Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Trunk Lid/Liftgate

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REMOVAL & INSTALLATION



1991-96 Coupe and 1991-95 Sedan

See Figures 1, 2, 3 and 4

  1. Disconnect the negative battery cable.
  2.  
  3. For Sedans, remove the trunk lid center panel and lower outer panel assemblies, as follows:
    1. Remove the trunk center panel assembly bolts, then rotate the panel outboard at the bottom and remove the panel from the vehicle.
    2.  
    3. Remove the license plate, then disconnect the lock rod from the trunk lock cylinder pawl.
    4.  
    5. Remove the lower outer panel attachment bolts.
    6.  
    7. Disengage the panel bottom flange from the inner panel by pulling the top of the panel rearward and the lower panel downward.
    8.  
    9. Remove the wiring harness retainer clip, then disconnect the license plate bulb sockets from the lamps.
    10.  
    11. Remove the trunk lid lower outer panel from the vehicle.
    12.  

  4.  
  5. For Coupes, remove the trunk lid lower panel, as follows:
    1. Remove the retaining screws from the reflex panels located on either side of the trunk lid, then remove the panels from the lid.
    2.  
    3. Remove the clip and disconnect the lock rod from the lock cylinder.
    4.  
    5. Remove the screws and plastic retainers, then remove the lower panel from the trunk lid.
    6.  
    7. If necessary, remove the sealing sleeve, lock cylinder retainer, reinforcement and the lock cylinder.
    8.  

  6.  
  7. Remove the wiring harness grommet from the inner panel by pushing rearward. Pull the wiring harness inside the trunk lid through the grommet hole.
  8.  
  9. Disconnect the trunk lid release cable from the lock.
  10.  
  11. Unplug the center stop lamp wiring harness connector.
  12.  
  13. Open the wiring harness routing connectors, then remove the harness and lock cable from the rear of the trunk lid.
  14.  
  15. Remove the trunk lid-to-hinge attachment bolts, then, with the aid of an assistant, remove the trunk lid from the vehicle.
  16.  

To install:
  1. With the help of an assistant, lower the trunk lid onto the hinges and install the attaching bolts. Check trunk alignment and adjust, as necessary, then tighten the retaining bolts.
  2.  
  3. Route the wiring harness and lock cable through the connectors on the rear of the trunk lid, then lock the harness and cable into the connectors.
  4.  
  5. Install the wiring harness to the center stop lamp terminal.
  6.  
  7. Connect the lock release cable to the lock.
  8.  
  9. Install the wiring harness through the rear compartment lid inner panel, then seat the wiring harness grommet to the panel.
  10.  
  11. For Coupes, install the trunk lid lower panel, as follows:
    1. If removed, install the lock cylinder into the panel, then install the reinforcement and retainer to the lock cylinder. Install the sealing sleeve to the cylinder.
    2.  
    3. Install the lower panel to the trunk lid and secure using the retaining screws. Tighten the screws slowly and evenly to 53 inch lbs. (6 Nm), using multiple passes.
    4.  
    5. Connect the lock rod to the lock cylinder using the clip.
    6.  
    7. Install the reflex panels using the retaining screws. Make sure the sealing feature of the screws and panels is adequate. If necessary, replace the seals or apply a body caulking compound to make sure no water or moisture will intrude.
    8.  

  12.  
  13. For the Sedan, install the trunk lid lower outer panel and center panel assemblies, as follows:
    1. Position the lower outer panel to the trunk lid and connect the license plate bulb sockets to the license plate lamps.
    2.  
    3. Connect the wiring harness retainer clip to the trunk lid lower outer panel.
    4.  
    5. Install the bottom flange of the lower outer panel over the lower edge of the trunk lid inner panel, then install the attaching bolts and tighten to 53 inch lbs. (6 Nm).
    6.  
    7. Connect the lock rod to the lock cylinder pawl.
    8.  
    9. Position the upper edge of the center panel to the trunk lid, then rotate the bottom of the center panel inboard.
    10.  
    11. Check to see that the sealing feature of the bolts is adequate and, if necessary, replace the bolts or seal using a body caulking compound to protect against water intrusion.
    12.  
    13. Loosely install the attaching bolts and check the panel alignment. Adjust the alignment, as necessary, and tighten the bolts. Install the license plate.
    14.  

  14.  
  15. Connect the negative battery cable.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: Trunk lid center panel assembly-Sedan



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Fig. Fig. 2: Trunk lid lower outer panel assembly-Sedan



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Fig. Fig. 3: Remove the reflex panels from the trunk lid-Coupe



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Fig. Fig. 4: It will be necessary to use a socket and extension to reach some of the reflex panel screws which are recessed in the trunk lid-Coupe

1997-98 Coupe and 1996-98 Sedan

See Figure 5

  1. Disconnect the negative battery cable.
  2.  
  3. Open the trunk lid and pull back the left side carpet.
  4.  
  5. Disengage the trunk lid wiring harness from the body harness at the blue connector on the wheelhousing.
  6.  
  7. Remove the trunk lid-to-hinge attachment bolts, then with the aid of an assistant, remove the trunk lid from the vehicle.
  8.  
  9. If replacing the trunk lid, remove the license plate, lock cylinder, lock, center panel and wiring harness.
  10.  

To install:
  1. With the help of an assistant, lower the trunk lid onto the hinges and install the attaching bolts. Check trunk alignment and adjust, as necessary, then tighten the retaining bolts to 89 inch lbs. (10 Nm).
  2.  
  3. Connect the trunk lid wiring harness to the body connector and place the carpet back to its correct position.
  4.  
  5. Connect the negative battery cable.
  6.  



Click image to see an enlarged view

Fig. Fig. 5: Trunk lid assembly removal

Wagon

See Figure 6

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the trim access plate from the inner liftgate trim panel.
  4.  
  5. Unplug the wiring connectors and the window washer hose.
  6.  
  7. Remove the rubber grommet between the liftgate and body, then retrieve the wires and washer hose from the liftgate.
  8.  
  9. Either support the liftgate using a prop or have an assistant hold the liftgate, then remove the liftgate struts.
  10.  
  11. Use a soft marker to scribe small alignment marks for installation purposes. With the help of an assistant, remove the hinge attachment bolts from the liftgate and remove the liftgate from the vehicle.
  12.  

To install:
  1. Raise the liftgate into position and align the marks made during removal, then install the gate to the hinges and tighten the bolts to 89 inch lbs. (10 Nm).
  2.  
  3. Install the struts.
  4.  
  5. Check and adjust the liftgate alignment, as necessary.
  6.  
  7. Route the wiring harness and washer hose through the liftgate, then connect the harness to the terminals and hose to the window washer.
  8.  
  9. Install the trim panel access plate.
  10.  
  11. Install the rubber grommet between the liftgate and the body.
  12.  
  13. Connect the negative battery cable.
  14.  



Click image to see an enlarged view

Fig. Fig. 6: The liftgate is attached to each hinge with 2 bolts

ALIGNMENT



Coupe and Sedan

See Figure 7

  1. To adjust the trunk lid cross-car, loosen the hinge-to-package shelf retainers and position the assembly, as needed.
  2.  
  3. To adjust the front of the trunk lid fore, aft, up or down, loosen the lid-to-hinge arm bolts and position the lid, as needed.
  4.  
  5. To adjust the rear of the trunk lid up and down, loosen the striker retainers and move the striker upward or downward, as needed.
  6.  
  7. When all adjustments are made, tighten the package shelf retainers to 19 ft. lbs. (25 Nm). Tighten the trunk lid bolts and/or striker bolts to 89 inch lbs. (10 Nm).
  8.  



Click image to see an enlarged view

Fig. Fig. 7: The front of the trunk lid is adjusted using the hinge bolts

Wagon

The Wagon liftgate may be adjusted up, down or cross-car by loosening the hinge-to-liftgate bolts. Fore and aft adjustments are usually made using the hinge-to-body bolts.

 
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