Rattle Noise From Headliner Area - Install Foam Spacers On Headliner (99-T-69)

Publication date: 2001-10-12
Reference number: 99-T-69

RATTLE NOISE FROM HEADLINER AREA - INSTALL FOAM SPACERS ON HEADLINER

TECHNICAL SERVICE BULLETIN

Reference Number(s): 99-T-69, Date of Issue: December, 1999

Rattle Noises From Headliner Area (Install Soft Foam Spacers on Headliner).

2000 Saturn L-Series vehicles built between and including VINs YY600001 - YY613712

Customers may comment of rattle noises heard from area of dome lamp, sunroof, or headliner during normal operating conditions.

Wiring harnesses rattling between headliner and roof panel, or headliner alone rattling against roof panel.

Install soft foam spacers at headliner locations shown in this bulletin.

Test drive vehicle to verify condition and determine area of headliner rattle.
Remove headliner from vehide and place on a clean protected work surface. (Refer to "Headliner" removal procedure in the Interior Trim section of the 2000 L-Series Body/Electrical Volume II Service Manual.)
Obtain 51 cm (20 in.) of KENT Industries adhesive backed foam (P/N 46515). This foam is 25.4 mm (1 in.) wide so two pieces will have to be installed side-by-side on headliner to achieve width of spacers necessary.
Cut adhesive backed foam into ten equal 51 mm (2 in.) long pieces.
Install adhesive backed foam spacers side-by-side on headliner where indicated in illustrations.
- Sedan without sunroof requires eight soft foam spacers.
- Sedan with sunroof requires ten soft foam spacers.
- Wagon requires eight soft foam spacers.
Install headliner in vehicle. (Refer to "Headliner" installation procedure in the Interior Trim section of the 2000 L-Series Body/Electrical Volume II Service Manual.)
Test drive vehicle to verify repair.

Install four soft foam spacers centered at front cross bow and 30.5 cm (12 in.) from edge of headliner.

Install four soft foam spacers centered at rear cross bow and 30.5 cm (12 in.) from edge of headliner.

Fig 1: Sedan WIthout Sunroof Foam Spacer Location

Install four soft foam spacers centered 30.5 cm (12 in.) from edge of headliner and centered with dome lamp opening.

Install four soft foam spacers at corners of opening for center high-mount stop lamp (CHMSL).

Install two soft foam spacer on dome lamp wiring harness loop on passenger side of headliner.

Fig 2: Sedan WIth Sunroof Foam Spacer Location

Install four soft foam spacers centered at front cross bow and 30.5 cm (12 in.) from edge of headliner.

Install four soft foam spacers centered at rear cross bow and 30.5 cm (12 in.) from edge of headliner.

Fig 3: Wagon Foam Spacer Location

46515 KENT Industries Adhesive Backed Foam * .

* The foam can be obtained through KENT Industries at 1-800-654-6333 (Retailers in Canada call 1-800-663-2800).

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

Case Type: VW

Description: Install Foam Spacers

Labor Operation: Z4075

Time: Sedan 1.2 hrs

Time: Wagon 1.4 hrs