Upper Door Frame - Water leaks To Interior
BULLETIN NO.: 94-T-52BISSUE DATE: February, 1996
GROUP/SEQ. NO.: Body-15
CORPORATION NO.: 481506R
SUBJECT:
Waterleak at Front Upper Door Frame
(Adjust Front Upper Door Frame and Apply Sealer to Door Opening Joint[s])
Due to a random collation error by the printer in the previous printing of this bulletin, this bulletin supercedes bulletin 94-T-52A, which should be discarded.
MODELS AFFECTED:
*1991 - 1995 Saturns and 1996 Saturn Coupes*
CONDITION:
Customer may comment of water dripping from top of door frame area.
CAUSE:
This condition may be caused by the seal between the front side door (primary) weatherstrip and space frame. There also may be a low spot in the sealer at the door opening joint(s).
CORRECTION:
Adjust top of door frame inward to achieve a better seal between the front side door (primary) weatherstrip and the space frame. Also, if required, add sealer to door frame joint(s).
PROCEDURE:
1. With the aid of a helper, direct an unrestricted flow of water over the top of door frame, one side of the vehicle at a time.
2. Inspect the top of the door from the inside of the vehicle:
^ If water is leaking between the front side door (primary) weatherstrip and space frame, proceed to the next step.
^ If water is not present in the immediate area, refer to "Waterleaks" in the "General Information" section of the appropriate year "Body/Collision Repair Service Manual" for the vehicle being worked on.
3. Open door and lower door glass to the full-down position.
NOTICE:
Care should be taken not to over bend the door frame which could impair door glass operation or door closing. It is better to adjust the door frame in small increments to achieve the required fit.
4. Grasp the upper door frame at top of frame and carefully pull the door frame inboard along the entire top of door frame.
5. After a slight adjustment has been made, proceed to the next Step and perform the "Dollar Bill" test.
6. Dollar bill test:
a. Place a dollar bill or similar size piece of paper between the front side door (primary) weatherstrip and the contact surface of the space frame, then close the door.
IMPORTANT:
Make sure to leave the window in the full-down position. This equalizes pressure inside the vehicle when the door is closed and allows the dollar bill (or piece of paper) to stay in the correct position.
b. Slowly withdraw the dollar bill or piece of paper after the door is closed to check the amount of pressure on the front side door (primary) weatherstrip.
c. There should be a medium amount of resistance as the dollar bill (or piece of paper) is slowly withdrawn. Continue around the entire upper door frame.
^ If there is little or no resistance, it indicates there is insufficient contact to form a good seal between the front side door (primary) weatherstrip and the space frame. Repeat steps 3 through 6, until door frame is correctly adjusted.
^ If there is a medium amount of resistance, proceed to the next step.
7. After door is properly adjusted, check door glass operation by raising and lowering the door glass. Also, check door operation by opening and closing the door to make sure it operates correctly.
8. To verify that the waterleak has been repaired, apply an unrestricted flow of water over the door frame (as explained in step 1 of this bulletin).
^ If waterleak has been repaired, return vehicle to customer.
^ If waterleak is still present and the vehicle is a:
- Coupe, built after and including VIN PZ317192, proceed to step 9.
- Sedan or Wagon, built after and including VIN PZ317192, proceed to step 10.
^ If waterleak is still present and the vehicle does not fall into the years or VIN ranges given in the previous step, repeat steps 3 through 7 until waterleak is repaired.
9. On Coupes:
a. Make sure door opening space frame lap joints are clean and dry.
IMPORTANT:
Some vehicles may have black tape over existing sealer. Remove and discard this black tape before applying new sealer.
b. Using a seal sealer such as Kent Industries *High Tech Leak Check Seam Sealer, Black (P/N 10070)* or equivalent, fill the two space frame lap joints until flush with the space frame using a flat-bladed tool to keep the sealer smooth.
c. Allow the sealer to completely dry and water test to make sure waterleak has been repaired.
^ If waterleak is still present, repeat steps 3 through 7 until waterleak is repaired.
^ If waterleak has been repaired, return vehicle to customer.
10. On Sedan or Wagon:
a. Make sure door opening space frame lap joint is clean and dry.
IMPORTANT:
Some vehicles may have black tape over existing sealer. Remove and discard this black tape before applying new sealer.
b. Using a seal sealer such as Kent Industries *High Tech Leak Check Seam Sealer, Black (P/N 10070)* or equivalent, fill the one space frame lap joint until flush with the space frame using a flat-bladed tool to keep the sealer smooth.
c. Allow the sealer to completely dry and water test to make sure waterleak has been repaired.
^ If waterleak is still present, repeat steps 3 through 7 until waterleak is repaired.
^ If waterleak has been repaired, return vehicle to customer.
CLAIM INFORMATION:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as shown.