For 1990-2009 cars

# Front Fender Chips Paint of Fascia at Forward Tip

Subject: | Front Fender Chips Paint of Fascia at Forward Tip -- Install Front Fender Spacer Blocks and Repair Paint Damage

Models: | 1997 Saturn Coupes built before and including VIN VZ231504

### Condition:

Some customers may comment that the paint appears to be chipped on the fascia, beneath the forward most tip of the front fender.

### Cause:

Hugh ambient temperatures in combination with direct sunlight cause thermal growth of fender and fascia, resulting in interference condition at the forward most tip of the front fender. This causes the thermoplastic olefin (TPO) beneath the paint to yield, giving the appearance of a paint chip. Some fenders may also have a clearcoat drip at the forward tip, which increases and localizes the interference between the fender and fascia.

### Correction:

Trim ribs from the fascia and/or remove the fender clearcoat drip, if present. Install a urethane spacer block the inside forward tip of the front fender using the following procedure and repair the paint damage as necessary.

### Procedures:

1. Remove the front fascia. Refer to Front Fascia removal in the Front End section of the Body/Repair Service Manual.
2. Check the front fascia for ribs.

• | If ribs are present:

| Notice: To prevent gouging the fascia, lay a razor blade or feeler gage along side the rib to be removed to provide a surface for the razor blade to ride on while cutting the rib off.

1. | Use a razor knife to remove ribs on the fascia to make rib areas flush with the adjacent surface.

Ribs will not be on later built vehicles.

2. | Sand the rib area flush with the adjacent surface.

3. | Repair the paint on the fascia as necessary.

4. | Proceed to the next step.

• | If ribs are not present, proceed to the next step.

3. Check the front nose of the fender for paint drip.

• | If paint drip is present at the front nose of the fender, remove the paint drip using a fine file or Emory board. After removing the paint drip, proceed to the next step.

• | If a paint drip is not present at the front nose of the fender, proceed to the next step.

Important: Urethane spacer blocks are color coded. A right side urethane spacer block is Black P/N 21110250, a left side spacer block is Brown P/N 21110251. The stepped side of the urethane block is the side that contacts the fascia.

4. Install urethane spacer blocks to the underside of the front nose of the fender.

• | If the vehicle was built after and including VIN VZ206245, the fenders have a molded tab to retain the urethane spacer block.

1. | Install the urethane spacer block to the inside of the front nose of the fender.

2. | Proceed to step 6.

• | If the vehicle was built before and including VIN VZ206244, the urethane blocks must be glued in place.

1. | Position the urethane spacer block in the front nose of the fender and mark the position where the forward step/portion of the block is 1.5 mm (1/16 in) below the lower outboard edge of the fender.

2. | Remove the urethane spacer block and apply Loctite® Quick Tite Super Glue Gel P/N 21602, 2 gram tube, or equivalent instant adhesive designed for porous surfaces.

3. | Install the urethane spacer block into the front nose of the fender, aligning the mark made in step 4a with the edge of the fender.

5. If necessary, trim the urethane spacer block using a fine file to adjust the fender to fascia gap.
6. Install the front fascia. Refer to the Front Fascia installation procedure in the Front End section of the Body/Repair Service Manual.

### Parts Requirements:

Part Number | Description
--- | ---
21110250 | Block -- Urethane Spacer --Right Side Black Spacer
21110251 | Block -- Urethane Spacer --Left Side Brown Spacer

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 | Install Front Fender Spacer Blocks -- Both Sides of Vehicle | T9742 | 0.80 hrs
-- | ADD: | Color/Clear Coat One Piece Material Allowance | -- | 1.40 hrs AK