Waterleak at the Front Upper Door Frame. Saturn Saturn 1992

For 1990-2009 cars

# Waterleak at the Front Upper Door Frame

Subject: | Waterleak at the Front Upper Door Frame (Adjust the Front Upper Door Frame and Apply Sealer to the Door Opening Joints) -- Due to random collation error by the printer in the previous printing of this bulletin, this bulletin supersedes bulletin 94-T-52A which should be discarded.

Models: | 1991-1995 Saturns and 1996 Saturn Coupes

### Condition:

The customer may comment of water dripping from the top of the door frame area.

### Cause:

This condition may be caused by the seal between the front side door, primary, weatherstrip and space frame. There may also be a low spot in the sealer at the door opening joint.

### Correction:

Adjust the top of the door frame inward to achieve a better seal between the front side door, primary, weatherstrip and the space frame. Also, if required, add sealer to the door frame joints.

### Procedure:

1. With the aid of a helper, direct an unrestricted flow of water over the top of the door frame, one side of the vehicle at a time.
2. Inspect the top of the door from the inside of the vehicle:

• | If water is leaking between the front side door, primary, weatherstrip and the space frame, proceed to the next step.

• | If water is not present in the immediate area, refer to Waterleaks in the General Information section of the appropriate year Body/Collision Repair Service Manual for the vehicle being worked on.

3. Open the door and lower the door glass to the full-down position.

Notice: Care should be taken not to over bend the door frame which could impair door glass operation or door closing. It is better to adjust the door frame in small increments to achieve the required fit.

4. Grasp the upper door frame at the top of the frame and carefully pull the door frame inboard along the entire top of the door frame.
5. After a slight adjustment has been made, proceed to the next step and perform the Dollar Bill test.
6. Dollar Bill Test

• | Place a dollar bill or similar size piece of paper between the front side door, primary, weatherstrip and the contact surface of the space frame, then close the door.

| Important: Make sure to leave the window in the full-down position. This equalizes the pressure inside the vehicle when the door is closed and allows the dollar bill, or piece of paper, to stay in the correct position.

• | Slowly withdraw the dollar bill or piece of paper after the door is closed to check the amount of pressure on the front side door, primary, weatherstrip.

• | There should be a medium amount of resistance as the dollar bill, or piece of paper is slowly withdrawn, Continue around the entire door frame.

- | If there is little or no resistance, it indicates there is insufficient contact to form a good seal between the front side door, primary, weatherstrip and the space frame. Repeat step 3 through 6, until the door frame is correctly adjusted.

- | If there is a medium amount of resistance, proceed to the next step.

7. After the door is properly adjusted, check the door glass operation by raising and lowering the door glass. Also, check the door operation by opening and closing the door to make sure it operates correctly.
8. To verify that the waterleak has been repaired, apply an unrestricted flow of water over the door frame -- as described in step 1 of this bulletin.

• | If the waterleak has been repaired, return the vehicle to the customer.

• | If the waterleak is still present and the vehicle is a:

- | Coupe, built after and including VIN PZ317192, proceed to step 9.

- | Sedan or Wagon, built after and including VIN PZ317192, proceed to step 9.

• | If the waterleak is still present and the vehicle does not fall into the years or VIN ranges given in the previous step, repeat steps 3 through 7 until the waterleak is repaired.

9. On Coupes:

• | Make sure the door opening space frame lap joints are clean and dry.

| Important: Some vehicles may have black tape over existing sealer. Remove and discard this tape before applying new sealer.

• | Using a seal sealer such as Kent Industries High Tech Leak Check Seam Sealer, Black P/N 10070 or equivalent, fill the 2 space frame lap joints until flush with the space frame using a flat-bladed tool to keep the seal smooth.

• | Allow the sealer to completely dry and water test to make sure the waterleak has been repaired.

- | If the waterleak is still present, repeat steps 3 through 7 until the waterleak is repaired.

- | If the waterleak has been repaired, return the vehicle to the customer.

10. On Sedan or Wagon

• | Make sure the door opening space frame lap joint is clean and dry.

| Important: Some vehicles may have black tape over existing sealer. Remove and discard this tape before applying new sealer.

• | Using a seal sealer such as Kent Industries High Tech Leak Check Seam Sealer, Black P/N 10070 or equivalent, fill the 2 space frame lap joints until flush with the space frame using a flat-bladed tool to keep the seal smooth.

• | Allow the sealer to completely dry and water test to make sure the waterleak has been repaired.

- | If the waterleak is still present, repeat steps 3 through 7 until the waterleak is repaired.

- | If the waterleak has been repaired, return the vehicle to the customer.

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 | Adjust Front Upper Door Frame Waterleak -- Right Door | T9677 | 0.30 hrs
-- | VW | Adjust Front Upper Door Frame Waterleak -- Left Door | T9678 | 0.30 hrs
-- | ADD: | To Seal The Door Opening Joints After VIN PZ317192 | -- | 0.10 hrs