Two weeks ago, the WPRT came to our town. In case you didn't know, that's the Wrangler Pro Rodeo Tour to all you NFL, NBA and NHL fans across the USA. Except for checking out those custom-painted big rigs that rumbled through town, our daily routine really didn't change much. Heck, we've always had big four-wheel-drives, cowboys and live stock trucks parading up and down the main street.

We try to keep life around here as simple and honest as possible. Most folks in these parts call our daily routine, "just plain, easy living." However, a couple of days after the rodeo hit town, our local tow service dragged this little coupe into our service drive. All of us looked at each other, jaws dropping. One of the technicians asked, "What in carnation is that thing?" "I don't know," I said. "But I have a feeling it's going to be really interesting."

Giant flowers and balloons were painted all over it. Except for the mirror-tinted windshield, all of the other windows were painted too. I think it was the weirdest vehicle I'd ever seen. Reluctantly, I grabbed my clipboard and a repair order and went outside to see what could possibly be the problem with this car - besides the obvious.

Before I could reach the tow truck, this clown jumped out of the passenger side. I'm not kidding, a rodeo clown in full clown attire and make-up. "I've had it in five different shops all over the nation, and no one has figured out this problem yet. It's really starting to bug me." "Whoa, slow down feller," I said. "Why don't you start from the beginning? First, what kind of car is this?"

"It's a 1996 Saturn® with a 1.9 liter, single overhead cam, four cylinder engine," he said. It was funny to hear that kind of information coming out of a clown's mouth. Starting to see the makings of a great story to tell the guys down at the Lodge, I asked, "Okay, and what seems to be the problem?"

"The thing keeps intermittently stalling. When it does run, it runs rough or surges and the 'check engine' light comes on," he related. I gave him an estimate for diagnosing the problem and brought the car into the shop. Before we started, I checked for Technical Service Bulletins (TSBs) for his vehicle in my ALLDATA automotive information system. Yes, that's right. We might be laid back on most things except when it comes to having accurate, current automotive information.

After a quick search, I did find one TSB that matched his description. The TSB stated that some 1995 and 1996 Saturns® built up to and including VIN TZ360348; the engine will crank but not start, start then stall, or surge, run rough and then stall during light throttle conditions. In some cases, one or more diagnostic trouble codes (DTCs) or Information Flags may be present.

The TSB further related that one or more wires located outside of the wiring harness conduit could chafe against the intake manifold. When the insulation on the wire(s) rubs off, it causes a short-to-ground in that particular circuit(s). A short-to-ground in a circuit(s) will cause one or more of the following conditions:

A) Engine cranks but will not start.
The injector B+ circuit may have a chafe in the insulation, causing a short-to-ground. In some cases, the short-to-ground may cause the injector fuse to open. If the fuel injector B+ circuit shorts-to-ground, none of the fuel injectors will energize, preventing fuel delivery to the engine. If the injector B+ circuit shorts-to-ground, DTCs P0201, P0202, P0203, P0204, and/or P1599 may be stored in the PCM memory.

B) Engine starts then stalls, or engine surges or stalls during light throttle condition.
Manifold absolute pressure (MAP) sensor reference voltage circuits may have a chafe in the insulation, causing a short-to-ground. This condition may cause the engine to start then stall or surge, or stall during a light throttle condition. If this reference voltage circuit shorts-to-ground, DTCs 22, 32 or 34, or Information Flags 54 and 76 for 1995 vehicles; or DTCs P0107, P0122, P1107, P1122, P1406, P1599 and/or P1635, for 1996 vehicles may be stored in the PCM memory.

C) Engine misfires, stalls, or runs rough.
The fuel injector ground circuit(s) may have chafed insulation, causing a short-to-ground. This condition may cause the fuel injector to deliver fuel to the engine when not required. If the injector ground circuit(s) short-to-ground, DTC 45 for 1995 vehicles or DTCs P1599, P0172, P0201, P0202, P0203, P0204, P0300, P0301, P0302, P0303 and/or P0304 for 1996 vehicles may be stored in the PCM memory.

	NOTE: Refer to the illustration for location of where wires may chafe against the intake manifold.
	Use the following procedure to verify and repair the condition.
	1. Check wiring conduit to see if any wire(s) are outside of the conduit. If wire(s) are located outside of the conduit, disconnect wires from injectors and MAP sensor and pull the harness down through the intake manifold runners
	2. Completely remove the wire(s) from the conduit and check for chafing.
	3. If chafing is evident, use Saturn® approved Packard Crimp and Seal splices (Salmon/Pink [OTC # 217670]) found in the Saturn wire repair kit or equivalent, and repair damaged circuit(s).

The "check engine" light was on, so the technician first checked diagnostic trouble codes and came up with code P0201. This meant that, possibly, an injector ground circuit was shorted-to-ground. Following the TSB harness location information, we quickly found the problem. After making the necessary repairs, he changed the engine oil and filter. (He had noticed the engine oil had been diluted with fuel.) Also, he performed an exhaust back-pressure test in order to check for a possible clogged catalytic converter. It was fine.

With the repairs made and the bill paid our, shall we say, "entertaining" customer drove out as one happy clown. Once again, my ALLDATA automotive information system had salvaged my easy-living lifestyle, and I had a great story to tell the guys down at the Lodge.