REAR PASSENGER FOOTWELL CARPET WET

SUBJECT: Rear Passenger Footwell Carpet Wet (Seal Rear Door Inner Panel Water Liner) --------------------------------------------------------------

MODELS AFFECTED: 1996 Saturn Sedans and Wagons ------------------------------

CONDITION:

---------- The rear passenger footwell carpet may be wet.

CAUSE:

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The rear passenger footwell carpet may be wet due to wrinkles in the lower half of the rear door water liner seal and/or the loss of adhesion between the rear door water liner and the door inner panel.

CORRECTION:

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Perform the following procedures to seal the lower edge of the rear door water liner with a butyl rubber adhesive strip and install a rubber patch over rear inner door trim panel hole. If rear door trim panel has a rear attachment hook, it must be removed.

PROCEDURES

1. Verify that the rear door water liner is the source of the waterleak by running an unrestricted flow of water along the rear door glass, on top of the outer sealing strip.

2. Inspect for water trails or drops at lower perimeter of inner door trim panel.

* If water trails are present at lower perimeter of inner door trim panel, proceed to next step.

* If water trails are not present at lower perimeter of inner door trim panel, refer to "Waterleaks" in the "General Information" section of the "1996 Body/Repair Service Manual."

3. Remove fasteners from center of inside door handle assembly. Slide door handle assembly forward, while pulling outward from the trim panel. Using a thin screwdriver, disengage lock and latch rod from retainers.

4. On vehicles with manual windows, disengage manual window handle regulator clip, using a window handle tool. Remove window handle from vehicle.

5. Open access cover at rear of door trim panel and remove door trim panel fastener.

6. Remove door trim panel fasteners at pull cup location.

7. Pull up on door trim panel assembly to disengage trim panel to door structure attaching hooks and remove door trim panel.

8. Remove energy absorbing foam material from door structure.

9. Carefully peel up the lower edge of the rear door water liner.

10. Using the edge of the water liner as a guide, install a continuous length of butyl rubber such as Kent Industries Versatape VT-B 20290 or equivalent beneath the outer edge of the lower half of the water liner.

11. Install removed edges of water liner on top of the butyl rubber. Make sure there are no wrinkles in water liner.

12. Apply light pressure to the water liner edges with either a roller or similar tool for the entire bonded surface to ensure a water tight seal.

IMPORTANT: Wrinkles in the lower half of the water liner bond joint will result in a waterleak.

13. Remove upper (white liner) cone array.

14. Install 3Ml Electrical Moisture Sealant Patches (P/N 06149) or equivalent over the 25 x 25 mm upper rear trim panel attachment hole and the 25 x 30 mm access hole located directly above it in the inner door structure. (Holes are located in the inner door where the upper [white liner] cone array was removed from.)

15. If the vehicle was built before and includes VIN TZ243340, remove the upper rear attachment hook using a utility knife or fine saw blade. On vehicles built after and including VIN TZ243341, the attachment hook is no longer present.

16. Water test vehicle to verify repair.

CAUTION:

IF ENERGY ABSORBING FOAM IS REMOVED FROM DOOR, IT MUST BE REPLACED WITH A NEW PART. IF OMITTED FROM THE DOOR, THE VEHICLE WILL NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS), SUBJECTING THE RETAILER TO POSSIBLE CIVIL PENALTIES FOR MAKING THE VEHICLE INOPERATIVE TO THE FMVSS, AND INCREASING THE RISK OF INJURY TO THE VEHICLE OCCUPANTS.

17. Remove tape backing from new energy absorbing foam and install to door structure.

18. Position door trim panel to door structure at attaching hooks. Lock in door trim panel by pushing downward on door trim panel.

19. Install door trim panel fasteners at pull cup and at rear of door trim panel. Close access cover.

20. With window closed, install door handle onto vehicle with handle pointed in a forward and slightly upward position.

21. Position door handle assembly in trim panel. Tip handle outward at top. Using a thin hook style tool, lift latch and lock rods in trim panel and slide rearward to engage tabs.

22. Install screw in handle.

23. On vehicles with manual windows, install manual window regulator handle clip onto handle.

PARTS REQUIREMENTS:

21098732 Absorber-Rear Door Energy (RH) 21098733 Absorber-Rear Door Energy (LH) VT-B 20290 Versatape (Kent Industries) or equivalent 06149 Electrical Moisture Sealant Patches (3MO) or equivalent

CLAIM INFORMATION:

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

Labor Case Operation Type Description Code Time ---- ----------- ----------- ----

VW Seal Right Rear Door Inner T9720 0.9 hrs Panel Water Liner

VW Seal Left Rear Door Inner T9721 0.9 hrs Panel Water Liner

General Motors 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 a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.