CAMPAIGN: DOOR HINGES L BODY VEHICLES. Chevrolet Beretta 1987

For 1990-2009 cars

# CAMPAIGN: DOOR HINGES L BODY VEHICLES

#### Subject: PRODUCT SAFETY CAMPAIGN 88C26(d) - DOOR HINGES

--- REISSUE ---

#### Model and Year: 1987-88 CHEVROLET CORSICA AND BERETTA

#### To: All Chevrolet Dealers

THIS BULLETIN CANCELS AND SUPERSEDES CAMPAIGN BULLETINS 88C26 (a), 88C26 (b) & 88C26 (c). THE INFORMATION FROM THESE BULLETINS HAS BEEN COMBINED IN THIS BULLETIN AND THE SERVICE PROCEDURE AND CLAIM INFORMATION SECTIONS HAVE BEEN REVISED. ALL COPIES OF BULLETINS 88C26 (a), 88C26 (b) & 88C26 (c) SHOULD BE DESTROYED. REVISED INFORMATION IS SHOWN IN BOLD TYPE AND DENOTED BY A # SIGN.

The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to repair within sixty (60) days after tender of a vehicle is prima facia evidence of failure to repair within a reasonable time.

If the condition is not adequately repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation.

To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter that was sent to owners, the owners are being instructed to contact the Chevrolet Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the autually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.

#### DEFECT INVOLVED

General Motors has determined that a defect which relates to motor vehicle safety exists in certain 1987-88 Chevrolet Corsica and Beretta 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 scrapping 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 care 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 models.

General Motors 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 model vehicles. This is the result of low failure rates and lack of reported injuries due to rear door hinge pin failures. Nonetheless, for customer satisfaction purposes, General Motors 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 Beretta and Corsica models and some 1988 Beretta and Corsica models within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ----- ---- ------- 1987 "L" Wilmington "Y" HY100014 HY106246

1987 "L" Linden "E" HE100001 HE110672

1988 "L" Wilmington "Y" JY200001 JY268966

1988 "L" Linden "E" JE200O01 JE299428

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and were furnished to involved dealers with the original campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the original campaign bulletin has no involved vehicles currently assigned.

#### OWNER NOTIFICATION

Owners have been notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin).

#### DEALER CAMPAIGN RESPONSIBILITY

All unsold new vehicles in dealers' 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 service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

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 enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

#### PARTS INFORMATION:

Parts required to complete this campaign 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).

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.

#### 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.

#### 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 return 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 PROCEDURE:

#### 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 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 on page 6).

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 REPLACE 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 campaign action. install Campaign Identification Label and return vehicle to owner or dealer stock.

For Corsica model vehicles, proceed to the "Rear Door Hinge. Replacement" procedure on page 7.

#### REAR DOOR HINGE REPLACEMENT

#### 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 on page 6).

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 NOTE) 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 through 28 for remaining hinge.

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

32. Tighten and torque hinge attachment to 20 - 28 Nm (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.

#### CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label". Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label, is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner. Additional "Campaign Identification Label" can be obtained from DAC.

Apply "Campaign Identification Label" only on a clean, dry surface.

#### CLAIM INFORMATION

Submit a Product campaign claim with the information indicated below:

* *** FAILED PARTS LABOR LAB OTH NET REPAIR PERFORMED PC PART NO. ALLOW CC-FC OP HRS HRS AMT --------------------------------------------------------------------------- Inspect/Double Hung Hinges - - - - - SK-00 V6058 0.2 0.1 - - Previously In- stalled-All Doors

Install New Door Hinges - All Four 4 22583167 ** SK-00 V6059 2.9 0.1 $#.## (4) Doors - Corsica

Install New Door Hinges - Three (3) 3 22583167 ** SK-00 V6061 2.5 0.1 $#.## Doors (Two Front & One Rear) - Corsica

Install New Door Hinges - Three (3) 3 22583167 ** SK-00 V6062 2.2 0.1 $#.## Doors (One Front & One Rear) - Corsica

Install New Door Hinges - Two (2) 2 22583167 ** SK-00 V6063 1.8 0.1 - -

Install New Door Hinges - Two (2) 2 22583167 ** SK-00 V6064 1.5 0.1 $#.## Doors (One Front & One Rear) - Corsica

Install New Door Hinges - Two (2) 2 22583169 ** SK-00 V6065 1.1 0.1 $#.## Rear Door - Corsica

Install New Door Hinges - One (1) 1 22583167 ** SK-00 V6066 1.0 0.1 - - Front Door

Install New Door Hinges - One (1) 1 22583169 ** SK-00 V6067 0.5 0.1 $#.## Rear Door - Corsica

**** Sublet Campaign Repair - Beretta 2 22583167 ** SK-00 V6068 -.- 0.1 $#.## 2 Doors

**** Sublet Campaign Repair - Corsica 4 22583167 ** SK-00 V6069 -.- 0.1 $#.## 4 Doors

Reimburse Owner For Prior Door - - - -- VB-95 T1544 -.- 0.2 - - Hinge Repair

#### NOTICE: TIME FOR PAINTING REAR DOOR HINGES IS INCLUDED IN THE LABOR TIMES FOR OPERATIONS V6059, V6061, V6062, V6064, V6065 & V6067.

* Campaign 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 represets the cost plus 30% for paint (5 oz. spray can) used in conjunction with labor operations V6059, V6061, V6062, V6064, V6065, V6067 & V6069.

#### NOTICE: Some vehicles 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".

**** Labor operations V6068 & V6069 are 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 labor rate multiplied by the applicable labor hours. Wholesale authorization "E" is not allowed for V6068 & V6069.

#### NOTICE

Labor operations V5540-V5549 and V6060 used in Product Safety Campaign 88C26 (c) have been eliminated. All claims for prior repairs using these labor operations must be submitted before July 28, 1992. Any claims using these labor operations and submitted on or after this date will be rejected.

Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim Submission.

#### REIMBURSEMENT

Customer requests for reimbursement of prior repairs to correct a previous door hinge pin (single hung fixed-pin design) fatigue fracture are to be submitted according to the instructions in this bulletin using the attached "Request For Reimbursement" form. Additional copies of the form are to be reproduced by the dealer. Owners must submit original repair invoices along with proof of payment (charge card receipt, copy of cancelled check, or receipt marked "PAID" if paid-in-cash). The customer repair invoice should provide the description of the repair made and the person or facility performing the repair. These documents are to be retained by the dealer with the dealer repair order and supporting warranty records. Note that residents of Connecticut and Virginia must submit requests for reimbursement in writing directly to Chevrolet Motor Division.

PRODUCT SAFETY CAMPAIGN 88C26 (D) DOOR HINGES -REISSUE-

#### TO: ALL CHEVROLET DEALERS

#### ATTENTION:

DEALER MANAGER

#### MODEL & YEAR: 1987-88 CHEVROLET CORSICA AND BERETTA

THIS IS TO ADVISE YOU OF A REISSUED CAMPAIGN BULLETIN WHICH CANCELS SUPERSEDES BULLETINS 88C26 (A), 88C26 (B) & 88C26 (C). THE INFORMATION FROM THESE BULLETINS HAS BEEN COMBINED IN THE REISSUED BULLETIN AND THE SERVICE PROCEDURE AND CLAIM INFORMATION SECTIONS HAVE BEEN REVISED.

LABOR OPERATIONS V5540 THROUGH V5549 AND V6060 USED IN THE SUPERSEDED BULLETINS HAVE BEEN ELIMINATED. ALL CLAIMS FOR PRIOR REPAIRS USING THESE LABOR OPERATIONS MUST BE SUBMITTED BEFORE JULY 28, 1992. ANY CLAIMS SUBMITTED ON OR AFTER THIS DATE WILL BE REJECTED. THE REISSUED DEALER CAMPAIGN BULLETINS WERE MAILED JULY 2, 1992.

PLEASE COMMUNICATE THIS INFORMATION TO YOUR SERVICE MANAGER.

EDWARD JOHNSON MANAGER-DEALER OPERATIONS

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.