HEADLAMP COVER CONTACTS HOOD WHEN IN RAISED POSITION. Saturn Saturn 1991

For 1990-2009 cars

# HEADLAMP COVER CONTACTS HOOD WHEN IN RAISED POSITION

#### SUBJECT: Headlamp Cover Contacts Hood When Headlamp is in Raised Position (Realignment of Headlamp Assembly) 1991 Saturn Coupes.

CONDITION: Headlamp cover contacts hood when the headlamp is in the raised position.

CAUSE: Improper alignment of headlamp assembly

CORRECTIVE ACTION: Align headlamp assembly according to the following procedure:

#### PROCEDURE:

1. With the hood closed, raise the headlamps to the open position.

2. With the headlamps open, measure the clearance between headlamp cover and hood panel at location "A", shown in the figure. A minimum 1 mm (0.039 in.) gap is required between the headlamp assembly and hood.

3. If the gap is not within specification, refer to the "Headlamp Panel Adjustment" procedures in the "Front End" section of the "Body Service Manual."

4. If, after following the headlamp adjustment procedures, the 1 mm (0.039 in.) gap cannot be obtained, repair using the following procedure, referring to the figure.

a. Open the hood and loosen the headlamp housing attachment screws at location "A" and "B".

b. Remove the screw at location "C" and insert a 3 mm washer at location "C", between the "L" bracket and the upper tie bar. Install screw at location "C" and tighten. Torque: 9 N-m (80 lbs-in)

c. Before tightening screw at location "A", pull up on front fascia exposing 2 mm (0.079 in.) of the slot in the adjustment bracket above screw and tighten screws at locations "A" and "B". Torque: 9 N - m (80 lbs-in)

d. Close the hood and headlamp housing while checking for flushness of headlamp cover to hood. Adjustment can be done by adjusting the hood latch and inboard hood bumpers. Check for proper hood latch operation after adjustment.

e. After all adjustments are made, check headlamp aim. Refer to the "Headlamp Aiming-Coupe" procedures in the "Front End" section of the "Body Service Manual."

f. Repair any paint damage due to contact of the headlamp panels, according to the "Body Paint" procedures in the "General Information" section of the "Body Service Manual."

CLAIM INFORMATION: A claim should be submitted only for the repairs performed, by way of the Saturn Dealer System and must include the case detail as follows:

Labor Case Operation Type Description Code Time ----- ------------------------ ------------- VW Hood Assembly Alignment B1500 0.4 hrs VW Headlamp Cover Adjustment B1390 0.2 hrs (per side) VW Headlamp Adjustment and Shim Installation T9519 0.4 hrs (per side) VW Headlamp Aiming N0225 0.4 hrs

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