For 1990-2009 cars

# REVISION: FRT. DOOR WINDOW BINDING AND/OR INOPERABLE

#### Subject: FRONT DOOR WINDOW BINDING AND/OR INOPERABLE

#### Models: Certain 1992 Buick Skylark, Skylark GS and 1992 Pontiac Grand Am Sedans

THIS REVISION BULLETIN IS BEING REVISED TO ADD PONTIAC PART NUMBERS AND A PONTIAC SERVICE PROCEDURE. THIS REVISION SUPERSEDES BULLETIN 1N18. PLEASE DESTROY 1N18.

General Motors of Canada Limited has determined that certain 1992 Buick Skylark, Skylark GS and Pontiac Grand Am Sedan model vehicles may exhibit a condition in which front door windows require excessive effort to raise after being lowered, or may be completely inoperable. This condition is a result of some window regulator assemblies being installed incorrectly at the vehicle assembly plant. The inner panel cam may have been installed backwards (180 deg. out of position) due to an error in manufacturing at the window regulator plant. When this condition occurs in a vehicle, excessive force will be required to raise the window from open to closed position. This will be most noticeable to customers in vehicles not equipped with power windows, but will eventually lead to deformation of the window regulator. If this condition continues to exist, customers may not be able to raise the front door window(s) to closed position.

To correct this condition, dealers are to inspect vehicles for correct installation of the window regulator assemblies, and where necessary replace the regulator assemblies.

#### VEHICLES INVOLVED:

Involved are certain 1992 Buick Skylark, Skylark GS and Pontiac Grand Am Sedan models built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----------------- ---------- ---- -------- -------- 1992 Buick Skylark and GS Lansing South C NC600081 NC602381 1992 Pontiac Grand Am Lansing South C NC200023 NC201972 1992 Pontiac Grand Am Lansing North M NM000001 NM000142

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

#### DEALER CAMPAIGN RESPONSIBILITY:

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, age of vehicle, or ownership, from this time forward.

Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service, you are to ensure the campaign correction has been made before selling or releasing the vehicle.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.

#### CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

#### OWNER NOTIFICATION:

DCS messages, dated September 23 and 27, 1991, were sent to all GM Dealers with instructions to hold all suspect vehicles until the campaign service procedure has been performed. All suspect vehicles MUST be held at dealers and repaired before owners take possession of these vehicles. Completion of this campaign lifts hold on second population of VIN's in the DCS message dated September 27, 1991. There will be no owner notification.

#### PARTS INFORMATION:

#### NOTICE: Do not order parts unless you have a vehicle involved in this campaign.

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- -------------------------------- ---------------- 16621658 Regulator Asm-F/D-RH Pwr Wdw - Buick Only 1 as required

16621659 Regulator Asm-F/D-LH Pwr Wdw - Buick Only 1 as required

16625522 Regulator Asm-F/D-RH Pwr Wdw - Pontiac Only 1 as required

16625523 Regulator Asm-F/D-LH Pwr Wdw - Pontiac Only 1 as required

16625524 Regulator Asm-F/D-RH Man Wdw - Buick/Pontiac 1 as required

16625525 Regulator Asm-F/D-LH Man Wdw - Buick/Pontiac 1 as required

22566142 Rivet - 1/4" x 1/2" peel type 8 as required Regulator to inner door

NPN Rivet - 3/16" x 5/16" Steel Truss Head; 6 as required Semi-tubular Electric motor to regulator

PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ------------ ------------------------- -------------- 1A R & R Trim Panel Assemblies (2) and 1.1 Inspect Cam Position Only

2A R & R Trim Panel Assemblies (2), 1.7 Inspect, and Replace One Power Window Regulator Assembly Part Numbers 16621658 or 16621659 - Buick 16625522 or 16625523 - Pontiac

3A R & R Trim Panel Assemblies (2), 2.3 Inspect, and Replace Both Power Windows Regulator Assemblies Part Numbers 16621658 or 16621659 - Buick 16625522 or 16625523 - Pontiac

4A R & R Trim Panel Assemblies (2), 1.6 Inspect, and Replace One Manual Window Regulator Assembly Part Numbers 16625524 or 16625525

5A R & R Trim Panel Assemblies (2), 2.1 Inspect, and Replace Both Manual Window Regulator Assemblies Part Numbers 16625524 or 16625525

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 30% to cover parts handling.

An allowance of $2.50 has been included in above repair codes 2A, 3A, 4A, and 5A for the 3/16" x 5/16" rivets.

#### SERVICE PROCEDURE - FOR BUICK:

Inspect Regulator Cam (Both Sides)

1. On vehicles with manual windows, remove the window regulator handle (window crank) using tool J-9886.

2. Remove the centre trim plate from the door handle escutcheon by prying out at the rear using a thin bladed screwdriver. (See Figure 1).

3. Remove one (1) screw from the upper, forward end of the door trim pull handle. (See Figure 2).

4. Remove the door trim pull handle by pushing outward (towards outside of car) on the bottom of the handle and pulling inward (toward inside of car) at the top of the handle. The handle should "roll" out of its installed position as the retainers on the bottom disengage.

5. Remove one (1) screw from the location that was covered by the door trim pull handle.

6. Remove the manual lock rod knob by prying out on the front edge of the knob while holding the knob in the forward (unlocked) position.

7. Remove the door handle escutcheon by pulling away from the trim panel at the bottom. Slide the escutcheon forward to clear the lock rod.

8. On vehicles equipped with power door locks, disconnect the power door lock switch.

9. Remove the door handle escutcheon from the door trim panel.

10. Remove the reflector from the rear of the door trim panel by disengaging the front of the reflector using a thin bladed screwdriver, and then pulling the reflector straight out from the door (if the door was closed, you would pull the partially disengaged reflector directly toward the inside of the car). (See Figure 3).

11. Remove one (1) screw from the location that was covered by the reflector.

12. Remove two (2) screws from the shoulder belt escutcheon at the upper rear of the door trim panel and remove the shoulder belt escutcheon.

13. Remove one (1) screw from the location that was covered by the shoulder belt escutcheon.

14. Remove the four (4) remaining trim panel retaining screws.

15. On the driver's side door of a vehicle equipped with power windows, disengage the power window switch from the trim panel by prying upward and outward at the bottom of the switch using a thin bladed screwdriver.

#### NOTE: Ignition switch must be in the off position. This will eliminate the possibility of shorting out the switch.

16. Grasp the trim panel and gently pull outward to release the trim panel fasteners from the retainers.

17. Disengage the trim panel from the door by lifting at the bottom to disengage the door panel hooks from the slots at the top of the inner door panel.

18. Disengage the lap and shoulder belts from the trim panel.

19. On the passenger's side door of vehicles with power windows, disconnect the power window switch connector.

20. Remove the trim panel and set the panel carefully aside for later reinstallation.

21. Disconnect the lap and shoulder belt solenoid connectors and remove the lap and shoulder belt retractors.

22. Carefully peel the water deflector upward far enough to completely uncover the large access hole in the door inner panel.

23. Inspect the window regulator cam for correct orientation by observing the position of the longer and shorter notches in the cam (See Figure 4). The longer notch should be toward the front of the vehicle. It may be necessary to reach inside the door panel to actually "feel" the notches in the CAM to determine the position of the longer and shorter notches. This can be done with the door glass in the full-up position.

If the regulator cam is correctly oriented, (longer notch is toward the front of die vehicle), reinstall the door trim panel assembly following the procedure in steps 38 through 58 of the service procedure section of this bulletin. Perform the same inspection of the regulator cam for the opposite side.

If the regulator cam is = correctly oriented (longer notch is toward the rear of the vehicle), proceed to steps 24 through 58 to replace the regulator assembly.

Replace Regulator Assembly (one or both sides)

24. Position the water deflector so that it will not be damaged while removing the regulator assembly.

25. Cycle the window to the full-down position and remove the door glass inner belt sealing strip by pulling up to disengage the strip from the door flange.

26. Cycle the window to half-down position and remove the two (2) nuts that attach the regulator assembly to the sash attachments riveted to the bottom of the window.

27. While holding onto the window, cycle the regulator to full-down position.

28. Remove the window from the door by sliding the window rearward and rotating the front of the window upward, removing the assembly from the door. Carefully set the window aside for later reinstallation.

29. Remove the regulator assembly from the door using the following procedure: A) Drill out four (4) rivets using a 1/4" (6.3 mm) drill bit. B) Remove two (2) bolts that secure the regulator cam to the door. C) On vehicles with power windows, disconnect the power window electrical connector. D) Remove regulator assembly from door through large access hole in inner door panel.

30. On vehicles with power windows, transfer the power window motor to the new regulator assembly using the following procedure:

#### CAUTION:

WHEN REMOVING THE ELECTRIC MOTOR FROM THE REGULATOR ASSEMBLY, THE SECTOR GEAR MUST BE LOCKED IN POSITION. THE REGULATOR ARM IS UNDER TENSION FROM THE COUNTER BALANCE SPRING AND CAN CAUSE PERSONAL INJURY IF THE SECTOR GEAR IS NOT LOCKED IN POSITION.

A) Remove the power window motor from the regulator assembly by drilling out three (3) rivets using a 3/16" (4.8 mm) drill bit.

B) Install the electric motor to the new regulator assembly using three (3) 3/16" x 5/16" truss head, semi-tubular, steel rivets.

31. Install the new regulator assembly to the door using the following procedure:

A) Install four (4) rivets, P/N 22566142 to attach the regulator assembly to the door using J-29022 heavy duty rivet gun.

B) Position the regulator cam so that the longest notch is toward the front of the vehicle. See Figure 4. Additionally, the arrow on the cam should be pointing towards the front of the vehicle when the cam is properly oriented. Install two (2) bolts to secure the cam to the door panel. Tighten to 11 N.m (8 lbs. ft).

On vehicles equipped with power windows, reconnect the power window harness connector to the power window electric motor on the regulator assembly.

32. Cycle the regulator assembly to the full-down position.

33. Install the window to the door and align the sash attachments to the regulator assembly. Make sure the window is properly aligned in the front and rear glass run channels.

34. While holding onto the window, cycle the regulator to the half-up position.

35. Install the two nuts that attach the regulator assembly to the sash attachments riveted to the bottom of the window. Tighten to 11 N.m (8 lbs. ft.).

36. Cycle the door glass to the full-down position.

37. Position and install the door glass inner belt sealing strip to the door flange.

38. Position and reinstall the water deflector to the door. If necessary, use waterproof tape to properly secure the water deflector in position.

39. Reinstall the shoulder and lap belt retractors and tighten nuts to 28 N.m (21 lbs. ft.).

40. Connect the lap and shoulder belt solenoid connectors.

41. Position the door trim panel near the door.

42. On the passenger's side door of vehicles equipped with power windows, connect the power window harness to the power window switch.

43. Route the lap and shoulder belts through the slots in the door trim panel.

44. Make sure that all required electrical harnesses are routed through their correct trim panel openings before engaging the door trim panel to the door.

45. Position the door trim panel to the door and engage the trim panel hooks in the slots at the top of the inner door panel.

46. Push in on the trim panel to engage the push-in fasteners.

47. On the driver's side door of vehicles equipped with power windows, connect the power window harness and power window lockout harness to the power window switch.

Install the switch to the trim panel by positioning it in the opening and pushing in on the switch until seated.

48. Install eight (8) trim panel retaining screws.

49. Reinstall the reflector to the rear of the door trim panel.

50. Reinstall the door handle escutcheon.

On vehicles equipped with power door locks, reconnect the power door lock switch to the door lock harness.

51. Reinstall the manual lock rod knob.

52. Reinstall one (1) screw in the location to be covered by the door trim pull handle.

53. Reinstall the door trim pull handle by engaging retaining clips on bottom and reinstalling one (1) screw to the upper, forward end of the handle.

54. Reinstall the centre trim plate to the door handle escutcheon.

55. On vehicles with manual windows, reinstall the window regulator handle (window crank).

56. Check the window for proper operation by cycling from full-up to full-down at least five (5) times.

57. Repeat the window operation check and regulator cam inspection for the passenger side, and if necessary, replace the window regulator assembly following the procedure above.

58. Install campaign identification label.

#### SERVICE PROCEDURE - FOR PONTIAC:

1. Remove all the threaded fasteners which attach the door trim panel to the door. See Section 10-6 of die Service Manual.

2. Remove the manual lock rod knob by prying out on the front edge of the knob while holding the knob in the forward (unlocked) position.

3. Remove the inside door handle escutcheon by pulling out at the bottom and disengaging the top of the escutcheon from the door trim panel. It will be necessary to push the lock rod rearward to pull the bottom of the escutcheon outward. Remove the escutcheon from the inside door handle.

4. On vehicles equipped with power door locks, remove the door lock switch escutcheon by disengaging the retainers with a thin bladed screwdriver. Disconnect the door lock harness and remove the switch and escutcheon from the trim panel. See Section 10-6 of the Service Manual.

5. Remove the shoulder belt escutcheon by prying at the inboard edge with a thin bladed screwdriver. See Section 10-6 of the Service Manual.

6. On vehicles with manual windows, remove the window regulator handle (window crank) using tool J9886.

7. Grasp the trim panel and gently pull outward to release the trim panel fasteners from the retainers.

8. Lift at the rear of the panel to disengage the upper front lip of the trim panel from under the outside mirror escutcheon. Remove the trim panel by lifting at the bottom to disengage the door panel hooks from the slots at the top of the inner door panel.

9. Disengage die lap belt from the door trim panel and set the trim panel carefully aside for later reinstallation.

10. Disconnect die lap and shoulder belt solenoid connectors and remove the lap and shoulder belt retractors following the procedure in Section 10-11 of the Service Manual.

11. Remove the trim panel support bracket by removing three (3) screws.

12. Carefully peel the water deflector upward far enough to completely uncover the large access hole in die door inner panel.

13. Inspect the window regulator cam for correct orientation by observing the position of die longer and shorter notches in the cam (see Figure 4). The longer notch should be toward the front of the vehicle. It may be necessary to reach inside the door panel to actually "feel" the notches in the cam to determine the position of the longer and shorter notches. This can be done with the door glass in the full up position.

If the regulator cam is correctly oriented, (longer notch is toward the front of the vehicle), reinstall the door trim panel assembly following the procedure in Steps 27-37 of the Service Procedure section of this bulletin. Perform the same operation check and regulator cam inspection on the opposite side.

If the regulator cam is not correctly oriented (longer notch is toward the rear of the vehicle), proceed to Steps 14 through 37 to replace the regulator assembly.

14. Position the water deflector so that it will not be damaged while removing the regulator assembly.

15. Cycle the window to the full-down position and remove the door glass inner belt sealing strip by pulling up to disengage the strip from the door flange.

16. Cycle the window to half-down position and remove the two (2) nuts that attach the regulator assembly to the sash attachments riveted to the bottom of the window.

17. While holding onto the window, cycle the regulator to full-down position.

18. Remove the window from the door by sliding the window rearward and rotating the front of the window upward, removing the assembly from the door. Carefully set the window aside for later reinstallation.

19. Remove the regulator assembly from the door using the following procedure: a. Drill out four (4) rivets using a 1/4" (6.3mm) drill bit. b. Remove two (2) bolts that secure the regulator cam to the door. c. On vehicles with power windows, disconnect the power window electrical connector. d. Remove regulator assembly from door through large access hole in inner door panel.

20. Install the new regulator assembly to the door using the following procedure: a. Install four (4) rivets, P/N 22566142 to attach the regulator assembly to the door using J29022 heavy duty rivet gun. b. Position the regulator cam so that the longest notch is toward the front of the vehicle (see Figure 4). Additionally, the arrow on the cam should be pointing towards the front of the vehicle when the cam is properly oriented. Install two (2) bolts to secure the cam to the door panel. Tighten to 11 N.m (8 lbs. ft.).

On vehicles equipped with power windows, reconnect the power window harness connector to the power window electric motor on the regulator assembly.

21. Cycle the regulator assembly to the full-down position.

22. Install the window to the door and align the sash attachments to the regulator assembly. Make sure the window is properly aligned in the front and rear glass run channels.

23. While holding onto the window, cycle the regulator to the half-up position.

24. Install the two nuts that attach the regulator assembly to the sash attachments riveted to the bottom of the window. Tighten to 11 N.m (8 lbs. ft.).

25. Cycle the door glass to the full-down position.

26. Position and install the door glass inner belt sealing strip to the door flange.

27. Position and reinstall the water deflector to the door. If necessary, use waterproof tape to properly secure the water deflector in position.

28. Install the trim panel support bracket using three (3) screws.

29. Reinstall the shoulder and lap belt retractors and connect the solenoid connectors following the procedure in Section 10-11 of the Service Manual.

30. Route the lap belt through the slot in the door trim panel.

31. Position the upper front lip of the door trim panel under the outside mirror escutcheon and engage the trim panel hooks in the slots at the top of the inner door panel.

32. Push in on the trim panel to engage the push-in fasteners.

33. On vehicles with manual windows, reinstall the window regulator handle (window crank).

34. Reinstall the shoulder belt escutcheon to the door trim panel.

35. On vehicles equipped with power door locks, connect the door lock switch to the door lock harness and reinstall the door lock switch and escutcheon to the trim panel.

36. Reinstall the door handle escutcheon.

37. Reinstall the manual lock rod knob.

38. Reinstall the threaded fasteners which attach the door trim panel to the door.

39. Check the window for proper operation by cycling from full-up to full-down at least five (5) times.

40. Repeat the window operation check and regulator cam inspection for the passenger side and, if necessary, replace the window regulator assembly following the procedure above.

41. Install Campaign Identification Label.

#### INSTALLATION OF IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

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.