SPECIAL POLICY ADJUSTMENT DOOR HINGES MAY BREAK. Chevrolet Beretta 1988

For 1990-2009 cars

# SPECIAL POLICY ADJUSTMENT DOOR HINGES MAY BREAK

#### MODELS: 1988-89 Chevrolet Corsica and Beretta 1988-89 Pontiac Tempest and Grand Prix 1988-89 Oldsmobile Cutlass Supreme 1988-89 Buick Regal All With 8.7mm Conical Pin Door Hinges

General Motors of Canada has determined that CERTAIN 1988-89 Chevrolet Corsica, Beretta; Pontiac Tempest, Grand Prix; Oldsmobile Cutlass Supreme; and Buick Regal 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, Beretta; Pontiac Tempest, Grand Prix; Oldsmobile Cutlass Supreme; and Buick Regal model vehicles with 8.7mm conical pin door hinges built within the following VIN breakpoints:

PLANT YEAR MODEL & BODY CODE CODE FROM THROUGH ---- ----------------- ----- ---- ------- 1988 Chevrolet Corsica/Beretta (L) "Y" JY268967 JY291806 1988 Chevrolet Corsica/Beretta (L) "Y" JY500001 JY686336 1988 Chevrolet Corsica/Beretta (L) "E" JE299429 JE320793 1988 Chevrolet Corsica/Beretta (L) "E" JE500001 JE677999 1988 Pontiac Tempest (L) "Y" JY804718 JY805631 1988 Pontiac Tempest (L) "Y" JY900001 JY913429 1988 Pontiac Grand Prix (W) "F" JF200001 JF286357 1988 Oldsmobile Cutlass Supreme (W) "D" JD300001 JD394723 1988 Buick Regal (W) "1" J1400001 J1529270 1989 Chevrolet Corsica/Beretta (L) "Y" KY100001 KY257763 1989 Chevrolet Corsica/Beretta (L) "E" KE1OOOO1 KE262340 1989 Pontiac Tempest (L) "Y" KY700001 KY714838 1989 Pontiac Grand Prix (W) "F" KF200001 KF230159 1989 Oldsmobile Cutlass Supreme (W) "D" KD300001 KD313504 1989 Buick Regal (W) "1" K1400001 J1445087

#### 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. For Chevrolet Corsica, Beretta and Pontiac Tempest models, double-hung design hinges will be used to replace the failed single hung hinges (Figure 1,). For Pontiac Grand Prix, Oldsmobile Cutlass Supreme and Buick Regal, 11.3mm single-hung hinges will be used to replace the 8.7mm single hung hinges when a failure occurs.

This Special Policy Adjustment Bulletin should be filed in the three ring binder previously furnished to dealers by General Motors.

#### OWNER NOTIFICATION

Owners will be notified of this Special Policy by General Motors of Canada (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.

#### REIMBURSEMENT

#### NOTICE: When a customer with a Chevrolet Corsica, Beretta or Pontiac Tempest 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 illustration on previous page.)

And when a customer with a Pontiac Grand Prix, Oldsmobile Cutlass Supreme or Buick Regal requests reimbursement, dealers are to schedule an appointment to have all door hinges (including those replaced previously) replaced with the 11.3mm hinges required for this special policy.

Customer claims for reimbursement on previously paid repairs to correct a fractured door hinge are to be submitted by December 31, 1992. 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.

Authorization is required on a claims submissions which fall into into the owner reimbursement category. Labour Operation Tl834 is to be used for owner reimbursement only.

#### PARTS INFORMATION

Parts for this special policy will be available beginning March 2, 1992 and should be ordered through regular channels, as follows:

****FOR "L" VEHICLE MODELS****

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.

Due to initial parts quantity restrictions, please limit the ordering of hinge kits to previous hinge fracture rates experienced by this vehicle population.

****FOR "W" VEHICLE MODELS****

Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 10218446 Left Door Hinge Kit 1 10218445 Right Door Hinge Kit 1

Each door hinge kit contains 2 hinges, 4 nuts and 4 bolts.

Due to initial parts quantity restrictions, please limit the ordering of hinge kits to previous hinge fracture rates experience by this vehicle population.

SERVICE PROCEDURE FOR CHEVROLET CORSICA BERETTA PONTIAC TEMPEST "L" VEHICLE MODELS -----------------------------------------------------------------------------

#### 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.

#### 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 5).

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

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 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 on page 5).

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 26 through 27 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 23 through 31 for opposite rear door.

SERVICE PROCEDURE FOR GRAND PRIX, OLDSMOBILE, CUTLASS SUPREME AND BUICK REGAL "W" VEHICLE MODELS

#### NOTICE: THIS PROCEDURE DIFFERS 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 are NOT to be painted.

#### 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 both door locations.

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

4. 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 ).

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

6. Remove front tire and wheel assembly.

7. Starting at top centre of front wheelhouse liner, remove all attaching screws located rearward of top centre of liner.

8. Loosen liner from fender and position liner forward of front suspension assembly.

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

10. 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.

11. Remove hinge attaching fasteners and hinge from vehicle.

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

13. Repeat steps 1 1 and 12 for remaining hinge.

14. Repeat Steps 4 through 13 for remaining front door.

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

16. Inspect edges of tape on doors and with aid of a helper, align doors as necessary.

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

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

19. Reinstall insulator covers between fenders and hinge pillars.

20. Reposition and install wheelhouse liners using original screws.

21. Reinstall tire and wheel assemblies.

22. Carefully remove reference tape from door, rocker and quarter.

23. Lower hoist and remove vehicle.

#### WARRANTY CLAIM INFORMATION

When performing the repair as outlined in this special policy, the dealer is requested to submit a warranty claim for credit as follows:

****FOR "L" VEHICLE MODELS****

Labour Operation Parts Net Time Number Description Allowance Amount Allowance --------- ----------- --------- ------ --------- T1831 Install New Door Hinges - * -- 1.8 Beretta

T1832 Install New Door Hinges - * ** Corsica and Tempest $#.## 3.1

***

T1833 Sublet Body Shop Work * $#.## and Repair - Beretta/Corsica Tempest

T1834 Reimbursement for previous see instructions for Reimbursement repairs

* 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 used in conjunction with labour operation T1832.

*** Labour operations T1833 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.

****T1832 includes .2 hours to paint rear door hinges.

****FOR "W" VEHICLE MODELS****

Labour Operation Parts Net Time Number Description Allowance Amount Allowance --------- ----------- --------- ------ --------- T1831 Install New Door Hinges - * -- 1.6 Coupe

T1833 ** Sublet Body Shop Work * $#.## and Repair

TI834 Reimbursement For Prior see instructions for Reimbursement Repairs

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

** Labour operation TI 833 is to be used by dealers who sublet body shop work and repair. Note that this amount should not exceed allowable dollar limits that would have been calculated at the dealers approved warranty labour rate multiplied by the applicable labour hours.

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

Dear General Motors Customer:

We at General Motors of Canada are very proud of the Chevrolet Corsica, Beretta; Pontiac Tempest, Grand Prix; Oldsmobile Cutlass Supreme, and Buick Regal lines 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 General Motors customers with 1988-89 Chevrolet Corsica, Beretta; Pontiac Tempest, Grand Prix; Oldsmobile Cutlass Supreme, and Buick Regal models 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 vehicles are not experiencing this problem. Nevertheless, we are taking action for all Chevrolet Corsica, Beretta; Pontiac Tempest, Grand Prix; Oldsmobile Cutlass Supreme, and Buick Regal 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 General Motors dealer to seek reimbursement. Simply bring this letter and your original paid receipt for the repair to your dealer by December 31, 1992 to file a reimbursement claim.

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.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your 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. Subsequent to contacting your dealer, further assistance, if required, may be obtained from our Customer Assistance Centre, toll free, by calling 1-800-263-3777 (English), or 1-800-263-7854 (French).

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

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.