SPECIAL POLICY:REAR SIDE CARGO DOOR DOES NOT STAY. Chevrolet Export Express 1997

For 1990-2009 cars

# SPECIAL POLICY:REAR SIDE CARGO DOOR DOES NOT STAY

#### NOTE: GM OF CANADA VERSION OF 98040 IS LOCATED BELOW THE U.S. VERSION ______________________________________________________________________

SPECIAL POLICY 98040 SEPTEMBER, 1998

#### SUBJECT: 98040 - SPECIAL POLICY - REAR SIDE CARGO DOOR DOES NOT STAY OPEN

#### MODELS: 1996-97 CHEVROLET AND GMC G VANS WITH SIDE CARGO DOORS (RPO E24)

********************************************************************** THIS SPECIAL POLICY IS IN EFFECT UNTIL SEPTEMBER 30, 1999 **********************************************************************

CONDITION

SOME CUSTOMERS OF 1996-97 G VANS EQUIPPED WITH SIDE CARGO DOORS (RPO E24) MAY COMMENT ABOUT THE REAR SIDE CARGO DOOR NOT STAYING OPEN AND/OR THE DOOR CONTACTING THE REAR QUARTER PANEL.

CAUSE

THE ORIGINAL DESIGN DID NOT HAVE A FEATURE TO CONTROL AN OPEN DOOR.

SPECIAL POLICY PRODUCT ENHANCEMENT

THIS SPECIAL POLICY COVERS THE CONDITION DESCRIBED ABOVE UNTIL SEPTEMBER 30, 1999. DEALERS ARE TO INSTALL A REAR SIDE CARGO DOOR CHECK LINK USING THE PART NUMBER LISTED BELOW. USE THE FOLLOWING SERVICE PROCEDURE. THIS WILL BE PERFORMED AT NO CHARGE TO THE CUSTOMER DURING THIS TIME.

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1996-97 CHEVROLET AND GMC G VANS EQUIPPED WITH SIDE CARGO DOORS (RPO E24) AND BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS:

YEAR DIVISION MODEL PLANT CODE FROM THROUGH

1996 CHEVROLET G WENTZVILLE "1" T1000008 T1044630 1997 CHEVROLET G WENTZVILLE "1" V1000003 V1097892 1996 GMC G WENTZVILLE "1" T1000010 T1044627 1997 GMC G WENTZVILLE "1" V1000001 V1097901

PARTS INFORMATION

PART NUMBER DESCRIPTION QUANTITY/ VEHICLE 15011044 LINK KIT 1

CUSTOMER NOTIFICATION

CUSTOMERS WILL BE NOTIFIED OF THIS SPECIAL POLICY ON THEIR VEHICLES BY GENERAL MOTORS (SEE COPY OF TYPICAL CUSTOMER LETTER INCLUDED WITH THIS BULLETIN - ACTUAL DIVISIONAL LETTER MAY VARY SLIGHTLY).

SERVICE PROCEDURE

SERVICE PROCEDURE

1. REMOVE THE REAR SIDE DOOR TRIM PANEL FROM THE VEHICLE, IF EQUIPPED. REFER TO SECTION 10A1 OF THE SERVICE MANUAL.

2. REMOVE THE PASSENGER BODY SIDE TRIM PANEL FROM THE VEHICLE, IF EQUIPPED. REFER TO SECTION 10A4 OF THE SERVICE MANUAL.

3. ALIGN THE TEMPLATE FOR THE CHECK LINK BRACKET MOUNTING HOLES BETWEEN THE UPPER AND LOWER SIDE DOOR HINGES (FIGURE 1, ITEM 2).

4. ALIGN THE TEMPLATE FOR THE CHECK LINK STUD PLATE TO THE FLAT AREA AT THE REAR OF THE SIDE DOOR OPENING ACROSS FROM THE HOLE INDICATED ON THE SIDE DOOR TEMPLATE (FIGURE 2, ITEM 1).

#### CAUTION:

STANDARD SHOP PRACTICES, PARTICULARLY EYE PROTECTION, SHOULD BE FOLLOWED DURING THESE OPERATIONS TO AVOID PERSONAL INJURY.

5. DRILL FOUR 1/8" PILOT HOLES FOR THE CHECK LINK BRACKET MOUNTING STUDS AT THE POINTS INDICATED ON THE REAR SIDE DOOR TEMPLATE.

6. DRILL FOUR 5/16" HOLES FOR THE CHECK LINK BRACKET MOUNTING STUDS THROUGH THE PILOT HOLES DRILLED IN STEP 5.

7. DRILL FOUR 1/8" PILOT HOLES AT THE CORNERS OF THE REAR SIDE DOOR TEMPLATE FOR THE CHECK LINK ACCESS OPENING.

8. DRILL FOUR 1/4" HOLES THROUGH THE PILOT HOLES DRILLED FOR THE CHECK LINK ACCESS OPENING IN STEP 7.

9. USING A DIE GRINDER WITH A CUT-OFF WHEEL, OR THE EQUIVALENT, CUT ALONG THE LINES ON THE REAR SIDE DOOR TEMPLATE FOR THE CHECK LINK ACCESS OPENING IN ORDER TO CONNECT THE 4 HOLES DRILLED IN STEP 8.

10. USING A FILE OR DEBURRING TOOL, REMOVE ANY BURRS OR SHARP EDGES FROM THE CHECK LINK ACCESS HOLE IN THE REAR SIDE DOOR.

11. REMOVE THE METAL CUTOUT AND ANY OTHER DEBRIS FROM THE REAR SIDE DOOR.

12. DRILL TWO 1/8" PILOT HOLES AT THE POINT INDICATED ON THE TEMPLATE ON THE SIDE DOOR OPENING.

13. FROM INSIDE THE VEHICLE, DRILL TWO 3/8" HOLES THROUGH THE PILOT HOLES. PARTIALLY CLOSE THE REAR SIDE DOOR IN ORDER TO AVOID DAMAGE TO THE REAR SIDE DOOR WHEN DRILLING THESE HOLES.

14. APPLY TOUCH-UP PAINT TO ALL EXPOSED METAL EDGES.

#### IMPORTANT: PAINT THE CHECK LINK TO MATCH THE BODY COLOR.

15. INSTALL THE REAR SIDE DOOR CHECK LINK THROUGH THE ACCESS HOLE IN THE REAR SIDE DOOR.

16. INSTALL THE CHECK LINK STUD PLATE TO THE SIDE DOOR OPENING (FIGURE 3).

17. INSTALL THE CHECK LINK TO THE STUDS (FIGURE 3, ITEM 3).

18. INSTALL THE CHECK LINK RETAINING NUTS TO THE STUDS ON THE REAR SIDE DOOR OPENING (FIGURE 3, ITEM 2).

19. TIGHTEN THE CHECK LINK RETAINING NUTS TO 30 NM (22 FT. LB.).

20. INSTALL THE CHECK LINK BRACKET TO THE REAR SIDE DOOR (FIGURE 4, ITEM 3).

21. INSTALL THE CHECK LINK BRACKET RETAINING NUTS TO THE REAR SIDE DOOR (FIGURE 4, ITEM 1).

22. TIGHTEN THE CHECK LINK BRACKET RETAINING NUTS TO 12 NM (108 IN. LB.).

23. CLOSE THE REAR SIDE DOOR IN ORDER TO ENGAGE THE CHECK LINK TO THE CHECK LINK BRACKET.

24. CAREFULLY OPEN AND CLOSE THE DOOR TO ENSURE THAT THE REAR SIDE DOOR CHECK LINK IS OPERATING CORRECTLY.

25. INSTALL THE PASSENGER BODY SIDE TRIM PANEL TO THE VEHICLE, IF EQUIPPED. REFER TO SECTION 10A4 OF THE SERVICE MANUAL.

26. INSTALL THE REAR SIDE DOOR TRIM PANEL TO THE VEHICLE, IF EQUIPPED. REFER TO SECTION 10A1 OF THE SERVICE MANUAL.

FIGURE 1 - CHECK LINK BRACKET MOUNTING HOLE TEMPLATE

LEGEND 1. REAR SIDE DOOR ASSEMBLY 2. BRACKET MOUNTING HOLE TEMPLATE

FIGURE 2 - CHECK LINK STUD PLATE TEMPLATE

LEGEND 1. CHECK LINK STUD PLATE TEMPLATE

FIGURE 3 - INSTALLING CHECK LINK ASSEMBLY

LEGEND 1. SIDE DOOR CHECK LINK ANCHOR 2. SIDE DOOR CHECK LINK NUT 3. SIDE DOOR CHECK LINK ASSEMBLY 4. FRONT AND SIDE DOOR OPENING FRAME ASSEMBLY

FIGURE 4 - CHECK LINK BRACKET INSTALLATION

LEGEND 1. SIDE DOOR CHECK LINK BRACKET NUT 2. SIDE DOOR ASSEMBLY 3. SIDE DOOR CHECK LINK BRACKET ASSEMBLY

CLAIM INFORMATION

#### IMPORTANT: THIS SPECIAL POLICY IS IN EFFECT UNTIL SEPTEMBER 30, 1999. DURING THE TIME THAT THIS SPECIAL POLICY IS IN EFFECT, THE FOLLOWING LABOR CODES AND TIMES SHOULD BE USED FOR CLAIM SUBMISSION.

PART FAILED PARTS LABOR LABOR REPAIR PERFORMED COUNT PART NO. ALLOW CC-FC OP * MODEL HOURS

INSTALL LINK KIT 1 --- * MK-95 T5511

05 MODEL (CARGO) 0.8 05 MODEL WITH YF7 1.1 (UPFITTED) 06 MODEL (PASSENGER) 1.3

* THE "PARTS ALLOWANCE" SHOULD BE THE SUM TOTAL OF THE CURRENT GMSPO DEALER NET PRICE PLUS 40% FOR LINK KIT NEEDED TO COMPLETE THE REPAIR.

FIGURES: 4

GM BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THESE 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 TOOLS, EQUIPMENT, 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 YOUR DEALER/RETAILER FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.

WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION

98040

(SAMPLE OF NOTIFICATION USED)

DEAR CHEVROLET EXPRESS/GMC SAVANA CUSTOMER:

THIS LETTER IS TO INFORM YOU OF A SERVICE UPDATE AVAILABLE AT YOUR CHEVROLET/GMC DEALER IN THE EVENT YOU ARE DISSATISFIED WITH THE OPERATION OF THE REAR SIDE CARGO DOOR. THIS IS THE RESULT OF COMMENTS RECEIVED ABOUT THE REAR SIDE CARGO DOOR CLOSING DURING LOADING AND UNLOADING OF THE VEHICLE WHEN PARKED ON AN INCLINE.

A SERVICE KIT HAS BEEN DEVELOPED FOR THE INSTALLATION OF A DOOR CHECK STRAP WHICH WILL ASSIST IN KEEPING THE DOOR OPEN WHILE LOADING AND UNLOADING THE VEHICLE. YOUR CHEVROLET/GMC DEALER HAS THE NECESSARY INSTRUCTIONS, AND THE REQUIRED PARTS KIT IS CURRENTLY AVAILABLE. IF YOU DESIRE THIS IMPROVEMENT BE MADE TO YOUR VEHICLE, PLEASE CONTACT YOUR CHEVROLET/GMC DEALER TO SCHEDULE AN APPOINTMENT. THIS IMPROVEMENT WILL BE AVAILABLE TO YOU AT NO CHARGE UNTIL SEPTEMBER 30, 1999.

YOUR SATISFACTION WITH YOUR CHEVROLET EXPRESS/GMC SAVANA VAN IS OF THE UTMOST IMPORTANCE TO US AND WE HAVE TAKEN THIS ACTION TO ENSURE THAT YOUR OWNERSHIP EXPERIENCE IS A PLEASURABLE ONE.

COPYRIGHT 1998 GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.

********************************************************************** GM OF CANADA VERSION ********************************************************************** SPECIAL POLICY 98040 SEPTEMBER 1998

SPECIAL POLICY

#### SUBJECT: 98040 REAR SIDE CARGO DOOR DOES NOT STAY OPEN

#### MODELS: 1996-97 CHEVROLET AND GMC G VANS WITH SIDE CARGO DOORS (RPO E24)

********************************************************************** THIS SPECIAL POLICY IS IN EFFECT UNTIL SEPTEMBER 30, 1999 **********************************************************************

CONDITION

SOME CUSTOMERS OF 1996-97 G VANS EQUIPPED WITH SIDE CARGO DOORS (RPO E24) MAY COMMENT ABOUT THE REAR SIDE CARGO DOOR NOT STAYING OPEN AND/OR THE DOOR CONTACTING THE REAR QUARTER PANEL.

CAUSE

THE ORIGINAL DESIGN DID NOT HAVE A FEATURE TO CONTROL AN OPEN DOOR.

SPECIAL POLICY PRODUCT ENHANCEMENT

THIS SPECIAL POLICY COVERS THE CONDITION DESCRIBED ABOVE UNTIL SEPTEMBER 30, 1999. DEALERS ARE TO INSTALL A REAR SIDE CARGO DOOR CHECK LINK USING PART NUMBER 15011044. THIS WILL BE PERFORMED AT NO CHARGE TO THE CUSTOMER AT THIS TIME.

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1996-97 CHEVROLET AND GMC G VANS EQUIPPED WITH SIDE CARGO DOORS (RPO E24) AND BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS:

YEAR DIVISION MODEL PLANT CODE FROM THROUGH

1996 CHEVROLET G WENTZVILLE "1" T1000008 T1044630 1997 CHEVROLET G WENTZVILLE "1" V1000003 V1097892 1996 GMC G WENTZVILLE "1" T1000010 T1044627 1997 GMC G WENTZVILLE "1" V1000001 V1097901

PARTS INFORMATION

PARTS REQUIRED TO COMPLETE THIS CAMPAIGN ARE TO BE OBTAINED FROM GENERAL MOTORS SERVICE PARTS OPERATIONS (GMSPO).

PART NUMBER DESCRIPTION QUANTITY/VEHICLE 15011044 LINK KIT 1

CUSTOMER NOTIFICATION

CUSTOMERS WILL BE NOTIFIED OF THE SPECIAL POLICY BY GENERAL MOTORS OF CANADA LIMITED (SEE COPY OF OWNER LETTER INCLUDED WITH THIS BULLETIN).

SERVICE PROCEDURE

1. REMOVE THE REAR SIDE DOOR TRIM PANEL FROM THE VEHICLE, IF EQUIPPED. REFER TO SECTION 10A1 OF THE SERVICE MANUAL.

2. REMOVE THE PASSENGER BODY SIDE TRIM PANEL FROM THE VEHICLE, IF EQUIPPED. REFER TO SECTION 10A4 OF THE SERVICE MANUAL.

3. ALIGN THE TEMPLATE FOR THE CHECK LINK BRACKET MOUNTING HOLES BETWEEN THE UPPER AND LOWER SIDE DOOR HINGES (FIGURE 1, ITEM 2).

4. ALIGN THE TEMPLATE FOR THE CHECK LINK STUD PLATE TO THE FLAT AREA AT THE REAR OF THE SIDE DOOR OPENING ACROSS FROM THE HOLE INDICATED ON THE SIDE DOOR TEMPLATE (FIGURE 2, ITEM 1).

#### CAUTION:

STANDARD SHOP PRACTICES, PARTICULARLY EYE PROTECTION, SHOULD BE FOLLOWED DURING THESE OPERATIONS TO AVOID PERSONAL INJURY.

5. DRILL FOUR 3.18 MM (1/8") PILOT HOLES FOR THE CHECK LINK BRACKET MOUNTING STUDS AT THE POINTS INDICATED ON THE REAR SIDE DOOR TEMPLATE.

6. DRILL FOUR 7.94 MM (5/16") HOLES FOR THE CHECK LINK BRACKET MOUNTING STUDS THROUGH THE PILOT HOLES DRILLED IN STEP 5.

7. DRILL FOUR 3.18 MM (1/8") PILOT HOLES AT THE CORNERS OF THE REAR SIDE DOOR TEMPLATE FOR THE CHECK LINK ACCESS OPENING.

8. DRILL FOUR 6.35 MM (1/4") HOLES THROUGH THE PILOT HOLES DRILLED FOR THE CHECK LINK ACCESS OPENING IN STEP 7.

9. USING A DIE GRINDER WITH A CUT-OFF WHEEL, OR THE EQUIVALENT, CUT ALONG THE LINES ON THE REAR SIDE DOOR TEMPLATE FOR THE CHECK LINK ACCESS OPENING IN ORDER TO CONNECT THE 4 HOLES DRILLED IN STEP 8.

10. USING A FILE OR DEBURRING TOOL, REMOVE ANY BURRS OR SHARP EDGES FROM THE CHECK LINK ACCESS HOLE IN THE REAR SIDE DOOR.

11. REMOVE THE METAL CUTOUT AND ANY OTHER DEBRIS FROM THE REAR SIDE DOOR.

12. DRILL TWO 3.18 MM (1/8") PILOT HOLES AT THE POINT INDICATED ON THE TEMPLATE ON THE SIDE DOOR OPENING.

13. FROM INSIDE THE VEHICLE, DRILL TWO 9.53 MM (3/8") HOLES THROUGH THE PILOT HOLES. PARTIALLY CLOSE THE REAR SIDE DOOR IN ORDER TO AVOID DAMAGE TO THE REAR SIDE DOOR WHEN DRILLING THESE HOLES.

14. APPLY TOUCH-UP PAINT TO ALL EXPOSED METAL EDGES.

#### IMPORTANT: PAINT THE CHECK LINK TO MATCH THE BODY COLOUR.

15. INSTALL THE REAR SIDE DOOR CHECK LINK THROUGH THE ACCESS HOLE IN THE REAR SIDE DOOR.

16. INSTALL THE CHECK LINK STUD PLATE TO THE SIDE DOOR OPENING (FIGURE 3).

17. INSTALL THE CHECK LINK TO THE STUDS (FIGURE 3, ITEM 3).

18. INSTALL THE CHECK LINK RETAINING NUTS TO THE STUDS ON THE REAR SIDE DOOR OPENING (FIGURE 3, ITEM 2).

19. TIGHTEN THE CHECK LINK RETAINING NUTS TO 30 N M (22 FT. LB.).

20. INSTALL THE CHECK LINK BRACKET TO THE REAR SIDE DOOR (FIGURE 4, ITEM 3).

21. INSTALL THE CHECK LINK BRACKET RETAINING NUTS TO THE REAR SIDE DOOR (FIGURE 4, ITEM 1).

22. TIGHTEN THE CHECK LINK BRACKET RETAINING NUTS TO 12 N M (108 IN. LB.).

23. CLOSE THE REAR SIDE DOOR IN ORDER TO ENGAGE THE CHECK LINK TO THE CHECK LINK BRACKET.

24. CAREFULLY OPEN AND CLOSE THE DOOR TO ENSURE THAT THE REAR SIDE DOOR CHECK LINK IS OPERATING CORRECTLY.

25. INSTALL THE PASSENGER BODY SIDE TRIM PANEL TO THE VEHICLE, IF EQUIPPED. REFER TO SECTION 10A4 OF THE SERVICE MANUAL.

26. INSTALL THE REAR SIDE DOOR TRIM PANEL TO THE VEHICLE, IF EQUIPPED. REFER TO SECTION 10A1 OF THE SERVICE MANUAL.

FIGRE 1 - CHECK LINK BRACKET MOUNTING HOLE TEMPLATE

LEGEND

1. REAR SIDE DOOR ASSEMBLY

2. BRACKET MOUNTING HOLE TEMPLATE

FIGURE 2 - CHECK LINK STUD PLATE TEMPLATE

LEGEND

1. CHECK LINK STUD PLATE TEMPLATE

FIGURE 3 - INSTALLING CHECK LINK ASSEMBLY

LEGEND

1. SIDE DOOR CHECK LINK ANCHOR

2. SIDE DOOR CHECK LINK NUT

3. SIDE DOOR CHECK LINK ASSEMBLY

4. FRONT AND SIDE DOOR OPENING FRAME ASSEMBLY

FIGURE 4 - CHECK LINK BRACKET INSTALLATION

LEGEND

1. SIDE DOOR CHECK LINK BRACKET NUT

2. SIDE DOOR ASSEMBLY

3. SIDE DOOR CHECK LINK BRACKET ASSEMBLY

CLAIM INFORMATION

#### IMPORTANT: THIS SPECIAL POLICY IS IN EFFECT UNTIL SEPTEMBER 30, 1999. DURING THE TIME THAT THIS SPECIAL POLICY IS IN EFFECT, THE FOLLOWING LABOUR CODES AND TIMES SHOULD BE USED FOR CLAIM SUBMISSION.

REPAIR PART FAILED PARTS LABOR LABOR PERFORMED COUNT PART NO. ALLOW CC-FC OP * MODEL HOURS

INSTALL LINK KIT 1 --- * MK-95 T5511

05 MODEL (CARGO) 0.8

05 MODEL WITH YF7 (UPFITTED) 1.1

06 MODEL (PASSENGER) 1.3

* THE "PARTS ALLOWANCE" SHOULD BE THE SUM TOTAL OF THE CURRENT GMSPO DEALER NET PRICE PLUS 40% FOR LINK KIT NEEDED TO COMPLETE THE REPAIR.

GM BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THESE 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 TOOLS, EQUIPMENT, 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 YOUR DEALER/RETAILER FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.

WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION

COPYRIGHT 1998 GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.