For 1990-2009 cars

# Rattle Noises from Headliner Area

Subject: | Rattles 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: | 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 CF-5)

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 tow pieces will have to installed side-by-side on headliner to achieve width of spacers necessary.
4. Cut adhesive backed foam into ten equal 51mm (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 on the following pages.

5. Install adhesive backed foam spacer 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 spacer.

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 without sunroof:

On 2000 vehicles

• | Install four soft foam spacers centered at front cross bow and 30.5 cm (12 in.)

• | Install four soft foam spacer centered at rear cross bow and 30.5 (12 in.) form 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

### On Sedan with sunroof

On 2000 vehicles

• | Install four soft foam spacers centered 30.5 cm (12 in.) from headliner and centered with dome lamp opening.

• | Install four soft foam spacers at corners of opening for center high-mount stop lamp (CHMSL).

• | Install two soft foam spacers on dome lamp wiring harness loop on passenger side if 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

• | 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.

#### Part Requirements

46515 KENT Industries Adhesive Backed Foam *
*The foam can be obtained through KENT Industries at 1-800-654-6333 (Retailers in Canada Call 1-800-663-2800)

### CLAIM INFORMATION

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:

Case Type | Description | Labor Operation Code | Time
--- | --- | --- | ---
VW | Remove Headliner and Install Foam Spacers

• | Sedan

• | Wagon

Z4075

1.2 hrs

1.4 hrs