DOOR HINGE REPL.-NEW POLICIES, PROC. & LABOR ALLOW. (L CAR). Chevrolet Beretta 1990

SUBJECT: DOOR HINGE REPLACEMENTS (NEW POLICIES, PROCEDURES AND LABOUR ALLOWANCES)

VEHICLES AFFECTED: 1989-1992 "L AND W" MODELS

APPLICATION:

----------- "L" MODEL

Chevrolet Corsica/Beretta

1989 (after the following VIN breakpoints) through 1992

Chevrolet Corsica/Beretta Linden Built KE 262341 Chevrolet Corsica/Beretta Wilmington Built KY 257764

Pontiac Tempest

1989 (after the following VIN breakpoints) through 1991 - GM of Canada dealers

1989 (after the following VIN breakpoints) through 1992 - North American Export Sales dealers

Pontiac Tempest Wilmington Built KY 714839 (Canada only)

"W" MODEL

Buick, Oldsmobile and Pontiac "W" coupes/sedans

1989 (after following VIN breakpoints) through 1992

Chevrolet "W" coupes/sedans

1990 through 1992

Oldsmobile Cutlass Supreme Doraville KD 313505 Oldsmobile

Pontiac Grand Prix Fairfax KF 230160 Pontiac

Buick Regal Oshawa 2 K1 448000 Buick

New policies, procedures and labour time allowances have been developed regarding door hinge servicing on 1989 through 1992 "L" and "W" coupes/sedans.

POLICY:

------ If a single door hinge on any door at any location requires replacement, the second or remaining hinge must be replaced at the same time.

SERVICE PARTS:

Service parts will be packaged in "door sets", or two hinges in each package. New part numbers are as follows:

Part Number Description ----------- ----------- "L" Models 22583166 Hinges, Right Front Door 22583167 Hinges, Left Front Door 22583168 Hinges, Right Rear Door 22583169 Hinges, Left Rear Door

"W" Models 10218445 Hinges, Right Front Door 10218446 Hinges, Left Front Door 10218447 Hinges, Right Rear Door 10218448 Hinges, Left Rear Door

PROCEDURES:

---------- "W" MODEL PROCEDURE ------------------- NOTICE: This procedure differs from the previous procedure (Removing the door from the vehicle) in that:

a. The door remains on the vehicle.

b. Access to both front door hinges is made through the front wheelhouse area.

c. The hinges come pre-primed.

NOTICE: In order to minimize door realignment, DO NOT remove both door hinges at the same time. Do each hinge separately, and replace any broken hinges first.

1. Place vehicle on hoist.

2. Using the proper lift points, raise vehicle to half up position (until wheel/tire is chest high).

NOTICE: Make sure that the doors are fully latched onto the lock striker and the doors are not locked.

3. Using two pieces of masking tape, place one piece to bridge the gap between the door and rocker panel and the second piece to bridge the gap between the door and quarter panel or rear door (to act as reference points for door alignment).

4. Cut the tape at the gap area using a utility knife or other suitable tool.

5. Remove the front tire and wheel assembly.

6. Starting at the top centre of the front wheelhouse liner, remove all attaching screws located rearward of the top centre of the liner.

7. Loosen the liner from the fender and position the liner forward of the front suspension assembly.

8. Remove the insulator cover attachments and insulator cover (located between fender and hinge pillar).

9. Clean the hinge mounting surfaces on the door and body with a rag and mark the hinge locations on the body surfaces with a grease pencil or other suitable marker.

10. Remove the hinge attaching the fasteners and hinge from vehicle.

11. Install the new hinge within the previously marked locations using the new fasteners and lightly tighten the fasteners.

12. Repeat steps 10 and 11 for remaining hinge.

13. Install tire/wheel with 3 nuts and lower the vehicle to ground level.

14. Inspect the edges of the tape on the door and with the aid of a helper, align the door as necessary.

15. Raise the vehicle to the previous position and remove the tire/wheel assembly.

16. Tighten and torque the hinge attachments to:

Bolts - 46 N.m (34 Lbs.Ft.)

Nuts - 27 N.m (20 Lbs.Ft.)

17. Reinstall the insulator cover.

18. Reposition and install the wheelhouse liner using the original screws.

19. Reinstall the tire and wheel assembly.

20. Remove the reference tape from the door, rocker and quarter.

21. Lower hoist and remove the vehicle.

Procedure for replacement - Rear Doors -

NOTICE: In order to minimize door realignment, DO NOT remove both door hinges at the same time. Do each hinge separately, and replace any broken hinges first.

1. Using two pieces of masking tape, place one piece to bridge the gap between the door and rocker panel and the second piece to bridge the gap between the door and quarter panel (to act as reference points for door alignment).

2. Cut the tape at the gap area using a utility knife or other suitable tool.

NOTICE: Make sure that the doors are fully latched onto the lock striker and the doors are not locked.

3. With the front door open to access the centre pillar and rear door hinge area, clean the hinge mounting surfaces on the door and body with a rag and mark the locations using a grease pencil or other suitable marker.

4. Remove the hinge attaching the fasteners and hinge from vehicle.

5. Install the new hinge within previously marked locations and lightly tighten the fasteners.

6. Repeat steps 3 through 5 for the remaining hinge.

7. Inspect the edges of tape on the door and align the door as necessary.

8. Tighten and torque the hinge attachments to:

Bolts - 46 N.m (34 Lbs.Ft.)

Nuts - 27 N.m (20 Lbs.Ft.)

9. Remove the reference tape from the door, rocker and quarter.

"L" MODEL PROCEDURE

1. Place vehicle on hoist.

2. Using the proper lift points, raise vehicle to half up position (until wheel/tire chest high).

NOTICE: Make sure that the doors are fully latched onto the lock striker and the doors are not locked.

4. Cut the tape at the gap area using a utility knife or other suitable tool.

5. Remove the front tire and wheel assembly.

6. Using a pin punch or awl and a hammer, and starting at rear of front wheelhouse liner, punch out the centre mandrels from the last five (5) plastic attaching rivets.

7. Remove attaching rivets and discard.

8. Remove remaining screw attachments and position the liner forward of the front suspension assembly. .

9. Remove the insulator cover attachments and insulator cover (located between fender and hinge pillar).

10. Clean hinge mounting surfaces on door and body with a rag and mark the hinge locations on the body surfaces with a grease pencil or other suitable marker.

11. Remove the hinge attaching fasteners and hinge from the vehicle.

12. Install new hinge within the previously marked locations using new fasteners and lightly tighten the fasteners.

13. Repeat steps 11 and 12 for remaining hinge.

14. Install tire/wheel with 3 nuts and lower vehicle to ground level.

15. Inspect the edges of the tape on the door and with the aid of a helper, align the door as necessary.

16. Raise vehicle to previous position and remove tire/wheel assembly.

17. Tighten and torque hinge attachments to:

20 - 28 N.m (1 5 - 20 Lbs.Ft.)

18. Reinstall insulator cover between fender and hinge pillar.

19. Reposition and install the wheelhouse liner using the rivets provided and original screws.

NOTICE: The plastic rivets used to retain wheelhouse liners to fender flanges require unique plastic rivet installing tools (longer draw or pull to set plastic mandrel). These type tools are common to most body repair shops and are available from various sources such as body/paint shop suppliers or local hand tool distributors.

20. Reinstall the tire and wheel assembly.

21. Remove the reference tape from door, rocker and quarter.

22. Lower hoist and remove vehicle.

Procedure for replacement - Rear Doors -

NOTICE: In order to minimize door realignment, DO NOT remove both door hinges at the same time. Do each hinge separately and, replace any broken hinges first.

2. Cut the tape at the gap area using a utility knife or other suitable tool.

NOTICE: Make sure that the doors are fully latched onto the lock striker and the doors are not locked.

4. Remove the hinge attaching the fasteners and hinge from the vehicle.

5. Install the new hinge within the previously marked locations and lightly tighten the fasteners.

6. Repeat steps 3 through 5 for the remaining hinge.

7. Inspect the edges of tape on the door and align the door as necessary.

8. Tighten and torque hinge attachments to:

20 - 28 N.m (15 - 20 Lbs.Ft.).

9. Remove reference tape from the door, rocker and quarter.

WARRANTY INFORMATION:

"W" MODEL

LABOUR OPERATION: TIME ALLOWANCE: ---------------- --------------

Front Doors: Both Right B4018 0.9 Hrs. Both Left B4019 0.9 Hrs. ADD: - W/Locking Wheel Covers/Nuts (One Or All) 0.1 Hrs. - To Colour Coat 0.3 Hrs. - Material Allowance GB

Rear Doors: Both Right B4418 0.5 Hrs. Both Left B4419 0.5 Hrs. ADD: - To Colour Coat 0.3 Hrs. - Material Allowance GB

"L" MODEL

LABOUR OPERATION: TIME ALLOWANCE: ---------------- --------------

Front Doors: Both Right B4018 1.0 Hrs. Both Left B4019 1.0 Hrs.

ADD:

- W/Locking Wheel Covers/Nuts (One Or All) 0.1 Hrs. - To Colour Coat 0.3 Hrs. - Material Allowance GB

Rear Doors: Both Right B4418 0.5 Hrs. Both Left B4419 0.5 Hrs.

ADD:

- To Colour Coat 0.3 Hrs. - Material Allowance GB

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.