Body - Front Door Glass Loose/Wind Noise/Water Leaks

TECHNICAL

Bulletin No.: 09-08-64-020

Date: May 20, 2009

Subject: Front Side Door Glass Loose in Channel, Wind Noise, Water Leak (Revise Window Regulator Mounting Hole)

Models:
2008-2010 Chevrolet Cobalt (Sedan Only)
2008-2010 Pontiac G5 (Sedan Only)

Condition

Some customers may comment that the left and/or right front side door glass may leave the rear of the front side door window weatherstrip run channel when being cycled up or down. This may also lead to wind noise and water leak issues in the upper B-pillar area.

Cause

This condition may be caused by the window glass rocking forward in the door as the window is cycled. This may allow the glass to disengage from the rear of the front side door window weatherstrip run channel. The rocking condition may be caused by the window regulator being improperly positioned within the door.

Correction

Cycle the glass down, then up. If the glass disengages from the rear of the front side door window weatherstrip run channel when the window glass is being lifted, proceed with the following repair steps. If the glass appears to be operating correctly, proceed with the established diagnostic and repair procedures in SI to correct the condition.

Note
Do not replace the front side door window weatherstrip unless it is damaged.

1. Lower the door glass approximately 75 mm (3 in) on the affected door.
2. Remove the front side door trim panel. Refer to Front Side Door Trim Panel Replacement in SI.
3. Remove the two bolts retaining the arm rest bracket and remove the bracket.





4. Partially remove the front side door water deflector in order to gain access to the rear regulator mounting bolt area.





5. Locate the upper regulator arm. Using a paint pen, mark the present location on the inner door panel as shown.





6. Measure down 5 mm (3/16 in) from this marked location and create a second mark. This is the new upper regulator arm location.
7. Remove the bolt securing the upper regulator arm to the inner door panel.





8. Using a suitable tool, enlarge the mounting hole in the inner door panel as shown.
9. Apply small amount of a general purpose grease, such as GM P/N 1051344 (in Canada, use P/N 993037) Wheel Bearing Lubricant, or the equivalent, to the bare metal edges of the repair area in order to prevent corrosion.
10. Install the bolt securing the upper regulator arm to the inner door panel. Do not tighten.





11. Position the upper regulator arm at the new location created in Step 5.
12. With the regulator arm positioned, tighten the bolt.

Tighten
Tighten the bolt to 10 Nm (89 lb in).

13. Cycle the door glass up and down to verify the condition has been corrected.
14. Reinstall the front side door water deflector.
15. Reinstall the arm rest bracket.
16. Reinstall the front side door trim panel. Refer to Front Side Door Trim Panel Replacement in SI.





Parts Information

Warranty Information





For vehicles repaired under warranty, use the table above.





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