POPPING NOISE FROM LEFT A PILLAR(INSTALL BOLTS AND NUTS). Saturn Saturn 1994

For 1990-2009 cars

# POPPING NOISE FROM LEFT A PILLAR(INSTALL BOLTS AND NUTS)

#### SUBJECT: Popping Noise From Left A Pillar (Install Bolts and Nuts)

Due to revisions in the affected model years, this bulletin supercedes bulletin 94 - T - 04A, which should be discarded.

#### MODELS AFFECTED: 1993-1995 Saturns

CONDITION: When starting or stopping the vehicle or when going over bumps, a popping noise may be heard from the base of the left hand A pillar area.

CAUSE: Some 1993 - 1995 Sedans and Wagons may exhibit a popping noise where the A pillar, hinge pillar and engine compartment frame rail are joined together. This popping noise is caused by a slight flexing at the point where they are joined together.

CORRECTIVE ACTION: Remove rear of front fender and install two bolts and nuts as explained in the procedure in this bulletin.

#### PROCEDURE

1. Raise hood.

2. Disconnect negative battery terminal.

3. Turn the powertrain control module (PCM) retaining screw, with a screwdriver, 1/4 turn counterclockwise and carefully place PCM on the floor of the vehicle.

4. If equipped with ABS brakes, turn the ABS control module retaining screw, with a screwdriver, 1/4 turn counterclockwise and carefully place ABS control module on the floor of the vehicle.

5. Remove three bolts from electronic brake control module and PCM bracket assembly and remove from vehicle.

6. Roll back insulation from hole in cockpit module.

#### NOTE: For the following two steps (7 and 8), refer to the "Front End" section of the "Body/Collisi Repair Service Manual."

7. Remove left fender to wheelhouse liner fasteners around entire wheel opening.

8. Remove left front fender lower extension.

9. Remove all fasteners from top and rear of upper fender. Pull fender away from body to access lower A pillar area.

10. Drill two, 6.35 mm (1/4in.) holes, positioned 20 mm (0.79 in.) forward and rearward of center weld, and 20 mm (0.79 in.) from top of frame rail.

#### IMPORTANT: Make sure to drill through all three layers of sheet metal before installing bolts in the next step.

11. Using 3M WINDO-WELD Primer (Black) (P/N 08643) or equivalent, prime edges of drilled holes.

12. From the inside of the vehicle, install two bolts (P/N 11508956) into the drilled holes.

13. Seal around outside of bolt with 3M Heavy DRIP-CHECK Sealer (Gray) (P/N 08531) or equivalent.

14. Install nuts (P/N 11509220) onto bolts and tighten.

Torque: 20 N,m (15 ft-lbs)

15. Position fender to vehicle and install fasteners. Align fender as necessary.

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

#### NOTE: For the following two steps (16 and 17), refer to the "Front End" section of the "Body/Collision Repair Service Manual."

16. Install left front fender lower extension.

17. Install wheelhouse liner to fender fasteners.

18. Reposition insulation moved from hole in cockpit module.

19. Install electronic brake control module and PCM bracket assembly.

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

20. If equipped with ABS brakes, push ABS control module up into electronic brake control module and PCM bracket assembly until two clicks are heard.

21. Push PCM up into electronic brake control module and PCM bracket assembly until two clicks are heard.

22. Connect battery negative cable.

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

23. Close hood.

PARTS REQUIREMENTS: 11508956 Bolt/Screw Asm - Flat Washer & Metric Hex Head 11509220 Nut Asm - Conical Spacer Washer/Metric Style 2 HE

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 Remove Front Fender and T9658 1.4 hrs Install Two Bolts into A Pillar

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.