Roof Panel Flexing During Sunroof Operation or Sunroof Rattling on Rough Road Surfaces (Apply Urethane Structural Adhesive to Roof Reinforcement Stiffening Bead)

Some customers may comment that during operation of the sunroof, the roof panel may flex in either the right or left corner of the roof forward of the sunroof. Some customers may comment on a rattle noise coming from the roof area forward of the sunroof.

The inner roof structure used to support the sunroof may be missing one or more toggle locks. (A toggle lock is a manufacturing process that engages layers of metal together through the use of a "dimpling" process.)

Apply urethane adhesive to the area of the inner roof panel that has a toggle lock missing.

1. Open sunroof far enough to expose the area where the sunroof seal contacts the front roof flange.



2. Inspect roof at sunroof roof flange for 3 toggle locks (Toggle locks are small indentations in the metal that mechanically join layers of metal together. A toggle lock tool mark resembles a spot weld).

•	If one or two of the three toggle locks are missing, proceed to Step 3.

•	If all three toggle locks are missing, roof panel must be replaced. For roof panel replacement, refer to "Roof Panel Replacement" in the Collision Repair section of the 2003 Saturn ION Service Manual, Vol. 3.

Important: During headliner removal, care must be used when separating the headliner hook and loop (Velcro®) fasteners so as not to tear the hook and loop fastener away from the headliner material.

3. Once it has been determined that there is a missing toggle lock, remove the interior headliner. Refer to "Headliner Replacement" in the Body and Accessories section of the 2003 Saturn ION Service Manual, Vol. 3.



4. After the headliner is removed, locate the roof panel reinforcement urethane access hole adjacent to the missing toggle lock.




Important: Trim urethane tube nozzle at a 45° angle. The cut angle should be rotated upward so it is facing the roof panel. Do not trim more than 25 mm (1 in) from the nozzle of the urethane tube. Trimming more than 25 mm (1 in) from the tube will not allow the nozzle to reach far enough into the access hole to reach the reinforcement stiffening bead.

5. Using 3M® P/N 0869, Fast Cure Auto Glass Urethane Adhesive (or equivalent), insert nozzle into the roof panel reinforcement access hole with the nozzle pointed inward and toward the reinforcement stiffening bead.




Important: Urethane tube nozzle must be directed inward toward the reinforcement stiffening bead. Do not just fill the area of the urethane access hole. To ensure proper repair, urethane must be forced in to the stiffening bead area.

6. Pump the urethane into the stiffening bead area until urethane "squeeze-out" is visible at the forward trim edge of reinforcement.

Important: Make sure the urethane "squeeze-out" does not drip on any interior components.

7. Let urethane cure for one hour prior to installing headliner.
8. Install headliner. Refer to "Headliner Replacement" in the Body and Accessories section of the 2003 Saturn ION Service Manual, Vol. 3.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for A9220 (Panel, roof-repair). An "add time" condition is provided to apply urethane adhesive for repair performed according to this bulletin.