REAR LIFTGATE ELECTRIC RELEASE INSTALLATION. Saturn Saturn 1993

For 1990-2009 cars

# REAR LIFTGATE ELECTRIC RELEASE INSTALLATION

Due to several minor revisions shown in shaded areas (including the brown 46-way connector being changed to black 46-way connector) this bulletin supercedes Special Policy Bulletin 93-P-01, which should be discarded.

#### SUBJECT: REAR LIFTGATE ELECTRIC RELEASE INSTALLATION

YEAR and MODEL: 1993 SATURN WAGONS

#### TO: ALL SATURN RETAILERS

#### SPECIAL POLICY

Recently produced Saturn wagons (SW1 and SW2 models) are equipped with a rear liftgate electric release. However, this feature was not available at the start of wagon production, and approximately 2,400 of the earliest Saturn wagons were produced without it. To help ensure customer enthusiasm, we would like to provide the owners of these early wagons with the opportunity to have this feature installed on their cars at no charge to them. This bulletin provides the procedure for installing the rear liftgate electric release for wagons that were manufactured without this feature.

#### VEHICLES INVOLVED

All wagons built prior to PZ202923 (except vehicles included in the attached listing entitled "Non-Involved Vehicles within Vin Range") were manufactured without a rear liftgate electric release.

Approximately 350 of the earliest wagons will require a more extensive installation procedure than the other wagons involved in this Special Policy. The two VIN ranges below will allow retail personnel to identify the proper service procedure for all vehicles involved in this Special Policy.

#### VIN RANGE 1

To add this feature on vehicles built before and including VIN PZ150367 refer to the service procedure outlined in Section 1, which is on page 4 of this bulletin.

#### VIN RANGE 2

To add this feature on vehicles built between and including VIN PZ150368 and PZ202922 refer to the service procedure outlined in Section 2, which is on page 27 of this bulletin.

#### IMPORTANT: 109 vehicles within VIN range 2 were built with a rear liftgate electric release and will not need to have this feature installed. (Refer to the attached listing entitled "Non-Involved Vehicles within Vin Range") which is on page 35 of this bulletin.

#### OWNER NOTIFICATION

Owners of wagons produced without the rear liftgate electric release feature will be notified of this Special Policy by Saturn. (Refer to the owner letter included with this bulletin.)

#### FACILITY VIN LISTING

A list of vehicles assigned to you (Facility VIN Listing), which our records indicate were sold by or shipped to you, (or which are located in close proximity to your facility), is enclosed for your follow-up program. The Facility VIN Listing contains:

o Complete Vehicle Identification Number;

o Owner name, address and telephone number; and

o VIN's of vehicles, which according to Saturn records are in retail stock.

The Facility VIN Listing (with owner information) is furnished to involved Retailers with the Special Policy Bulletin. Although these vehicles are assigned to your facility, it is important to note that owners can take their vehicles to the Saturn Retail Facility of their choice to have this Special Policy performed.

Those Retailers not involved initially in this Special Policy will receive a message at the top of a blank Facility VIN Listing that states: NO VEHICLES ASSIGNED AT THIS TIME FOR SPECIAL POLICY 93PO1.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of the law in several states. Accordingly, you are urged to limit the use of this listing to the follow up necessary to make owners aware of this Special Policy. Those records updated with California DMV registration information will have the following message printed adjacent to the appropriate VIN: "OWNER INFORMATION UPDATED BY CALIFORNIA DMV; PUBLICATION PROHIBITED."

#### RETAILER RESPONSIBILITY

Retailers are to service all vehicles subject to this Special Policy at no charge to owners, regardless of mileage, age of vehicle, or ownership prior to December 31, 1994. Retailers are also to install the rear liftgate electric release in wagons subject to this Special Policy that enter their vehicle inventory. Also, whenever a wagon subject to this Special Policy is in your Retail Facility for service prior to December 31, 1994, Retailers are to encourage owners of these vehicles to have the Special Policy performed.

In keeping with Saturn's efforts to maintain customer satisfaction, Retailers are to take steps, as necessary, to ensure that all owners of wagons subject this Special Policy are aware of the availability of the rear liftgate electric release.

#### PARTS INFORMATION

1. A pre-shipment of parts required to perform this special policy has been automatically sent to you from Saturn Service Parts Operations (SSPO). The initial shipment will be followed up with recommended stocking policies... so Retailers will not need to order parts.

2. Parts questions may be directed to your Saturn Parts Support Analyst.

Quantity Required Part Number Description Per Vehicle ----------- ----------- ----------------- Parts Required for Performing the Procedure in Section 1

22144103 ACTUATOR ASM-L/GATE INCLUDES L/GATE LOCK ACTUATOR( FOAM-L/GATE, STUD-L/GATE) 1 21097022 HANDLE ASM-F/TANK FILL DR LAT REL CBL 1 21097025 CLIP-L/GATE LKG ROD 1 21097027 ROD - L/GATE LK ACTR 1 21097076 NUT-L/GATE LK ACTR 2 21097023 CABLE ASM - R/CMPT LID LK REL 1 21090208 HANDLE-R/CMPT LID LK REL CBL 1 21022516 HARNESS ASM-BODY WRG HARN EXTN 1 21022412 HARNESS ASM-L/GATE WRG 1

Parts Required for Performing the Procedure in Section 2

22144103 ACTUATOR ASM-L/GATE (INCLUDES L/GATE LOCK ACTUATOR,FOAM - L/GATE, STUD - L/GATE) 1 21097022 HANDLE ASM-F/TANK FILL DR LAT REL CBL 1 21097025 CLIP-L/GATE LKG ROD 1 21097027 ROD - L/GATE LK ACTR 1 21097076 NUT-L/GATE LK ACTR 2 21097023 CABLE ASM-R/CMPT LID LK REL 1 21090208 HANDLE-R/CMPT LID LK REL CBL 1

#### SECTION 1

#### INSTALLATION PROCEDURES FOR VEHICLES BUILT BEFORE, AND INCLUDING VIN PZ150367

#### Removal

1. Disconnect negative battery cable. (See figure 1)

2. Remove bolts from drivers seat tracks to floor, tip seat and disconnect wire harness and remove seat. (See figure 1)

3. Raise rear section of front body hinge pillar garnish molding (sill molding) by pulling up at clip locations just enough to clear center pillar garnish molding. (See figure 2)

4. Pull left rear seat bolster at top to disengage fastener and remove bolster. (See figure 3)

5. Release seat back latch and tilt seat back forward. (See figure 3)

6. Disengage cargo floor carpet from seat back. (See figure 3)

7. Remove plastic clip from outboard pivot pin. (See figure 3)

8. Slide seat back towards inside of vehicle to position pivot pin relief slot at floor bracket and lift pivot pin out of floor bracket. (See figure 3)

9. Lift seat back out of outboard floor bracket and remove seat back. (See figure 3)

10. Remove seat cushion. (See figure 4)

a. Push on retainer tabs located at the front bottom of seat cushion assembly.

b. Guide seat belt buckles through seat cushion and remove seat cushion assembly.

11. Remove screws that attach the left rear lower garnish (sill molding) behind the rear seat side bolster. (See figure 5)

12. Starting at the front of the molding, pull firmly on the garnish molding at the clip location to remove. (See figure 5)

13. Pull firmly on bottom of front upper garnish molding to partially remove it and expose upper screw on the center pillar garnish molding. (See figure 6)

14. Remove screw at top of center pillar garnish molding. (see figure 6)

15. Starting at front lower edge of center pillar garnish molding, guide edge of molding in an upward motion over body weld flange. (See figure 6)

16. Guide seat belt through bottom of the center pillar garnish molding and remove garnish molding. (See figure 6)

17. Remove fuel door release knob by placing one end of a long, flat tool behind the knob and while holding opposite end, strike the tool near the knob with a hammer. (See figure 7)

18. Fold carpet back to provide access to the release handle assembly. (See figure 7)

19. Disconnect harness cover retainers from floor reinforcement. (See figure 8)

20. Remove bolt and pull fuel tank fill door latch release handle assembly out of floor reinforcement. (See figure 8)

21. Disconnect cable from fuel tank fill door latch release handle assembly. (See figure 8)

22. For automatic transaxle, tape the release button in on the the shift lever handle. (See figure 9)

23. For manual transaxle, pull knob up and remove. (See figure 9)

24. Remove liner in rear storage tray and remove two screws under liner. (See figure 9)

25. Remove the two screws on the front sides of the console. (See figure 9)

26. Apply parking brake and remove the trim plate below the park brake lever by lifting at the rear edge and working the plate up evenly. (See figure 9)

27. Remove both ashtrays. (See figure 10)

28. Disconnect front ashtray light from console. (See figure 11)

29. For power window/mirror equipped cars: (See figure 12)

a. Remove the window/mirror switch by sliding switch forward then lifting rear edge.

b. Remove connector position assurance (CPA) devices and disconnect electrical connectors.

30. Remove side trim panels. (See figure 13)

31. Lift rear of console. From under side of console, release and push out both seat belt bezels. (See figure 14)

32. Lift console out while feeding seat belts through openings. (See figure 14)

33. Remove push pins at front of left rear wheelhouse upper trim finish panel, guide shoulder belt through trim and remove upper trim finish panel. (See figure 15)

34. Remove headliner trim finish panel molding assembly by pulling at clip locations. (See figure 16)

35. Remove left body rear panel assembly by pulling at clip locations. (See figure 17)

36. Remove three screws in the top of rear end trim finish panel assembly (sill molding). (See figure 18)

37. Pull upward on rear end trim finish panel assembly at clip location and remove. (See figure 18)

38. Remove cargo net. (See figure 19)

39. Remove cargo compartment carpet. (See figure 19)

40. Remove two left hand cargo net retainers. (See figure 19)

41. Remove left rear wheelhouse trim molding assembly fasteners, pull on molding to disengage clips and remove. (See figure 20)

42. Remove wedge blocks from rear liftgate. (See figure 21)

43. Remove rear liftgate inner lower trim panel assembly fasteners by pushing in center pin of each fastener until it clicks (approximately 1/8 in.) and remove fasteners. (See figure 22)

44. Inserting a screwdriver into hole at top of rear liftgate lower trim panel assembly on wiper pivot hump, push upward on screwdriver to disengage clips at center of panel. Grasp upper edge of trim panel and pull downward to disengage remaining clips. (See figure 22)

45. Remove rear liftgate upper garnish molding fasteners by pushing center pin of each fastener until it clicks and remove fastener. (See figure 23)

46. Remove rear liftgate upper garnish molding. (See figure 23)

47. Using template provided at the back of this bulletin, drill two 8 mm holes in rear liftgate. (See figure 24)

#### IMPORTANT: Template has two holes shown on it that align with two holes in rear liftgate that are used for rear liftgate lower trim.

48. Remove rear liftgate lid lock release cable from key cylinder. (See figure 25)

49. Remove lock latch from rear liftgate and remove cable from lock latch assembly. (See figure 25)

#### Installation

1. Attach new rear liftgate lid lock release cable (P/N 21097023) to lock latch assembly.

2. Install new rear liftgate lock rod clip (P/N 21097025) into lock latch assembly.

3. Install lock latch assembly to rear liftgate.

Torque: 10 N-m (89 in-lbs.)

4. Attach rear liftgate lid lock release cable to key cylinder.

5. Disconnect black 46-way I/P junction block connector and remove terminal position assurance (TPA) device.

6. Install orange wire (circuit 1936) terminal from body wiring harness extension (P/N 21022516) into cavity F4 of connector (shown in view A of illustration on facing page). (See figure 26)

7. Install TPA device to I/P junction block connector and install connector to I/P junction block.

8. Place body wiring harness extension over existing body harness.

9. Install black wire (Circuit 155AY) terminal from body wiring harness extension into cavity K of black, left rear body ground splice pack (shown in view B of illustration on facing page). (See figure 26)

10. Run body wiring harness extension up left side of rear D pillar. (See figure 27)

11. Using electrical tape, attach body wiring harness extension to existing body wiring harness. (See figure 27)

12. Run connector of body wiring harness extension through flex boot and then through hole at rear liftgate. (See figure 28)

13. Connect body wiring harness extension to rear liftgate wiring harness assembly (P/N 21022412). (See figure 29)

14. Using electrical tape, attach new liftgate wiring harness assembly to rear liftgate washer hose. (See figure 29)

#### IMPORTANT: Do not pinch rear washer hose.

15. Connect rear liftgate actuator assembly (P/N 22144103) to connector and install liftgate actuator and rear liftgate lock rod (P/N 21097027) and rear liftgate lock actuator nuts (P/N 21097076). (See figure 30)

Torque: 8 N-m (71 in-lbs)

16. Attach fuel filler door release cable to fuel tank fill door latch release cable handle assembly (P/N 21097022). (See figure 31)

17. Position fuel tank fill door latch release cable handle assembly to floor reinforcement and attach with bolt. (See figure 31)

Torque: 10 N-m (89 in-lbs)

18. Connect electrical connector from fuel tank fill door latch release cable handle assembly to new body wiring harness extension connector. (See figure 31)

19. Secure new body wiring harness extension to main body wiring harness every five to six inches with electrical tape. (See figure 31)

20. Install wiring harness cover retainer. (See figure 31)

21. Connect negative battery cable. (See figure 31)

Torque: 17 N-m (151 in-lbs)

#### NOTE: Verify functional operation of rear liftgate electric release.

22. Using fuel tank fill door latch release cable handle, operate rear liftgate electric release to make sure that it fully disengages from the striker. (See figure 32)

23. Reposition carpeting. (See figure 32)

24. Install rear liftgate knob (P/N 21090208) and fuel door knob on fuel tank fill door latch release cable handle assembly. (See figure 32)

25. Set front of console over shifter. (See figure 32)

26. Lift rear of console up and feed seat belts and bezels through console. Push in both seat belt bezels. (See figure 32)

27. For power window/mirror equipped vehicles: (See figure 33)

a. Connect switch electrical connectors and install CPA devices.

b. Install the window/mirror switch by inserting front edge first and snapping rear of switch into position.

28. Install front ashtray light to console. (See figure 34)

29. Align console at front and rear locating pins and push down to engage clips, then install both ashtrays. (See figure 35)

30. Install the two screws and liner in the rear storage tray. (See figure 36)

31. Install the two screws on the front sides of the console. (See figure 36)

32. Apply the parking brake and install the trim plate below the park brake lever by locating plate alignment pins and pressing into place. (See figure 36)

33. Install side trim panels. (See figure 37)

34. For manual transaxle, install knob. (See figure 37)

35. For automatic transaxle, remove tape from release button. (See figure 37)

36. Guide seat belt through bottom of the center pillar garnish molding. (See figure 38)

37. Starting at the front lower edge of center pillar garnish molding, guide edge of molding in an upward motion over body weld flange. (See figure 38)

38. Install screw at top of center pillar garnish molding. (See figure 38)

39. Install front upper center garnish molding by pushing firmly on bottom of molding. (See figure 38)

40. Install left front body hinge pillar garnish molding (sill molding). (See figure 39)

41. Install left rear wheelhouse trim molding. (See figure 40)

42. Starting at the front of the left rear lower garnish molding, push down at the clip locations to install. (See figure 41)

43. Install screws that attach the left rear lower garnish molding behind the rear seat side bolster. (See figure 41)

44. Install left body rear panel assembly by pushing at clip locations. (See figure 42)

45. While guiding the shoulder belt through the trim, install left rear wheelhouse upper trim finish panel and push pins. (See figure 43)

46. Install headliner trim finish panel molding assembly by pushing at clip locations. (See figure 44)

47. Install three screws in the top of rear end trim finish panel assembly (sill molding). (See figure 45)

48. Install rear liftgate upper garnish molding and install the fasteners. (See figure 46)

#### IMPORTANT: Do not pinch rear washer hose or wiring.

49. Install rear liftgate inner lower trim panel assembly and install fasteners. (See figure 47)

#### IMPORTANT: Do not pinch rear washer hose or wiring.

50. Install wedge blocks to rear liftgate. (See figure 48)

51. Install two left hand cargo net retainers. (See figure 49)

Torque: 10 N-m (89 in-lbs.)

52. Install cargo compartment carpet. (See figure 49)

53. Install cargo net. (See figure 49)

54. While guiding seat belt buckles through seat cushion, push down retainer tabs located at the front bottom of rear seat cushion to install. (See figure 50)

55. Install left rear seat back. (See figure 51)

56. Guide seat back assembly onto center pivot pin. Align outer pivot pin relief with outer bracket and guide outer pivot pin into outer bracket. (See figure 51)

57. Slide seat back inboard to engage pivot pin into outer bracket. (See figure 51)

58. Install plastic clip on outboard pivot pin. (See figure 51)

59. Install left rear seat bolster by pushing at top to engage fastener. (See figure 51)

60. Engage cargo floor carpet to seat back. (See figure 51)

61. After applying Loctite 242 (or equivalent), install bolts through driver's seat tracks to floor. (See figure 52)

Torque: 35 N-m (26 ft-lbs.)

IMPORTANT- Connect electrical connector and verify operation of the lap belt indicator light.

#### SECTION 2

#### INSTALLATION PROCEDURES FOR VEHICLES BUILT AFTER, AND INCLUDING VIN PZ150368

Removal

1. Disconnect negative battery cable. (See figure 53)

2. Remove bolts from driver's seat tracks to floor, tip seat and disconnect wire harness and remove seat. (See figure 53)

3. Raise rear section of left front body hinge pillar garnish molding (sill molding) by pulling up at clip locations just enough to clear center pillar garnish molding. (See figure 54)

4. Remove fuel door release knob by placing one end of a long, flat tool behind the knob and while holding opposite end, strike the tool near the knob with a hammer. (See figure 55)

5. Fold carpet back to provide access to the release handle assembly. (See figure 55)

6. Disconnect harness cover retainers from floor reinforcement. (See figure 56)

7. Remove bolt and pull fuel tank fill door latch release handle assembly out of floor reinforcement. (See figure 56)

8. Disconnect cable from fuel tank fill door latch release handle assembly. (See figure 56)

9. Remove wedge blocks from rear liftgate. (See figure 57)

10. Remove rear liftgate inner lower trim panel assembly fasteners by pushing in center pin of each fastener until it clicks (approximately 1/8 in.) and remove fasteners. (See figure 58)

11. Inserting a screwdriver into hole at top of rear liftgate lower trim panel assembly on wiper pivot hump, push upward on screwdriver to disengage clips at center of panel. Grasp upper edge of trim panel and pull downward to disengage remaining clips. (See figure 58)

12. If required, using template provided at the back of this bulletin, drill two 8 mm holes in rear liftgate. (See figure 59)

#### IMPORTANT: Template has two holes shown on it that align with two holes in rear liftgate that are used for rear liftgate lower trim.

13. Remove rear liftgate lid lock release cable from key cylinder. (See figure 60)

14. Remove lock latch from rear liftgate and remove cable from lock latch assembly. (See figure 60)

#### Installation

1. Attach new rear liftgate lid lock release cable (P/N 21097023) to lock latch assembly.

2. Install new rear liftgate lock rod clip (P/N 21097025) into lock latch assembly.

3. Install lock latch assembly to rear liftgate.

Torque: 10 N-m (89 in - lbs.)

4. Attach rear liftgate lid lock release cable to key cylinder.

5. Connect rear liftgate actuator assembly (P/N 22144103) to connector and install rear liftgate actuator and rear liftgate lock rod (P/N 21097027) and rear liftgate lock actuator nuts (P/N 21097076). (See figure 61)

Torque: 8 N-m (71 in-lbs)

6. Attach fuel filler door release cable to fuel tank fill door latch release cable handle assembly (P/N 21097022). (See figure 62)

7. Position fuel tank fill door latch release cable handle assembly to floor reinforcement and attach with bolt. (See figure 62)

Torque: 10 N-m (89 in-lbs)

8. Connect electrical connector from fuel tank fill door latch release cable handle assembly to body wiring harness connector. (See figure 63)

9. Install wiring harness cover retainer. (See figure 63)

10. Connect negative battery cable. (See figure 63)

Torque: 17 N-m (151 in-lbs)

#### NOTE: Verify functional operation of rear liftgate electric release.

11. Using fuel tank fill door latch release cable handle, operate rear liftgate electric release to make sure that it fully disengages from the striker. (See figure 64)

12. Reposition carpeting. (See figure 64)

13. Install rear liftgate knob (P/N 21090208) and fuel door knob on fuel tank fill door latch release cable handle assembly. (See figure 64)

14. Install left front body hinge pillar garnish molding (sill molding). (See figure 64)

15. Install rear liftgate inner lower trim panel assembly and install fasteners. (See figure 65)

IMPORTANT. Do not pinch rear washer hose or wiring.

16. Install wedge blocks to rear liftgate. (See figure 66)

17. After applying Loctite 242 (or equivalent), install bolts through driver's seat tracks to floor. (See figure 67)

Torque: 35 N-m (26 ft-lbs.)

#### IMPORTANT: Connect electrical connector and verify operation of the lap belt indicator light.

#### CREDIT

1. To receive credit for performing the procedure in Section 1, submit a claim with the information below:

Failed Parts Sale Case Labor Labor Installation Performed Part # Allow Type Type OP Hours

Install Jumper Harness, 21022516 * WS SP T9643 3.7 hrs Actuator and Electric Release Handle

2. To receive credit for performing the procedure in Section 2, submit a claim with the information below:

Failed Parts Sale Case Labor Labor Installation Performed Part # Allow Type Type OP Hours

Install Actuator and 22144103 * WS SP T9644 1.4 hrs Electric Release Handle

3. Check your Saturn SERVICE LINE Claim Memorandum daily. Remember to code the claim as a WS sale type, and SP case type. Contact your field representative if you need assistance.

* The Parts Allowance should be the sum of the current SSPO Retailer Net price plus 30% of all parts required for the installation.

#### NON-INVOLVED VEHICLES WITHIN VIN RANGE

PZ197080 PZ199031 PZ199325 PZ199612 PZ199852 PZ197091 PZ199042 PZ199336 PZ199622 PZ199862 PZ197102 PZ199055 PZ199347 PZ199632 PZ199872 PZ197115 PZ199066 PZ199361 PZ199642 PZ199882 PZ197126 PZ199080 PZ199375 PZ199652 PZ199892 PZ197137 PZ199091 PZ199387 PZ199662 PZ199902 PZ197150 PZ199102 PZ199400 PZ199672 PZ199912 PZ197161 PZ199115 PZ199412 PZ199682 PZ199922 PZ197172 PZ199126 PZ199425 PZ199692 PZ199932 PZ197185 PZ199140 PZ199436 PZ199702 PZ199942 PZ197581 PZ199151 PZ199447 PZ199712 PZ199952 PZ197592 PZ199165 PZ199461 PZ199722 PZ199962 PZ197605 PZ199176 PZ199476 PZ199732 PZ199972 PZ197616 PZ199187 PZ199487 PZ199742 PZ197627 PZ199200 PZ199500 PZ199752 PZ197640 PZ199211 PZ199512 PZ199762 PZ197651 PZ199225 PZ199526 PZ199772 PZ197662 PZ199236 PZ199540 PZ199782 PZ197675 PZ199247 PZ199551 PZ199792 PZ197686 PZ199260 PZ199562 PZ199802 PZ198981 PZ199271 PZ199572 PZ199812 PZ198995 PZ199285 PZ199582 PZ199822 PZ199007 PZ199297 PZ199592 PZ199832 PZ199020 PZ199311 PZ199602 PZ199842

June 15, 1993

Dear 1993 Saturn Wagon Owner:

We're writing to let you know of a feature for your 1993 Saturn Wagon that has just become available at your Retail facility.

As we hope you know, we'll always do our best to make sure that all Saturn owners are completely satisfied with their cars. That's why we're offering to you, at no charge, a remote liftgate release for your Saturn Wagon. This feature, which is now standard equipment on wagons currently being built, will allow you to release the wagon liftgate from inside the car. To accept our offer, just present this letter to your Saturn Retailer before December 31, 1994, and they'll be happy to install this feature for you. But please call your Retailer first, so that you can arrange a mutually convenient service appointment. Also, your Retailer can give you more details or answer any additional questions you might have.

We hope that this feature adds to your satisfaction and that your Saturn Wagon gives you many miles of enjoyable driving.

Sincerely,

Saturn Corporation

General Motors bulletins are intended for use by professional technicians, not a "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 trained technicians have the equipment, tools, safety instructions and know-how 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 a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.