Quarter Outer Panel - Extension Bracket Rivets Corroding
BULLETIN NO.: 97-T-1OISSUE DATE: April, 1997
GROUP/SEQ. NO.: Body-03
CORPORATION NO.: 781505
SUBJECT:
Quarter Outer Panel Extension Bracket Rivets Corroding (Replace with New Rivets)
MODELS AFFECTED:
1997 Saturn Coupes built before and including VIN VZ282795
CONDITION:
The quarter outer panel extension bracket rivets are corroding, causing a corrosion stain along the inside forward edge of the quarter panel.
CAUSE:
Bare metal is exposed when the rivet mandrel is sheared during assembly of the quarter panel. Upon exposure to moisture, this bare metal corrodes.
CORRECTION:
Replace quarter outer panel extension bracket rivets with new quarter outer panel extension bracket rivets which have an aluminum mandrel according to the following procedures.
PROCEDURES
1. Remove the pushpin fasteners from the right and left rocker cover panels.
2. Slide rocker cover panel towards front of vehicle, disengaging cover panel from quarter panel, rocker cover panel support and front fender.
3. Remove both rocker cover panels.
NOTICE:
Care should be taken to prevent the quarter panel from being damaged while drilling out the rivets. If too much pressure is applied on the drill, it can cause the rivet head to push through the panel causing damage to the panel. Also, if the rivet head spins, the panel may be damaged.
4. Using a 4.5 mm, 3/16 in. or No. 16 drill bit, carefully drill out the two quarter panel bracket rivets on each side of the vehicle.
^ If any rivet begins to spin, proceed to step 5.
^ If the rivets do not spin, proceed to step 6.
5. If any rivet begins to spin:
^ Remove the two front lower horizontal and vertical attachment bolts on the side of the vehicle where the rivet(s) have spun.
^ Using a pair of pliers, hold the back of the rivet(s) while drilling the rivet(s).
^ Remove all pieces of rivet(s) that fell inside the quarter panel(s).
^ Proceed to step 7.
6. If rivets have not spun:
^ Remove the two front lower horizontal attachment bolts and loosen the lower front vertical fastener on each side of the vehicle.
^ Pull out the lower front portion of the quarter panels and remove the pieces of the rivets that fell inside.
7. Install all quarter panel bolts that were removed.
8. Tighten all quarter panel bolts that were either removed or loosened.
Torque: 10 N.m (89 in-lbs)
9. Apply touch up paint to the exposed substrate around the hole openings in the quarter panel and allow to dry.
10. Install new rivets (P/N 10125439).
11. Position rocker cover panel tabs into slots in front fender, rear quarter panel and rocker cover panel support.
12. Slide rocker cover panels rearward, locking panels in place.
13. Install pushpin fasteners
PARTS REQUIREMENTS:
10125439 Rivet
CLAIM INFORMATION:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as shown.