CAMPAIGN: TRUNK ASSEMBLY (INTERIM SERVICE PROCEDURES). Saturn Saturn 1992

For 1990-2009 cars

# CAMPAIGN: TRUNK ASSEMBLY (INTERIM SERVICE PROCEDURES)

#### SUBJECT: TRUNK LOCK ASSEMBLY

YEAR and MODEL: 1991,1992, and 1993 SATURN TWO-DOOR SC and SC2 MODELS

#### TO: ALL SATURN RETAILERS and AUTHORIZED SERVICE PROVIDERS

We've recently learned that the trunk lock assemblies on all SC and SC2 (two-door) models shipped to date may not perform as they should ... which may create a security risk for personal articles left in the car, since access to the trunk could be gained without the key and without damage to the car. Parts to repair the trunk lock mechanism are expected to arrive at retail facilities soon.

Saturn will notify SC and SC2 owners that this condition exists with their cars and advise them to contact their Retailers and arrange to have their trunk lock mechanisms repaired.

Additionally, Saturn will provide owners with instructions on how they can temporarily disable the trunk key release mechanism to eliminate the security risk until repairs are made. After disabling the key release mechanism, owners will still be able to open their trunk by using the remote release lever inside the car near the driver's seat. Retailers are to perform this interim service procedure for customers upon request, only if parts are not available to complete the campaign.

#### NOTE: THIS CAMPAIGN IS NOT COMPLETE UNTIL PERMANENT CORRECTIVE ACTION HAS BEEN PERFORMED ON THE CAR.

#### VEHICLES INVOLVED

The following two-door models will require this campaign:

All 1991 and 1992 Saturn SC's.

All 1993 Saturn SC2's up to, and including, VIN PZ143666 ... except for the 277 VIN's on the listing included in this bulletin (refer to "Non - involved Vehicles within VIN Range"). Because Saturn builds by sequence order, which does not always match VIN order, there were some non - involved vehicles within the VIN range that do not require this campaign. It is important to note that campaign claims will only be paid on involved vehicles.

#### OWNER NOTIFICATION

Saturn will notify owners of this campaign involving their cars and will advise them:

1. That parts to repair their trunk lock mechanism will be available to Retailers soon. Owners will also be instructed to contact their Retailer and arrange to have the campaign completed;

2. To temporarily disable the trunk key release mechanism to eliminate this security risk in the meantime. Instructions are being provided with the owner letter, to allow owners to perform the interim service procedure themselves; and,

3. To contact their Retailer or the Saturn Assistance Center if they have any questions or need assistance.

#### FACILITY VIN LIST

A list of vehicles assigned to you (Facility VIN Listing), which our records indicate were sold by or shipped to you, is enclosed for your follow-up program. The Facility VIN Listing contains:

o Complete Vehicle Identification Number; o Owner name, address and telephone number; and, o VIN's of vehicles which, according to Saturn records, are in retail stock.

The Facility VIN Listing (with owner information) is furnished to involved Retailers with the Product Campaign Bulletin. Although these vehicles are assigned to your facility, please note that owners can take their vehicles to any Saturn Retail Facility to have this campaign performed.

Those Retailers not involved initially in this campaign will receive a message at the top of a blank Facility VIN Listing that states: NO VEHICLES ASSIGNED AT THIS TIME FOR CAMPAIGN 93C01.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of the law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Those records updated with California DMV registration information will have the following message printed adjacent to the appropriate VIN:

"OWNER INFORMATION UPDATED BY CALIFORNIA DMV; PUBLICATION PROHIBITED."

REMOTE OWNER STRATEGY

In order to minimize customer inconvenience and ensure the highest possible customer satisfaction, owners who live approximately 125 miles or more from an open Saturn Retail Facility or Authorized Service Provider will be contacted by Saturn to arrange to have their vehicles serviced at a convenient location. Saturn Field Service Engineers will oversee this activity. Therefore, you may notice that not all vehicles which were sold by you are on your Facility VIN Listing.

TRANSFER OF CAMPAIGN RESPONSIBILITY

Saturn vehicles that have been sold by you, which may be closer in proximity to another Saturn Retailer, may still appear on your Facility VIN Listing. If either you or the vehicle owner determines that it is more desirable for a vehicle on your Facility VINListing to be serviced by another Saturn Retailer, campaign responsibility may be transferred by contacting the Saturn Assistance Center (1-800-828-2112, prompt 6). The Assistance Center will aid in identifying the proper servicing Retailer. All changes to campaign responsibility will be reflected in your next monthly Unfixed VIN Report. All other changes in vehicle status (e.g., scrapped, stolen, etc.) are to be made in accordance with section 4.4.3 of the Saturn Service Policies and Procedures Manual (Notifying Saturn of Vehicle Status Change).

RETAILER RESPONSIBILITY

1. Retailers are to repair the trunk lock mechanisms on all Saturn SC's and SC2's in retail inventory, using the permanent corrective action procedure in this bulletin.

2. Retailers will not deliver any Saturn SC's and SC2's in retail inventory until the permanent corrective action is performed.

3. Upon owner request, Retailers are to disable the trunk key release mechanism on any affected owner's vehicle if parts are not available, or if the Retailer is otherwise unable to complete the campaign.

4. Retailers are to service all vehicles involved in this campaign, at no charge to the owner, regardless of mileage, age of vehicle, or ownership. In the future, whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory. or is in your retail facility for service, you should ensure that the campaign correction has been completed before reselling or releasing the vehicle. Owners of vehicles recently sold from your new vehicle inventory are to be contacted, and arrangements made, to make the required correction according to the instructions contained in this bulletin.

PARTS INFORMATION

1. No parts are required to disable the trunk key release mechanism.

2. A pre-shipment of parts required to perform the permanent corrective action for this campaign will be automatically sent to you from Saturn Service Parts Operations (SSPO). The initial shipment will be of sufficient quantity to cover immediate requirements and will be followed up with supplemental shipments ... so Retailers will not need to order parts.

3. Parts questions may be directed to your Saturn Parts Support Analyst.

Required Parts Quantity Required Part Number Description Per Vehicle 21097037 Rod - R/cmpt Lid Lk Cyl 1 21097041 Pawl - R/cmpt Lid Lk Cyl 1 21077507 Retainer (yellow clip) 1 21020792 Strap - R/cmpt Lid Ham & CBL 1 21077508 E-Clip

*As Required (original parts may be re-used if not damaged during the repair procedure)

SUGGESTIONS FOR ENSURING CUSTOMER SATISFACTION

As you know, Saturn's success hinges upon our ability to execute superior customer support throughout the ownership experience, especially when occasional corrective actions such as this are required. Saturn recognizes that, because of the magnitude of this situation, some Retailers will have a large number of affected vehicles.

Retailers should have an "action plan" so that they can quickly perform the campaign procedure ... minimizing customer inconvenience. Some thought starters include:

1) Schedule appointments to avoid problems, so that the campaign can be performed quickly.

2) Attempt to "talk customers through" the interim service procedure on the telephone if they are not able to have the permanent corrective action performed immediately.

3) Attempt to schedule customers to come in during your facility's non - peak hours . . . strong consideration should be given to extending service hours (evenings/weekends).

4) Utilize additional Retailer resources to minimize owner wait time and reduce inconvenience (e.g., leveraged service capacity).

5) Use the enclosed "Vehicle LOG - IN Sheet," rather than attempting to immediately open and complete CSO'S, if cars are "backing-up in the service lane." CSO's should then be completed later that day, as time permits.

6) Perform the campaign procedure while cars wait in the service lane.

Again, whatever "action plan" you choose, it is imperative that every effort is made to accommodate the owner. As always, please coordinate with the Saturn Assistance Center to help ensure customer satisfaction.

SERVICE PROCEDURE

I. PERMANENT CORRECTIVE ACTION, REPAIR TRUNK LOCK MECHANISM

PART A - REMOVAL OF THE LID LOCK CYLINDER ROD

(Refer to Figure 1 for Steps 1-4)

1. Open rear compartment lid.

2. Check to see if the lid lock cylinder rod has been removed. If present, it can be seen through the access hole on the inside of the rear compartment lid.

3. If the lid lock cylinder rod has been removed, perform only step 5, then go to Part B of this service procedure. If it has not been removed, proceed to the next step.

4. With a screwdriver or your fingers, disengage the lid lock cylinder rod from the lid lock cylinder rod retainer (yellow clip) by lightly prying outwards on the retainer to disengage the lid lock cylinder rod.

I. PERMANENT CORRECTIVE ACTION, REPAIR TRUNK LOCK MECHANISM (Cont"d)

PART A - REMOVAL OF THE LID LOCK CYLINDER ROD

(Refer to figure 2 for Step 5)

5. Using a screwdriver, pry the rear compartment lid lock cover from the rear compartment lid lock assembly.

(Refer to figure 3 for Step 6)

6. Locate and remove the lid lock cylinder rod (by sliding it out through the lid lock release lever slot) and discard.

I. PERMANENT CORRECTIVE ACTION, REPAIR TRUNK LOCK MECHANISM (Cont-'d)

PART B - REMOVE AND REPLACE REAR COMPARTMENT LID LOCK CYLINDER PAWL AND RETAINER (YELLOW CLIP)

(Refer to figure 4 for Steps 1-4)

1. Locate and remove E-ring retainer clip at rear of lock cylinder.

2. Remove lid lock cylinder pawl with lid lock cylinder rod retainer (yellow clip) attached, and discard.

3. Install new lid lock cylinder rod retainer (yellow clip, P/N 21077507) onto the new lock cylinder pawl (P/N 21097041).

4. Install new lid lock cylinder pawl and lid lock cylinder rod retainer (yellow clip) assembly onto the lock cylinder and retain with the original E-ring retainer clip.

I. PERMANENT CORRECTIVE ACTION, REPAIR TRUNK LOCK MECHANISM (Contd)

PART C - INSTALLATION OF THE LID LOCK CYLINDER ROD

(Refer to figure 5 for Step 1)

1. Insert the top (green) of the new lid lock cylinder rod (P/N 21097037), through the lid lock release lever slot in the lid lock assembly and insert it into lid lock cylinder rod retainer (yellow clip).

#### NOTE: The top of the new lid lock cylinder rod is marked in green.

(Refer to figure 6 for Step 2)

2. Engage lid lock cylinder rod retainer (yellow clip) onto the lid lock cylinder rod. When engaged, the lid lock cylinder rod will protrude downward approximately 27 mm (1 1/16 in.) out of the lid lock release lever slot.

I PERMANENT CORRECTIVE ACTION, REPAIR TRUNK LOCK MECHANISM (Cont-d)

PART D - REAR COMPARTMENT LID JUMPER WIRING HARNESS ROUTING

(Refer to figure 7 for Steps 1-7)

1. Gently pull the slack in the rear compartment lid wire harness through the rectangular access hole on the left hand side (driver's side) of the rear compartment lid lock.

2. Make a loop in the wire harness to take up all the slack at the rear compartment lid lock assembly.

3. Retain the loop in the wire harness with tie strap (P/N 21020792) and cut off the tie strap excess.

4. Insert the wire harness loop back through the rear compartment lid rectangular access hole.

5. Cycle the lid lock cylinder with the key, checking that the new lid lock cylinder pawl and/or lid lock cylinder rod does not contact or interfere with the wire harness.

6. Reinstall the rear compartment lid lock cover by pushing it back into position.

7. When complete, close rear compartment lid and unlock with the key, checking for proper lock cylinder operation and compartment lid release.

II. INTERIM SERVICE PROCEDURE

#### HOW TO DISABLE REAR COMPARTMENT LID KEY RELEASE MECHANISM

1. If an owner requests that the procedure in the bulletin be performed and you do not have all of the parts necessary to complete it, you should disable the key release mechanism by performing Part A of this service bulletin. When complete, reinstall the rear compartment lid lock cover.

#### NOTE: This campaign is not complete until permanent corrective action has been performed on the car.

CAMPAIGN COMPLETION LABEL ========================= Because disabling the trunk key release mechanism is only an interim security measure, the campaign will not e considered complete until the mechanism is actually repaired. Do not use a Campaign Completion Label disabling the mechanism.

Upon completion of the campaign (repair trunk lock mechanism), a Campaign Completion Label should e placed on a clean, dry surface of the radiator core support in an area clearly visible when the hood is aised. Each label provides a space to print in ink (or type) the campaign number (93C0l) and the five 5) digit facility code of the Retailer performing the campaign service.

#### CREDIT

1. To receive credit for repairing the trunk lock mechanism, submit a claim with the information below:

Failed Part Parts Sale Case Labor Labor Add Repair Performed Number Allowance Type Type Op Hours Hours* mechanism 21097037 ** WC VC V7730 .3 .1

2. To receive credit for disabling the trunk key release mechanism, submit a claim with the information below:

Sale Case Labor Labor Repair Performed Type Type Op Hours Disable trunk key release WC VC V7731 .2 mechanism

* Campaign Administrative Allowance

** The Parts Allowance should be the sum total of the current SSPO Retailer Net price plus 30% of all parts required for the repair.

Refer to the Customer Service Order Preparation Manual for details on Product Campaign Claim Submission.

October 26, 1992

Dear Saturn Coupe Owner:

There is nothing as important to us as how you feel about your Saturn. If there is ever anything that might compromise your ownership experience, we want to address it right away ... which is why we're writing.

Unfortunately, we recently learned that the trunk lock assembly on your Saturn coupe (2-door SC or SC2) may not perform as it should. This may create a security risk for personal articles left in your car, since access to your trunk could be gained without the key and without damage to your car. So, of course, you will want to get the lock fixed as soon as possible. Replacement parts required to correct this condition are expected to arrive at Retail facilities by Friday. October 30th. Please contact your Retailer and arrange to have this important service performed.

Until then, there are some simple steps that you should take immediately to maintain the security of your car. You can easily do this by disabling the trunk key release mechanism. We have attached instructions that will show you how. After this is done, you will still be able to open your trunk by using the remote release lever inside the car near the driver's seat.

If you have any questions or need assistance, please contact your Retailer or the Saturn Assistance Center (1-800-553-6000).

What Saturn will do: o We will repair the trunk lock assembly at no charge to you and with the least possible inconvenience.

What you o Please contact your Saturn Retailer and arrange to have should do: this service performed.

o Just so you're aware, the permanent corrective action should take less than thirty minutes ... although a little additional time may be needed for paperwork and processing.

o In the meantime, disable the trunk key release mechanism using the attached instructions. This should take you only a few minutes to do.

We sincerely regret any inconvenience this causes you. Also, we want you to know that we will continue to do everything we can to ensure that you are completely satisfied with your Saturn and with us as a company. Sincerely,

Saturn Corporation

#### HOW TO DISABLE TRUNK KEY RELEASE MECHANISM

(Refer to figure 8 for Step 1)

1. Open the trunk lid.

(Refer to figure 9 for Step 2)

2. Use a screwdriver or your fingers to disengage the yellow clip from the lock rod.

(Refer to figure 10 for Step 3)

3. Using a screwdriver, pry the latch cover off.

(Refer to figure 11 for Step 4)

4. Remove the lock rod and dispose of it and push the latch cover back into place.

#### Non-involved Vehicles within VIN Range

PZ132404 PZ142310 PZ142658 PZ143006 PZ143348 PZ134900 PZ142316 PZ142664 PZ143012 PZ143354 PZ135577 PZ142322 PZ142670 PZ143018 PZ143360 PZ135919 PZ142328 PZ142676 PZ143024 PZ143366 PZ136621 PZ142334 PZ142682 PZ143030 PZ143372 PZ136975 PZ142340 PZ142688 PZ143036 PZ143378 PZ137341 PZ142346 PZ142694 PZ143042 PZ143384 PZ137783 PZ142352 PZ142700 PZ143048 PZ143390 PZ137825 PZ142358 PZ142706 PZ143054 PZ143396 PZ137914 PZ142364 PZ142712 PZ143066 PZ143402 PZ138921 PZ142370 PZ142718 PZ143072 PZ143408 PZ138951 PZ142382 PZ142724 PZ143078 PZ143414 PZ139274 PZ142388 PZ142730 PZ143084 PZ143420 PZ139418 PZ142394 PZ142736 PZ143090 PZ143426 PZ140324 PZ142400 PZ142742 PZ143096 PZ143432 PZ141110 PZ142406 PZ142748 PZ143102 PZ143438 PZ141170 PZ142412 PZ142754 PZ143108 PZ143444 PZ141230 PZ142418 PZ142760 PZ143114 PZ143450 PZ141416 PZ142424 PZ142766 PZ143120 PZ143456 PZ141506 PZ142430 PZ142772 PZ143126 PZ143462 PZ141692 PZ142436 PZ142778 PZ143132 PZ143468 PZ141788 PZ142442 PZ142784 PZ143138 PZ143474 PZ141830 PZ142448 PZ142790 PZ143144 PZ143480 PZ141890 PZ142454 PZ142796 PZ143150 PZ143486 PZ141902 PZ142460 PZ142802 PZ143156 PZ143492 PZ142010 PZ142466 PZ142808 PZ143162 PZ143498 PZ142016 PZ142472 PZ142814 PZ143168 PZ143504 PZ142046 PZ142478 PZ142820 PZ143174 PZ143510 PZ142118 PZ142484 PZ142826 PZ143180 PZ143516 PZ142124 PZ142490 PZ142832 PZ143186 PZ143522 PZ142148 PZ142496 PZ142838 PZ143192 PZ143528 PZ142154 PZ142502 PZ142844 PZ143198 PZ143534 PZ142160 PZ142508 PZ142850 PZ143204 PZ143540 PZ142166 PZ142514 PZ142856 PZ143210 PZ143546 PZ142172 PZ142520 PZ142862 PZ143216 PZ143552 PZ142178 PZ142526 PZ142874 PZ143222 PZ143558 PZ142184 PZ142538 PZ142880 PZ143228 PZ143564 PZ142190 PZ142544 PZ142886 PZ143234 PZ143570 PZ142196 PZ142550 PZ142892 PZ143240 PZ143576 PZ142202 PZ142556 PZ142898 PZ143246 PZ143582 PZ142208 PZ142562 PZ142904 PZ143252 PZ143588 PZ142214 PZ142568 PZ142910 PZ143258 PZ143594 PZ142226 PZ142574 PZ142916 PZ143264 PZ143600 PZ142232 PZ142580 PZ142922 PZ143270 PZ143606 PZ142238 PZ142586 PZ142928 PZ143276 PZ143612 PZ142244 PZ142592 PZ142934 PZ143282 PZ143618 PZ142250 PZ142598 PZ142940 PZ143288 PZ143624 PZ142256 PZ142604 PZ142946 PZ143294 PZ143630 PZ142262 PZ142610 PZ142958 PZ143300 PZ143636 PZ142268 PZ142616 PZ142964 PZ143306 PZ143642 PZ142274 PZ142622 PZ142970 PZ143312 PZ143648 PZ142280 PZ142628 PZ142976 PZ143318 PZ143654 PZ142286 PZ142634 PZ142982 PZ143324 PZ143660 PZ142292 PZ142640 PZ142988 PZ143330 PZ142298 PZ142646 PZ142994 PZ143336 PZ142304 PZ142652 PZ143000 PZ143342

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.