For 1990-2009 cars

# ROOF RATTLE ON WAGON (ADD AIR-DRY ANTI-FLUTTER MATTER)

#### SUBJECT: ROOF PANEL RATTLE ON WAGON (ADD AIR-DRY ANTI-FLUTTER MATERIAL)

#### MODELS AFFECTED: 1998 SATURN WAGONS BUILT BETWEEN AND INCLUDING THE FOLLOWING VINS WZ216393 THROUGH WZ229877

#### CONDITION:

RATTLE NOISE COMING FROM INSIDE INNER ROOF PANEL WHEN DRIVING VEHICLE. THE RATTLE NOISE SOUNDS LIKE IT IS COMING FROM DIRECTLY ABOVE THE DRIVER'S AND PASSENGER'S HEAD.

#### CAUSE:

IMPROPER APPLICATION OF ANTI-FLUTTER MATERIAL IN BETWEEN ROOF OUTER PANEL AND ROOF PANEL BOW.

#### CORRECTION:

APPLY AIR-DRY ANTI-FLUTTER MATERIAL BETWEEN ROOF OUTER PANEL AND ROOF PANEL BOW.

#### PROCEDURE:

1. REMOVE HEADLINER. (REFER TO "HEADLINER - WAGON" REMOVAL PROCEDURE IN THE "VEHICLE INTERIOR SYSTEMS" SECTION OF THE 1998 "BODY/REPAIR SERVICE MANUAL.")

--------------------- FIGURE --------------------- 2. CHECK AIR-DRY ANTI-FLUTTER MATERIAL BETWEEN THE ROOF OUTER PANEL AND THE ROOF BOW USING A BUSINESS CARD. INSERT THE BUSINESS CARD IN ALL LOCATIONS SHOWN IN ILLUSTRATION, AT BOTH FRONT AND REAR SIDE OF THE ROOF BOW, UNTIL LOCATIONS WHERE AIR-DRY ANTI-FLUTTER MATERIAL NEEDS TO BE ADDED. IMPORTANT: COVER THE SEATS FOR PROTECTION BEFORE APPLYING REPAIR MATERIAL.

3. USING 3M[emsp ] ULTRA PRO PILLAR FOAM (P/N 051135 08457)(OR EQUIVALENT), APPLY THE EXPANDABLE FOAM MATERIAL IN THE AREAS IDENTIFIED IN STEP 2. BECAUSE THIS MATERIAL EXPANDS, ONLY SMALL AMOUNTS ARE REQUIRED IN THE REPAIR LOCATIONS. 4. REMOVE ANY EXCESSIVE CURED MATERIAL. 5. ROAD TEST VEHICLE TO ENSURE THAT RATTLE HAS BEEN REPAIRED. 6. INSTALL HEADLINER. (REFER TO "HEADLINER - WAGON" INSTALLATION PROCEDURE IN THE "VEHICLE INTERIOR SYSTEMS" SECTION OF THE 1998 "BODY/REPAIR SERVICE MANUAL.")

#### PARTS REQUIEMENTS:

051135 08457 3M[emsp ] ULTRA PRO PILLAR FOAM

#### CLAIM INFORMATION:

TO RECEIVE CREDIT FOR THIS REPAIR DURING THE WARRANTY COVERAGE PERIOD, SUBMIT A CLAIM THROUGH THE SATURN DEALER SYSTEM AS FOLLOWS:

LABOR CASE OPERATION TYPE DESCRIPTION CODE HOURS

VW ADD AIR-DRY ANTI-FLUTTER MATERIAL T9787 1.4 HRS

FIGURES: 01 ATTACHMENTS: 00

SATURN BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINE TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HO TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE YOUR SATURN RETAILER FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.

COPYRIGHT 1998 SATURN CORPORATION U.S.A. ALL RIGHTS RESERVED.