CAMPAIGN: DOOR HINGES L BODY VEHICLES. Chevrolet Corsica 1987

SUBJECT: DOOR HINGES

MODELS: 1987-88 Chevrolet Corsica, Beretta and Pontiac Tempest

TO: ALL GENERAL MOTORS DEALERS

THIS BULLETIN CANCELS AND SUPERSEDES CAMPAIGN BULLETINS 9A24 (1987-88 CHEVROLET CORSICA AND PONTIAC TEMPEST) AND 9A25 (1987-88 CHEVROLET BERETTA). THE INFORMATION FROM THESE BULLETINS HAS BEEN COMBINED IN THIS BULLETIN AND THE SERVICE PROCEDURE AND PARTS AND LABOUR CLAIM INFORMATION SECTIONS HAVE BEEN REVISED. ALL COPIES OF BULLETINS 9A24 (1987-88 CHEVROLET CORSICA AND PONTIAC TEMPEST) AND 9A25 (1987-88 CHEVROLET BERETTA) SHOULD BE DESTROYED.

General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1987-88 Chevrolet Corsica, Beretta and Pontiac Tempest model vehicles.

A door hinge pin may break while opening or closing a door. If the upper hinge pin breaks, the end of the door nearest the door handle may drop down making it difficult to reposition and close properly. If the lower hinge pin breaks, the failure may be much less noticeable than an upper hinge failure. For example, opening or closing the door may require slightly increased effort or may produce a popping or scraping noise.

Failure to repair either of these hinge separations may reduce the structural integrity of the side of the car and increase risk of an injury in case of certain types of accidents. If the vehicle experiences one of these hinge failures, the car should be towed immediately to a dealership for repair at no charge to the customer.

Also, failure to immediately repair any hinge separation may ultimately lead to a failure of the other hinge on the same door. This not only further increases the risk of injury in certain types of accidents, but could result in that door opening while driving down the road.

To correct this condition, dealers are to replace door hinges on all affected vehicles.

General Motors of Canada Limited does not believe that an unreasonable risk of accidents or injuries under the Safety Act exists relative to hinge failures in the rear doors of certain 1987-88 Corsica and Tempest model vehicles. This is a result of low failure rates and a lack of reported injuries due to rear door hinge pin failures. Nonetheless, for customer satisfaction purposes, General Motors of Canada Limited will replace all rear door hinges when the subject vehicles are returned to dealers for the front door hinge safety recall repairs.

VEHICLES INVOLVED:

Involved are all 1987 Chevrolet Corsica, Beretta and Pontiac Tempest models and some 1988 Corsica, Beretta and Tempest models within the following VIN breakpoints:

Year Model Plant Plant Code From Through ---- ----- ----- ---------- ----- ------- 1987 Chev Corsica Wilmington "Y" HY100014 HY106246 1987 Chev Corsica Linden "E" HE100001 HE110672 1988 Chev Corsica Wilmington "Y" JY200001 JY268966 1987 Chev Beretta Wilmington "Y" HY100014 HY106246 1987 Chev Beretta Linden "E" HE100001 HE110672 1988 Chev Beretta Wilmington "Y" JY200001 JY268966 1988 Chev Beretta Linden "E" JE210673 JE299428 1987 Pont Tempest Wilmington "Y" HY700000 HY700523 1988 Pont Tempest Linden "E" JY800000 JY804843

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

DEALER CAMPAIGN RESPONSIBILITY:

All unsold new vehicles in dealer's possession and subject to this campaign must be held and inspected/repaired per the Service Procedure of this Campaign Bulletin before owners take possession of these vehicles.

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, age of vehicle, or ownership, from this time forward.

Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service, you are to ensure the campaign correction has been made before selling or releasing the vehicle.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin.

In summary, whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign connection has been made before selling or releasing the vehicle.

CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors. The listings provided are for campaign activity only and should not be used for any other purpose.

REIMBURSEMENT

Customer claims for reimbursement on previously paid repairs to correct a previous door hinge pin (single hung fixed-pin design) fatigue fracture will be considered. Owners (and/or prior owners) must submit original documentation which reasonably confirms the amount of unreimbursed repair expense(s), a description of the repair, and the person or entity performing the repair. Review the owner's documentation, and process under T1544.

PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- ------------ ---------------- 22583167 Left Front Door Hinge Kit 1 22583166 Right Front Door Hinge Kit 1 22583169 Left Rear Door hinge Kit 1 (Not Used On Beretta Models) 22583168 Right Rear Door Hinge Kit 1 (Not Used On Beretta Models)

Front door hinge kits contain 2 hinges, 4 nuts, 4 bolts and 10 rivets. Rear door hinge kits contain 2 hinges.

PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ----------- -------------- FOR CHEVROLET CORSICA AND PONTIAC TEMPEST SUBMIT CLAIM UNDER 9A24 AND FOR CHEVROLET BERETTA SUBMIT CLAIM UNDER 9A25.

1A Inspect/Double Hung Hinges Previously .3 Installed - All Doors [9A24/9A25]

2A* Install New Door Hinges - All Four (4) Doors - 3.0 Corsica/Tempest [9A24]

3A* Install New Door Hinges - Three (3) Doors 2.6 (Two Front & One Rear) - Corsica/Tempest [9A24]

4A* Install New Door Hinges - Three (3) Doors 2.3 (One Front & Two Rear) - Corsica/Tempest [9A24]

5A Install New Door Hinges - Two (2) Front Doors - Beretta 1.9 [9A251

9A* Install New Door Hinges - Two (2) Doors 1.6 (One Front & One Rear) - Corsica/Tempest [9A24]

AA* Install New Door Hinges - Two (2) Rear Doors - 1.2 Corsica/Tempest [9A24]

BA Install New Door Hinges - One (1) Front Door 1.1 [9A24/9A25]

CA* Install New Door Hinges - One (1) Rear Door - .6 Corsica/Tempest [9A24]

6A** Sublet Campaign Repair [9A24/9A25]

T1544 Reimburse Owner For Prior Door Hinge Repair See Inst- [9A24/9A25] ructions for Re- imburse- ment

Time allowance includes 0. 1 hour for dealer administrative detail associated with this campaign. Repair Codes 2A, 3A, 4A, 9A, AA and CA include cost for paint. Parts credit will be based on dealer net plus 30% to cover parts handling.

* TIME FOR PAINTING REAR DOOR HINGES IS INCLUDED IN THE LABOUR TIMES FOR REPAIR CODES 2A, 3A, 4A, 9A, AA AND CA.

** Repair Code 6A is to be used by dealers who sublet body shop work and repair. Note that the amount claimed should not exceed allowable dollar limits that have been calculated at the dealers approved warranty labour rate multiplied by the applicable labour hours.

SERVICE PROCEDURE:

NOTICE: THESE PROCEDURES DIFFER FROM PREVIOUS HINGE REPLACEMENT METHODS BECAUSE:

a. Doors remain on vehicle.

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

c. Hinges come pre-printed and ONLY REAR DOOR HINGES are to be painted.

INSPECTION

Inspect all doors for "Double Hung Hinges" (see illustration below). If "Double Hung Hinges" are already installed on all doors, no further hinge service is necessary. Install Campaign Identification Label and retum vehicle to owner or dealer stock.

If the vehicle does not have "Double Hung Hinges" already installed on all doors, proceed with the repair procedures which follow for those doors requiring "Double Hung Hinges."

REPAIR PROCEDURES

NOTICE: IN ORDER TO MINIMIZE DOOR REALIGNMENT, DO NOT REMOVE BOTH DOOR HINGES AT THE SAME TIME. DO EACH HINGE SEPARATELY AND, IF BROKEN HINGES ARE NOTED DURING VEHICLE INSPECTION, REPLACE BROKEN HINGES FIRST.

1. Place vehicle on hoist.

2. Obtain hinges for all doors and (for Chevrolet Corsica and Pontiac Tempest model vehicles) paint to match vehicle colour.

3. On Chevrolet Corsica and Pontiac Tempest model vehicles, scuff sand and paint REAR DOOR HINGES ONLY using proper colour. While allowing painted hinges to dry, perform front door hinge replacement.

FRONT DOOR HINGE REPLACEMENT

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

NOTICE: MAKE SURE THAT DOORS ARE FULLY CLOSED (FIRMLY LATCHED ONTO LOCK STRIKER) AND DOORS ARE NOT LOCKED.

5. Using two pieces of masking tape, place one piece to bridge gap between door and rocker panel and second piece to bridge gap between door and quarter panel or rear door to act as reference points for door alignment (see illustration on page 7).

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

7. Remove front tire and wheel assembly.

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

9. Remove attaching rivets (not to be reused).

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

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

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

NOTICE: IF A BROKEN HINGE WAS NOTED DURING INSPECTION, IT SHOULD BE REPLACED BEFORE ANY OTHER HINGE IS REPLACED.

13. Remove hinge attaching fasteners and hinge from vehicle.

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

15. Repeat steps 13 and 14 for remaining hinge.

16. Repeat Steps 5 through 15 for remaining front door.

17. Install both tire/wheel assemblies to vehicle and lower vehicle to ground level.

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

19. Raise vehicle to previous position and remove tire/wheel assemblies.

20. Tighten and torque hinge attachments to 20 - 28 N.m (15 to 20 lb. ft.).

21. Reinstall insulator cover between fenders and hinge pillars.

22. Reposition and install wheelhouse liners using 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.

23. Reinstall tire and wheel assemblies.

24. Carefully remove reference tape from door, rocker and quarter. For Beretta model vehicles, this completes the repairs necessary for this campaign action. Install Campaign Identification Label and return vehicle to owner or dealer stock.

For Corsica and Tempest model vehicles, proceed to "Rear Door Hinge Replacement" procedure below.

NOTICE: IN ORDER TO MINIMIZE DOOR REALIGNMENT, DO NOT REMOVE BOTH DOOR HINGES AT SAME TIME. DO EACH HINGE SEPARATELY AND, IF BROKEN HINGES ARE NOTED DURING VEHICLE INSPECTION, REPLACE BROKEN HINGES FIRST.

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

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

NOTICE: MAKE SURE DOORS ARE FULLY CLOSED (FIRMLY LATCHED ONTO LOCK STRIKER) AND DOORS ARE NOT LOCKED.

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

NOTICE: IF A BROKEN HINGE WAS NOTED DURING INSPECTION, IT SHOULD BE REPLACED BEFORE ANY OTHER HINGE IS REPLACED.

28. Remove hinge attaching fasteners and hinge from vehicle.

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

30. Repeat steps 27 through 28 for remaining hinge.

31. Inspect edges of tape on door and align door as necessary.

32. Tighten and torque hinge attachments to 20 - 28 N.m (15 to 20 lb. ft.).

33. Remove reference tape from door, rocker and quarter.

34. Repeat steps 25 through 33 for opposite rear door.

35. Install Campaign Identification Label.

INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

Dear General Motors Customer:

General Motors of Canada has determined that a defect which relates to motor vehicle safety exists in certain 1987-88 Chevrolet Corsica and Pontiac Tempest model vehicles.

A hinge pin may break while opening or closing a door. If the upper hinge pin breaks, the end of the door nearest the door handle may drop down making it difficult to reposition and close properly. If the lower hinge pin breaks, the failure may be much less noticeable than an upper hinge failure. For example, opening or closing the door may require slightly increased effort, or may produce a popping or scraping noise.

Failure to repair either of these hinge separations may reduce the structural integrity of that side of the car and increase risk of injury in case of certain types of accidents.

To correct this condition, dealers are to replace all hinges on all affected vehicles. This service will be performed for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

Further assistance, if required, may be obtained from our Customer Assistance Centre, toll free, by calling 1-800-263-3777, or if you live in Quebec, 1-800-263-7854.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department General Motors of Canada Limited 9A24

Dear General Motors Customer:

General Motors of Canada has determined that a defect which relates to motor vehicle safety exists in certain 1987-88 Chevrolet Beretta model vehicles.

A door hinge pin may break while opening or closing the door. If the upper hinge pin breaks, the end of the door nearest the door handle may drop down making it difficult to reposition and close properly. If the lower hinge pin breaks, the failure may be much) less noticeable than an upper hinge failure. For example, opening or closing the door may require slightly increased effort or may produce a popping or scraping noise.

Failure to repair either of these hinge separations may reduce the structural integrity of the side of the car and increase risk of an injury in case of certain types of accidents.

To correct this condition, dealers are to replace door hinges oil all affected vehicles. This service will be performed for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

Further assistance, if required, may be obtained from our Customer Assistance Centre, toll free, by calling 1-800-263-3777.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department General Motors of Canada Limited

9A25

Object Number: 93004 Size: MF

Object Number: 80889 Size: FS

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.