DOOR WINDOW GLASS WILL NOT GO UP OR DOWN. Saturn SL1/SC1/SW1 1997

SUBJECT: DOOR WINDOW GLASS WILL NOT GO UP OR DOWN AND/OR RATTLES (ADD SHIMS UNDER DOOR GLASS INSULATOR DETENT TABS)

MODELS AFFECTED: 1996-1998 SATURN SEDANS AND WAGONS, 1997-1998 SATURN COUPES

CONDITION:

FRONT OR REAR DOOR GLASS WILL NOT GO UP OR DOWN AND/OR THE FRONT OR REAR DOOR GLASS RATTLES.

CAUSE:

THE WINDOW REGULATOR SASH BAR EAR FINISHING PROCESS MAY CREATE A RADIUS ON THE EDGE. WITH NORMAL CYCLING OF THE DOOR GLASS, THIS CAN ALLOW THE RETENTION TABS OF THE SIDE DOOR WINDOW GLASS INSULATORS TO MOVE ENOUGH TO RELEASE FROM THE SASH BAR. THIS CAUSES THE DOOR GLASS TO BECOME DISCONNECTED FROM THE WINDOW REGULATOR.

CORRECTION:

ADD RUBBER SHIMS TO THE DOOR GLASS UNDERNEATH THE DETENT TABS OF THE INSULATOR ACCORDING TO PROCEDURES IN THIS BULLETIN.

PROCEDURES:

1. REMOVE DOOR OUTER PANEL FROM DOOR WHERE GLASS IS NOT ATTACHED OR FROM DOOR WHERE GLASS RATTLES. (REFER TO EITHER "FRONT DOOR OUTER PANEL-COUPE," "FRONT DOOR OUTER PANEL-SEDAN AND WAGON," "REAR DOOR OUTER PANEL" IN THE "DOORS" SECTION OF THE APPROPRIATE YEAR "BODY/REPAIR SERVICE MANUAL.") IMPORTANT: THE SIDE DOOR INSULATOR IS CALLED THE DOOR SOUND DEADENER (FRONT DOORS) OR THE DOOR SOUND INSULATOR (REAR DOORS) IN THE SERVICE MANUAL. 2. REMOVE SIDE DOOR INSULATOR ASSEMBLY. (REFER TO "DOOR SOUND DEADENER PANEL - SEDAN/WAGON SHOWN - COUPE SIMILAR" FOR FRONT DOORS OR DOOR SOUND INSULATOR - SEDAN/WAGON" FOR REAR DOORS IN THE "DOORS" SECTION OF THE APPROPRIATE YEAR "BODY/REPAIR SERVICE MANUAL.") --------------------- FIGURE --------------------- 3. VERIFY THE DOOR WINDOW GLASS INSULATORS [emsp ]ARE IN PLACE AND NOT DAMAGED. . IF DOOR GLASS INSULATOR(S) ARE DAMAGED, REPLACE WITH NEW DOOR GLASS INSULATOR(S) (P/N 21098967), THEN PROCEED TO THE NEXT STEP. . IF DOOR GLASS INSULATORS ARE NOT DAMAGED, PROCEED TO THE NEXT STEP. 4. ALIGN WINDOW REGULATOR SASH BAR [emsp ] WITH INSULATORS [emsp ] AND SLIDE SASH ONTO INSULATORS. 5. CLEAN DOOR GLASS WITH ALCOHOL. IMPORTANT: PROPER LOCATION OF THE RUBBER SHIMS ARE CRITICAL. THE SHIMS MUST BE PLACED UNDER THE DETENT TABS OF THE FRONT INSULATOR IN THE FRONT SASH BAR EAR. THE FRONT SASH BAR EAR IS USED BECAUSE IT IS LONGER THAN THE REAR SASH BAR EAR. IF THE RUBBER SHIMS ARE INSTALLED IN THE REAR INSULATOR, THE DOOR GLASS MAY DISCONNECT FROM THE DOOR WINDOW REGULATOR. IMPORTANT: THE RUBBER SHIMS ARE CALLED "CHMSL INSULATORS" IN THE SATURN PARTS CATALOG. HOWEVER, THEY CAN BE USED FOR THIS REPAIR. 6. CAREFULLY LIFT UP ON THE FRONT INSULATOR DETENT TABS[emsp ](4), AND INSTALL RUBBER SHIMS (5) (P/N 15739432) ONTO GLASS AS SHOWN IN ILLUSTRATION. 7. CYCLE DOOR WINDOW 3-5 TIMES TO VERIFY PROPER OPERATION OF THE DOOR WINDOW REGULATOR AND DOOR WINDOW GLASS. IF WINDOW DOES NOT FUNCTION PROPERLY, REPAIR AND/OR REPLACE AFFECTED PART(S) AS REQUIRED. 8. INSTALL SIDE DOOR INSULATOR ASSEMBLY. (REFER TO "DOOR SOUND DEADENER PANEL - SEDAN/WAGON SHOWN - COUPE SIMILAR" FOR FRONT DOORS OR DOOR SOUND INSULATOR - SEDAN/WAGON" FOR REAR DOORS IN THE "DOORS" SECTION OF THE APPROPRIATE YEAR "BODY/REPAIR SERVICE MANUAL.") 9. INSTALL DOOR OUTER PANEL. (REFER TO EITHER "FRONT DOOR OUTER PANEL-COUPE," "FRONT DOOR OUTER PANEL-SEDAN AND WAGON," "REAR DOOR OUTER PANEL" IN THE "DOORS" SECTION OF THE APPROPRIATE YEAR "BODY/REPAIR SERVICE MANUAL.")

PARTS REQUIREMENTS:

15739432 INSULATOR-CHMSL (RUBBER SHIM) - 2 PER WINDOW 21098967 INSULATOR-SIDE DOOR WINDOW GLASS

CLAIM INFORMATION:

TO RECEIVE CREDIT FOR THIS REPAIR DURING THE WARRANTY COVERAGE PERIOD, SUBMIT A CLAIM THROUGH THE SATURN DEALER SYSTEM AS FOLLOWS:

CASE TYPE DESCRIPTION LABOR OPERATION CODE TIME VW ADD SHIMS UNDER DOOR GLASS INSULATOR DETENT TABS RIGHT FRONT DOOR T9783 0.8 HRS LEFT FRONT DOOR T9784 0.8 HRS RIGHT REAR DOOR T9785 0.7 HRS LEFT REAR DOOR T9786 0.7 HRS

FIGURES: 01

SATURN 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 YOUR SATURN RETAILER FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.