Subject: | Service Information and Installation Procedures for Trap- Resistant Trunk Kit |
Models: | 1991- 1999 Saturn vehicles |
The purpose of this bulletin is to inform Saturn Retailer personnel of the system function and procedure used to install the Trap-Resistant Trunk Kit.
The Trap-Resistant Trunk Kit is composed of three system components.
The first component of the kit is the trap-resistant latch system. The trap-resistant latch is modified decklid latch designed to help prevent a child from unintentionally closing and latching the decklid. Once the decklid has been opened by the key, vehicle interior release lever, or remote keyless entry (RKE) transmitter, the trap-resistant latch cannot be re-latched without the user performing a reset function. This reset function consists of cycling the latch reset lever twice after the decklid has been opened in order to enable the latch. If the latch is not enabled, the decklid will not latch and will not close.
The second component of the kit is the illuminated interior release handle. the interior release handle is a plastic yellow handle, pocketed in a black plastic housing, which is mounted inside the trunk to the decklid. The interior release handle was designed so that s small child trapped in the trunk could use it to open the decklid. The handle operates the decklid latch mechanically and is illuminated with two light-emitted diodes (LEDs) when the decklid is closed. The handle remains illuminated for a period of approximately one hour after the decklid is closed. The LEDs create a small parasitic load that will not drain the vehicle battery with normal usage.
The third component of the kit is the seat back tether system. The seat back tether system helps prevent a child from gaining access to the trunk of a vehicle from the vehicle interior. The seat back tether system utilizes two elastic straps (one per folding seat back), each permanently connected to a T-handle retainer mounted to the rear window panel in the trunk. To lock the folding seat backs, the user can partially fold down the seat backs and attach the elastic strap to a T-handle retainer mounted to the seat backs. When the elastic straps are attached to the T-handle retainers, the seat back cannot be folded down. To unlock the seat backs, the elastic straps must be removed from the retainers attached to the seat backs.
After completing the Trap-Resistant Trunk Kit installation procedure, use the steps at the end of the procedure to verify proper system function. Also be sure to provide the customer with the supplemental owner's handbook insert included in the kit and demonstrate the system function.
Trap-Resistant Latch and Interior Release Handle Installation
13.1. | For Coupes, install new lock cylinder rod (included in kit.) |
• | 1991 - 1996 model year Coupes require short lock rod. |
• | 1997 - 1999 model year Coupes require long lock rod. |
13.2. | For Sedans, use grinder or wire cutter and carefully remove 2 mm (5/64 in.) of length from latch end of existing lock cylinder rod. |
Important: vehicle equipped with or without the remote keyless entry (RKE) feature use the same trap-resistant latch that is included in the kit. This latch will function properly on all vehicles.
Important: All 1996 and some early 1997 vehicle were equipped with a ring terminal ground connector that must be installed between decklid and latch prior to installing latch.
Tighten
Tighten the retaining bolts to 10 N·m (89 lb in).
Important: Due to stiffness of cable conduit, it may be necessary to pre-bend cable conduit prior to handle installation.
Notice: If drill bit is allowed to drill into sheet metal at a depth greater than 6.5 mm (1/4 in), outer surface of exterior panel may be penetrated.
Important: Due to stiffness of cable conduit, it may be necessary to pre-bend cable conduit prior to handle installation
Tighten
Tighten the handle to 2.6 N·m (23 lb in).
Important: Cable clip must be installed to the decklid inner sheet metal panel in a location that will allow clip to fully seat in the space between inner and outer decklid sheet metal.
Notice: If drill bit is allowed to drill into sheet metal at a depth greater that 6.5 mm (1/4 in), outer surface of exterior panel may be penetrated.
1996 -- 1999 Coupe and Sedan
• | Cavity F on Sl vehicle |
• | Cavity H on 1997- 1999 SC vehicles |
• | Cavity D on 1996 SC vehicles |
• | Cavity E on SL vehicles |
• | Cavity G on 1998 -- 1999 SC vehicles |
• | Cavity J on 1997 SC vehicles |
• | Cavity B on 1996 SC vehicles |
1991 -- 1995 Coupe and Sedan
Important: On certain 1991 -- 1995 vehicles the BLK and WHT handle wires may need to be lengthened using same gage wire.
• | On 1991 -- 1994 vehicles, splice together handle ORN wire, existing latch ORN wire, and existing latch LT GRN wire. |
• | On 1995 vehicles, splice together handle ORN wire, existing latch ORN wire, and existing latch RED/BLK wire. |
Important: Extra 3-way black connectors and WHT wires may be supplied with kit and will into all be used.
Important: When drilling holes in seat backs, drill through two layers of plastic seat back frame, but do not push drill through seat cushion fabric.
Important: When drilling holes in rear window panel rail, frill through first layer of sheet metal only. Be sure to collect all metal flakes from vehicle interior.
Important: For 1991 vehicle and 1992 vehicles built before VIN NZ101500, the Rear Shelf Panel Front Finish Lace may not be installed or does not stay in place. Vehicles with this condition may have an exposed metal edge that could fray the Seat Back Tether System straps. If this condition exists, please reference Technical Information Bulletins 91-T-44 and 92-T-18 for further information.
• | Ensure new decklid latch is enabled only after two cycles of latch reset lever when decklid has been opened by the following methods: |
- | Opened with key |
- | Open with vehicle interior release lever |
- | Opened with remote keyless entry (RKE) transmitter (if equipped) |
• | Ensure seat back tether system straps are properly installed and functioning. |
• | Fold down rear seat backs and check the following: |
- | Verify trunk interior release handle functions with decklid closed. |
- | Ensure interior release handle LEDs illuminate and stay illuminated when decklid is closed and are not illuminated when decklid is open. |
Supply customer with owner's handbook insert and use the insert to demonstrate function of Trap-Resistant Trunk Kit.
21171240 Asm - Decklid Latch | ||
Kits Contents | ||
Parts Description | Quantity | Model Usage |
Interior Release Handle | 1 | All |
Interior Release Handle Cable | 1 | All |
Interior Release Handle Cable Clip | 1 | All |
Interior Release Handle Fasteners | 1 | All |
Interior Release Handle Template | 1 | All |
Interior Release Handle Wiring Harness | 1 | All |
Trap-Resistant Latch Assembly | 1 | All |
91-96 Coupe Decklid Lock Rod (Short ) | 1 | 91-96 Coupes |
97-99 Coupe Decklid Lock Rod (Long) | 1 | 97-99 Coupes |
Replacement Connector Pack (Extras Supplied | 1 | 91-95 All |
Replacement Wire and Terminal Pack (Extras Supplied) | 1 | 91-95 All |
Seat Back Tether Straps with Anchor | 2 | All |
Seat Back Anchor | 2 | All |
Rivet Nut | 4 | All |
Rivet Nut Installation Tool | 1 | All |
Instruction Sheet | 1 | All |
Owner's Handbook Insert | 1 | All |
Reimbursement for Parts: Saturn will subsidize the cost of the parts by selling the kits at a reduced price. The Retailer will be reimbursed for the price of the Trap-Resistant Trunk Kit by the customer. Submit a claim using Labor Operation Code Z4024 without any labor hours, and enter the Manufacturer's Suggested Retail Price (MRSP) of the kit using case type "CP."
Reimbursement for Labor: The Retailer will be reimbursed for installation labor through the submission of a claim using the applicable case type of "VW" or "VP." Submit the claim using Labor Operation Code Z4024 for 1.1 hours.
Due to the nature of the installation, the procedure is not intended for the "do it yourselfer." It is in the customer's best interest to have the kit installed by an authorized Saturn Retail facility. Therefore, Retailers should discourage over-the-counter sales since the MSRP includes the installation.
All claims submitted must be supported by s signed Customer Service Order.