Front Door - Rattle at Belt Line
BULLETIN NO.: 94-T-18ISSUE DATE: May, 1994
GROUP/SEQ. NO.: Body-06
CORPORATION NO.: 481501
SUBJECT:
Rattle in Front Door at Belt Line (Apply Anti-Rattle Material)
MODELS AFFECTED:
1991-1994 Saturns
CONDITION:
When driving and/or shutting the front door, a rattle is heard from the bottom of the door glass.
CAUSE:
Front door glass on Sedans and Wagons, and door glass spanner nuts on Coupes may contact the of outer seal reinforcement.
CORRECTION:
Install anti-rattle material to the outer seal strip reinforcement according to the following procedure.
PROCEDURE
1. Remove screw from mirror trim panel.
2. Loosen forward edge of window frame garnish molding and pull mirror trim panel rearward to disengage from door.
3. Remove foam filler from door frame.
4. Loosen outside rearview mirror attaching nuts.
5. Carefully lift up on outer sealing strip, starting at rear and work forward, releasing from outer belt flange.
6. Position door glass in full-up position.
7. Using a flashlight and marker, mark the center of the door glass spanner nuts on the outboard side of the outer sealing strip retaining flange.
IMPORTANT:
Mark the center of the door's front and rear spanner nuts.
8. Roll door glass to full-down position.
9. Using a clean cotton shop towel wrapped on a flat wooden ruler:
a. Clean inboard side of outer sealing strip reinforcement 76 mm (3 in.) fore and aft of each mark made in step 7.
b. Apply isopropyl alcohol to shop towel and wipe cleaned areas and allow to air dry.
10. Cut two, 102 mm (4 in.) strips of the loop material in a package of 3M(R) SCOTCHMATE Hook and Loop Fastening System (P/N 06480) or equivalent adhesive backed hook and loop material.
11. Using a thin flat ruler, back-wrap (adhesive side out) 25 mm (1 in.) of the ruler's end with masking tape.
12. Center a 102 mm (4 in.) strip of the loop material on the ruler, aligning the bottom edge of the strip with the bottom edge of the ruler. Press the loop material to the masking tape.
13. For the front spanner nut:
a. Peel tape from loop material and insert ruler, with loop material attached, 57 mm (2-1/4 in.) from top of outer sealing strip flange.
IMPORTANT:
Carefully hold glass inboard and keep ruler against glass until proper depth is acquired.
b. Center strip over mark, and press loop material against inside of outer sealing strip reinforcement.
c. Using a nylon or wooden stick (to keep from damaging ELPO coating), rub surface of loop material with pressure to ensure adhesion to the outer sealing strip reinforcement.
14. For the rear spanner nut, repeat steps 13a through 13c.
15. Position door glass to full-up position and inspect for proper placement of loop material.
16. Install outer sealing strip by sliding forward end of sealing strip beneath outside rearview mirror.
17. Align locating tab at rear of sealing strip with slot on door panel.
18. Starting at rear of seal strip, push seal strip down onto flange until fully seated.
Torque: 6 N-m (53 in.lbs.)
19. Tighten mirror attaching nuts.
20. Install foam filler to door frame.
21. Install mirror trim panel, retaining screw and garnish molding.
CLAIM INFORMATION:
To receive credit for this repair, submit a claim through the Saturn Dealer System as follows: (see illustration)