For 1990-2009 cars

# Installation Procedures for Trap Resistant Trunk Kit

Subject: | Service Information and Installation Procedures for Trap- Resistant Trunk Kit

Models: | 1991- 1999 Saturn vehicles

### Purpose

The purpose of this bulletin is to inform Saturn Retailer personnel of the system function and procedure used to install the Trap-Resistant Trunk Kit.

The Trap-Resistant Trunk Kit is composed of three system components.

The first component of the kit is the trap-resistant latch system. The trap-resistant latch is modified decklid latch designed to help prevent a child from unintentionally closing and latching the decklid. Once the decklid has been opened by the key, vehicle interior release lever, or remote keyless entry (RKE) transmitter, the trap-resistant latch cannot be re-latched without the user performing a reset function. This reset function consists of cycling the latch reset lever twice after the decklid has been opened in order to enable the latch. If the latch is not enabled, the decklid will not latch and will not close.

The second component of the kit is the illuminated interior release handle. the interior release handle is a plastic yellow handle, pocketed in a black plastic housing, which is mounted inside the trunk to the decklid. The interior release handle was designed so that s small child trapped in the trunk could use it to open the decklid. The handle operates the decklid latch mechanically and is illuminated with two light-emitted diodes (LEDs) when the decklid is closed. The handle remains illuminated for a period of approximately one hour after the decklid is closed. The LEDs create a small parasitic load that will not drain the vehicle battery with normal usage.

The third component of the kit is the seat back tether system. The seat back tether system helps prevent a child from gaining access to the trunk of a vehicle from the vehicle interior. The seat back tether system utilizes two elastic straps (one per folding seat back), each permanently connected to a T-handle retainer mounted to the rear window panel in the trunk. To lock the folding seat backs, the user can partially fold down the seat backs and attach the elastic strap to a T-handle retainer mounted to the seat backs. When the elastic straps are attached to the T-handle retainers, the seat back cannot be folded down. To unlock the seat backs, the elastic straps must be removed from the retainers attached to the seat backs.

After completing the Trap-Resistant Trunk Kit installation procedure, use the steps at the end of the procedure to verify proper system function. Also be sure to provide the customer with the supplemental owner's handbook insert included in the kit and demonstrate the system function.

### Procedure

Trap-Resistant Latch and Interior Release Handle Installation

1. Remove the 10A Body fuse from instrument panel fuse block.
2. Open decklid.
3. On 1991 - 1995 models, remove and discard black plastic decklid latch cover.
4. Remove decklid latch retaining bolts.
5. Disconnect vehicle interior release cable.
6. For Sedans, disconnect lock cylinder rod from latch. For Coupes, remove lock cylinder rod from vehicle.
7. Disconnect electrical connectors.
8. Remove existing decklid latch and discard.
9. Cut out center of interior handle template and place over interior release handle.
10. Select hole locations on template for appropriate vehicle type and model year.
11. Mark hole location(s) on release handle as shown on template.
12. Drill 3 mm (1/8 in.) hole at marks on handle.
13. Install decklid lock cylinder rod to lock cylinder and new latch.

13.1. | For Coupes, install new lock cylinder rod (included in kit.)

• | 1991 - 1996 model year Coupes require short lock rod.

• | 1997 - 1999 model year Coupes require long lock rod.

13.2. | For Sedans, use grinder or wire cutter and carefully remove 2 mm (5/64 in.) of length from latch end of existing lock cylinder rod.

Important: vehicle equipped with or without the remote keyless entry (RKE) feature use the same trap-resistant latch that is included in the kit. This latch will function properly on all vehicles.

14. Reconnect vehicle interior release cable end fitting into lower slot of new trap-resistant latch, and clip cable conduit to latch housing.
15. Insert release handle cable end fitting into upper slot of new trap-resistant latch, and clop cable conduit to latch housing.

Important: All 1996 and some early 1997 vehicle were equipped with a ring terminal ground connector that must be installed between decklid and latch prior to installing latch.

16. Install trap-resistant latch-to-decklid retaining bolts

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

17. Connect cable end fitting to release handle lever on back side of release handle.
18. Connect cable conduit to release handle housing.
19. If not already connected, connect release handle wiring harness (included in kit) to release handle.

Important: Due to stiffness of cable conduit, it may be necessary to pre-bend cable conduit prior to handle installation.

20. Align handle to decklid sheet metal as shown on appropriate model year illustration on the following pages.
21. Using the release handle as a template, mark one hole location on decklid sheet metal.

Notice: If drill bit is allowed to drill into sheet metal at a depth greater than 6.5 mm (1/4 in), outer surface of exterior panel may be penetrated.

Important: Due to stiffness of cable conduit, it may be necessary to pre-bend cable conduit prior to handle installation

22. Center-punch and drill 3 mm (1/8 in.) hole at mark on decklid.
23. Install release handle with one release handle-to-decklid fastener (P/N 11515005 included in kit).

Tighten
Tighten the handle to 2.6 N·m (23 lb in).

24. Using interior release handle as a template, align release handle to decklid according to appropriate model year illustration selected from step 20.
25. Drill 3 mm (1/8 in.) holes at remaining release handle-to-decklid fasteners (P/N 11515005 included in kit).
26. Install cable clip to release handle cable.

Important: Cable clip must be installed to the decklid inner sheet metal panel in a location that will allow clip to fully seat in the space between inner and outer decklid sheet metal.

27. Mark a position on decklid inner panel that will allow cable clip to fully seat in decklid sheet metal. Position release handle cable clip as close as possible to center of cable.

Notice: If drill bit is allowed to drill into sheet metal at a depth greater that 6.5 mm (1/4 in), outer surface of exterior panel may be penetrated.

28. Center-punch and drill 6.5 mm (1/4 in.) hole at mark on inner panel.
29. Apply 3M Windo-Weld Primer (P/N 08643) or equivalent to bare metal edges of hole.
30. Install release handle cable and cable clip to decklid.

### Trap-Resistance Latch and Interior Release Handle Electrical Installation

1996 -- 1999 Coupe and Sedan

1. Wrap entire length of handle wiring harness with tape to prevent damage to wires.
2. Route handle wires along existing decklid harness over to bottom of decklid hinge.
3. Insert handle wires into existing clips along decklid harness.
4. Place handle ORN wire in approximately three feet of conduit (P/N 21023494) and route in through holes in the bottom of rear window panel over to the cargo lamp.
5. Remove cargo lamp housing and disconnect cargo lamp if needed.
6. Splice handle ORN wire to cargo lamp ORN wire, circuit 340, using splice sleeves supplied with kit.
7. Tape wire to prevent damage due to sharp metal edges.
8. Cut to length and splice handle WHT wire to vehicle RED/BLK wire, circuit 744, using splice sleeves supplied with kit. The vehicle RED/BLK wire can be found at decklid in-line connector rear base of decklid hinge and will be located in one of the following cavities:

• | Cavity F on Sl vehicle

• | Cavity H on 1997- 1999 SC vehicles

• | Cavity D on 1996 SC vehicles

9. Cut to length and splice handle BLK wire to vehicle BLK wire, circuit 550, using splice sleeves supplied with kit. The vehicle BLK wire can be found at decklid in-line connector near base of decklid hinge and will be located in one of the following cavities:

• | Cavity E on SL vehicles

• | Cavity G on 1998 -- 1999 SC vehicles

• | Cavity J on 1997 SC vehicles

• | Cavity B on 1996 SC vehicles

10. Secure all wires to vehicle with tape to prevent damage.
11. Connect cargo lam connector and replace cargo lamp housing if removed.
12. Install 10A BODY fuse in instrument panel fuse block.
13. Reconnect existing latch electrical connector(s) to new latch.

1991 -- 1995 Coupe and Sedan

Important: On certain 1991 -- 1995 vehicles the BLK and WHT handle wires may need to be lengthened using same gage wire.

1. Route handle ORN wire over to latch area.
2. Cut existing latch connector off and splice the following wires together using splice sleeves supplied with kit:

• | On 1991 -- 1994 vehicles, splice together handle ORN wire, existing latch ORN wire, and existing latch LT GRN wire.

• | On 1995 vehicles, splice together handle ORN wire, existing latch ORN wire, and existing latch RED/BLK wire.

3. Secure all connections and wire with tape to prevent damage to wires.

Important: Extra 3-way black connectors and WHT wires may be supplied with kit and will into all be used.

4. Using one black 3-way connector (P/N 12047781) and one WHT wire (P/N 12112316) supplied with kit, insert WHT wire into cavity C of black 3-way connector body.
5. Connect the black 3-way connector to latch assembly.
6. Route handle WHT wire over to latch connector.
7. Cut to length and splice handle WHT wire and remaining length of handle WHT wire to lumber WHT wire coming from cavity C of the black 3-way connector .
8. Wrap entire length of handle wiring harness with tape to prevent damage to wires.
9. Route handle BLK wire and remaining length of handle WHT wire along existing decklid harness over to bottom of decklid hinge.
10. Insert handle wires into existing clips along decklid harness.
11. Place WHT and BLK handle wires in approximately three feet of conduit (P/N 21023494) and route them along bottom of rear window panel over to cargo lamp area.
12. Remove cargo lamp housing and disconnect cargo lamp if needed.
13. Cut cargo lamp BLK wire in half allowing enough room for splices.
14. Splice handle WHT wire to one cargo lamp BLK wire using splice sleeves supplied with kit.
15. Splice handle BLK wire to other cargo lamp BLK wire using splice sleeves supplied with kit.
16. Tape and secure all wires to prevent damage due to sharp metal edges.
17. Connect cargo lamp connector and install cargo lamp housing if removed.
18. Install 10A Body fuse in instrument panel fuse block.

### Seat Back Tether System Installation

1. Open decklid and place a piece of masking tape (51 mm [2 in.] minimum width) on both rear seat backs along edge of rear window panel lip.
2. Fold down seat backs. Place a mark on the masking tape in the middle of each seat back, 40 mm (1.5 in.) down from the top edge of the tape.

Important: When drilling holes in seat backs, drill through two layers of plastic seat back frame, but do not push drill through seat cushion fabric.

3. Drill 10 mm (3/8 in.) holes through seat back frames at marks on masking tape.
4. Fold up seat backs.
5. Using soft marker, mark locations on rear window panel rail (hollow box section) to line up with holes in seat back. Marks should be in center of rear window panel rail horizontal surface.

Important: When drilling holes in rear window panel rail, frill through first layer of sheet metal only. Be sure to collect all metal flakes from vehicle interior.

6. Center-punch, pre-drill 5 mm (3/16 in.) holes, and final-drill 10 mm (3/8in.) holes at marks on rear window panel rail.
7. Apply 3M® WINDO-WELD Primer (P/N 08643) to equivalent to bare metal edges of hole.
8. Fasten a rivet nut onto installation tool (both included in kit)
9. Place installation tool with rivet nut into hole in rear window panel.
10. Use a wrench to hold installation tool nut. Tighten installation tool bolt until rivet nut is collapsed and will not rotate in hole.
11. Remove masking tape from seat backs and install rivet nuts in remaining rear window panel hole and in both seat backs.

Important: For 1991 vehicle and 1992 vehicles built before VIN NZ101500, the Rear Shelf Panel Front Finish Lace may not be installed or does not stay in place. Vehicles with this condition may have an exposed metal edge that could fray the Seat Back Tether System straps. If this condition exists, please reference Technical Information Bulletins 91-T-44 and 92-T-18 for further information.

12. Place a small amount of Loctite 242® Threadlocker, or equivalent, on threads of T-handles.
13. Install T-handles with attached straps (stitched end) to rear window panel rivet nuts. Ensure T-handle are in the lateral position.
14. Install T-handles are in the lateral position.
15. Attach loose end of the strap to seat back T-handles.

### System Functional Check

• | Ensure new decklid latch is enabled only after two cycles of latch reset lever when decklid has been opened by the following methods:

- | Opened with key

- | Open with vehicle interior release lever

- | Opened with remote keyless entry (RKE) transmitter (if equipped)

• | Ensure seat back tether system straps are properly installed and functioning.

• | Fold down rear seat backs and check the following:

- | Verify trunk interior release handle functions with decklid closed.

- | Ensure interior release handle LEDs illuminate and stay illuminated when decklid is closed and are not illuminated when decklid is open.

### Customer Demonstration and Owner's Handbook Insert

Supply customer with owner's handbook insert and use the insert to demonstrate function of Trap-Resistant Trunk Kit.

#### Parts Requirement

21171240 Asm - Decklid Latch
Kits Contents
Parts Description | Quantity | Model Usage
Interior Release Handle | 1 | All
Interior Release Handle Cable | 1 | All
Interior Release Handle Cable Clip | 1 | All
Interior Release Handle Fasteners | 1 | All
Interior Release Handle Template | 1 | All
Interior Release Handle Wiring Harness | 1 | All
Trap-Resistant Latch Assembly | 1 | All
91-96 Coupe Decklid Lock Rod (Short ) | 1 | 91-96 Coupes
97-99 Coupe Decklid Lock Rod (Long) | 1 | 97-99 Coupes
Replacement Connector Pack (Extras Supplied | 1 | 91-95 All
Replacement Wire and Terminal Pack (Extras Supplied) | 1 | 91-95 All
Seat Back Tether Straps with Anchor | 2 | All
Seat Back Anchor | 2 | All
Rivet Nut | 4 | All
Rivet Nut Installation Tool | 1 | All
Instruction Sheet | 1 | All
Owner's Handbook Insert | 1 | All

### Claim Information

Reimbursement for Parts: Saturn will subsidize the cost of the parts by selling the kits at a reduced price. The Retailer will be reimbursed for the price of the Trap-Resistant Trunk Kit by the customer. Submit a claim using Labor Operation Code Z4024 without any labor hours, and enter the Manufacturer's Suggested Retail Price (MRSP) of the kit using case type "CP."

Reimbursement for Labor: The Retailer will be reimbursed for installation labor through the submission of a claim using the applicable case type of "VW" or "VP." Submit the claim using Labor Operation Code Z4024 for 1.1 hours.

Due to the nature of the installation, the procedure is not intended for the "do it yourselfer." It is in the customer's best interest to have the kit installed by an authorized Saturn Retail facility. Therefore, Retailers should discourage over-the-counter sales since the MSRP includes the installation.

All claims submitted must be supported by s signed Customer Service Order.