SPECIAL POLICY ADJUSTMENT DOOR HINGES MAY BREAK

Subject: SPECIAL POLICY ADJUSTMENT DOOR HINGES

Model and Year: 1988-89 CORSICA & BERETTA W/8.7MM CONICAL PIN DOOR HINGES

To: All Chevrolet Dealers

General Motors has determined that certain 1988-89 Chevrolet Corsica and Beretta model vehicles with 8.7mm conical pin door hinges have had a door hinge break while opening or closing a door. If the lower hinge breaks, the door may require more effort to close, or a popping or scraping noise might be heard. If the upper hinge breaks, the end of the door nearest the door handle may drop down, making the door difficult to reposition and close properly.

NOTICE

It has been determined that a primary cause of door hinge fractures is corrosion of the door hinge. Accordingly, the majority of vehicles experiencing this condition will be located in high corrosion areas (Canadian Maritime Provinces, New England, Great Lakes States).

As a result (and also due to limited parts availability) owner mailings will be phased out first to owners of vehicles located in high corrosion areas and then expanded to include other regions. Dealers should be certain to consider this corrosion factor when placing parts orders.

VEHICLES INVOLVED

Involved are certain 1988-89 Chevrolet Corsica and Beretta model vehicles with 8.7mm conical pin door hinges built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ---- ---- ------- 1988 L-Car Wilmington "Y" JY268967 JY686336

" " Linden "E" JE299429 JE677999

1989 L-Car Wilmington "Y" KY100001 KY257763

" " Linden "E" KE100001 KE262340

SPECIAL POLICY ADJUSTMENT

This Special Policy covers the condition described above for ten (10) years and unlimited mileage with no deductible from the date the vehicle was originally placed into service regardless of ownership. Correction at no charge to the customer will consist of replacing all door hinges on involved vehicles which experience failure of any single-hung door hinge. Double-hung design hinges will be used to replace the failed single hung hinges (see illustration).

This "Special Policy Adjustment Bulletin" should be filed in your "Special Policy Adjustment Bulletins" binder previously furnished to dealers by General Motors.

REIMBURSEMENT

NOTICE: When a customer requests reimbursement, dealers are to schedule an appointment to have all single-hung door hinges on the vehicle replaced with double-hung door hinges (see illustrations).

Customer claims for reimbursement on previously paid repairs to correct a fractured door hinge are to be submitted by Dec. 31, 1992 according to the forms and instructions included in this bulletin (additional copies may be reproduced locally - the time limitation for presenting the original paid receipt may be longer depending upon the law in your state). Owners must submit original documentation which reasonably confirms the amount of unreimbursed repair expense(s), a description of the repair, date of the repair and the person or entity performing the repair. Note that residents of Connecticut and Virginia must submit requests for reimbursement in writing directly to Chevrolet Motor Division per instructions in the owner letter.

OWNER NOTIFICATION

Owners will be notified of this Special Policy by Chevrolet Motor Division (See copy of owner letter included with this bulletin). Owner mailings will be phased out first to owners located in high corrosion areas and then expanded to include other regions.

PARTS INFORMATION

Parts for this Special Policy will be available beginning March 2, 1992 and are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).

Quantity/ Part Number Description 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 1 0 rivets. Rear door hinge kits contain 2 hinges.

Due to initial parts quantity restrictions, please limit the ordering of hinge kits to your previous dealership experience with this condition.

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-primed and ONLY REAR DOOR HINGES are to be painted using a 5 oz. spray can of appropriate color obtained from GMSPO or a local supplier.

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 WRITE-UP, REPLACE BROKEN HINGES FIRST.

1. Place vehicle on hoist.

2. Obtain hinges for all doors and (for Corsica model vehicles) correct 5 oz. can of spray paint to match vehicle color.

3. On Corsica model vehicles, Scuff sand and paint REAR DOOR HINGES ONLY using proper color. 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 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).

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 center 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 WRITE-UP, 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 Nm (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 assembly.

24. Carefully remove reference tape from door, rocker and quarter. For Beretta model vehicles, this completes the repairs necessary for this special policy. For Corsica 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 WRITE-UP, 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).

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 center 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 WRITE-UP, 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 thru 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 Nm (1 5 to 20 lb. ft.).

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

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

CLAIM INFORMATION

Submit a claim with the information indicated below:

* *** REPAIR FAILED PARTS CC-FC LABOR LAB 0TH NET PERFORMED PC PART NO. ALLOW OP HRS HRS AMT ----------------------------------------------------------------------------- Install New Door 2 22583167 ** VB-95 T1831 1.8 -- $#.## Hinges - Beretta

Install New Door 4 22583167 ** VB-95 T1832 2.9 -- $#.## Hinges - Corsica

Reimbursement For Prior Door Hinge - -- -- VB-95 T1834 -.- 0.2 $#.## Replacement

* Administrative Allowance.

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.

*** The $#.## identified in the "Net Amount" column represents the cost plus 30% for paint (5 oz. spray can) used in conjunction with labor operation T1832. If the repair is sublet the sublet amount should be claimed in the "Net Amount" column.

NOTICE: Some vehicles involved in this Special Policy may necessitate additional labor or parts to repair vehicle damage caused by a hinge failure prior to the repair being performed. The additional expense is to be submitted on the claim in the 'Net Amount' column and requires the wholesale authorization "E".

Refer to the Chevrolet Claims Processing Manual for details on claim submission.

REQUEST FOR REIMBURSEMENT INSTRUCTIONS 1988 - 89 CORSICA & BERETTA w/8.7mm CONICAL PIN DOOR HINGES (REQUEST FOR REIMBURSEMENT MUST BE SUBMITTED BY DECEMBER 31,1992) ----------------------------------------------------------------- Connecticut & Virginia residents MUST write: Chevrolet Motor Division, Customer Assistance Center, P.O. Box 7047, Troy, MI 48007-7047 for reimbursement,

1 R.O. # & DATA The dealership should enter the repair order number and date of the owner's or dealer's paid receipt or invoice.

2 REQUEST DATE (MONTH, DAY) Date owner or dealer requested reimbursement.

3 VEHICLE IDENTIFICATION NUMBER VIN involved.

4 MILEAGE Enter mileage at time of transaction. (If not available, enter

5 CC/FC Code is preprinted on form.

6 LABOR OPERATION Labor Operation as referenced in bulletin.

7&8 SUBLET DMN & Enter total amount of reimbursement. (Do not LINE TOTAL enter parts or labor hours on claim.)

9 AUTH CODE If the amount of reimbursement approved is $400 or less, no authorization is needed. If the amount exceeds $400, advise customer to contact Chevrolet Customer Assistance at 1-800-222-1020.

10 REQUESTED Dealer Service Manager enter amounts REIMBURSEMENT determined from owner supplied invoices or paid receipts, which are covered. (Maximum amount is $400.)

11 APPROVED AMOUNT Dealer Service Manager to determine based on reimbursement policy of this bulletin. (Maximum amount is $400.)

12 740 STAMP Dealer Service Manager is to stamp reimbursement form including date and signature. (No Authorization Code is required.)

13 DEALER REFERENCE INFORMATION A. Enter Document Number & Line Number on which claim was submitted.

B. Enter Claim Memo Number and Date when claim is credited.

C. Enter number of dealer check to owner, if applicable. Date check was written, if applicable. Date copy of check was attached to OWNER REQUEST FOR REIMBURSEMENT file.

14 OWNER INFORMATION Must include telephone number.

15 DEALER INFORMATION Includes Dealer Code, Dealer Name, Service Manager's signature and social security number. To be completed by Service Manager.

16 EXPLAIN Should the dealer Service Manager determine, after review of owner's invoices/receipts, that the reimbursement case is not eligible; Service Manager should write reason on worksheet, explain to owner, and place a copy of the worksheet in the file.

17 The dealer is then to issue the owner a check for the reimbursement in the approved amount. A copy of the check issued to the owner is to be attached to the dealer's file copy of the request and retained for 24 months from date of credit.

Dear 1988-89 Chevrolet Corsica or Beretta Owner:

We at Chevrolet are very proud of the Corsica/Beretta line, and sincerely hope that you are happy with your vehicle. We are also proud of the warranty coverage that we provide you. Sometimes, however, we need to make some special arrangements so that things which might happen, even to a very small number of our customers, are handled properly.

Some Chevrolet customers with 1988-89 Corsicas or Berettas may have a door hinge break while opening or closing a door. if a lower hinge breaks, it will require more effort to close the door, or you may hear a popping or scraping noise. if an upper hinge breaks, the end of the door nearest the door handle will drop down, making it difficult to reposition and close the door properly.

Most Corsicas and Berettas are not experiencing this problem. In fact, because the condition is primarily a corrosion problem, very few vehicles outside New England and the Great Lakes States are likely to experience a broken hinge. Nevertheless, we are taking action for all Corsica and Beretta owners.

- We are providing owners with special coverage for this hinge condition. In the event of any door hinge failure, all door hinges will be replaced at no charge to the owner. This coverage will be in effect for 10 years and unlimited mileage from the date the vehicle was originally placed in service regardless of ownership.

- If you have already paid for some or all of the cost to have a broken door hinge replaced, you may contact your Chevrolet dealer to seek reimbursement (except for residents of Connecticut and Virginia). Connecticut and Virginia residents must write to Chevrolet Motor Division, Customer Assistance Center, P.O. Box 7047, Troy, MI 48007-7047, for reimbursement. In either situation, please provide your original paid receipts or invoices verifying the repair, the amount charged, proof of your payment and date of payment of those charges. This information must be provided by December 31, 1992 (this time limitation for presenting the receipt may be longer depending upon the law in your state).

If your car ever has a broken door hinge, we suggest that you fully close the door, lock it, and take advantage of this coverage as soon as you can.

We are sorry it this condition causes you any inconvenience. By taking this action, however, we hope to show that we value having you as a Chevrolet customer.

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.