SMU - SEC. 10-13 - REV. REMOVE AND INSTALL PROC. FOR HEADER

SUBJECT: SERVICE MANUAL UPDATE - SECTION 10-13 - REVISED REMOVE AND INSTALL PROCEDURE FOR HEADER WEATHERSTRIP AND RETAINERS

MODELS: 1995-98 CHEVROLET CAVALIER (CONVERTIBLE ONLY) 1995-98 PONTIAC SUNFIRE (CONVERTIBLE ONLY)

THIS BULLETIN IS BEING ISSUED TO REVISE THE REMOVE AND INSTALL PROCEDURE FOR HEADER WEATHERSTRIP AND RETAINERS, CONVERTIBLE ONLY, IN SECTION 10-13 OF THE SERVICE MANUAL.

PROCEDURE:

HEADER WEATHERSTRIP AND RETAINERS

REMOVE OR DISCONNECT -

IMPORTANT:

REMOVING THE WEATHERSTRIP RETAINERS IS NOT NECESSARY IF ONLY THE WEATHERSTRIP IS TO BE SERVICED.

1. UNLATCH AND LOWER FOLDING TOP.

2. WINDSHIELD GARNISH MOLDING. REFER TO WINDSHIELD GARNISH MOLDING IN THIS SECTION.

3. PUSH-PIN RETAINERS SECURING THE HEADER WEATHERSTRIP AT TOP OF THE LH AND RH A-PILLARS.

4. CLIPS SECURING THE HEADER WEATHERSTRIP AT BOTTOM OF THE LH AND RH A-PILLARS.

5. HEADER WEATHERSTRIP BY PULLING UP WHILE SEPARATING THE ADHESIVE BOND WITH A FLAT BLADED TOOL.

6. SCREWS SECURING A-PILLAR WEATHERSTRIP RETAINER.

7. SCREWS SECURING HEADER WEATHERSTRIP RETAINER.

8. HEADER WEATHERSTRIP RETAINER.

9. HEADER GARNISH MOLDING RETAINER.

CLEAN

- ADHESIVE FROM PARTS THAT WILL BE REUSED

- FOAM TAPE FROM PARTS THAT WILL BE REUSED

- FOAM TAPE FROM HEADER SURFACE

- BUTYL TAPE FROM HEADER SURFACE

INSPECT

- HEADER WEATHERSTRIP FOR HOLES, RIPS OR BREAKS IN THE SURFACE SKIN. IF HOLES, RIPS OR BREAKS ARE FOUND, THE WEATHERSTRIP MUST BE REPLACED.

INSTALL OR CONNECT -

1. 50.8 MM (2 IN) LONG X 12.7 MM (1/2 IN) WIDE X 1.6 MM (1/16 IN) THICK BUTYL TAPE TO HEADER SURFACE CENTERED OVER BOTH DITCH MOLDINGS. SEE FIGURES 1 AND 2.

2. 1,524 MM (60 IN) LONG X 25.4 MM (1 IN) WIDE X 3.2 MM (1/8 IN) THICK PVC CLOSED-CELL FOAM TAPE CENTERED SIDE-TO-SIDE TO HEADER SURFACE. SEE FIGURE 3.

3. 1,524 MM (60 IN) LONG X 12.7 MM (1/2 IN) WIDE X 1.6 MM (1/16 IN) THICK BUTYL TAPE RUNNING FROM TOP END OF ONE A-PILLAR WEATHERSTRIP RETAINER, UP AND ACROSS THE HEADER, OVERLAPPING THE DITCH MOLDINGS BUTYL AND TO THE TOP EDGE OF THE OTHER A-PILLAR. DO NOT REMOVE THE PROTECTIVE BACKING FROM THE BUTYL TAPE AT THIS TIME. SEE FIGURE 4.

4. HEADER WEATHERSTRIP RETAINER TO HEADER.

5. SCREWS SECURING HEADER WEATHERSTRIP RETAINER.

6. WINDSHIELD GARNISH MOLDING. REFER TO WINDSHIELD GARNISH MOLDING IN THIS SECTION.

7. CONTINUOUS 4.8 MM (3/16 IN) DIAMETER BEAD OF PUMPABLE BUTYL INSIDE HEADER WEATHERSTRIP RETAINER, OUT AND DOWN TO BOTH A-PILLAR WEATHERSTRIP RETAINERS. SEE FIGURE 5.

8. LAY FRONT HEADER WEATHERSTRIP IN POSITION TO THE HEADER RETAINER.

9. PUSH-PIN RETAINERS TO SECURE LH AND RH ENDS OF WEATHERSTRIP TO HEADER CORNERS.

10. USING A PLASTIC TRIM STICK OR WHEEL-TYPE INSTALLATION TOOL, INSTALL THE FRONT OF WEATHERSTRIP INTO THE RETAINER.

11. BOTTOM CLIPS OF WEATHERSTRIP AT THE A-PILLAR.

12. REMOVE PROTECTIVE BACKING FROM THE BUTYL TAPE.

13. SMOOTH OUT WEATHERSTRIP IN THE HEADER RETAINER TO WORK OUT ANY WRINKLES ALONG HEADER AND AT THE A-PILLARS. ENSURE THE A-PILLAR CORNERS OF WEATHERSTRIP DO NOT EXCESSIVELY ROLL DOWNWARD. OTHERWISE, THE DOOR GLASS, WHEN CLOSED, WILL PULL SEAL DOWNWARD MORE.

14. PUMPABLE BUTYL AT LH AND RH BOTTOM ENDS OF THE A-PILLAR PART OF THE WEATHERSTRIP. SEE FIGURE 6.

15. A-PILLAR PART OF THE WEATHERSTRIP TO WEATHERSTRIP RETAINER, USING A PLASTIC TRIM STICK.

16. WEATHERSTRIP ALL ALONG THE BUTYL STRIP.

17. CLOSE CONVERTIBLE TOP AND FULLY RAISE THE DOOR WINDOWS. ENSURE THE DOOR WINDOW TO A-PILLAR CORNER SEAL IS A PROPER FIT.

FIGURES: 06 ATTACHMENTS: 00

FIGURE 1 1. DITCH MOLDING 2. BUTYL TAPE

FIGURE 2 1. BUTYL TAPE 2. HEADER SURFACE

FIGURE 3 1. FOAM TAPE 2. HEADER SURFACE

FIGURE 4 1. 1,524 MM (60 IN) LONG BUTYL TAPE 2. HEADER SURFACE

FIGURE 5 1. PUMPABLE BUTYL

FIGURE 6 1. PUMPABLE BUTYL

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.

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