Headlamp Assemblies may Rattle and/or Vibrate (Add Rubber Shim to Headlamp Mounting Bracket)

Some customers may comment about a rattle noise coming from the front of the vehicle and/or the headlamp beam vibrating when the vehicle is idling. This is more noticeable in vehicle equipped with automatic transaxles and the gear selection in Reverse or Drive with the brakes applied.

Excessive clearance between where the headlamp housing mounting bracket finger inserts into the core support headlamp mounting bracket.

Install a rubber shim onto the headlamp housing mounting bracket as described in the following procedure.

1. Verify condition by grabbing the headlamp around the lens near the center of the vehicle and try to move the lens in--and--out.

•	If the headlamp has excessive movement, proceed to Step 2.

•	If the headlamp does not have excessive movement, refer to other service information for assistance in diagnosing the complaint.

2. Remove headlamp(s) where the movement exists (Refer to Headlamp Housing Removal" procedure in the Body/Repair Service Manual.)
3. Remove excessive flashing from headlamp mounting bracket, with a file if necessary, at the location of where the bumper is to be installed. Clean mounting surface area with alcohol and allow to dry. Install rubber shim (P/N 15739432) onto headlamp mounting bracket as shown in illustration.




Important: When installing the headlamp assembly, some force will be required to position the headlamp mounting bracket finger into the core support mounting bracket. The addition of the bumper creates a tight fit.

4. Carefully install headlamp. (Refer to "Headlamp Housing Installation" procedure in the Body/Repair Service Manual.)

To receive credit for this repair during the warranty coverage period, submit claim through the Saturn Dealer system as follows: