OBJECTIONABLE WINDOW CRANK EFFORTS FOR FRONT DOOR WINDOW. Saturn Saturn 1994

For 1990-2009 cars

# OBJECTIONABLE WINDOW CRANK EFFORTS FOR FRONT DOOR WINDOW

#### SUBJECT: Objectionable Window Crank Efforts for Front Door Window (Check, Align or Replace Window Weatherstrip)

#### MODELS AFFECTED: 1991-1994 Saturns

CONDITION: Some owners may experience objectionable window cranking effort required when lowering or raising front door window.

CAUSE: Objectionable window cranking effort may be caused by one or more of the following:

o Front door glass misadjusted causing higher than normal crank efforts.

o Window regulator clutch housing grease thickens in low temperatures and/or over a period of time.

o Glass run weatherstrip bunches in upper corners.

CORRECTION: Inspect front door window system for potential causes of high-crank efforts and repair according to procedures in this bulletin.

#### PROCEDURES

1. Remove outer door panel. (Refer to "Doors" section of the "Body/Collision Repair Service Manual.")

2. Lower window and inspect front side door window upper weatherstrip for excessive wear (felt surface worn off). If wear exists and/or the vertical legs of front side door window upper weatherstrip move up with front door glass (bunches in the upper corners) proceed to step 2a. If the vertical legs do not move with front door glass or if no excessive wear is found, proceed to step 3.

a. Replace front side door window upper weatherstrip per procedures in the "Doors" section of the "Body/Collision Repair Service Manual."

b. Before installing front side window upper weatherstrip, apply a 3.18 mm (1/8 in.) diameter bead of 3M's Weatherstrip Adhesive (P/N 08011) 1) or equivalent weatherstrip adhesive in the bottom of the front door glass guide. Also apply to the entire length of the B pillar portion (vertical) of the front door window frame before installing front side door window upper weatherstrip.

c. Adjust upper window frame in or out, to prevent upper edge of front door glass from digging into weatherstrip.

d. Align front door as required.

e. If window cranking effort is still objectionable, proceed to step 3.

3. Check front door glass alignment for proper inner panel cam and front door glass guide adjustments.

a. Check inner panel cam adjustment by:

1. Raise front door glass to full-up position.

2. Using a fine tip dry erase marker, trace around the perimeter of the front door glass at window frame.

3. Lower front door glass 51 mm (2 in.) and inspect drawn lines for parallelism to edge of front door glass.

4. A properly adjusted inner panel cam will exhibit a drawn line parallel with the edge of glass around its perimeter. If lines are parallel, proceed to step 3b. If lines are not parallel proceed to step 4.

b. Check front door glass guide adjustment by checking the fore/aft play of the front door glass at the following three locations:

o 25.4 mm (1 in.) from the top

o At the mid point

o At the full-down position

A properly adjusted front door glass guide will allow a slight fore/aft movement at all three locations.

If there is excessive movement (more than 2 mm [0.08 in.]) or no fore/aft movement, proceed to step 4. If okay, proceed to step 5.

4. Re-align front door glass as follows:

a. Loosen front door glass guide bolts.

b. Loosen inner panel cam bolts.

c. Lower the front door glass 25.4 mm (1 in.) from top of window frame.

d. With front door glass fully seated in the rear glass run channel and the top edge of front door glass parallel with the top of the window frame, adjust the forward end of the inner panel cam (downward for Sedans and Wagons, upwards for Coupes) until a light pressure is applied to the bottom of the front door glass.

e. Snug, then tighten inner panel cam bolts.

Torque: 6 N-m (53 in-lbs)

f. Lower front door glass to 76 mm (3 in.) from the top position.

g. With front door glass fully seated in the rear glass run channel, adjust the top of front door glass guide so that it is lightly seated against front edge of front door glass using light rearward pressure.

h. Snug top guide bolt.

i. Lower front door glass to 51 mm (2 in) from the full-down position.

j. Fully seat front door glass in the rear glass run channel. Adjust the bottom of front door glass guide so that it is lightly seated against front edge of front door glass using light rearward pressure.

k. Snug bolt.

l. On Sedans and Wagons, snug middle guide bolt.

m. Tighten front door glass guide bolts.

Torque: 6 N-m (53 in-lbs)

n. Cycle front door glass to verify proper alignment.

#### CAUTION:

TO PREVENT EYE AND SKIN DAMAGE, SAFETY GLASSES AND RUBBER GLOVES SHOULD BE WORN WHEN USING PRESSURIZED SOLVENTS AND COMPRESSED AIR.

5. Line bottom of front door cavity with cotton shop rags.

6. Clean dark graphite grease from regulator sector gear and clutch housing using brake cleaner with a straw nozzle and cotton shop rags.

#### IMPORTANT: Rear edge of front door glass should always stay in rear glass run channel as window is rolled up and down.

#### IMPORTANT: Protect adjacent areas from overspray by deflecting overspray with hand-held cardboard or metal splash shield.

7. Lower and raise window at least three times, then clean dark graphite grease from regulator sector gear and clutch housing using brake cleaner with a straw nozzle and cotton shop rags.

8. Use saturated rags at bottom of front door to wipe sector gear free of dark graphite grease.

9. Clean up excess solvent with dry rags.

10. Using air nozzle, blow clutch housing dry.

11. Liberally pack clutch housing using Mobil 1 High Performance synthetic universal grease or equivalent and cycle front door glass once and repack clutch housing.

12. Liberally apply Mobil 1 High Performance synthetic universal grease or equivalent to sector gear.

13. Using Kent Industries Dry Lube (P/N 50077) or equivalent, lubricate front door glass run weatherstrip using manufacturer's recommendations.

14. Cycle front door glass to verify repair.

15. Install outer door panel using procedure in the "Doors" section of the "Body/Collision Repair Service Manual."

#### PARTS REQUIREMENTS:

21096794 WEATHERSTRIP ASM-FRT S/D WDO UPR, RIGHT SIDE (A27) 21096795 WEATHERSTRIP ASM-FRT S/D WDO UPR, LEFT SIDE (A27) 21096796 WEATHERSTRIP ASM-FRT S/D WDO UPR, RIGHT SIDE (A35, A69) 21096797 WEATHERSTRIP ASM-FRT S/D WDO UPR, LEFT SIDE (A35, A69)

CLAIM INFORMATION: To receive credit for this repair, submit a claim through the Saturn Dealer System as follows: Labor Case Operation Type Description Code Time

VW Check Glass Run Weatherstrip T9663 1.4 hrs Door and Glass Alignment and Lubricate Window Regulator-Right Front Door VW Check Glass Run Weatherstrip T9664 1.4 hrs Door and Glass Alignment and Lubricate Window Regulator-Left Front Door

Add if required:

A. To Replace Front Door Glass Run Weatherstrip 0.3 hrs

B. To Align Front Door

All models accept SC, SC1, SC2 0.9 hrs SC, SC1, SC2 1.0 hrs C. To Align Door Glass 0.2 hrs

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.