Body Pop or Click Noise at Rear When Driving Over Bumps at Slow Speeds – 2014-2016 Chevrolet Malibu

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Bulletin No.: 15-NA-075 Date: Dec-2015 Subject: Body Pop or Click Noise at Rear When Driving Over Bumps at Slow Speeds Attention: This Bulletin also applies to any of the models that may be Export vehicles. Brand: Model: Model Year: VIN: Engine: Transmission: from to from to Chevrolet Malibu 2014 2015 All All Chevrolet Malibu Limited 2016 2016 All All Condition Some customers may comment that an intermittent pop or click noise is heard when driving over bumps at slower speeds. This noise may be most noticed near the passenger side C-pillar, just behind the rear seatback. Cause The cause of the condition may be due to a process weld missing from the passenger side inner body sheet metal. This process weld normally joins the right quarter inner panel brace to the right quarter inner panel to reduce noise between the two panels. The vehicles missing the process weld were specifically found to be Fairfax built vehicles. All vehicle testing and validation were performed without this process weld. Plant Location VIN position 11 – F (Fairfax) Correction For those vehicles missing the weld, a rivet will need to be installed at the location noted in the repair procedure below. Service Procedure: Verify the missing weld and install the rivet referenced in the parts table following the steps below. 1 1. Lower the passenger side seatback and remove the upper/forward fastener (1) from the right rear compartment side trim panel. 2. Pull back the front portion of the trim panel and acoustic material to access the forward right side of the inner rear compartment. 3. Inspect the inner sheet metal to verify the missing weld. Examples of a proper weld (1) and missing weld (2) are shown in the graphic above. 2 4. Accessing the area through the rear seat opening, locate the large circular opening (1) just below the compartment lid strut. The added rivet will be located above and forward of this opening. Important: Though not visible, the above illustration shows the position of the right quarter inner panel brace, located behind the quarter inner panel. The added rivet MUST be contained within the cross-hatch area (1) to ensure it engages both layers of sheet metal. 5. Mark a location on the right rear inner sheet metal in the approximate location shown by the rivet in the illustration above. Ensure the location will allow installation of the rivet on the flat surface of the sheet metal, as close to the wall radius as possible without causing interference. 6. Center punch the location. 3 Important: Ensure that the drilled hole and rivet is fully contained within the flange of the right quarter inner panel brace. As shown in the example above, avoid the hole/rivet position extending outside the edge of the brace. Note: The position of the right quarter inner brace can vary slightly due to possible build variation in the body sheet metal. Ensure the two layers of sheet metal overlap in the spot where the center punch is made. 7. Insert a finger through the circular opening, feeling for the edge of the right quarter inner brace (1). Ensure the center punch is within the flange of the quarter inner brace. 8. Place a drill stop or masking tape at a depth of 15 mm (0.590 in) on to a 6.8 mm (17/64 in) drill bit. 9. Drill a hole at the location of the center punch. Clean any burrs or rough edges from the drilled hole. 4 10. *Prepare a small portion of catalyzed primer in a mixing cup. Note: *Refer to the current GM Approved Refinish Materials booklet (GMW-15406) for specific products. To access the booklet, go to www.genuinegmparts.com. Click on Collision Repair. From this page, Click on Paint Shop. Select current GM Approved Refinish Materials. In Canada, the GM Approved Refinish Materials Booklet is also available in GM GlobalConnect in the REFERENCE LIBRARY under Service Department. 11. Using a small brush, apply primer around the edges of the drilled hole. Also, dip the tip of the rivet into the primer. 12. Install the rivet using a rivet gun. 13. Reposition the acoustic material and the trim panel. 14. Reinstall the upper/forward trim panel fastener and raise the seatback. Parts Information 5 Description Part Number Quantity RIVET ASM – INTERLOCK 11561547 1 Warranty Information Labor Operation Description Labor Time Material Allowance 1480608* Install Rivet to Passenger Rear Compartment Inner Sheet Metal 0.4 hr $4.50 USD $5.97 CAD *This is a unique Labor Operation for Bulletin use only. Version 1 Modified
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