Interior - Rattling From Headliner Area
BULLETIN NO.: 99-T-69BISSUE DATE: August, 2001
CATEGORY TYPE: Body-22
CATEGORY: Interior Trim
CORPORATION NO.: 99-08-59-005B
SUBJECT:
Rattle Noises from Headliner Area
(Install Soft Foam Spacers on Headliner)
This bulletin has been revised to include 2002 model year vehicles and supersedes bulletin 99-T-69A, which should be discarded.
Refer to Technical Bulletin 00-T-17B for information regarding sagging headliners on sedans equipped with power sunroofs (RPO CF5).
MODELS AFFECTED:
2000 - 2002 Saturn L-Series vehicles
CONDITION:
Some customers may comment about rattle noises heard in area of dome lamp, sunroof, or headliner during normal operating conditions.
CAUSE:
Wiring harness rattling between headliner and roof panel, or headliner alone rattling against roof panel.
CORRECTION:
Install soft foam spacers at headliner locations shown in this bulletin.
PROCEDURE
1. Test drive vehicle to verify condition and determine area of headliner rattle.
IMPORTANT:
Refer to Technical Bulletin 00-T-17B to repair sagging headliner condition on sedans equipped with power sunroofs (RPO CF5).
2. Remove headliner from vehicle and place on a clean protected work surface. (Refer to "Headliner" removal procedure in the Interior Trim section of the appropriate model year L-Series Body/Electrical Volume II Service Manual.)
3. Obtain 51 cm (20 in.) of KENT Industries adhesive backed foam (P/N 46515). This foam is 25.4 mm (1 in.) wide, so two pieces will have to be installed side-by-side on headliner to achieve width of spacers necessary.
4. Cut adhesive backed foam into ten equal 51 mm (2 in.) long pieces.
IMPORTANT:
Since foam spacer locations are different between model years, be sure to follow the location description for the model year being repaired.
5. Install adhesive backed foam spacers side-by-side on headliner where indicated in illustrations.
^ Sedan without sunroof requires eight soft foam spacers. Sedan with sunroof requires ten soft foam spacers
^ Wagon requires eight soft foam spacers.
6. Install headliner in vehicle. (Refer to "Headliner" installation procedure in the Interior Trim section of the appropriate model year L-Series Body/Electrical Volume II Service Manual.)
7. Test drive vehicle to verify repair.
On Sedan with sunroof:
On 2000 vehicles
^ Install four soft foam spacers centered 30.5 cm (12 in.) from edge of headliner and centered with dome lamp opening.
^ Install four soft foam spacers at comers of opening for center high-mount stop lamp (CHMSL).
^ Install two soft foam spacers on dome lamp wiring harness loop on passenger side of headliner.
On 2001 and 2002 vehicles
^ Install four soft foam spacers at front cross bow and 40.6 cm (16 in.) from edge of headliner. Install four soft foam spacers at rear cross bow and 40.6 cm (16 in.) from edge of headliner.
On Wagon:
On 2000 vehicles
^ Install four soft foam spacers centered at front cross bow and 30.5 cm (12 in.) from edge of headliner.
^ Install four soft foam spacers centered at rear cross bow and 30.5 cm (12 in.) from edge of headliner.
On 2001 and 2002 vehicles
^ Install four soft foam spacers at front cross bow and 40.6 cm (16 in.) from edge of headliner. Install four soft foam spacers at rear cross bow and 40.6 cm (16 in.) from edge of headliner.
PARTS REQUIREMENTS:
CLAIM INFORMATION:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System shown.
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