Rattle or Buzz Noise from Rear of Passenger Compartment (Install Foam Tape to Curtain Inflator (Side Airbag) Module)

Some customers may comment on a rattle or buzzing noise from the rear passenger compartment.

This condition may be caused by the curtain inflator (side airbag) module contacting the vehicle frame.

Install foam tape to the side of the curtain inflator module as described in this bulletin.

Caution: WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SIR COMPONENTS OR THE SIR WIRING, YOU MUST DISABLE THE SIR SYSTEM. REFER TO "SIR DISABLE/ENABLE PROCEDURE (FOR FRONTAL AND CURTAIN INFLATORS)" IN THE SIR SUB-SECTION OF THE 2002 -- 2003 SATURN L-SERIES SERVICE MANUAL. FAILURE TO FOLLOW THE CORRECT PROCEDURE COULD CAUSE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR UNNECESSARY SIR REPAIRS.

DISABLING THE CURTAIN INFLATORS

1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead.
2. Turn ignition switch to the OFF position and remove the key.
3. Remove IGN1 mini-fuse from underhood fuse block.
4. Remove left rear seat shoulder belt cover to expose shoulder belt fastener.
5. Remove left shoulder belt fastener and left shoulder belt.
6. Fold down rear seat back.
7. Route left shoulder belt out of C-pillar trim access slot.
8. Remove left C-pillar trim by pulling gently at C-pillar clip locations.
9. Repeat steps 4 -- 8 for right side.



10. Remove Connector Position Assurance (CPA) retainer.
11. Disconnect left and right curtain inflator module (YEL 2-way) connectors.




Caution: SIR SYSTEM SHOULD BE DISABLED BEFORE REMOVAL OF THE INFLATOR. DO NOT TWIST THE INFLATOR.

12. Remove only the fasteners from inflator module to spaceframe and remove module.




Important: The foam tape must be securely fastened between the backlite flange of the body and the airbag canister when the airbag is fully installed.

13. Install foam tape approximately 110 mm (4.25 in.) in length x 11 mm (0.4 in.) wide and 12 mm (0.5 in.) thick to the inflator module as shown in the illustration. Use Kent Industries E-V-R Tite Adhesive backed pressure sensitive sponge rubber weatherstrip (Kent P/N 40130) or equivalent.



14. Install inflator module and fasteners to spaceframe taking care not to twist the airbag inflator when installed.

Tighten
Tighten the Curtain Inflator Retaining Bolt to 10N·m(89 in-lbs).

ENABLING THE CURTAIN INFLATORS

1. Connect the left and right curtain inflator module (YEL 2-way) connectors.
2. Install CPA retainers.



3. Position left C-pillar to vehicle.
4. Install left C-pillar trim by pushing gently at clip locations.

Caution: APPLY LOCTITE® 242, OR EQUIVALENT, TO ALL RESTRAINT FASTENERS PRIOR TO INSTALLATION.

5. Install left rear shoulder belt to C-pillar.

Tighten
Tighten the Rear Shoulder Belt-to-C-Pillar to 35N·m(26 ft-lbs).

6. Install left rear shoulder belt fastener cover.
7. Route left shoulder belt into C-pillar trim at access slot.
8. Repeat steps 3 -- 8 for the right side.
9. Fold up rear seat back.
10. Operate rear seat shoulder belts to verify proper function.
11. Install IGN1 mini-fuse in under hood fuse block. Enable the SIR System.
12. Turn ignition ON and verify AIR BAG telltale operates properly.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for C9993 (Module, Drive/Passenger/Side, Left/Right Side Inflator Modules - Repair).