Recall - Roof Panel Assembly: Overview
Bulletin No:96-C-01
Date:
February, 1996
Group:
BDCR SAFETY
PRODUCT CAMPAIGN BULLETIN
SUBJECT: ROOF PANEL ASSEMBLY
YEAR and MODEL: 1996 SATURN WAGONS
TO: ALLSATURN RETAILERS and AUTHORIZED SERVICE PROVIDERS
The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a product campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to adequately repair within sixty (60) days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge, or a refund of the purchase price, less a reasonable allowance for depreciation.
To avoid having to provide these burdensome soutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the owner letter, owners are being instructed to contact the Saturn Assistance Center if their Retailer does not remedy the condition within five (5) days of the service date. If the condition is not remedied within a reasonable time, owners are instructed how to contact the National Highway Traffic Safety Administration.
DEFECT INVOLVED
Saturn has decided that a defect that relates to motor vehicle safety exists in some 1996 Saturn Wagons produced before January 2, 1996. Some of the welds between the roof and roof internal reinforcement panels may not meet specifications. In c vrash there is possibility of a partial separation of the roof panel flange sides, exposing an occupant to an increased risk of injury.
The action being taken to correct this condition is the installation of structural fasteners along the vehicle roof flange, on both sides of the vehicle.
VEhICLES INVOLVED
Saturn Wagons in the following VIN range will require this campaign, except for the VINs on the listing included in this bulletin. (Refer to "Non-Involved Vehicles within VIN Range.")
TZ161695 through TZ238354
Also, the following VINs not in the above range are to be included in this campaign:
TZ240509, TZ241168
Because Saturn builds by sequence order, which does not always match VIN order, there were some non-involved vehicles within the VIN range that do not require this campaign. These exclusions are comprehended in the attached listing of non-involved vehicles. It is important to note that campaign claims will only be paid on involved vehicles.
OWNER NOTIFICATION
Owners of 1996 Wagons involved will be notified of th is campaign by Saturn. Saturn will also notify owners of 1996 Wagons non-involved by this condition, that their vehicles are not involved in this campaign. This will alleviate any concerns these customers may have regarding this issue. (Refer to the Involved and Non-Involved owner letters included in this bulletin.)
FACILITY VIN LISTING
A list of vehicles assigned to you (Facihiy VIN Listing), which our records indicate were sold by or shipped to you, (or are located in close proximity to your facility) is enclosed.
This listing contains:
- Owner's name with address and telephone number;
- Complete Vehicle Identification Number (VIN); and
- VIN's of vehicles, which according to Saturn records are in retail stock
The Facility VIN Listing (with owner information) is furnished to involved Retailers with the Product Campaign Bulletin. Although these vchicles are assigned to your facility, it is important to note that owners may elect to have their vehicle serviced at the Saturn Retail Facility of their choice.
Those Retailers not involved initially in this campaign will receive a message at the top of a blank Facilify VIN Listing that states: NO VEHJCLES ASSIGNED AT THIS TIME FOR CAMPAIGN 96C01.
These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of the law ]n several states. Accordingly, you are urged to limit the use of this listing to the follow up necessary to complete this campaign. Those records updated with Califnrnia DMV registration information will have the following message printed adjacent to the appropriate VIN: "OWNER INFORMATION UPDATED BY CALIFORNIA DMV; PUBLICATION PROHIBITED."
REMOTE OWNER STRATEGY
In order to minimize customer inconvenience aud eusure the highest level of customer satisfaction, owners who live in a remote location from an open Saturn Retail Facility may be contacted by Saturn to arrange to have their vehicles serviced in a manner convenient to them. Therefore, you may notice that not all vehicles which were sold by you are on your Facility VIN Listing.
RETAILER RESPONSIBILITY
All unsold new vehicles in Retailers' possession and subject to this campaign must be held at the retail facility and repaired per the service procedure of this campaign bulletin before owners take possession of these vehicles.
Retailers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.
Owners of vehicles that appear on your facility VIN listing are to be contacted by the Retailer and arrangements made to make the required correction according to procedure contained in this bulletin.
In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your retail facility for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.
TRANSFER OF CAMPAIGN RESPONSIBILITY
Saturn vehicles that have been sold by you, which may be closer in proximity to another Saturn Retailer, may still appear on your Facility VIN Listing. If either you or the vehicle owner determines that it is more desirable for a vehicle on your Facility VIN Listing to be serviced by another Saturn Retailer, campaign responsibility may be transferred by 1) submitting a Campaign Vehicle Action Report to your field representative, or 2) submitting an update in owner information to the Saturn Owner of Record system, via SERVICELINE, for Field Organization review and approval. A copy of the Campaign Velucle Action Report can be found in your Service Support Activities Folder. All changes to campaign responsibility will be reflected in your next monthly Unfixed VIN Report.
All other changes in vehicle status (e.g., scrapped, stolen, etc.) are to be made in accordance with section 4.4.3 of the Service Policy and Procedure Manual (Notifying Saturn of Vehicle Status Change).
PARTS INFORMATION
1. A small amount of 3M Butyl Primer, 3M ULTRA PRO Seam Sealer, and 3M Automotive Refinishing 'Tape is required, as indicated in the Service Procedure, and may be procured locally or through 3M Automotive Trade Products, 1(800) 521-8180, extension 6890.
2. A pre-shipment of structural fasteners required to perform this campaign has been automatically sent to you from Saturn Service Parts Operations (SSPO). The initial shipment will be followed up with additional shipments on a fair share basis... so Retailers will not need to order parts, other than the 3M products.
3. Parts questions may be directed to your Saturn Parts Support Analyst.
4. Required Parts:
SUGGESTIONS FOR ENSURING CUSTOMER SATISFACTION
As you know, Saturn's success hinges upon our ability to execute superior customer support throughout the ownership experience, especially when important corrcctive actions such as this are required.
It is imperative that every effort is made to accommodate the affected owners. If you have any questions, please coordinate with the Saturn Assistance Center to help ensure customer satisfaction.
SERVICE PROCEDURES
Materials Needed
- Power Drill
- Center Punch
- Snap-on� Rivet Tool HP2OOA or equivalent rivet tool with the ability to accept 1/8 to 3/16 in. rivets
- Drill Bit Depth Gage/Stop
- 11/64 in. or #20 Machining Drill Bit
- 11/2-2 inch wide Blade Putty Knife
- 3M� Automotive Refinishing Tape PIN 06340 (or equivalent two inch wide masking tape)
- 3M� Butyl Primer (Black) PIN 08643 or equivalent
- 3M� ULTRA PRO Seam Sealer PIN 08302 (Clear) or equivalent
- Structural Fastener PIN21170334 (38 required, 19 per side)
- Safety glasses
CAUTION: PROTECT YOURSELF BY WEARING SAFETY GLASSES WHEN PERFORMING THIS PROCEDURE.
1. Remove left and right side roof side outer front panels:
a. Remove windshield pil:[ar lower side applique by removing one retaining screw and sliding applique up and rearward to allow tab b disengage from key hole.
b. Remove five retaining screws from roof side outer front panel.
c. Slide roof side outer front panel forward to release from roof side outer rear panel.
2. Remove left and right side rear side door frame rear panels:
a. Remove four retaining screws from rear side door frame rear panel.
b. Pull front of panel to disengage tabs from roof side outer rear panel.
c. Pull rear side door frame rear panel upward to disengage from quarter panel.
3. Remove left and right side roof side outer rear panels:
a. Remove three retaining screws from roof side outer rear panel.
b. Slide panel rearward and remove from vehicle.
4. Install a two inch wide strip of 3M Automotive Refinishing Tape P/N 06340 (or equivalent two inch masking tape), along the right and left side edges of the roof above the flanges to protect painted surfaces.
5. With the doors closed, install another two inch wide strip of 3M Automotive Refinishing Tape P/N 06340 (or equivalent two inch masking tape), along the spaceframe and quarter glass to prevent metal filings from falling into the door openings.
6. Locate holes to be drilled by measuring 5-8 mm (3/16-5/16 in.) rear of each existing weldspot, and no further inboard than the center of the weld flange. Avoid locating holes on weldspots or weld indentations. (Refer to facing illustration for location of holes. There will be 19 holes drilled per side.)
7. Mark each hole location with a center punch, leaving a small indentation to prevent drill bit from "wandering" when drilling the holes.
8. Position a putty knife in a vise and bend approximately 19 mm (3/4 in.) from the end, creating a 40-45 degree bend.
9. Wrap the bent end of the putty knife with 3M Automotive Refinishing Tape PIN 06340 (or equivalent two inch masking tape). Insert putty knife between roof and spaceframe when drilling the holes to prevent damage to corrosion protection on spaceframe.
IMPORTANT: Clearance between roof and spaceframe may vary slightly. It some cases, it may be necessary to adjust the roof panel side flange upward to obtain clearance for the drill bit and structural fastener.
10. Drill holes using a 11/64 in. or #20 drill bit with a depth gauge set at 3.175 mm (1/8 in.).
11. Use an air gun or vacuum to clear all metal filings from the side of the vehicle.
12. Using a sponge swab saturated with 3M Butyl Primer (P/N 08643) or equivalent etching primer, daub each hole making sure to coat the bare metal edges. Allow etching primer to air dry according to manufacturer's recommendations.
13. Install and compress (pop) 5/16 in. diameter by 5mm long stainless steel structural fasteners (P/N 21170334) into drilled holes (19 per side).
14. Remove masking tape.
15. Apply 3M ULTRA PRO Seam Sealer (P/N 08302) or equivalent over each structural fastener. After applying seam sealer to structural fasteners, brush over seam sealer with a brush.
16. Using a putty knife as a gage, make sure there is at least a 3 mm (1/8 in.) gap between the base of the structural fasteners and spaceframe. Use the putty knife to adjust the flange upward if needed.
17. Install left and right side roof side outer rear panels:
a. Position roof side outer panel. Slide forward into place.
b. Install three retaining screws. Torque: 1.5 Nm (13 in-lbs)
18. Install left and right side rear side door frame rear panels:
a. Install rear of rear side door frame rear panel into rear quarter panel.
b. Bngage tabs at top of panel to slots in roof side outer rear panel.
c. Install four retaining screws. Tighten in sequence shown. Torque: 1.5 Nm (13 in-lbs)
19. Install left and right side roof side outer front panels:
a. Position roof side outer front panel between fender and cowl. Position to roof and slide into roof side outer rear panel.
b. Install five retaining screws to roof side outer front panel. Tighten in sequence shown. Torque: 1.5 Nm (13 in-lbs)
c. Install left and right side windshield pillar lower side applique. Positidn applique to pillar, slide forward and down until applique contacts fender.
20. Affix the Campaign Completion Label to the radiator core support.
CAMPMGN COMPLETION LABEL
Upon completion of the campaign, a Campaign Completion Label should be affixed on a clean, dry surface of the radiator core support in an area clearly visible when the hood is raised. Each label provides a space to print in ink (or type) the campaign number (96C01) and the five (5) digit facility code of the Retailer performing the campaign service.