RETRACTABLE HEADLAMPS OPERATE SLOWLY OR INTERMITTENTLY. Saturn Saturn 1991

For 1990-2009 cars

# RETRACTABLE HEADLAMPS OPERATE SLOWLY OR INTERMITTENTLY

#### SUBJECT: RETRACTABLE HEADLAMPS OPERATE SLOWLY OR INTERMITTENTLY, OR BINDS (REPLACE HEADLAMP ACTUATOR ASSEMBLY, INSTALL PROTECTIVE BOOT AND LUBRICATE)

#### MODELS AFFECTED: ALL 1991 AND 1992 SATURN SC COUPES AND 1993 SATURN SC2 COUPES BUILT BEFORE, AND INCLUDING VIN PZ275987.

#### CONDITION:

SOME CUSTOMERS MAY COMMENT THAT THE HEADLAMPS OPERATE SLOWLY OR INTERMITTENTLY, OR BIND. HEADLAMPS MAY ALSO BE NOISY WHEN OPENING.

#### CAUSE:

CORROSION FORMS ON SHAFT OF THE HEADLAMP ACTUATOR ASSEMBLY AND/OR AT THE JOINTS OF THE HEADLAMP LINKAGE ON THE HEADLAMP ASSEMBLY.

#### CORRECTION:

REPLACE THE HEADLAMP ACTUATOR ASSEMBLY, INSTALL A PROTECTIVE RUBBER BOOT, AND LUBRICATE THE HEADLAMP LINKAGE USING THE PROCEDURES IN THIS BULLETIN.

PROCEDURES 1. OPEN HOOD AND RAISE RETRACTABLE HEADLAMPS. 2. DISCONNECT BATTERY NEGATIVE CABLE. 3. REMOVE RIGHT AND LEFT HEADLAMP BEZEL RETAINING SCREWS AND REMOVE BEZELS FROM HEADLAMP HOUSING ASSEMBLIES. --------------------------------- FIGURE ---------------------------------

4. IF EQUIPPED, REMOVE AIR CONDITIONING INLET DUCT ASSEMBLY. 5. DISCONNECT ELECTRICAL CONNECTOR AT HEADLAMP ACTUATOR ASSEMBLY THAT IS NOT OPERATING CORRECTLY AND UNCLIP ELECTRICAL CONNECTOR FROM HEADLAMP ASSEMBLY. 6. REMOVE NUT, SECURING HEADLAMP LINKAGE TO HEADLAMP ACTUATOR ASSEMBLY SHAFT. 7. REMOVE THREE HEADLAMP ACTUATOR ASSEMBLY TO HEADLAMP HOUSING BOLTS. -------------------------------- FIGURE -------------------------------- 8. FREE HEADLAMP LINKAGE FROM HEADLAMP ACTUATOR ASSEMBLY SHAFT AND REMOVE HEADLAMP HOUSING BOLTS. 9. INSTALL NEW HEADLAMP ACTUATOR ASSEMBLY (LH-P/N 21095841 OR RH- P/N 21095842) BY INSERTING THE HEADLAMP ACTUATOR ASSEMBLY SHAFT INTO THE HEADLAMP LINKAGE AND POSITIONING HEADLAMP ACTUATOR ASSEMBLY INTO VEHICLE. 10. INSTALL THREE HEADLAMP ACTUATOR ASSEMBLY TO HEADLAMP HOUSING BOLTS AND TIGHTEN. TORQUE: 5.5 N.M (46 LBS. IN.) 11. INSTALL NUT TO HEADLAMP ACTUATOR ASSEMBLY SHAFT TO SECURE HEADLAMP LINKAGE. TORQUE: 5.5 N.M (46 LBS. IN.) IMPORTANT: APPLY LOCTITE(R) 242 THREADLOCKER OR EQUIVALENT TO THE HEADLAMP ACTUATOR SHAFT NUT BEFORE INSTALLING NUT TO HEADLAMP ACTUATOR SHAFT. 12. CONNECT ELECTRICAL CONNECTOR TO HEADLAMP ASSEMBLY. 13. CLIP ELECTRICAL CONNECTOR TO HEADLAMP ASSEMBLY. 14. GREASE HEADLAMP ACTUATOR LINKAGE ASSEMBLIES ON BOTH THE LEFT AND RIGHT HAND HEADLAMP ACTUATOR ASSEMBLIES USING SATURN ANTI-SEIZE NICKEL COMPOUND (P/N 21485279) OR PERMATIX ANTI-SEIZE LUBRICANT (P/N 133K) OR EQUIVALENT. ----------------------------------- FIGURE ----------------------------------- 15. CONNECT BATTERY NEGATIVE CABLE. 16. CLOSE HOOD. 17. OPERATE HEADLAMPS TO MAKE SURE OF PROPER OPERATION. IMPORTANT: IF THERE IS AN OBVIOUS DIFFERENCE IN THE OPENING OR CLOSING SPEED BETWEEN THE LEFT AND RIGHT HEADLAMPS, REPLACE THE OTHER HEADLAMP ACTUATOR ASSEMBLY, REPEATING STEPS 1, 2 AND 5 THROUGH 17. 18. INSTALL PROTECTIVE BOOTS (P/N 16521527) TO THE LEFT AND RIGHT HAND HEADLAMP ACTUATOR ASSEMBLIES. IMPORTANT: IF THE PROTECTIVE BOOT OR EITHER HEADLAMP ACTUATOR ASSEMBLY CONTACTS THE FRONT FASCIA SUPPORT, ADJUST THE FRONT FASCIA SUPPORT AS REQUIRED. -------------------------------- FIGURE -------------------------------- 19. OPEN HOOD AND RAISE RETRACTABLE HEADLAMPS. 20. INSTALL HEADLAMP BEZELS TO THE LEFT AND RIGHT HAND HEADLAMP ASSEMBLIES AND TIGHTEN THE SCREWS. 21. IF EQUIPPED, INSTALL AIR CONDITIONING INLET DUCT ASSEMBLY. 22. CLOSE HOOD.

PARTS REQUIREMENTS 21095841 KIT-LH HEADLAMP ACTUATOR ASSEMBLY 21095842 KIT-RH HEADLAMP ACTUATOR ASSEMBLY 16521527 BOOT 21485279 COMPOUND-ANTI-SEIZE NICKEL

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 REPLACE HEADLAMP ACTUATOR ASSEMBLY, T9629 1.2 HRS LUBRICATE LINKAGE AND INSTALL PROTECTIVE BOOTS

#### ADD:

A. TO REPLACE BOTH HEADLAMP ACTUATOR ASSEMBLIES, IF NECESSARY 0.7 HRS

FIGURES: 0

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.

COPYRIGHT 1993 SATURN CORPORATION U.S.A. ALL RIGHTS RESERVED.