CAMPAIGN: REAR DOOR LATCH. Geo Metro 1995

For 1990-2009 cars

# CAMPAIGN: REAR DOOR LATCH

#### Subject: PRODUCT CAMPAIGN 95-C-66 - REAR DOOR LATCH

#### Model and Year: 1995 CHEVROLET GEO METRO 4-DOOR SEDAN

#### To: All Chevrolet Geo Dealers

General Motors has determined that certain 1995 Chevrolet Geo Metro 4-Door Sedan model vehicles built with manual door locks, may experience an inoperative rear door lock mechanism during outside rear door handle operation. This condition is caused by the deformation of the internal door latch lever.

To prevent the possibility of this condition from occurring, dealers are to install a new reinforcing brace to support the latch lever and eliminate deflection.

#### VEHICLES INVOLVED

Involved are certain 1995 Chevrolet Geo Metro 4-Door Sedan model vehicles built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ---- ----- -------- 1995 Metro Ingersoll "6" S6700175 S6793041

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

#### PARTS INFORMATION

#### NOTICE:

A pre-shipment of part number 91173162 will be sent to involved dealers the week of January 28, 1996. Preshipment will equal parts for 20% to 25% of the number of vehicles to be repaired. Pre-shipment parts will be charged to the dealers, open parts account.

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2). All Goodwrench part system test retailers should order on a "VIP" order.

Quantity/ Part Number Description Vehicle ----------- ----------- -------- 91173162 Reinforcement Kit, Rear Door Latch 1

#### OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin).

#### DEALER CAMPAIGN RESPONSIBILITY

All unsold new vehicles in dealers' possession and subject to this campaign must be held and inspected/repaired per the service procedure of this campaign bulletin before owners take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owners letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

#### SERVICE PROCEDURE

#### NOTE: CHECK VEHICLE HISTORY FOR PRIOR WARRANTY REPAIR TO INSTALL LATCHES - 30018636-8. IF BOTH REAR LATCHES HAVE BEEN PREVIOUSLY INSTALLED, NOTE THE REPAIR ORDER NUMBER AND DATE AND PROCEED TO STEP 19 AND INSTALL CAMPAIGN LABEL. USE LABOR OPERATION V9880.

#### SERVICE T0 BE PERFORMED ON BOTH REAR DOORS

1. Remove rear window regulator handle, door trim panel and water deflector following applicable Service Manual Procedure, Section 10-6, Rear Door Trim.

2. Inspect to determine if a NEW door latch mechanism, with extended set plate, has already been installed (Figure 1, Page 4)(repair performed under warranty).

A). Proceed to Step #3 if New latch mechanism IS NOT present.

B). Proceed to Step #17 if New latch mechanism is present.

3. Remove rear door handle rod.

4. Remove door handle push rod from rear door handle and remove lock knob by rotating.

5. Remove bushing from door outside handle (Figure 2).

6. Loosen three (3) screws securing door latch.

7. Aligning screw hole in door inner panel and reinforcement brace. Install reinforcement brace between door inner panel and door latch using screw supplied in kit (Figure 3), torque to 2.0-2.5 Nm (1.5-1.8 lb. ft.).

#### Note: Ensure edge of brace is flush with edge of door insert panel (Figure 4).

8. Tighten three (3) screws securing door latch and torque to 6.0 Nm + .5 Nm (53 lb. in. + 4 lb. in.).

9. Install "One Touch Clip" to handle.

#### Note: Ensure opening is directed to the inside of vehicle (Figure 5).

10. Ensure door handle push rod is pushed completely down and door handle is completely closed then install "One Touch Clip" to the push rod (Figure 6).

11. Measure door latch release position according to the following procedure (See Figure 7, Page 7):

A). Lock door latch by pushing in its claw with a screwdriver. If a click is heard twice, it is locked securely.

B). Apply a scale so that it is at a right angle to door surface and contacts outside handle as shown on next page.

C). Operate outside handle until a click is heard, and measure dimension (a) [Spec: 14-18mm (0.56-0.70in.)].

12. If measurement is not within specifications, remove push rod from "One Touch Clip" and adjust accordingly. If measurement is within specification, proceed to Step 13.

13. Install rear door handle rod.

14. Check interior and exterior rear door handle operation with inside door lock UNLOCKED.

15. Check interior and exterior rear door handle operation with inside door lock LOCKED.

16. Apply small amount (1cc) of grease to door latch spring.

17. Install water deflector, interior door trim panel and window regulator handle following applicable Service Manual Procedure, Section 10-6, Rear Door Trim.

18. Perform steps 1 through 17 on other rear door.

19. Install Campaign Identification Label.

#### CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected 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 and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner. When using the new campaign identification label, be sure to install the clear protective covering. Additional "Campaign Identification Labels" can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday through Friday 8:00 a.m. to 4:30 p.m. EST). Ask for Item Number S-1015 when ordering.

Apply "Campaign Identification Label" only on a clean, dry surface.

#### CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

FAILED PARTS LABOR LABOR REPAIR PERFORMED PC PART NO. ALLOW CC-FC OP HOURS ---------------- -- -------- ----- ----- ----- ----- Inspect Records For Both Door - -- -- Latches Previously installed MA-96 V9880 0.2 Under Warranty - Part Number 30018636-8

Inspect - Both Doors Have New Latch Previously Installed - No - -- -- MA-96 V9881 0.4 Brace Kit Required

Inspect - One Door Has New 1 91173162 ** MA-96 V9882 0.5 Latch Previously Installed - One Door Requires Brace Installation

Add: Two Doors Require Brace - -- -- -- - 0.2

* For Campaign Administrative Allowance, add 0.1 hours to the "Labor Hours"

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 40% of all parts required for the repair.

Refer to the General Motors Claims Processing Manual for details on Product Campaign Claim Submission.

Dear Chevrolet Geo Metro Owner:

This notice is sent to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.

REASON FOR THIS RECALL

General Motors has determined that certain 1995 Chevrolet Geo Metro 4-Door Sedan model vehicles built with manual door locks, may experience an inoperative rear door lock mechanism during outside rear door handle operation. This condition is caused by the deformation of the internal door latch lever.

WHAT WE WILL DO

To prevent the possibility of this condition from occurring, dealers are to install a new reinforcing brace to support the latch lever and eliminate deflection. This service will be performed for you at no charge.

WHAT YOU SHOULD DO

Please contact your Chevrolet Geo dealer as soon as possible to arrange a service date and so the dealer may order the necessary parts for the repair. Instructions for making this correction have been sent to your dealer and parts are available. You may ask your dealer if you wish to know how much time will be needed to schedule and process your vehicle.

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Chevrolet Motor Division GENERAL MOTORS CORPORATION

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.