IMPROPER FIT/ALIGNMENT OF REAR COMPARTMENT LID

SUBJECT: IMPROPER FIT/ALIGNMENT OF REAR COMPARTMENT (DECK) LID, REAR FASCIA AND TAIL LAMPS (ADJUST REAR COMPARTMENT LID, FASCIA/SHIM TAIL LAMPS)

MODELS: 1997 PONTIAC GRAND PRIX (COUPES AND SEDANS)

CONDITION:

SOME OWNERS MAY COMMENT THAT THE FIT OR ALIGNMENT OF THE REAR COMPARTMENT (DECK OR TRUNK) LID TO THE QUARTER PANELS IS NOTICEABLY DIFFERENT FROM ONE SIDE OF THE VEHICLE TO THE OTHER. THEY MAY ALSO COMMENT THAT THE REAR FASCIA AND TAIL LAMPS DO NOT FIT OR ALIGN WELL WITH THE DECK LID.

CAUSE:

THE DECK LID AND REAR FASCIA MAY HAVE BEEN IMPROPERLY ADJUSTED DURING VEHICLE ASSEMBLY.

CORRECTION:

VERIFY AND ADJUST THE DECK LID, REAR FASCIA AND TAIL LAMPS USING THE FOLLOWING PROCEDURE.

IMPORTANT:

BEFORE BEGINNING, VERIFY THAT BOTH OVERSLAM BUMPERS ARE SCREWED INTO THE DECK LID COMPLETELY. DO NOT USE THE OVERSLAM BUMPERS FOR ADJUSTMENT OF THE DECK LID HEIGHT. SEE FIGURE 1. AFTER ALL ADJUSTMENTS HAVE BEEN MADE, REPOSITION BOTH OVERSLAM BUMPERS SO THAT THEY ARE ONLY MAKING LIGHT CONTACT WITH THE BODY AND ARE NOT SUPPORTING THE DECK LID.

DECK LID TO QUARTER PANEL GAPS + FORE/AFT ALIGNMENT

INSPECTION

WITH THE DECK LID IN THE CLOSED POSITION, VISUALLY INSPECT THE GAPS BETWEEN THE QUARTER PANEL AND DECK LID ALONG BOTH SIDES. SEE FIGURE 2.

1. VERIFY THAT THE GAP ON THE LEFT SIDE AND RIGHT SIDE ARE BOTH EVEN FROM FRONT TO REAR, AND THAT THEY ARE THE SAME WIDTH. IF THE GAPS ARE NOT EVEN FROM FRONT TO REAR, OR ONE SIDE IS WIDER THAN THE OTHER, THEN THE DECK LID WILL REQUIRE ADJUSTMENT.

2. VERIFY THAT THE REAR EDGES OF THE DECK LID ALIGN EVENLY WITH, OR DO NOT EXTEND MORE THAN 2 MM BEYOND THE REAR EDGES OF THE QUARTER PANELS. IF BOTH REAR EDGES OF THE DECK LID ARE NOT EVEN WITH THE QUARTER PANELS, OR EXTEND BEYOND THE QUARTER PANELS BY MORE THAN 2 MM, THEN THE DECK LID WILL REQUIRE ADJUSTMENT.

ADJUSTMENT

1. LOOSEN THE TWO (2) HINGE TO DECK LID ATTACHING NUTS ON EACH SIDE ONLY AS MUCH AS NECESSARY TO OBTAIN MOVEMENT OF THE DECK LID ON THE HINGES. DO NOT REMOVE THE NUTS.

2. CAREFULLY CLOSE THE DECK LID UNTIL CONTACT IS MADE WITH THE WEATHERSTRIPS.

3. CAREFULLY MOVE THE DECK LID AS NECESSARY TO OBTAIN EVEN GAPS ALONG BOTH QUARTER PANELS FROM FRONT TO REAR AND ALIGN BOTH REAR EDGES OF THE DECK LID EVEN WITH, OR SO THAT THEY DO NOT EXTEND BEYOND THE REAR EDGES OF THE QUARTER PANELS BY MORE THAN 2 MM.

4. WHEN PROPERLY POSITIONED, CAREFULLY RAISE THE DECK LID ONLY FAR ENOUGH TO ACCESS THE ATTACHING NUTS.

IMPORTANT:

WHEN RAISING THE DECK LID, DO NOT ALLOW IT TO MOVE ON THE HINGES. ALSO, CHECK TO SEE THAT THE DECK LID DOESN'T CONTACT THE QUARTER PANELS AS SHOWN IN FIGURE 2, ITEM 6.

5. LIGHTLY TIGHTEN THE TWO ATTACHING NUTS ON EACH SIDE OF THE DECK LID.

6. RAISE THE DECK LID COMPLETELY AND FINISH TIGHTENING THE ATTACHING NUTS TO 25 N.M (18 LB FT).

7. CAREFULLY CLOSE THE DECK LID AND CHECK THE ALIGNMENT TO BOTH QUARTER PANELS AND ALSO THE ALIGNMENT OF THE LATCH AND STRIKER. ADJUST LATCH AND STRIKER AS NECESSARY. TIGHTEN LATCH ATTACHING BOLTS TO 10 N.M (88 LB IN) AND STRIKER ATTACHING BOLTS TO 16 N.M (11 LB FT).

8. CAREFULLY OPEN THE DECK LID AGAIN WHILE CHECKING FOR CLEARANCE TO THE QUARTER PANELS AT THE LOCATION SHOWN IN FIGURE 2. IF CONTACT IS BEING MADE, PROCEED TO THE SECTION ON DECK LID TO QUARTER PANEL FLUSHNESS AFTER COMPLETION OF THIS PROCEDURE.

NOTICE:

TO AVOID PAINT DAMAGE, OPEN THE DECK LID SLOWLY WHEN CHECKING FOR CLEARANCE.

9. APPLY TOUCH UP PAINT AS NECESSARY TO ANY EXPOSED METAL SURFACES.

DECK LID TO QUARTER PANEL FLUSHNESS

INSPECTION

WITH THE DECK LID IN THE CLOSED POSITION, VISUALLY INSPECT THE FLUSHNESS OF THE LID TO THE QUARTER PANELS ALONG BOTH SIDES. SEE FIGURE 3.

1. CHECK FOR FLUSHNESS AT THE REAR OF THE DECK LID (LOCATION "1") AND AT THE FRONT (LOCATION "2"). IF ONE OR BOTH LOCATIONS ARE NOT FLUSH, THEN THE DECK LID WILL REQUIRE ADJUSTMENT.

2. CAREFULLY OPEN THE DECK LID WHILE CHECKING FOR CLEARANCE TO THE QUARTER PANELS AT THE LOCATIONS SHOWN IN FIGURE 2. IF CONTACT IS BEING MADE, IT WILL BE NECESSARY TO ADJUST THE HINGE ADJUSTABLE BUMPER SHOWN IN FIGURE 3.

NOTICE:

TO AVOID PAINT DAMAGE, OPEN THE DECK LID SLOWLY WHEN CHECKING FOR CLEARANCE.

ADJUSTMENT -- FLUSHNESS

USE THE INFORMATION IN FIGURE 3 TO OBTAIN THE REQUIRED FLUSHNESS AT BOTH DECK LID TO QUARTER PANEL LOCATIONS. TIGHTEN THE DECK LID HINGE TO QUARTER PANEL BOLTS TO 25 N.M (18 LB FT) AND APPLY TOUCH UP PAINT AS NECESSARY TO ANY EXPOSED METAL SURFACES.

ADJUSTMENT -- HINGE ADJUSTABLE BUMPER

1. WITH THE DECK LID PARTIALLY OPEN, PLACE A STRIP OF PAPER BETWEEN THE HINGE ADJUSTABLE BUMPER AND THE HINGE TRAVEL STOP. ALLOW THE END OF THE PAPER TO STICK OUT BETWEEN THE DECK LID AND BACK GLASS LACE MOLDING.

2. CLOSE THE DECK LID COMPLETELY.

3. GRASP THE END OF THE PAPER AND SLOWLY TRY TO PULL IT OUT.

-- IF THE BUMPER IS PROPERLY ADJUSTED, A SLIGHT DRAG OR RESISTANCE SHOULD BE FELT.

-- IF THE PAPER CANNOT BE REMOVED, OR CAN BE REMOVED USING CONSIDERABLE EFFORT, THE BUMPER NEEDS TO BE ADJUSTED DOWN TO REDUCE THE AMOUNT OF CONTACT BEING MADE.

-- IF THE PAPER REQUIRES NO EFFORT (NO CONTACT BEING MADE), OR VERY LITTLE EFFORT, THE BUMPER NEEDS TO BE ADJUSTED UP TO INCREASE THE AMOUNT OF CONTACT BEING MADE.

4. AFTER ADJUSTING, CLOSE THE DECK LID AND SLOWLY REOPEN IT WHILE CHECKING FOR CLEARANCE AT THE LOCATIONS SHOWN IN FIGURE 2.

-- IF THERE IS ANY CONTACT BETWEEN THE DECK LID AND QUARTER PANELS, IT WILL BE NECESSARY TO LOOSEN THE HINGE TO DECK LID ATTACHING NUTS AND MOVE THE DECK LID REARWARD TO OBTAIN CLEARANCE.

IMPORTANT:

MOVING THE DECK LID REARWARD MAY CAUSE THE FORE/AFT ALIGNMENT TO THE QUARTER PANELS TO BE OFF BY UP TO 2 MM.

DECK LID TO REAR FASCIA

INSPECTION

WITH THE DECK LID IN THE CLOSED POSITION, VISUALLY INSPECT THE FORE/AFT ALIGNMENT OF THE DECK LID TO THE REAR FASCIA AT THE TWO LOCATIONS SHOWN IN FIGURE 4. IF THE DECK LID IS TOO FAR FORWARD OR REARWARD AT EITHER LOCATION, AN ADJUSTMENT OF THE REAR FASCIA WILL BE REQUIRED.

IMPORTANT:

BEFORE ADJUSTING THE REAR FASCIA, THE ALIGNMENT OF THE DECK LID TO THE REAR QUARTER PANELS MUST BE CORRECT. DO NOT ATTEMPT TO ADJUST THE REAR FASCIA UNLESS THE DECK LID ALIGNMENT IS CORRECT. IN ADDITION, REVIEW THE TAIL LAMP TO DECK LID FORE/AFT ALIGNMENT INFORMATION BEFORE PROCEEDING.

ADJUSTMENT

IMPORTANT:

SOME PRODUCTION VEHICLES WERE ASSEMBLED WITH A SCREW/BOLT AND J-NUT REPLACING THE OUTBOARD PLASTIC PUSH-IN RETAINER ON EACH SIDE. IF THE VEHICLE ALREADY HAS SCREWS/BOLTS AT THE TWO LOCATIONS SHOWN IN FIGURE 5, LOOSEN BOTH AND PROCEED TO STEP 9. DO NOT INSTALL SCREWS/BOLTS AND J-NUTS ON VEHICLES THAT DO NOT REQUIRE A REAR FASCIA ADJUSTMENT.

1. OPEN THE DECK LID AND REMOVE THE FOUR (4) REAR FASCIA TO REAR END PANEL PLASTIC PUSH-IN RETAINERS AT THE LOCATIONS SHOWN IN FIGURE 5.

2. REMOVE BOTH REAR TAIL LAMP ASSEMBLIES.

3. CAREFULLY PULL THE REAR FASCIA REARWARD TO EXPOSE THE REAR END PANEL. SEE FIGURE 5.

4. INSTALL J-NUTS, P/N 12337917, ON THE REAR END PANEL AT THE TWO LOCATIONS SHOWN IN FIGURE 5.

5. REPOSITION THE REAR FASCIA OVER THE REAR END PANEL.

6. INSTALL PUSH-IN PLASTIC RETAINERS IN THE CENTER TWO HOLES.

7. INSTALL SCREWS/BOLTS, P/N 11503982, IN THE OUTBOARD HOLES ON EACH SIDE AND TIGHTEN ONLY UNTIL LIGHT CONTACT IS MADE WITH THE FASCIA. DO NOT TIGHTEN SECURELY.

8. REINSTALL BOTH TAIL LAMP ASSEMBLIES.

9. CLOSE THE DECK LID AND MOVE THE REAR FASCIA FORWARD OR REARWARD AS NECESSARY TO ALIGN WITH THE DECK LID.

10. ONCE ALIGNED, HOLD THE REAR FASCIA IN POSITION WHILE OPENING THE DECK LID.

11. TIGHTEN THE TWO (2) SCREWS/BOLTS TO 10 N.M (88 LB IN).

12. CLOSE THE DECK LID AND CHECK ALIGNMENT.

TAIL LAMP TO DECK LID FORE/AFT ALIGNMENT

INSPECTION

WITH THE DECK LID IN THE CLOSED POSITION, VISUALLY INSPECT THE FORE/AFT ALIGNMENT OF BOTH TAIL LAMP INBOARD CORNERS TO THE DECK LID. SEE FIGURE 6. IF THE INBOARD CORNER OF EITHER TAIL LAMP IS TOO FAR FORWARD (RECESSED) OR REARWARD (PROTRUDING), THEN THAT TAIL LAMP WILL REQUIRE ADJUSTMENT.

IMPORTANT:

WHEN THE TAIL LAMPS ARE PROPERLY ALIGNED, THE GAP BETWEEN THE DECK LID AND THE MIDDLE OF THE TAIL LAMPS MAY BE WIDER THAN THE GAP AT THE DECK LID CORNERS. SEE FIGURE 8. THIS CONDITION IS NORMAL.

REARWARD ADJUSTMENT (TO CORRECT A RECESSED LAMP)

1. OPEN THE DECK LID AND PULL BACK THE TRUNK COMPARTMENT CARPET TO EXPOSE THE THREE (3) PLASTIC TAIL LAMP RETAINERS.

2. REMOVE THE THREE (3) PLASTIC FASTENERS AND CAREFULLY PULL THE TAIL LAMP AWAY FROM THE VEHICLE. IT IS NOT NECESSARY TO DISCONNECT THE ELECTRICAL CONNECTIONS FROM THE LAMP.

3. TO MOVE THE INBOARD CORNER OF THE TAIL LAMP REARWARD (OUTBOARD), INSTALL FLAT WASHERS (1/4 I.D BY 3/4 O.D.) AS NECESSARY TO THE INBOARD TAIL LAMP MOUNTING STUD. SEE FIGURE 7.

IMPORTANT:

ONLY USE FLAT WASHERS THAT HAVE AN ANTI-CORROSION COATING. IF THE FLAT WASHERS TO BE USED DO NOT HAVE ANY ANTI-CORROSION PROTECTION, IT WILL BE NECESSARY TO APPLY TOUCH UP PAINT TO THEM PRIOR TO THE INSTALLATION OF THE TAIL LAMP TO THE VEHICLE.

4. INSTALL THE TAIL LAMP TO THE VEHICLE AND CHECK THE ALIGNMENT TO THE DECK LID.

5. INSTALL THE THREE (3) PLASTIC TAIL LAMP FASTENERS AND TIGHTEN TO 5 N.M (44 LB IN).

6. REPOSITION THE TRUNK COMPARTMENT CARPET AND CLOSE THE DECK LID.

FORWARD ADJUSTMENT (TO CORRECT A PROTRUDING LAMP)

SOME PRODUCTION VEHICLES WERE ASSEMBLED WITH FLAT WASHERS (SHIMS) ADDED TO THE TAIL LAMP INBOARD MOUNTING STUD. IF ADJUSTMENT IS REQUIRED TO CORRECT A PROTRUDING LAMP CONDITION, REMOVE THE FLAT WASHERS AS NECESSARY. FOLLOW THE "REARWARD ADJUSTMENT" PROCEDURE AND SUBSTITUTE "REMOVE" FLAT WASHERS FOR "INSTALL" FLAT WASHERS IN STEP 3.

PARTS INFORMATION:

P/N DESCRIPTION QUANTITY === =========== ========

11503982 SCREW 2 12337917 J-NUT 2

PARTS ARE CURRENTLY AVAILABLE FROM GMSPO.

WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OPERATION NUMBER DESCRIPTION LABOR TIME =============== =========== ==========

B5400 REAR COMPARTMENT LID - 0.3 HR ALIGN

ADD: ALIGN ONE TAIL LAMP 0.1 HR

ADD: ALIGN BOTH TAIL LAMPS 0.3 HR AND/OR ALIGN REAR FASCIA

FIGURES: 08 ATTACHMENTS: 00

FIGURE 1: 1. DECK LID OVERSLAM BUMPER

FIGURE 2: 1. QUARTER PANEL TO DECK LID GAPS 2. DECK LID 3. RIGHT QUARTER PANEL 4. INCORRECT ALIGNMENT - MORE THAN 2 MM REARWARD 5. CORRECT ALIGNMENT 6. CHECK FOR CLEARANCE WHEN OPENING DECK LID.

FIGURE 3: 1. REAR OF DECK LID WHERE FLUSHNESS TO QUARTER PANEL IS CHECKED. 2. FRONT OF DECK LID WHERE FLUSHNESS TO QUARTER PANEL IS CHECKED. 3. LOOSENING THESE BOLTS WILL ALLOW THE REAR OF THE DECK LID TO BE RAISED OR LOWERED. 4. LOOSENING THESE BOLTS WILL ALLOW THE FRONT OF THE DECK LID TO BE RAISED OR LOWERED. 5. HINGE ADJUSTABLE BUMPER

FIGURE 4: 1. REAR VIEW OF TWO LOCATIONS WHERE DECK LID TO REAR FASCIA ALIGNMENT IS CHECKED. 2. RIGHT SIDE VIEW OF REAR FASCIA, DECK LID AND TAIL LAMP. 3. RIGHT SIDE VIEW SHOWING INCORRECT ALIGNMENT. 4. RIGHT SIDE VIEW SHOWING CORRECT ALIGNMENT. 5. DECK LID LOCK CYLINDER

FIGURE 5: 1. PLASTIC PUSH-IN RETAINERS. 2. TWO LOCATIONS WHERE SCREWS WILL REPLACE PLASTIC PUSH-IN RETAINER. 3. REAR END PANEL (SHOWN WITH REAR FASCIA REMOVED). 4. INSTALL J-NUTS AT THESE HOLE LOCATIONS.

FIGURE 6: 1. WHERE TAIL LAMP TO DECK LID ALIGNMENT NEEDS TO BE INSPECTED 2. REAR FASCIA 3. RIGHT TAIL LAMP 4. DECK LID 5. INCORRECT TAIL LAMP ALIGNMENT 6. CORRECT TAIL LAMP ALIGNMENT

FIGURE 7: 1. BACK SIDE OF RIGHT TAIL LAMP ASSEMBLY 2. INBOARD MOUNTING STUD TO BE SHIMMED

FIGURE 8: 1. GAP BETWEEN TAIL LAMP AND DECK LID CORNER 2. GAP BETWEEN MIDDLE OF TAIL LAMP AND DECK LID

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.

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