DOOR HINGE REPL.-NEW POLICIES, PROC. & LABOR ALLOW. (L CAR). Chevrolet Corsica 1992

For 1990-2009 cars

# DOOR HINGE REPL.-NEW POLICIES, PROC. & LABOR ALLOW. (L CAR)

#### Subject: DOOR HINGE REPLACEMENTS

#### Model and Year: 1989-92 CORSICA AND BERETTA

Application: 1989 (after the following VIN breakpoints) through 1992 "L" coupes / sedans

Linden Built KE 262341 Wilmington Built KY 257764

New policies, procedures and labor time allowances have been developed regarding door hinge service on 1989-92 "L" coupes / sedans.

#### Policy:

------ If a single door hinge on any door at any location requires replacement, the second or remaining hinge must be replaced at the same time.

Service parts will be packaged in "door sets", or two hinges in each package and all attaching holes are prepierced. New part numbers are as follows:

PART NUMBER DESCRIPTION ----------- ----------- 22583166 Hinges, Right Front Door 22583167 Hinges, Left Front Door 22583168 Hinges, Right Rear Door 22583169 Hinges, Left Rear Door

#### NOTICE: This procedure differs from the previous procedure (removing the door from the vehicle) in that:

a. The door remains on the vehicle.

b. Access to both front door hinges is made through the front wheelhouse area.

c. The hinges come pre-primed.

#### NOTICE: In order to minimize door realignment, DO NOT remove both door hinges at the same time. Do each hinge separately, and replace any broken hinges first.

#### Procedure:

---------

1. Place vehicle on hoist.

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

#### NOTICE: Make sure that the doors are fully latched onto the lock striker and the doors are not locked.

3. Using two pieces of masking tape, place one piece to bridge the gap between the door and rocker panel and the second piece to bridge the gap between the door and quarter panel or rear door (to act as reference points for door alignment).

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

5. Remove the front tire and wheel assembly.

6. Using a pin punch or awl and a hammer, and starting at rear of front wheelhouse liner, punch out the center mandrels from the last five (5) plastic attaching rivets.

7. Remove attaching rivets and discard.

8. Remove remaining screw attachments and position the liner forward of the front suspension assembly.

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

10. Clean hinge mounting surfaces on door and body with a rag and mark the hinge locations on the body surfaces with a grease pencil or other suitable marker.

11. Remove the hinge attaching fasteners and hinge from the vehicle.

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

13. Repeat steps 11 and 12 for remaining hinge.

14. Install tire/wheel with 3 nuts and lower vehicle to ground level.

15. Inspect the edges of the tape on the door and with the aid of a helper, align the door as necessary.

16. Raise vehicle to previous position and remove tire/wheel assembly.

17. Tighten and torque hinge attachments to: 20 - 28 N.m (1 5 - 20 Lbs.Ft.)

18. Reinstall insulator cover between fender and hinge pillar.

19. Reposition and install the wheelhouse liner using the 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.

20. Reinstall the tire and wheel assembly.

21. Remove the reference tape from door, rocker and quarter.

22. Lower hoist and remove vehicle.

#### Procedure for replacement - Rear Doors -

#### NOTICE: In order to minimize door realignment, DO NOT remove both door hinges at the same time. Do each hinge separately and, replace any broken hinges first.

1. Using two pieces of masking tape, place one piece to bridge the gap between the door and rocker panel and the second piece to bridge the gap between the door and quarter panel (to act as reference points for door alignment).

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

#### NOTICE: Make sure that the doors are fully latched onto the lock striker and the doors are not locked.

3. With the front door open to access the center pillar and rear door hinge area, clean the hinge mounting surfaces on the door and body with a rag and mark the locations using a grease pencil or other suitable marker.

4. Remove the hinge attaching the fasteners and hinge from the vehicle.

5. Install the new hinge within the previously marked locations and lightly tighten the fasteners.

6. Repeat steps 3 through 5 for the remaining hinge.

7. Inspect the edges of tape on the door and align the door as necessary.

8. Tighten and torque hinge attachments to: 20 - 28 N.m (1 5 - 20 Lbs. Ft.).

9. Remove reference tape from the door, rocker and quarter.

#### Warranty Information:

Labor Operation: Time Allowance: Front Doors: ----------- Both Right B4018 1.0 Hrs. Both Left B4019 1.0 Hrs.

#### ADD:

- W/Locking Wheel Covers/Nuts (One Or All) .1 Hrs.

- To Color Coat .3 Hrs.

- Material Allowance GB

#### Rear Doors:

Both Right B4418 .5 Hrs. Both Left B4419 .5 Hrs.

#### ADD:

- To Color Coat .3 Hrs.

- Material Allowance GB

Parts are currently available from GMSPO.

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.