Retractable Headlamps - Intermittent or Operates Slowly
BULLETIN NO.: 93-T-24ISSUE DATE: September, 1993
GROUP/SEQ. NO.: Body-12
CORPORATION NO.: 381509
SUBJECT:
Retractable Headlamps Operate Slowly or Intermittently, or Bind (Replace Headlamp Actuator Assembly, Install Protective Boot and Lubricate)
MODELS AFFECTED:
1991 and 1992 Saturn SC Coupes and 1993 Saturn SC2 Coupes built before, and including VIN PZ275987.
CONDITION:
Some customers may comment that the headlamps operate slowly or intermittently, or bind. Headlamps may also be noisy when opening.
CAUSE:
Corrosion forms on shaft of the headlamp actuator assembly and/or at the joints of the headlamp linkage on the headlamp assembly.
CORRECTION:
Replace the headlamp actuator assembly, install a protective rubber boot, and lubricate the headlamp linkage using the procedures in this bulletin.
PROCEDURES
1. Open hood and raise retractable headlamps.
2. Disconnect battery negative cable.
3. Remove right and left headlamp bezel retaining screws and remove bezels from headlamp housing assemblies.
4. If equipped, remove air conditioning inlet duct assembly.
5. Disconnect electrical connector at headlamp actuator assembly that is not operating correctly and un-clip electrical connector from headlamp assembly.
6. Remove nut securing headlamp linkage to headlamp actuator assembly shaft.
7. Remove three headlamp actuator assembly to headlamp housing bolts.
8. Free headlamp linkage from headlamp actuator assembly shaft and remove headlamp actuator assembly.
9. Install new headlamp actuator assembly (LH-P/N 21095841 or RH-P/N 21095842) by inserting the headlamp actuator assembly shaft into the headlamp linkage and positioning headlamp actuator assembly into vehicle.
10. Install three headlamp actuator assembly to headlamp housing bolts and tighten.
Torque: 5.5 N-m (46 in.lbs.)
11. Install nut to headlamp actuator assembly shaft to secure headlamp linkage.
Torque: 5.5 N-m (46 in.lbs.)
IMPORTANT:
Apply Loctite(R) 242 Threadlocker or equivalent to the headlamp actuator shaft nut before installing nut to headlamp actuator shaft.
12. Connect electrical connector to headlamp actuator assembly.
13. Clip electrical connector to headlamp assembly.
14. Grease headlamp actuator linkage assemblies on both the left and right hand headlamp actuator assemblies using Anti - Seize Nickel Compound (P/N 21485279) or Permatex(R) Anti-Seize Lubricant (P/N 133K) or equivalent.
15. Connect battery negative cable.
16. Close hood.
17. Operate headlamps to make sure of proper operation.
IMPORTANT:
If there is an obvious difference in the opening or closing speeds between the left and right headlamps, replace the other headlamp actuator assembly, repeating steps 1, 2, and 5 through 17.
18. Open Hood.
19. Install protective boots (P/N 16521527) to the left and right hand headlamp actuator assemblies.
IMPORTANT:
If the protective boot of either headlamp actuator assembly contacts the front fascia support, adjust the front fascia support as required.
20. Raise retractable headlamps.
21. Install headlamp bezels to the left and right hand headlamp assemblies and tighten the screws.
22. If equipped, install air conditioning inlet duct assembly.
23. Close hood.
PARTS REQUIREMENTS:
21095841 Kit-LH Headlamp Actuator Assembly
21095842 Kit-RH Headlamp Actuator Assembly
16521527 Boot
21485279 Compound-Anti-Seize Nickel
CLAIM INFORMATION:
To receive credit for this repair, submit a claim through the Saturn Dealer System. See illustration.