SERVICE MANUAL UPDATE GTU OPTION ADDITIONAL INFO.

SERVICE MANUAL UPDATE - GTU OPTION SERVICE INFORMATION

VEHICLES AFFECTED: 1988 BERETTA GTU OPTION ------------------

SERVICE MANUAL UPDATE

Information contained in this bulletin is an addendum to the 1988 Corsica/Beretta Section 10 - Body in the Service Manual.

When servicing items related to the 1988 Beretta GTU option, the following procedures should be used as reference.

REAR COMPARTMENT LID SPOILER INSTALLATION (with deck lid replaced)

Figure 1

1. Cover entire trunk well then locate centerpunch and drill four 7.9 mm (5/16") diameter holes in locations shown in Figure 1.

IMPORTANT: Drill the two outermost holes thru the inner and outer deck lid panels. 2. Create two small outdings in the inner trunk structure using a long center punch thru the innermost holes at center and tap with a small hammer. 3. Drill one 12.7mm (1/2") hole in locations shown in Figure 1.

4. With decklid open, drill four 19.0 mm (3/4") holes using the two outer 7.9 mm holes and the outdings as guides.

IMPORTANT: Only drill these holes thru the inner trunk lid structure as they are for access to the spoiler mounting studs. 5. Prime four inner holes and five outer holes with zinc chromate primer.

Clean: Remove all metal shavings from decklid and trunk well. ------

REAR COMPARTMENT LID SPOILER

Figure 2

Remove or Disconnect

1. Plugs (1)

2. Nuts(2)

3. Wire harness, from center high mounted stop lamp.

4. Rear compartment lid spoiler (4), by carefully lifting, freeing the studs and center high mounted stop lamp wire outlet from holes in decklid.

Install or Connect

IMPORTANT: Care should be taken to prevent water leaks in the rear compartment area when sealing surfaces are disturbed. Holes in the rear compartment lid for mounting studs that could permit water entry into the rear compartment must be sealed with a presealed washer or body caulking compound.

1. Rear compartment lid spoiler (4)

2. Nuts (2)

TIGHTEN Nuts to maximum 12 N - m (8 Ft. Lbs.)

3. Plugs

4. Center high mounted stop lamp (3) to wire harness.

CENTER HIGH MOUNTED STOP LAMP

Figure 3

Remove or Disconnect

1. Wire harness (3), from inside trunk

2. Screws (5)

3. Lens and seal (4)

4. Lamp assembly (2), pulling grommet from hole in deck lid

Install or Connect

1. Wire harness, plug grommet into deck lid hole and connect wiring inside trunk

2. Lamp assembly

3. Lens and seal

4. Screws

OUTSIDE MIRRORS

Figure 4

The door outside mirrors are stud mounted to the door filler. The mirror face can be replaced without removing the entire mirror assembly. Left side flat and right side convex mirror faces must be replaced with

Remove or Disconnect

1. Door trim panel

2. Upper trim panel

3. Sound deadener

4. Nuts (2)

5. Remote control cable (4) from upper trim panel

6. Mirror (1) and filler (3)

Install or Connect

1. Filler (3) over studs on mirror (1)

2. Control cable (4) through filler (3) and connect to upper trim panel

3. Nuts (2)

TIGHTEN Nuts to 5 to 8 N - m (42 To 72 In-Lbs)

4. Sound deadener

5. Upper trim panel

6. Trim panel

MIRROR FACE REPLACEMENT

CAUTION:

To minimize the chance of personal injury, gloves and safety glasses should be worn when removing broken glass.

NOTICE: When breaking mirror, cover painted surface of door to avoid damage.

Remove or Disconnect

1. Mirror face from the mirror by placing tape over mirror face, then breaking mirror face.

2. All pieces of glass from mirror frame.

Install or Connect

1. Mirror face to mirror frame by removing paper backing from back side of mirror face to expose adhesive.

2. Center mirror in mirror frame and press firmly to ensure adhesion of the mirror face to the mirror frame.

LOWER ROCKER PANELS

Figures 5, 6 and 7

The lower rocker panels are attached to the body panels with screws as shown in Figure 5. The lower rocker mounting "Z" brackets are attached to the rocker panels with self tapping screws as shown in Figure 5. If a rocker panel is replaced a new "L" bracket will have to be installed. The "L" bracket is attached to the rocker panel with self tapping screws and to the lower rocker with adhesive tape as shown in Figure 6.

IMPORTANT: When removing or installing rocker panels, care should be exercised.

o Adjacent finishes should be protected to prevent damage to finish. o Proper care should be used to guard against rocker panel damage.

Remove or Disconnect (Figure 7)

1. Screw (3), from front wheelwell.

2. Screws (4), from front of rear wheelwell.

3. Screws (5), from underside of lower rocker attaching "Z" brackets (2) to car body.

4. Lower rocker (1), by carefully lifting up to release lower rocker from adhesive strip attaching lower rocker to "L" bracket. If lower panel does not release, apply heat using a hot air gun. Make certain gun is moved in a circular motion and held 152 mm (6") from part.

Install or Connect (Figure 7)

1. Adhesive strip, to clean "L" bracket.

2. Lower rocker, by aligning with "L" bracket and

CHROME EXHAUST TIPS

Figure 8

If a new muffler system is installed, the tailpipe tips will need to be cut off as shown in Figure 8.

Remove or Disconnect

1. Nuts (3)

2. Clamps (2)

3. Exhaust tips (1)

Install or Connect

1. Chrome exhaust tips, as shown in Figure 8.

2. Muffler clamps

3. Nuts

DECAL AND EMBLEM REPLACEMENT

To remove stick-on emblems, apply heat using a hot air gun making certain gun is moved in a circular motion and held a minimum of 152 mm (6") from emblem.

WINDSHIELD DECAL

Figure 9

Clean windshield thoroughly with transit coating top comers as reference, locate decal to windshield and press with squeegee. Peel paper off carefully,

DASH PANEL EMBLEM

Figure 10

To install, wash area with detergent and water and wipe dry. Wipe area with oil free naphtha or alcohol. Peel paper backing from emblem and press in place in recessed area of dash as shown. Apply constant pressure to emblem for 30 seconds. Emblem cannot be repositioned after contact with car.

"GTU" BODY SIDE DECAL AND REAR FASCIA DECALS

Figures 11 and 12

Peel paper backing from decal and align: - "GTU" Body Side decal with quarter panel lower molding and door opening as shown in Figure 11. - "GTU" rear fascia decal with left deck lid gap and fascia molding character line as shown in Figure 12. - Rear fascia "Chevrolet" decal with right deck lid gap and fascia molding character line as shown in figure 12. Press with squeegee and carefully peel off protective paper.

ACCENT STRIPE

Remove paper backing and apply accent stripe to fascia, body side and window moldings as shown in Figure 13.

DOOR EMBLEM

Figure 14

Remove or Disconnect

1. Existing door hardware (Reference Service Manual).

2. Remove nut (1) on backside of emblem (2).

3. Carefully pull emblem (2) away from door panel.

Install or Connect

1. Insert emblem mounting stud thru door panel.

2. Fasten nut (1) on backside of emblem (2).

3. Reinstall door panel and trim hardware. (Reference Service Manual).

Remove or Disconnect

1. Remove lower valance (7) retaining screws (8) and U-nuts (2).

2. Remove two bolts (12) along wheelwell then remove valance (7) and spacer (11).

FRONT FASCIA

Figure 15

Remove or Disconnect

1. Remove 7 mm bolt/screw (12) from fender liner and one screw on underside of outboard edge of spoiler (7).

2. Remove U-nuts (2) from previously removed bolt locations.

3. Remove push-in retainers (5) from fascia assembly (14).

4. Remove screws (6) retaining grille (17).

5. Unplug marker lights (14).

6. Remove 10 mm bolts (1) retaining fascia to fender.

7. Carefully slide fascia (13) over and off impact bar.

8. Remove three screws (6) retaining air deflector (9) to fascia.

9. Remove screws (15) retaining marker light.

10. Bend tabs straight on insert molding (10) and remove from fascia.

11. Remove nut (3) from emblem (4) on backside of grille (17) remove emblem.

12. Remove 10 mm bolts retaining splash shield (16).

Install or Connect

1. Apply a suitable adhesive to the backside of molding (10) and position into slots on fascia (13). After centering, bend tabs on backside of molding securing molding to fascia (13).

2. Fasten marker lights (14) with screws (15).

3. Install air deflector (9) with screws.

4. Carefully slide fascia (13) over impact bar and into position.

5. Plug marker light (14) wiring harness together.

6. Fasten 10 mm bolts (1) joining fascia (13) to fender.

7. Insert emblem (4) into grille (17) and fasten with nut (3). Position grille (17) and fasten with screw (6).

8. Fasten push-in retainers (5).

9. Position "U" nuts (2) three on each fender liner and one per side on lower fender liner.

10. Fasten 7 mm bolt/screws (12) to fender liner, to locations where "U" nuts were previously installed.

11. Position splash shield (16) and fasten with 10 mm bolts (17).

12. Position "U" nuts (2) to spoiler (7) and fasten with screws (8) and bolts (12).

REAR FASCIA

Figure 16

Remove or Disconnect

1. Disconnect side marker light (11) from harness (13).

2. 10 mm bolt (9) on support brace.

3. Two retaining clips (8) from each side of rear fascia.

4. Remove eight 13 mm nuts (1).

5. Slide fascia (2) away from impact support.

6. Remove rear valance panels (6 and 7) by removing four self tapping screws u!) and "U" nuts (3).

7. Remove tape (15) from rear valance.

8. Unplug marker light bulb (11) from lens.

9. Unclip side marker light harness (11) from tab (2) in fascia support plate.

10. Remove seven push-in retainers (14) from fascia and impact bar.

11. Remove seven rivets (5) from fascia and reinforcement pad.

12. Unload impact bar and reinforcement pad from fascia.

13. Remove four clips (12) retaining lower valance.

14. Remove license plate light (16) retaining screws (17)

15. Lower valance (6 and 7) by installing four clips (12).

Install or Connect

1. Lower valance (6 and 7) by removing four clips (12).

2. Load impact bar (18) and reinforcement pad into fascia.

3. Fasten seven rivets (5) into fascia (2) and reinforcement pad.

4. Clip side marker light harness (11) into tab in fascia support plate.

5. Plug in side marker light bulb into lens and install (11).

6. Prime upper surface of rear fascia rocker and inner surface of rear valance panels with an adhesive primer.

7. Apply a strip of tape (15) 520.7 mm (20.5") long to primed surface.

8. Secure rear valance panels (6 and 7) to fascia (2) using four U-nuts (3) and four self tapping screws (4).

9. Install license plate light (16) with two screws (17).

10. Slide fascia (2) toward front of car keeping bolt heads in slots and aligning studs on impact bar with holes in support.

11. Loosely install four 13 mm nuts (1) per side to impact bar supports.

12. Insure a 4mm gap on top of fascia between fascia and tail light housing.

13. Secure eight 13 mm nuts (1) and torque to 27-40 N.m (20-29 Ft. Lbs.).

14. Install fascia retaining clips (8) connecting the fascia and fender flanges on each side.

15. Install one 10 mm bolt (9) per side to fascia support brace. Plug marker light into body harness (11).

16. Assure a correct fit between rear fascia and quarter panel sides.

PAINT PROCEDURES FOR BERETTA GTU GROUND EFFECTS

Parts must be wiped with wax and silicone remover prior to scuffing. Primer-Ditzler K-200 with a catalyst base coat Deltron: Red* 3794K Black 3961 White 3680

Clear coat Dau 82 Clear with Dau 2 BLTU 502 or 504 reducers

Requirements:

2 coats K-200 3 coats base 2 coats clear * PPG Paint Formula

For Wilmington red (variation #2) Code 71 Deltron DBU 3794 K (variation #2) This formula for one (1) quart: DMD 642 12 DMD 647 24 DMD 645 40 DMD 652 53 DMD 653 144 DMD 654 626 DMX 695 1042

The above formula will match the Beretta red used at Wilmington.

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.