SQUEAK AND RATTLE DIAG. GUIDE DIAGNOSTIC AID/CORRECTION

SUBJECT: SQUEAK AND RATTLE DIAGNOSTIC GUIDE (AID IN DIAGNOSIS)

VEHICLES AFFECTED: 1991 CHEVROLET CORVETTE (Y CAR)

The following information is being distributed as an aid in squeak and rattle diagnosis. The insulator material references describe either 3M# 06370 6mm(1/4" thick), #06375 3mm (1/8" thick) foam tapes; Dominion/American Sure Seal # RAB1 6mm (1/4" thick foam tape (or equivalent). The felt insulator material has adhesive backing and may be obtained from most local fabric stores.

Note: Reference specific item on removable roof front attaching bolt retainers (new parts and operation).

LEFT STDE INSTRUMENT PANEL

COMPONENT CORRECTION

- Instrument panel cover

1. Rattle forward of gauges cluster 1. Insulate area shown at A/C cross car duct. in Figure 1 and Figure 1, Section A (felt material) .

2. Rattle at front edge of cover 2. Reposition existing, near windshield. or install felt insulators on metal opening at all retainers, (see Figure 1, Section B). - Left defogger outlet

1. Buzzing against instrument 1. Apply felt insulator panel housing. 13mm x 76mm (1/2" X 3") as shown in Figure 2, view A). - A/C cross car duct

1. Rattle at top of instrument 1. Apply foam insulator panel housing. 3mm (1/8") to housing as shown in Figure 2, view A.

2. Rattle at left side SIR 2. Apply foam insulator bracket. 3mm (1/8") around bracket as shown in Figure 2 view B. - Instrumentation area

1. Squeak in instrument cluster 1. Apply felt insulators bezel to cover. to bezel edges and surfaces in locations as shown in Figure 3, views A and B.

RIGHT SIDE INSTRUMENT PANEL

COMPONENT CORRECTION

1. Rattle in glove box door to 1. Apply felt insulators glove housing. as shown in Figure 4, or in any contact area.

2. Buzzing of fuse box rivet 2. Apply small 6mm (1/4") heads to instrument panel foam insulator cover. between rivet head and cover as shown in Figure 5, view A.

3. Buzzing of fuse box door 3. Apply felt insulators in the opening. 6mm x 25mm (1/4" X 1") as shown in Figure 5, view B. Position felt into the radius of the opening.

CONSOLE

COMPONENT CORRECTION

1. Buzzing of A/C controller to 1. Apply double thick instrument panel housing. 6mm (1/4") foam with 6mm (1/4") hole around forward locator pin of controller and reinstall,see Fig. 6.

2. Squeak of console shift trim 2. Apply felt to right plate to console surfaces. side and left edge of trim plate, see Figure 7.

3. Squeak when opening console 3. Remove door and compartment door. carefully trim vinyl material away from door hinge spring area to provide slight clearance. DO NOT OVERTRIM.

OTHER INTERIOR ITEMS

COMPONENT CORRECTION

1. Buzzing of rear compartment 1. Adjust compartment stowage doors when closed. door lock striker for better fit.

2. Rattles in sun visors over 2. Replace sun visors any irregular road surfaces. with new part from CANSPO.

ROOFS AND CONVERTIBLES

COMPONENT CORRECTION

- Convertible top deck lid

1. Squeak at deck lid hinge pins. 1. Lightly lubricate with spray type lubrication.

2. Squeak at torque rod rollers to 2. Lightly lubricate rods and hinges. with spray type lubrication.

3. Rattle at underside of lid 3. Position foam with top down if center insulator 6mm (1/4") to insulator is missing. underside of panel above top bow at contact marks.

4. Rattles of release cable to 4. Apply foam insulators underside of lid. 3mm (1/8") to underside of lid in area of contact marks. - Removeable roof panel

1. Rattle of front attaching bolts 1. Install new bolt when panel is stowed in rear. retainers, P/N 10175804, see Figure 8.

Procedure:

1. Soak new retainers in warm water to aid in installation. 2. Remove roof panel and stow. 3. Remove upper trim covers at right and left latch areas. 4. Remove right and left sun visors, inside mirror and centre garnish moulding. 5. Carefully pry original retainer and bolt out of housing using a flat blade screwdriver or other suitable tool. 6. Install bolt in new retainer, align locating rib on retainer with notch in housing and press into place with a "C" clamp and socket. 7. Reinstall garnish moulding, inside mirror, sun visors and upper trim covers.

2. Rattle if roof panel frame 2. Reinstall and glue filler plugs become loose. plugs into position with small amount of P/N 12345096 * or 3M 08011.

UNDER THE VEHICLE

COMPONENT CORRECTION

- Heat shields

1. Rattle of fuel filter heat 1. Carefully bend to shield against right side provide clearance. frame rail.

2. Rattle of brake line heat shield 2. Carefully bend to to manifold heat shield (LT 5). provide clearance.

3. Buzzing of right side heat shield 3. Carefully bend to to toepan. provide clearance.

4. Rattle of left side heat shield 4. Carefully bend away to exhaust pipe flange (LT5). from flange to provide clearance.

- Brake lines and fuel lines

1. Rattle of brake lines to left 1. Secure the lines side frame rail. tightly to each other with plastic tie straps.

2. Rattle of fuel lines to right 2. Carefully bend to side frame rail. provide clearance.

DOOR HINGES

COMPONENT CORRECTION

1. Squeaks when opening doors at 1. Lubricate ALL hinge hinge torque rod contact areas. torque rod contact areas with 30 wt. motor oil or grease, see Figure 9.

UNDER THE HOOD

COMPONENT CORRECTION

1. Popping/clicking at left 1. Apply felt to front of windshield area. windshield stop at area contacting windshield edge, see Figure 10.

2. Popping/clicking at front of 2. Carefully trim edge windshield. Edge of cowl of cowl leaf screen leaf screen contacting in areas contacting flange on cowl. cowl flanges. 3. Squeak at left front windshield 3. Reposition ECM area. ECM cover to hood seal. cover forward or trim cover in contact areas.

4. Squeak at right side 4. Reposition hose of vehicle. Hose clamps clamps to provide for high fill container clearance to right contacting diagonal brace. diagonal brace, see Figure 11.

Use the most applicable Labour Operation and Time from the Canadian Labour Time Guide.

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.