For 1990-2009 cars

# Rear Exterior Door Panel is Not Tight Against the Door Structure

Subject: | Rear Exterior Door Panel is Not Tight Against the Door Structure -- Adjust the Door Structure Flange -- Due to revisions under Models Affected, this bulletin supersedes bulletin 96-T-19B, which should be discarded.

Models: | 1996-1999 Saturn Sedans and Wagons.

### Condition:

The rear upper corner of the rear exterior door panel does not stay tight against the door structure, causing a loose, non-flush condition.

### Cause:

The rear door side window outer sealing strip does not tightly hold the top of the exterior door panel to the door structure.

### Correction:

Remove the rear door side window outer sealing strip and adjust the door structure flange according to the procedures in this bulletin.

### Procedures:

1. Remove the retaining screw from the rear side door window frame front applique.
2. Starting at the front, gently lift the rear side door window outer sealing strip, disengaging it from the door structure and exterior door panel.

Important: A putty knife with the blade covered with tape may be used to gently pry the rear side door window outer sealing strip from the flange.

3. Cover the rear side door quarter vent glass with a thickly padded material, taping the material into place to avoid movement.
4. Using a wedge of wood and a light hammer, tap on the rear edge of the rear door structure flange, moving it inboard towards the center of the vehicle. The only part of the flange that should be moved is the part that is slightly curved. The amount of movement will vary according to the looseness of the panel.

Important: Do not change the position of the flange anywhere forward of the rear window glass channel.

5. Install the rear side door window outer sealing strip to the door and inspect the fit and flushness against the door structure. If required, adjust the flange again, using the procedure in step 4, until the side door window outer sealing strip is tight against the door structure.
6. Press the rear side door window outer sealing strip onto the outer belt flange.
7. Inspect the alignment at the front edge of the door.

Notice: Fastener Notice

8. Install the rear side door window frame front applique lower screw and tighten.

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

CLAIM INFORMATION | To receive credit for this repair, submit a claim through the Saturn dealer System as follows:
--- | ---
-- | Case Type | Description | Labor Operation Code | Time
-- | VW | Adjust the Rear Door Structure Flange -- Right Side | T9701 | 0.30 hrs
-- | VW | Adjust the Rear Door Structure Flange -- Left Side | T9702 | 0.30 hrs