LOOSE DOOR OUTER PANELS, BOND SEPARATIONS AT HEM AREA. Pontiac Firebird 1994

SUBJECT: LOOSE DOOR OUTER PANELS, BOND SEPARATIONS AT HEM AREA (REPAIR GUIDELINES AND PROCEDURES)

MODELS: 1993-94 CHEVROLET CAMARO 1993-94 PONTIAC FIREBIRD

---------------------------------------------------------------------- THIS BULLETIN REPLACES CORPORATE BULLETIN 431005 ISSUED AS A DCS MESSAGE BY THE MARKETING DIVISIONS. DCS MESSAGE NUMBERS WERE: CHEVROLET 01-081 PONTIAC TE32 ----------------------------------------------------------------------

THIS BULLETIN IS BEING ISSUED TO PROVIDE INFORMATION REGARDING VARIOUS DOOR OUTER PANEL SEPARATIONS AND SOME GUIDELINES TO SELECT THE PROPER REPAIR PROCEDURES.

IT IS EXPECTED THAT THESE REPAIRS WILL BE MADE IN A QUALITY BODY REPAIR FACILITY BY AN EXPERIENCED BODY TECHNICIAN USING THE PROPER EQUIPMENT AND MATERIALS.

CONDITION:

SOME OUTER DOOR PANELS MAY HAVE A BOND SEPARATION AT THE HEM AREA. THESE SEPARATIONS MAY BE SEEN AS:

TYPE 1: BOND SEPARATION AT THE REAR HEM, FROM THE OUTER BELT STRIP TO THE BODY SIDE MOLDING.

TYPE 2: BOND SEPARATION FOR THE FULL LENGTH OF THE REAR HEM AND PART OF THE LOWER EDGE ALONG THE ROCKER (BUT NO SURFACE DAMAGE TO INNER OR OUTER PANEL).

TYPE 3: BOND SEPARATION AS IN TYPE 2, BUT EITHER:

A) THE OUTER PANEL HAS SOME SURFACE CRACKING (USUALLY NEAR THE OUTER HANDLE), OR,

B) THE INNER PANEL HAS SOME SURFACE CRACKING IN THE HEM BONDING AREA.

CAUSE:

MAY BE DUE TO INSUFFICIENT ADHESIVE IN THE HEM BONDING AREA.

CORRECTION:

TYPE 1: REBOND THE DOOR OUTER PANEL TO THE INNER HEM AREA USING THE APPROPRIATE PROCEDURE.

TYPE 2: REINSTALL THE ORIGINAL DOOR OUTER PANEL TO THE ORIGINAL INNER PANEL USING THE APPROPRIATE PROCEDURE.

TYPE 3: A) REPLACE THE DOOR OUTER PANEL USING THE APPROPRIATE PROCEDURE.

B) REPLACE THE DOOR ASSEMBLY.

MATERIALS REQ'D: GM #12345726 STRUCTURAL BONDING ADHESIVE OR LORD FUSOR SMC BODY PANEL REPAIR ADHESIVE OR DOMINION/AMERICAN SURE SEAL # XRGM ADHESIVE, AND PORTABLE HEAT LAMP(S).

NOTE: IF THE GM STRUCTURAL BONDING ADHESIVE IS NOT AVAILABLE, THE LORD FUSOR MATERIAL CAN BE ORDERED FROM 1-800-525-7939.

WE BELIEVE THESE SOURCES AND THEIR PRODUCT TO BE RELIABLE. THERE MAY BE ADDITIONAL MANUFACTURERS OF SUCH PRODUCTS. GENERAL MOTORS DOES NOT ENDORSE, INDICATE ANY PREFERENCE FOR OR ASSUME ANY RESPONSIBILITY FOR THE PRODUCTS FROM THESE FIRMS OR FOR ANY SUCH ITEMS WHICH MAY BE AVAILABLE FROM OTHER SOURCES.

PROCEDURE FOR TYPE 1 REPAIR: (PARTIAL SEPARATION OF PANELS).

1. LOWER DOOR GLASS.

NOTE: PRIOR TO DISCONNECTING THE BATTERY CABLE, THE RADIO STATION SETTINGS SHOULD BE REVIEWED, RECORDED AND THEN RESET FOR THE CUSTOMER PRIOR TO DELIVERY.

2. DISCONNECT NEGATIVE BATTERY CABLE.

3. USE A "BLOCK" TO HOLD THE INNER AND OUTER PANELS SLIGHTLY APART AT THE REAR BELT OPENING.

4. CAREFULLY CLEAN ANY DIRT RESIDUE THAT MAY BE PRESENT IN THE BONDING AREA WITH ISOPROPYL ALCOHOL AND A CLEAN LINT FREE RAG.

5. PREPARE 3 TO 4 CLAMPS TO CORRECT DIMENSION FOR CLAMPING OUTER PANEL TO INNER PANEL, INCLUDING SPACE FOR PROTECTIVE MATERIAL FOR THE DOOR OUTER PANEL SURFACE.

NOTE: BE SURE THAT THE CLAMP PRESSURE ALLOWS A SLIGHT GAP FOR ADHESIVE THICKNESS (APPROXIMATELY .75 MM OR .030") AND IS NOT SO HIGH THAT THE PANEL SURFACES ARE DISTORTED, OR PANEL REFINISH REPAIRS WILL BE NECESSARY.

6. APPLY A SUFFICIENT BEAD OF GM #12345726 STRUCTURAL BONDING ADHESIVE OR EQUIVALENT TO THE HEM BONDING AREA.

7. PRESS THE OUTER PANEL TO THE INNER PANEL AND CHECK THE ADHESIVE "WET OUT" PATTERN TO ENSURE THE ENTIRE HEM FLANGE HAS ADHESIVE PRESENT. IF NECESSARY, ADD MORE ADHESIVE.

8. WHILE HOLDING THE PANELS TOGETHER, CLEAN ANY ADHESIVE SQUEEZE OUT IN THE HEM AREA PRIOR TO ADHESIVE CURING.

9. CLAMP THE PANELS TOGETHER AT THE PREDETERMINED LOCATIONS.

10. APPLY THE MANUFACTURER'S RECOMMENDED CURING PROCESSES AND TIME REQUIREMENTS (TYPICALLY REQUIRE SOME TYPE OF HEAT CURE CYCLE).

11. AFTER THE HEAT CURE CYCLE, REMOVE THE LAMP AND ALLOW VEHICLE SURFACES TO RETURN TO ROOM TEMPERATURE.

12. APPLY TOUCH UP PAINT TO ANY EXPOSED ADHESIVE SQUEEZE OUT.

LABOR OPERATION: A9340 RIGHT SIDE A9341 LEFT SIDE TIME ALLOWANCE: USE PUBLISHED ALLOWANCE MATERIAL ALLOWANCE: $15.00 FOR ADHESIVE MATERIALS.

PROCEDURE FOR TYPE 2 REPAIR: (REINSTALL THE ORIGINAL OUTER PANEL TO THE ORIGINAL INNER PANEL).

1. LOWER THE DOOR GLASS.

NOTE: SEE NOTE IN PROCEDURE 1 ABOUT RADIO STATION RESETS.

2. DISCONNECT NEGATIVE BATTERY CABLE.

3. REMOVE THE DOOR TRIM PANEL, WATER DEFLECTOR AND DISCONNECT THE RODS TO THE OUTSIDE HANDLE AND LOCK CYLINDER.

4. DISCONNECT AND REMOVE THE DOOR WIRING HARNESS.

5. REMOVE THE DOOR ASSEMBLY FROM THE VEHICLE AND PLACE ON A STAND, INNER PANEL SIDE DOWN.

6. USING A HEAT GUN AND A PRY TOOL, APPLY HEAT TO THE BOND AREA FROM THE INNER PANEL SIDE AND CAREFULLY PRY THE PANELS APART AS THE HEAT SOFTENS THE ADHESIVE.

7. ONCE THE PANELS ARE APART, CLEAN ANY LOOSE OR EXCESS ADHESIVE FROM THE BONDING AREAS ON BOTH PANELS WITH A SHARPENED PUTTY KNIFE OR SCRAPER.

8. ROUGH UP THE BOND AREAS ON BOTH PANELS WITH A PIECE OF #80 GRIT SANDPAPER TO PROMOTE ADHESION, AND BLOW OFF THE SANDING DUST WITH AN AIR HOSE.

9. PREPARE A NUMBER OF CLAMPS (APPROXIMATELY 15 TO 20) FOR HOLDING THE OUTER PANEL TO THE INNER PANEL DURING ADHESIVE CURE.

NOTE: BE SURE TO ALLOW ENOUGH ROOM FOR PROTECTIVE PADS ON THE OUTER PANEL AND ADHESIVE GAP (APPROXIMATELY .75 MM OR .030").

10. APPLY A 6 MM (1/4") TO 8 MM (5/16") BEAD OF ADHESIVE MATERIAL TO THE INNER PANEL HEM FLANGE BOND AREA.

11. WITH THE AID OF A HELPER, POSITION THE OUTER PANEL TO THE INNER PANEL, AND CLAMP THE TWO PANELS TOGETHER.

12. APPLY THE MANUFACTURER'S RECOMMENDED CURING PROCESS AND TIME REQUIREMENTS (TYPICALLY REQUIRE SOME TYPE OF HEAT CURE CYCLE).

13. AFTER THE HEAT CURE CYCLE, REMOVE THE HEAT SOURCE AND ALLOW THE DOOR TO RETURN TO ROOM TEMPERATURE.

14. APPLY TOUCH UP PAINT TO ANY EXPOSED ADHESIVE SQUEEZE OUT.

15. REINSTALL AND PROPERLY ALIGN THE DOOR ASSEMBLY TO THE VEHICLE.

NOTE: PRIOR TO DELIVERY TO THE CUSTOMER, THE VEHICLE SHOULD BE ROAD TESTED FOR WINDNOISE AND WATERLEAKS TO ENSURE PROPER DOOR ALIGNMENT.

16. REINSTALL THE WIRING HARNESS, LOCK CYLINDER AND OUTSIDE HANDLE RODS, WATER DEFLECTOR AND TRIM PANEL.

17. RECONNECT THE BATTERY CABLE AND RESET RADIO STATIONS.

LABOR OPERATION: S0800 (RIGHT) S0801 (LEFT)

TIME ALLOWANCE: USE PUBLISHED ALLOWANCE MATERIAL ALLOWANCE: $35.00 FOR ADHESIVE MATERIALS.

PROCEDURE FOR TYPE 3 REPAIR: (IF DAMAGE IS PRESENT IN THE OUTER PANEL SURFACE, INSTALL NEW OUTER PANEL).

FOLLOW THE SAME PROCEDURE FOR TYPE 2 REPAIRS EXCEPT THAT A NEW DOOR OUTER PANEL IS INSTALLED (AND REQUIRES PAINTING), AND THE BODY SIDE MOLDING MUST BE TRANSFERRED OR REPLACED.

ONCE THE NEW OUTER PANEL IS INSTALLED, THE NEW DOOR ASSEMBLY SHOULD BE "CUT IN" WITH BODY COLOR AND CLEARCOATED PRIOR TO INSTALLATION TO THE BODY.

LABOR OPERATION: S0800 (RIGHT), PLUS:A1230 (REFINISH, RIGHT) OR

S0801 (LEFT), PLUS:A1231 (REFINISH, LEFT)

TIME ALLOWANCE: USE PUBLISHED ALLOWANCES. MATERIAL ALLOWANCE: GL (FOR PAINT MATERIALS). $35.00 FOR ADHESIVE MATERIALS.

DOOR ASSEMBLY REPLACEMENT (IF INNER PANEL FLANGE IS DAMAGED).

THE COMPLETE DOOR ASSEMBLY SHOULD BE REPLACED, WITH THE INSIDE SURFACES AND EDGES OF THE DOOR "CUT IN" WITH BODY COLOR AND CLEARCOATED PRIOR TO INSTALLATION TO THE BODY.

ONCE THE HARDWARE IS TRANSFERRED FROM THE ORIGINAL DOOR TO THE NEW DOOR, THE DOOR AND GLASS ASSEMBLIES SHOULD BE ALIGNED PROPERLY, AND (AFTER PAINTING THE DOOR ASSEMBLY) SHOULD BE ROAD TESTED AND WATER TESTED FOR WINDNOISE OR WATER LEAKS.

NOTE: THE PROCEDURES TO OBTAIN NEW DECALS OR THE DECAL INFORMATION ON THE REAR FACING OF THE DOOR SHOULD BE FOLLOWED.

LABOR OPERATION: S0850 (RIGHT), PLUS:A1230 (REFINISH, RIGHT)

S0851 (LEFT), PLUS:A1231 (REFINISH, LEFT)

TIME ALLOWANCE: USE PUBLISHED ALLOWANCES. MATERIAL ALLOWANCE: GL (FOR PAINT MATERIALS).

PART AVAILABILITY:

PARTS ARE CURRENTLY AVAILABLE FROM GMSPO.

FIGURES: 0

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