EXPERTEC TSB (92-T-39A-SATURN)

EXPERTEC TSB

TECHNICAL SERVICE BULLETIN

FRONT OF HEADLINER WET WHEN VEHICLE PARKED DOWN ON INCLINE

Model(s): 1991-93 Saturn Sedans

Bulletin No.: 92-T-39A-SATURN

Date: November 1, 1993

MODELS AFFECTED

1991 - 1993 Saturn Sedans built before and including vehicle identification number (VIN) PZ122050, equipped with factory installed sunroofs.

CONDITION

If the vehicle is parked on an incline of approximately 11 degrees or greater, with front of vehicle at a downward angle, water may collect in the front of the sunroof module. This water may flow over the module and onto the headliner before draining out of forward drain hoses.

CAUSE

Sunroof module drain hoses are located 4 inches from the front corners of the module.

CORRECTION

Add two drain hoses at the front corners of sunroof module.

MATERIALS REQUIRED FOR THIS PROCEDURE

• PPG DP90/DP401 Primer, or equivalent.
• 3M 8101 Structural Adhesive, or equivalent.
• Two 5/16 x 1/4" plastic "T".
• 10' of 1/4" rubber hose.
• 2" of 1/4" steel tubing.
• Four 5/16" hose clamps.
• Four 1/4" hose clamps.
• Two push nuts P/N 14093869

PROCEDURE

1. Cycle sunroof to full-open position.
2. Open driver's and passenger's doors.
3. Protect the paint around the sunroof opening with a protective covering.
4. Remove headlining trim finish panel assembly. Refer to procedures under "Headlining" (Sedan) in the "Vehicle Interior Systems" section of the "Body/Collision Repair Service Manual."
5. Remove right and left body H/Pillar trim garnish moldings (known as the front lower garnish moldings). Refer to "Front Lower Garnish/Sill Molding" (Sedan), located in the "Vehicle Interior Systems" section of the "Body/Collision Repair Service Manual." Be careful not to break clips.
6. From top of vehicle, drill a 1/4" hole, 101.6 mm (4 in.) from the existing drain hole, at front of each corner of sunroof module.
   NOTE: Place a protective cover over the vehicle seats to protect them from metal shavings and primer.
7. Debur rough edges from the holes. Prime bare metal with a corrosion resistant primer such as PPG DP 90/DP 401, or equivalent.
8. Using a piece of 1/4" steel tubing, such as brake or power steering line:
   1. Cut two pieces 5/8" long.
   2. Flare one end of each tube and install the non-flared end of the tubes into the top of the module, so that the flared end fits against the top of the sunroof module.
   3. Install push nuts (P/N 14093869) onto tubes from the bottom (non-flared side) to help hold tube against side of module.
   4. Using 3M 8101 Structural Adhesive, or equivalent, attach the tube to the sunroof module. Smooth adhesive around the tube on the top and bottom side of the sunroof module.
   5. Allow to cure, according to manufacturer's instructions.
9. Attach a 5' section of 1/4" rubber hose to each tube installed in Step 8. Use a hose clamp to secure the hose to the tube.
10. Route both hoses along inside of vehicle, down the outside edge of the "A" pillars, so that hoses end up being between the windshield garnish molding assemblies and "A" pillar. Using duct tape, tape hoses to the "A" pillar.
    NOTE: The factory installed drain lines have been installed inside the "A" pillar making it impossible to run these added drain lines down the inside of the "A" pillar.
11. For Left Side of Vehicle (See Fig 2 thru Fig 5 ):
    1. Remove the indented cover, containing electrical connectors under the lower garnish kick panel molding.
    2. Cut the factory installed drain hose near where it enters the frame and install a 5/16 x 1/4" "T" into the factory installed drain hose.
    3. It will be necessary to drill 1/4" hole through the indented cover to allow the new drain hose to be installed.
    4. Install the new 1/4" drain hose to the "T".
12. For Right Side of Vehicle (See Fig 1 , Fig 6 & 7):
    1. Remove cover under molding.
    2. Cut the factory installed drain hose near where it enters the frame and install a 5/16 x 1/4" "T" into the factory installed drain hose.
    3. Install the new 1/4" drain hose to the "T".
13. Water test the vehicle with the rear wheels raised at least 12" off the ground and inspect for water leaks.
14. Install the covers on the left and right sides of the vehicle.
15. Install left and right body H/Pillar trim garnish moldings (known as the front lower garnish moldings). Refer to "Front Lower Garnish/Sill Molding" (Sedan), located in the "Vehicle Interior Systems" section of the "Body/Collision Repair Service Manual."
16. Install headlining trim finish panel assembly. Refer to procedures under "Headlining" (Sedan) in the "Vehicle Interior Systems" section of the "Body/Collision Repair Service Manual."

PARTS REQUIREMENTS

• 14093869, Push Nut (2)

CLAIM INFORMATION

To receive credit for this repair, submit a claim through the Saturn Dealer System as follows:

Case Type	Description	Labor Operation Code	Time
VW	Install Two New Drain Hoses in Front Corners of Sunroof Module	T9579	3.0 Hrs