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EXPERTEC TSB (94-T-11)

Publication date: 1994-03-29
Reference number: 94-T-11

EXPERTEC TSB

EXPERTEC TSB

TECHNICAL SERVICE BULLETIN

Reference Number(s): 94-T-11, Date of Issue:  03/29/94

DOOR MAY NOT OPEN USING EITHER INSIDE OR OUTSIDE DOOR

Model(s): 1991-93 Saturns

Bulletin No.: 94-T-11

Date: 03/29/1994

CONDITION

Some customers my experience a condition where a door may not open using either inside or outside door handles

CAUSE

Side door latch assembly may have broken internal parts

CORRECTION

Open affected door using procedures in this bulletin and replace side door latch assembly.

SERVICE PROCEDURES

FRONT DOOR

  1. Lower door glass of affected door.
  2. Remove outer sealing strip.
  3. Remove inner belt molding.
  4. Using a 14 inch flat bladed screwdriver, place tip of blade at location on side door latch assembly as shown.
  5. Tap screwdriver downward, piercing through plastic housing. This will cause side door latch assembly to release, allowing the door to open.
  6. Replace damaged side door latch assembly according to procedures in the "Doors" section of the "Body/Collision Repair Service Manual."
  7. Install inner belt molding.

REAR DOOR

  1. Lower door glass of affected door.
  2. Remove outer sealing strip.
  3. Partially remove secondary seal at upper rear corner of window frame.
  4. Pull top of upper window frame, approximately 13 mm (1/2 inch) away from roof drip molding and remove screw that retains top of rear stationary window.
  5. Remove outer door handle.
  6. At division post of rear door stationary window, gently pull outer door panel outboard approximately 35 mm (1.38 inches) and remove lower stationary window fastener.
  7. Remove rear half of glass run weatherstrip.
  8. Remove stationary window by pulling upper tip toward front of vehicle, followed by the bottom. Once rear of stationary window is out of rear window frame, tilt outboard and pull up removing window from vehicle.
  9. Remove inner sealing strip.
  10. Partially remove inner door trim panel at top.
  11. Remove foam filler at rear of door at belt.
  12. Using an 8 inch flat bladed screwdriver, place tip of blade at location on side door latch assembly as shown.
  13. Tap screwdriver downward, piercing through plastic housing. This will cause side door latch assembly to release, allowing the door to open.
  14. Install foam filler at rear of door at belt.
  15. Replace stationary window according to procedures in the "Doors" section of the "Body/Collision Repair Service Manual." Disregard step 5 of the service manual installation procedure.
  16. Install inner door trim panel at the top.
  17. Install inner sealing strip.
  18. Replace damaged side door latch assembly according to procedures in the "Doors" section of the "Body/Collision Repair Service Manual."

BULLETIN ILLUSTRATION LIST

Fig 1: Graphic
GE00W011062
Fig 2: Graphic
GE01W011062
Fig 3: Graphic
GE02W011062
Fig 4: Graphic
GE03W011062
Fig 5: Graphic
GE04W011062

PARTS INFORMATION

PARTS INFORMATION

Part Number Description
16606482 Front Side Door Lock Asm - Right
16606483 Front Side Door Lock Asm - Left
21097104 Rear Side Door Lock Asm - Right
21097105 Rear Side Door Lock Asm - Left
16606936 Clip

CLAIM INFORMATION

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

CLAIM INFORMATION

Case Type Description Operation Code Labor Time
VW Replace Right Front Side Door Lock Assembly T9653 1.1 hrs
VW Replace Left Front Side Door Lock Assembly T9654 1.1 hrs
VW Replace Right Rear Side Door Lock Assembly T9655 0.9 hrs
VW Replace Left Rear Side Door Lock Assembly T9656 0.9 hrs
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