For 1990-2009 cars

# Passenger Side Inflator Module (Air Bag) Rattles in I/P Brace Slots

Subject: | Passenger Side Inflator Module (Air Bag) Rattles in I/P Brace Slots (Adjust I/P Upper and Lower Inflator Module Mounting Slots.

Models: | 2000 Saturn L-Series Sedans and Wagons built before VIN YY618329

### Condition

Some customers may comment when traveling over rough road surfaces they experience a rattle coming from behind the right hand side of the instrument panel (I/P).

### Cause

Movement between the passenger side inflator module mounting grommets and I/P brace mounting slots.

### Correction

Reduce the dimension between the upper and lower horizontal flanges of the I/P brace mounting slots.

### Procedures

Caution: WHEN YOU ARE PERFORMING SERVICE ON OR NEAR SIR COMPONENTS OR SIR WIRING, YOU MUST DISABLE THE SIR SYSTEM. FAILURE TO FOLLOW THE CORRECT PROCEDURE COULD CAUSE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR UNNECESSARY SIR SYSTEM REPAIRS.

1. Turn steering wheel so vehicle wheels are pointing straight ahead.
2. Turn ignition switch to OFF position and remove key.
3. Remove IGN1 mini-fuse from under hood fuse block (UHFB).
4. Remove lower left I/P closeout panel (hush panel).
5. Release clips that secure yellow 2-way connectors to I/P brace.
6. Disconnect two yellow 2-way connectors.
7. Open glove compartment door.
8. Remove glove compartment lamp assembly by pulling on lamp plunger.
9. Disconnect wiring harness from glove compartment lamp.
10. Remove right lower I/P closeout panel (hush panel).
11. Pull closeout panel (hush panel) rearward to release forward retainers.
12. Remove right lower heater outlet duct and retainer and remove duct.
13. Remove glove compartment door lower fasteners and remove door.
14. Remove glove compartment fasteners.
15. Slowly remove glove compartment from I/P opening and tilt downward to expose BCM on top of glove compartment.
16. Remove BCM from glove compartment by sliding module out of attaching slots.

Caution: WHEN CARRYING AN UNDEPLOYED INFLATOR MODULE:

• | MAKE SURE AIR BAG OPENING (FRONT OF AIR BAG) POINTS AWAY FROM YOU.

• | DO NOT CARRY INFLATOR MODULE BY WIRING HARNESS OR CONNECTOR ON INFLATOR MODULE.

Caution: WHEN STORING AN UNDEPLOYED INFLATOR MODULE, MAKE SURE AIR BAG OPENING POINTS AWAY FROM SURFACE ON WHICH INFLATOR MODULE RESTS.

17. Observe Cautions when carrying a inflator module.
18. Disconnect passenger inflator module yellow 2-way connector from vehicle.
19. Remove fasteners securing passenger inflator module to I/P cross-car beam.
20. Push inflator module toward front of vehicle away from I/P and rotate round end downward.
21. Remove passenger inflator module through glove compartment opening.

Important: Right mounting bracket shown. Left mounting bracket similar.

Important: There is an oval hole in passenger inflator module mounting bracket. The measurements take in the following steps should be performed on the inside edges of module mounting bracket and centered with oval hole in bracket.

22. Measure passenger inflator module right mounting bracket sot on I/P cross-car beam at location (A).

(A) 19 mm (0.75 in. ) is the measurement the vehicle was manufactured with.

23. Using pliers, carefully crimp mounting bracket flanges at location (A) until measurement is 17mm (0.67 in).
24. Repeat above steps for left mounting bracket of passenger inflator module.

Important: Passenger inflator module wiring harness should route toward right side of vehicle.

25. Insert passenger inflator module through I/P opening with vinyl edge facing up and harness toward right side of vehicle.

Important: Passenger inflator module wiring harness must be routed between round guide pin and module mounting ear.

26. Insert inflator module guide pins into I/P brace slots and rotate round edge upward to align bolt holes.
27. Install passenger inflator module to I/P bracket fasteners.

Tighten
Tighten the fasteners to 10 N·m (89 lb in).

28. Connect yellow 2-way connector to vehicle wiring harness.
29. Install glove compartment partially into opening.
30. Install BCM to glove compartment by sliding module into attaching slots.
31. Route glove compartment lamp wiring harness through glove compartment opening.
32. Connect glove compartment lamp to vehicle wiring connector.
33. Snap lamp into opening in glove compartment.
34. Install glove compartment to I/P and install fasteners.

Tighten
Tighten the fasteners to 2.5 N·m (22 lb in).

35. Install right lower heater outlet duct and retainer.
36. Install right lower I/P closeout panel (hush panel) and retainers.
37. Install glove compartment door and install lower fasteners.

Tighten
Tighten the fasteners to 2 N·m (18 lb in).

38. Open and close glove compartment door and check glove compartment lamp to ensure proper operation.
39. Connect tow yellow 2-way connectors at I/P brace.
40. Secure clips that attach both yellow 2-way connectors to I/P brace.
41. Install IGN1 mini-fuse in underhood fuse block (UHFB).
42. Turn ignition ON and verify proper AIR BAG telltale operation.
43. Install left lower I/P closeout panel (hush panel) and retainers.

### CLAIM INFORMATION

Case Type | Description | Labor Operation Code | Time
--- | --- | --- | ---
VW | Crimp Passenger Air Bag Mounting Bracket Flange | Z4064 | 0.6 hrs