CREAKING NOISE FROM FRONT DOOR SERVICE PANELS WITH POP RIVETS. Pontiac Sunbird 1991

For 1990-2009 cars

# CREAKING NOISE FROM FRONT DOOR SERVICE PANELS WITH POP RIVETS

#### Subject: CREAKING NOISE FROM FRONT RIGHT OR FRONT LEFT DOOR (SECURE PANELS WITH MONO POP RIVETS)

#### Models Affected: 1991 SUNBIRD MODELS

#### Condition:

---------- Some owners of 1991 Sunbird coupe, convertible and sedan models may comment on a creaking noise coming from either the front right or front left door lower hinge when opening or closing the door.

#### Cause:

------ During assembly of the front body hinge pillar to the motor compartment side and wheelhouse front panel, some welds were mislocated and others were applied incorrectly. These improper welds allow the front body hinge pillar to rub against the motor compartment side and wheelhouse front panel in the area of the front door lower hinge, thereby creating the creaking noise.

#### Correction:

----------- Secure the two panels in the area of the front door lower hinge with three (3) mono pop rivets (P/N 22566142) using the following procedure:

1. Remove shroud side trim panel retaining screws, then remove trim panel.

2. Remove front screw from carpet retainer, then pull carpet from underneath carpet retainer and away from motor compartment side and wheelhouse front panel.

3. Peel noise insulator off of motor compartment side and wheelhouse front panel.

4. Drill three (3) 6.35 mm (.250 in.) diameter holes in area shown in Figure 1.

5. Install mono pop rivet, P/N 22566142 into previously drilled holes using rivet tool J 34940, or equivalent tool.

6. Clean area of debris, then install noise insulator.

7. Reposition carpet against motor compartment side and wheelhouse front panel and also under carpet retainer.

8. Install carpet retainer screw.

9. Install shroud side trim panel and retaining screws.

Parts are currently available from GMSPO.

Labor Operation Number: T1809 Labor Time: 0.4 Hour Per Side

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.