FRONT OF HEADLINER WET WHEN VEHICLE PARKED DOWN ON INCLINE. Saturn Saturn 1993

For 1990-2009 cars

# FRONT OF HEADLINER WET WHEN VEHICLE PARKED DOWN ON INCLINE

#### SUBJECT: Front of Headliner Wet When Vehicle Has Been Parked Facing Down on an Incline (Add Two Drains to Front of Sunroof Module)

Due to revisions in the affected model years and the addition of a VIN breakpoint, this bulletin supersedes bulletin 92-T-39, which should be discarded.

#### MODELS AFFECTED: 1991 - 1993 Saturn Sedans built before and including vehicle identification number (VIN) PZ122050, equipped with factory installed sunroofs.

CONDITION: If the vehicle is parked on an incline of approximately 11 degrees or greater, with front of vehicle at a downward angle, water may collect in the front of the sunroof module. This water may flow over the module and onto the headliner before draining out of forward drain hoses.

CAUSE: Sunroof module drain hoses are located 4 inches from the front corners of the module.

CORRECTION: Add two drain hoses at the front corners of sunroof module.

Materials required for this procedure.

o PPG DP90/DP401 Primer, or equivalent.

o 3M 8101 Structural Adhesive, or equivalent.

o Two 5/16 x 1/4" plastic "T".

o 10' of 1/4" rubber hose.

o 2" of 1/4" steel tubing.

o Four 5/16" hose clamps.

o Four 1/4" hose clamps.

o Two push nuts P/N 14093869

#### PROCEDURE:

--------- 1. Cycle sunroof to full-open position.

2. Open driver's and passenger's doors.

3. Protect the paint around the sunroof opening with a protective covering.

4. Remove headlining trim finish panel assembly. Refer to procedures under "Headlining" (Sedan) in the "Vehicle Interior Systems" section of the "Body/Collision Repair Service Manual."

5. Remove right and left body H/Pillar trim garnish moldings (known as the front lower garnish moldings). Refer to "Front Lower Garnish/Sill Molding" (Sedan), located in the "Vehicle Interior Systems" section of the "Body/Collision Repair Service Manual." Be careful not to break clips.

6. From top of vehicle, drill a 1/4" hole, 101.6 mm (4 in.) from the existing drain hole, at front of each corner of sunroof module.

#### IMPORTANT: Place a protective cover over the vehicle seats to protect them from metal shavings and primer.

7. Debur rough edges from the holes. Prime bare metal with a corrosion resistant primer such as PPG DP 90/DP 401, or equivalent.

8. Using a piece of 1/4" steel tubing, such as brake or power steering line:

o Cut two pieces 5/8" long.

o Flare one end of each tube and install the non-flared end of the tubes into the top of the module, so that the flared end fits against the top of the sunroof module.

o Install push nuts (P/N 14093869) onto tubes from the bottom (non- flared side) to help hold tube against side of module.

o Using 3M 8101 Structural Adhesive, or equivalent, attach the tube to the sunroof module. Smooth adhesive around the tube on the top and bottom side of the sunroof module.

o Allow to cure, according to manufacturer's instructions.

9. Attach a 5' section of 1/4" rubber hose to each tube installed in Step 8. Use a hose clamp to secure the hose to the tube.

10. Route both hoses along inside of vehicle, down the outside edge of the "A" pillars, so that hoses end up being between the windshield garnish molding assemblies and "A" pillar. Using duct tape, tape hoses to the "A" pillar

#### NOTE: The factory installed drain lines have been installed inside the "A" pillar making it impossible to run these added drain lines down the inside of the "A" pillar.

11. For left side of vehicle:

a. Remove the indented cover, containing electrical connectors under the lower garnish kick panel molding.

b. Cut the factory installed drain hose near where it enters the frame and install a 5/16 X 1/4" "T" into the factory installed drain hose.

c. It will be necessary to drill 1/4" hole through the indented cover to allow the new drain hose to be installed.

d. Install the new 1/4" drain hose to the "T"

12. For right side of vehicle:

a. Remove cover under molding.

b. Cut the factory installed drain hose near where it enters the frame and install a 5/16 X 1/4" "T" into the factory installed drain hose.

c. Install the new 1/4" drain hose to the "T"

13. Water test the vehicle with the rear wheels raised at least 12" off the ground and inspect for waterleaks.

14. Install the covers on the left and right sides of the vehicle.

15. Install left and right body H/Pillar trim garnish moldings (known as the front lower garnish moldings). Refer to "Front Lower Garnish/Sill Molding" (Sedan), located in the "Vehicle Interior Systems" section of the "Body/Collision Repair Service Manual."

16. Install headlining trim finish panel assembly. Refer to procedures under "Headlining" (Sedan) in the "Vehicle Interior Systems" section of the "Body/Collision Repair Service Manual."

PARTS REQUIREMENTS: 14093869 Push Nut (2) ------------------ CLAIM INFORMATION: To receive credit for this repair, submit a claim through the Saturn Dealer System as follows: Labor Case Operation Type Description Code Time -------------------------------------------------------- VW Install Two New Drain Hoses in T9579 3.0 hrs Front Corners of Sunroof Module

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.