For 1990-2009 cars

# Front Fender Chips Paint of Fascia at Forward Tip (Install Front Fender Spacer Blocks and Repair Paint Damage

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

Models: | 1996 -- 1998 Saturn SL2 Sedans and SW2 Wagons.

### Condition

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

### Cause

High 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 an 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 fascia and/or remove fender clearcoat drip (if present). Install urethane spacer block inside forward tip of front fender using a the following procedure and repair paint damage as necessary.

### Procedures

1. Remove front fascia. (Refer to " Front Fascia" removal procedure in the "Front End" section of the "Body/Repair Service Manual.")
2. Partial removal of the front fascia ribs is necessary.

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

2.1. | Use razor knife to remove shaded ribs in illustration. Make areas flush with adjacent surfaces.

2.2. | Sand rib area flush with adjacent surface.

2.3. | Repair paint on fascia as necessary.

3. Check from nose of fender for paint drip.

If paint drip is present at front nose of fender, remove paint drip using a fine file or emery board. After removing paint trip, proceed to nest step.

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

Important: Installation of the spacer blocks on the Sedan/Wagon is different than described in bulletin 97-T-35 for the coupe. Urethane spacer blocks are color coded. Right side urethane spacer block is "brown" (P/N 21110251), left side urethane spacer block is "black" (P/N 21110250)> This opposite of how it has been described for the coupe. 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.

4.1. | Urethane spacers must be glued in place.

4.2. | Position 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.

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

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

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

#### Parts Requirement

21110250 Block -- Urethane Spacer (black -- left side)
21110251 Block -- Urethane Spacer (brown -- right side)

### Claim Information

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:

Claim Information | Case Type | Description | Labor Operation | Time
--- | --- | --- | --- | ---
To receive credit for this repair during the warranty coverage period, submit a claim though the Saturn Dealer as follows | VW | Install Front Fender Spacer Blocks (Both Sides of Vehicle) | T9742 | .8 hrs
| Add: | Color/Clear Coat One Piece |  | 1.4 hrs
|  | Material Allowance |  | AK