For 1990-2009 cars

# Front Outside Handle Contacts Front Door Outer Panel When Opening Door From Outside Vehicle

Subject: | Front Door Outside Handle Contacts Front Door Outer Panel When Opening Door From Outside Vehicle (Remove Front Door Outer Panel and Adjust Door Structure Outward)

Models: | 1997 - 2000 Saturn S-Series Coupes

| 2000 Saturn S-Series and Wagons

### Condition

Front door outside handle contacts front door outer panel when opening door from outside vehicle.

### Cause

Front door outside handle is in-set too far by 3mm (0.12) in relations to front door outer panel.

### Correction

Remove front door outer panel and adjust door structure outward.

### Procedure

1. Remove front door outer panel. (Refer to "Front Door Outer Panel -- Sedan and Wagon" or "Front Door Outer Panel -- Coupe" removal procedure in the appropriate model year service manual.

• | For 1997 -- 1999 vehicles, procedures are located in the Doors section of 1997 -- 1999 Body Repair service manuals.

• | For 2000 vehicles, procedures are located in the Door/Windows/Mirrors section of the 2000 S-Series Body/Electrical Vol. 1 Service Manual.

2. Remove door insulator. (Refer to "Door Insulator" removal procedure in the appropriate model year service manual.)

Important: The window must be in the full UP position to perform the following step.

4. Using the door impact bar as a pivot point, adjust door structure outward using a pry bar in area that door outside handle is attached to.

Important: There must be free play in outside door handle-to-latch assembly rod. If free play is not present, adjust rod as necessary.

5. Install front door outer panel and check outside door handle operation. This check should include locking and unlocking door with key, opening door with outside door handle, and closing door.

• | If outside door handle does not rub on front door outer panel, remove outer panel and continue to step 5.

• | If outside door handle still rubs, repeat steps 1 through 4 until enough clearance is obtained to prevent rubbing.

6. Install door insulator. (Refer to "Door Insulator" installation procedure in the appropriate model year service manual.)
7. Install front door outer panel. (Refer to "Front Door Outer Panel -- Sedan and Wagon" or "Front Door Outer Panel -- Coupe" installation procedure in the appropriate mode year service manual.)

• | For 1997 -- 1999 vehicles, procedures are located in the Doors section of 1997 -- 1999 Body Repair service manual.)

• | For 2000 vehicles, procedures are located in the Door/Windows/Mirrors section of the 2000 S-Series Body/Electrical Vol. 1 Service Manual.

8. Check outside door handle operation. This check should include locking and unlocking door with key, opening door with outside door handle, and closing door.

### 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 | Adjust Outside Door Handle RH | Z4047 | 0.5hrs
Adjust Outside Door Handle LH | Z4048 | 0.5hrs

INC: Time to adjust outside door handle and install door outer panel two times if necessary to check outside door handle operation.