CAMPAIGN: FRT. DOOR WINDOW BINDING AND/OR INOPERABLE
Subject: PRODUCT CAMPAIGN 92-C-05 FRONT DOOR WINDOW BINDING AND/OR INOPERABLE
Models Affected: 1992 GRAND AM SEDAN
DEFECT INVOLVED
General Motors has determined that certain 1992 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 degrees 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 Pontiac Grand Am Sedan model vehicles built within the following VIN breakpoints: Up To And Year Plant Beginning Including ---- ----------- ----------- ---------- 1992 Lansing (C) NC200024 NC201972 1992 Lansing (M) NM000006 NM000142
Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identifica- tion Number, owner name and address data, and are furnished to the involved dealers with the campaign bulletin.
OWNER NOTIFICATION
A DCS message has been sent to all Pontiac 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. There will be no owner notification from Pontiac.
DEALER CAMPAIGN RESPONSIBILITY
In the unlikely event a vehicle has been sold prior to receiving the DCS message, the owner should be contacted and arrangement made to,make the required correction according to instructions contained in this bulletin.
PARTS INFORMATION
Parts required to complete this campaign are to be obtained from General Motors Service Parts Operation (GMSPO) via VIP and an involved VIN must be provided. All other order types will be cancelled.
Part Quantity Description Number Per Vehicle ---------------------------- ------- ------------ Regulator Assembly - Front Door Right Hand Power Window 16625522 1 As Required
Regulator Assembly - Front Door Left Hand Power Window 16625523 1 As Required
Regulator Assembly - Front Door Right Hand Manual Window 16625524 1 As Required
Regulator Assembly - Front Door Left Hand Manual Window 16625525 1 As Required
Rivet - Regulator To Inner Door 22566142 8 As Required
SERVICE PROCEDURE
1. Remove all the threaded fasteners which attach the door trim panel to the door. See section 10-6 of the 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 the lap belt from the door trim panel and set the trim panel carefully aside for later reinstallation.
10. Disconnect the 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 the door inner panel.
13. Inspect the window regulator cam for correct orientation by observing the position of the longer and shorter notches in the cam. See illustration. 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 thru 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" (6.3 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 thru 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 illustration. 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.
39. 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.
CAMPAIGN IDENTIFICATION LABEL
Each vehicle modified in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label." Each label provides a space to include the campaign number, the five digit dealer code of the dealer performing the campaign service, and the date the vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. Install the label only on a clean, dry surface of the radiator baffle where it is readily visible. (Additional campaign labels are available on stationery order as Form 7201-709).
CLAIM INFORMATION
A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.
DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:
*Other Failure Labor Labor Labor Operation Code Operation Hours Hours ----------------------- ----- -------- ----- ----- R&R Trim Panel Assemblies - 96 V7050 1.0 0.1 Inspect Cam Position Only On Both Doors
R&R Trim Panel Assemblies - 96 V7051 1.5 0.1 Replace One (1) Regulator Assembly
R&R Trim Panel Assemblies - 96 V7052 2.0 0.1 Replace Two (2) Regulator Assemblies
* In addition, dealerships will receive 0.1 hours credit for dealer administrative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed for credit. This entry will not require authorization.
FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.
Parts required are to be listed in your warranty claim in the normal manner. Parts will be credited at dealer net plus 30% dealer handling allowance.
Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the labor operation as outlined.
RECORDING COMPLETION
Repairs submitted for vehicles not involved in the campaign will not be paid. Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS."
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.
