Campaign - Incorrect Door Hinge Bolts

Incorrect Door Hinge Bolt
# 05055 - (May 12, 2005)

Models:
2005 Chevrolet Malibu, Malibu Maxx, Cobalt
2005 Pontiac Pursuit

An involved VIN listing is contained in the Administrative Message (U.S.) or Dealer Communication (Canada). If any of these vehicles are still in your inventory, perform this repair as soon as possible but no later than June 30, 2005, at which time this bulletin will expire.

Condition

Some vehicles may have been built with one or more incorrect door hinge bolts.

Correction

Inspect all door hinge bolts and replace as needed.

Inspection Procedure

1. Open the front door.








2. Using an inspection mirror, check the hinge to body bolts for the bolt grade number.

- Hinge to body bolts with the grade 10.9 are correct and require no further action.

- Hinge to body bolts with the grade 9.8 must be replaced.





3. Repeat the inspection for all front door hinge to body bolts.

Important:
There are two hinge to body bolts per hinge. There are two hinges per door.





4. Inspect the rear door hinge to body bolts for the grade number.

- Hinge to body bolts with the grade of 10.9 are correct and require no further action.

- Hinge to body bolts with the grade 9.8 must be replaced.

Front Door Bolt Replacement Procedure

1. Open and support the door.

2. Disconnect the rubber conduit from the A-pillar.





3. Disconnect the front door harness electrical connector.

4. Remove the bolt from the check link.

5. With an assistance, remove the door side hinge bolts.

6. With an assistant, remove the front door from the vehicle.

7. Working one bolt at a time, replace any hinge to body bolt identified through the inspection procedure as requiring replacement.

Tighten

^ Malibu -- Tighten the front door hinge fasteners to 26 Nm (19 lb ft).

^ Cobalt/Pursuit -- Tighten the front door hinge fasteners to 35 Nm (26 lb ft)





8. With an assistant, position the front door to the hinges.

9. With an assistant, install the door hinge to front door bolts.

Tighten

^ Malibu -- Tighten the door hinge bolts to 26 Nm (19 lb ft).

^ Cobalt/Pursuit -- Tighten the door hinge bolts to 25 Nm (18 lb ft).

10. Install the bolt to the check link.

Tighten

Tighten the check link bolt to 20 Nm (15 lb ft)

11. Connect the front door electrical harness.

12. Connect the rubber conduit to the A-pillar.

13. Remove the support from the front door.

14. Inspect the door for proper operation and alignment.

15. Repeat this procedure on the opposite side front door as required.

Rear Door Bolt Replacement Procedure

1. Open the front door in order to remove the rear door hinge bolts..





2. Working one bolt at a time, replace any hinge to body bolts identified through the inspection procedure as requiring replacement.

Tighten

^ Malibu -- Tighten the rear door hinge fasteners to 26 Nm (19 lb ft).

^ Cobalt/Pursuit -- Tighten the rear door hinge fasteners to 35 Nm (26 lb ft)

3. Paint installed bolts with touch-up paint to match the body color.

4. Repeat this procedure on the opposite side rear door as required.





Parts Information





Warranty Information





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