For 1990-2009 cars

# Front Door Trim Insert Cracking at Armrest

Subject: | Front Door Trim Insert Cracking at Armrest (Replace Door Trim Insert)

Models: | 2000 - 2001 Saturn S-Series vehicles up to and including VIN 1Z208670

### Condition

Some customer may comment the front door inner trim panel having a spongy feel or making a popping sound when depressed.

### Cause

This condition may be caused by a crack in the substrate backing of the door trim insert.

### Correction

Replace door trim insert using the procedure in this bulletin.

Notice: If door trim panel is cracked at armrest, it is only necessary replace the door time panel insert (Insert Kit-Frt S/D /T/PNL) and not the entire door panel assembly.

### Service Procedure

Caution: If energy absorber is removed from door, it must be replace with a new part. If omitted from the door, the vehicle will not meet federal motor vehicle safety standards (FMVSS), subjecting the retailer to possible civil penalties for making the vehicle inoperative to the FMVSS, and increasing risk of injury to the vehicle occupants.

1. Remove door trim panel. (Refer to "Front Door Trim Panel" removal in the 2000/2001 Door /Windows/Mirrors section of the Body/Electrical Volume I Service Manual).
2. Remove door pull cup.
3. Place the door trim panel (heat-staked side up) on a work bench with a cloth-type material to protect the panel's finish.

Important: Drill into the heat-staked stud just enough to cause the stud material to separate from the substrate (door trim panel) material.

5. Using a 7 mm (9/32 in.) drill bit, drill out the round heat-staked studs.
6. Remove the old door insert from the door trim panel.
7. Remove any heat stake material that may be left in the door trim panel holes or on the door trim panel substrate.

### Installation

1. Center the new door insert on the door trim panel substrate.
2. Place the door trim panel assembly back on the cloth-type protective material with the heat-stake side up.
3. Place one hand on the front side of the door trim panel (the side that is on the work bench) at one of the door insert corners. Press and hold the door insert heat stake against the door trim panel substrate.

Important: A desirable round heat stake weld should have an approximate diameter of 10 mm (13/32 in).

4. Using a Weller® model 8200 soldering gun (or equivalent) equipped with a flat tip, use a circular motion around the heat stake. Apply firm steady pressure to spread the heat stake material onto the door trim panel substrate to achieve a proper weld.
5. After the heat stake has been melted, keep steady pressure with your hand on the door insert for 30 seconds, to allow the heat stake to harden.
6. Repeat Steps 3 through 5 for the remaining door insert corners.
7. Continue to press and hold the door insert against the door trim panel substrate and heat stake the remaining door insert studs.
8. Verify that the door insert is securely heat staked to the door trim panel substrate in all locations.
9. Install the door pull cup.
10. Install the door trim panel. (Refer to "Front Door Trim Panel" installation in the 2000/2001 Doors/Windows/Mirrors section of the Body/Electrical Volume I service Manual).

#### Parts Requirements:

Refer to S-Series Parts and Illustration Catalog for specific (INSERT KIT-FRT S/D T/PNL) part number Notice: It is only necessary to replace the door trim panel insert and not the entire door panel assembly.

### CLAIM INFORMATION:

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System C3260 (Insert, Front Door Trim, Right - R&R or Replace) or C3261 (Insert, Front Door Trim, Left - R&R or Replace).