight trim bezel.

3. Disconnect spring and disengage adjusters from headlight retainer. Remove headlight from housing and disconnect electrical connector. Remove nut from headlight door motor shaft. Remove headlight door motor retaining bolts from headlight housing. Disconnect headlight door linkage and remove headlight door motor.

4. To install, reverse removal procedure. Apply Loctite No. 242 to headlight door motor shaft nut. Torque motor shaft nut to 46 INCH lbs. (5.2 N.m).

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Š 2004 Mitchell Repair Information Company, LLC.

1996 Saturn SC2 HEADLIGHT DOORS 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Headlight Doors

Fig. 6: Headlight Door Component Locations (SC1 & SC2) Courtesy of GENERAL MOTORS CORP.

WIRING DIAGRAM

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1996 Saturn SC2 HEADLIGHT DOORS 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Headlight Doors

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1996 Saturn SC2 HEADLIGHT DOORS 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Headlight Doors

Fig. 7: Headlight Door Wiring Diagram (SC1 & SC2)

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1996 Saturn SC2 INSTRUMENT PANEL 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Analog Instrument Panel

INSTRUMENT PANEL 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Analog Instrument Panel

DESCRIPTION & OPERATION The instrument cluster uses an electronic analog speedometer with stepper motor-driven odometers, analog fuel gauge and telltale indicator lights. The cluster is back-lit for nighttime illumination.

ANTI-LOCK BRAKE SYSTEM WARNING INDICATOR The ANTI-LOCK brake system warning indicator comes on as a bulb check when ignition switch is first turned to ON position. The indicator is controlled by the ABS module. The ABS system has a built-in self-check feature. The ABS self-check will be performed each time the engine is started. Indicator will come on if the ABS system is malfunctioning. Indicator will flash while driving if ABS system is functioning but requires service. Indicator will remain on until ignition switch is turned off or ABS system malfunction is repaired.

BATTERY (CHARGE) INDICATOR The battery (charge) indicator comes on as a bulb check when ignition switch is turned to the ON position, and remains on until voltage regulator senses voltage output from the generator. The indicator is controlled by a voltage regulator located within the generator. Indicator will come on if there is a malfunction in the charging system. Indicator will remain on until ignition switch is turned off or charging system malfunction is repaired.

BRAKE SYSTEM WARNING INDICATOR The BRAKE system warning indicator comes on as a bulb check when ignition is turned on. The indicator is controlled by a low brake fluid switch, ABS module or parking brake switch. Indicator will come on if brake fluid level is low, a mechanical malfunction occurs in the ABS system or the parking brake is engaged.

Indicator will remain on until ignition switch is turned off, brake fluid level is returned to normal, ABS system malfunction is repaired or parking brake is released.

COOLANT TEMPERATURE GAUGE Gauge receives a variable resistance signal from the coolant temperature gauge sender. If coolant temperature reaches 250°F (122°C) (Red zone), A/C should be turned off. Engine should then be turned off and allowed to cool.

COOLANT TEMPERATURE INDICATOR The coolant temperature indicator comes on as a bulb check when ignition is turned on. The indicator is controlled by the Powertrain Control Module (PCM). Indicator will also come on if the coolant temperature has exceeded the normal temperature, if the automatic transaxle has an overheat condition or if the radiator cooling fan is malfunctioning. Indicator will remain on until ignition switch is turned off, coolant or automatic transaxle fluid temperature returned to normal or radiator cooling fan is repaired.

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© 2004 Mitchell Repair Information Company, LLC.

1996 Saturn SC2 INSTRUMENT PANEL 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Analog Instrument Panel

FUEL GAUGE Fuel gauge receives a variable resistance signal from the fuel sender located in the fuel tank. The fuel gauge only operates when the ignition switch is in the ON position.

LOW COOLANT INDICATOR The LOW COOLANT indicator comes on as a bulb check when ignition is turned on. The indicator is controlled by a coolant level switch. Indicator will come on if coolant level is low. Indicator will remain on until ignition switch is turned off or coolant level is returned to normal.

OIL PRESSURE INDICATOR The oil pressure indicator comes on as a bulb check when ignition is turned on and remains on until oil pressure increases enough to open the oil pressure switch. The indicator is controlled by an oil pressure switch on SOHC or an oil pressure sender/switch on DOHC. Indicator will come on if the oil pressure has dropped to less than the normal operating range or the oil level is low. Indicator will remain on until ignition is turned off or oil pressure or oil level is returned to normal.

SERVICE ENGINE SOON INDICATOR The SERVICE ENGINE SOON indicator comes on as a bulb check when ignition is turned on. The indicator is controlled by the Powertrain Control Module (PCM). If indicator remains on while driving, a problem may exist with the engine control system, emission control system or automatic transaxle. Indicator will remain on until ignition is turned off or malfunction is repaired.

SHIFT TO D2 INDICATOR The SHIFT TO D2 indicator comes on as a bulb check when ignition switch is turned on. The indicator is controlled by the transmission controller located within the Powertrain Control Module (PCM). If indicator remains on while driving, a problem may exist with the automatic transmission control system. Indicator will remain on until ignition switch is turned off or malfunction is repaired.

SPEEDOMETER Powertrain Control Module (PCM) controls the speedometer. A high-to-low square wave signal is received by speedometer drive integrated circuit and produces pulses that are sent to speedometer drive coil. The integrated circuit also counts input pulses to drive odometer stepper motor.

UPSHIFT INDICATOR The upshift indicator comes on to inform vehicle operator when to shift to the next highest gear for maximum fuel economy. The indicator is controlled by the Powertrain Control Module (PCM).

TACHOMETER Electronic Ignition (EI) system module controls the tachometer. A low-to-high square wave signal is received Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:26:41 PM

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1996 Saturn SC2 INSTRUMENT PANEL 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Analog Instrument Panel

and produces pulses that are converted to RPM. Engine should never be operated if tachometer reading is in the Red zone.

AIR BAG PRECAUTIONS The following precautions should be taken when working with vehicles equipped with Supplemental Inflatable Restraint (SIR) air bag systems: z

z

z

Before performing any instrument panel testing, diagnosis or repair, disable SIR system by disconnecting negative battery cable and Yellow 2-pin connector at base of steering column.

Wait 20 minutes before making SIR repairs. SIR system retains enough voltage to deploy air bag for a short time after disconnecting power.

To avoid accidental air bag deployment, avoid SIR wiring harness when trouble shooting instrument panel components. All SIR wires are color-coded Yellow.

TESTING CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

INSTRUMENT CLUSTER RESISTANCE CHECK Instrument Cluster Inoperative/Inaccurate

1. Remove instrument cluster and place it upside down on anti-static mat. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Perform all resistance checks for suspect gauge between connector terminals noted in INSTRUMENT CLUSTER GAUGE CIRCUIT CONTINUITY CHECK table. Fuel and coolant temperature gauge checks should be made between metal clips that connect gauge to printed circuit board and specified terminal.

2. Ensure measured resistance for all checks is equal to or less than one ohm. If any resistance check is greater than one ohm, replace printed circuit board.

INSTRUMENT CLUSTER GAUGE CIRCUIT CONTINUITY CHECK Gauge Connector/Terminal Speedometer/Odometer C4/1 To C1/L Speedometer/Odometer C4/2 To C2/K Speedometer/Odometer C4/3 To C2/J Speedometer/Odometer C4/4 To C2/I Speedometer/Odometer C4/5 To Left Side Of ABS Bulb Tachometer C3/1 To Right Side Of ABS Bulb Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:26:41 PM

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© 2004 Mitchell Repair Information Company, LLC.

1996 Saturn SC2 INSTRUMENT PANEL 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Analog Instrument Panel

Tachometer Tachometer Tachometer Fuel Gauge Fuel Gauge Fuel Gauge Coolant Temperature Gauge Coolant Temperature Gauge Coolant Temperature Gauge

C3/2 To C1/L C3/3 To C1/K C3/4 To C2/K FUEL To C2/B B+ To C2/H GND To C2/K TEMP To C1/D B+ To C1/L GND To C1/E

SPEEDOMETER TEST Speedometer Inoperative

1. If speedometer is completely inoperative, check internal power supply. Turn ignition on, engine off.

Measure voltage (backprobe) between Natural color IPC 18-pin connector terminals "J" (Dark Blue/White wire) and "K" (White wire). If 7 volts or more are present, internal power supply is okay. Go to next step. If voltage is less than 7 volts, see INSTRUMENT CLUSTER RESISTANCE CHECK .

2. Turn ignition on. Using scan tool, observe status of SPEEDO FEEDBACK. If feedback status is high, go to step 4). If feedback status is not high, turn ignition off. Disconnect PCM J1 connector. Turn ignition on. Connect voltmeter between PCM connector terminal J1D06 (Dark Green wire) and ground.

3. If battery voltage is present, check for good terminal contact at PCM connector. If battery voltage is not present, turn ignition off. Reconnect PCM connector. Disconnect Black IPC connector. Connect fused jumper wire between IPC connector terminals "H" (Black wire) and "J" (Dark Green wire). If SPEEDO FEEDBACK status is HIGH, see INSTRUMENT CLUSTER RESISTANCE CHECK . If SPEEDO FEEDBACK status is not HIGH, repair open or short circuit to ground in Dark Green wire. If wire is okay, check for good terminal contact at PCM. 4. Drive vehicle for a short distance and observe status of SPEEDO FEEDBACK. If status toggles between HIGH and LOW, see INSTRUMENT CLUSTER RESISTANCE CHECK . If speedometer does not toggle between HIGH and LOW, disconnect Black IPC connector. If feedback status stays HIGH, check for short circuit to voltage in Dark Green wire. If circuit is okay, check for poor terminal contact at PCM. If feedback status does not stay HIGH, see INSTRUMENT CLUSTER RESISTANCE CHECK. Speedometer Inaccurate

1. Turn ignition on. Using scan tool, select "1.5 MPH/8KPH ()". Note speedometer position, then continue until test is completed.

2. If speedometer is 0-4 MPH, system is okay. If speedometer is not 0-4 MPH, check all system connectors and wiring. If all circuits are okay, see INSTRUMENT CLUSTER RESISTANCE CHECK .

FUEL GAUGE TEST Fuel Gauge Inaccurate

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1996 Saturn SC2 INSTRUMENT PANEL 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Analog Instrument Panel

1. Disconnect in-line fuel connector located in rear compartment, on driver side. Connect DVOM and Tester (SA9205Z) to terminals "B" (Black/White wire) and "C" (Purple wire). With engine off, turn ignition switch to RUN position.

2. Fuel gauge should indicate between full and empty depending on resistance setting. See FUEL GAUGE RESISTANCE table. Test fuel gauge beginning with low resistance setting to high resistance setting.

3. If fuel gauge does not operate as specified, replace instrument cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. FUEL GAUGE RESISTANCE Ohms 43.5 73 99 140 236

Fuel Gauge Reading Full 3/4 1/2 1/4 Empty

COOLANT TEMPERATURE GAUGE TEST Gauge Inaccurate

Functionality and accuracy of coolant temperature gauge can be tested by using scan tool which provides direct control of gauge through selectable temperature points. If gauge pointer falls within designated area for all of its test points, then gauge is okay. Check gauge circuits. If gauge pointer does not fall within designated area for all its test points, replace gauge. See COOLANT TEMPERATURE GAUGE TEST POINTS table.

COOLANT TEMPERATURE GAUGE TEST POINTS Test Point 0 2 4 1 3

Coolant Gauge Reading "C" 1/2 "H" 1/4 3/4

TACHOMETER TEST Tachometer Inaccurate

Use scan tool to compare RPM on tachometer to RPM on scan tool. Operate engine at several different speeds to verify if tachometer is operating correctly. If scan tool displays an RPM but tachometer does not, see INSTRUMENT CLUSTER RESISTANCE CHECK .

HEADLIGHT SWITCH Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:26:41 PM

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1996 Saturn SC2 INSTRUMENT PANEL 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Analog Instrument Panel

For testing information on headlight switch, see STEERING COLUMN SWITCHES article.

REMOVAL & INSTALLATION WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM procedures in appropriate AIR BAG RESTRAINT SYSTEM article.

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

INSTRUMENT CLUSTER Removal & Installation

1. Disable SIR system. See AIR BAG PRECAUTIONS . Remove screws from Diagnostic Link Connector (DLC) and steering filler panel. Remove hood release cable from lever. Remove steering column filler panel. Disconnect ignition switch electrical connector at right steering column bolt.

2. Remove steering column bolts and lower column on front seat. Remove bolts and pull instrument cluster trim bezel rearward at clip locations. Disconnect electrical connector from instrument panel dimmer switch. Disconnect electrical connectors from instrument panel cluster. Remove front and rear instrument panel cluster assembly screws. Remove instrument panel cluster assembly. See Fig. 1 . To install, reverse removal procedure.

Fig. 1: Removing Instrument Cluster (Saturn) Courtesy of GENERAL MOTORS CORP. Helpmelearn Repair Manuals Wednesday, February 15, 2006 7:26:41 PM

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1996 Saturn SC2 INSTRUMENT PANEL 1996 ACCESSORIES & EQUIPMENT General Motors Corp. Analog Instrument Panel

WIRING DIAGRAM

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