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Corrosion on Door White Deposits on Door Primary Weatherstrip

Subject:Corrosion on Door or White Deposits on Door Primary Weatherstrip -- Repair Door -- Due to revisions under Models Affected, this bulletin supersedes bulletin 97-T-23, which should be discarded.

Models:1997-1999 Saturn Coupes and, 1996-1999 Saturn Sedans and Wagons.



Condition:

Some owners may comment on corrosion developing on the door at the weatherstrip contact area and of a white powder developing on the primary weatherstrip surface.

Cause:

An abrasive substance that forms on the door primary weatherstrip abrades the corrosion protection applied to the door.

Procedure:

Inspect all doors and refer to the following Level of Damage Chart and perform the corrective procedure referred to in the chart.

Level Of Damage Chart

If the Door is...

Then...

Pitted Red Rust

Sand with 180 grit sandpaper or sand blast

Sand with 280 grit sandpaper

Sand with 400 grit sandpaper

Refinish the door. Refer to the recommended paint process in this bulletin

Surface Oxidation

Sand with 280 grit sandpaper

Sand with 400 grit sandpaper

Refinish the door. Refer to the recommended paint process in this bulletin

Minor Scuffing

Sand with 400 grit sandpaper

Refinish the door. Refer to the recommended paint process in this bulletin

Refer to the following Recommended Paint Repair Products Chart for the recommended repair products to refinish the repaired doors.

Recommended Paint Repair Products Chart

Supplier

Primer Process

Topcoat Process

AKZO Nobel/Sikkens

Washprimer CR

Autocryl Filler

Autocryl+

Flattening Agent

American Standbox

Etching Adhesion Primer

SX 11158+

2K Nonstop Primer Filler

Standocryl+

Flattening Agent

Dupont

615 Variprime

2610 Prime ® Seal

Chroma One+

4541 S Flattener

ICI Auto Color

P565-713 Chromat Free Etch Primer

P565-357-358 Wet on Wet Sealer

P420 Single Layer Black+

P565-554 Matting Agent

PPG

DP90

Deltron DCC9971

Sherwin Williams

E2 G980 G.B.P.

P6A48 Ultra Fill II

Ultra 7000+

T1F 271 Exterior

Flattening Base

Spies Hecker

Priomat 2688+

Permacron 8590

Permacron FP1004

We Believe these sources and their products to be reliable. There may be additional manufacturers of such products. Saturn does not endorse, indicate any preference for, or assume any responsibility for the products from these firms, or for any items which may be available from other sources.

After the door is refinished, install 3M® SCOTCHCAL Paint Protective Film P/N 84701, or equivalent, to the area of the door primary weatherstrip contact to door. This area can be determined by spraying the door primary weatherstrip with water and gently closing the door.


Object Number: 877992  Size: MF

Notice: When trimming paint protective film, be careful not to cut or scratch the paint beneath the protective film.

Notice: Do not bridge over seam sealant tape or rubber muckets used on the window frame to door joints on Sedans and Wagons with the paint protective film.

On Sedans and Wagons, install the paint protective film in 2 separate pieces to the window frame and door lower. Make sure the end points of the protective film are at the window frame to door lower joints as shown in the illustration.

Clean the door primary weatherstrip contact surface of the remaining doors with 3M® General Purpose Adhesive Cleaner P/N 08984 or equivalent, and apply 3M® SCOTCHCAL Paint Protective Film P/N 84701 or equivalent to the area of the door primary weatherstrip contact to the door.

Important: Make sure to wipe off excess silicone paste from the door primary weatherstrip with a clean dry cloth.

Clean the door primary weatherstrip surfaces with 3M® General Purpose Adhesive Cleaner P/N 08984 or equivalent, and apply a coat of 3M® Silicone Paste P/N 51135-08946 or equivalent.

Parts Requirements:

Part Number

Description

84701

3M® SCOTCHCAL Paint Protective Film

08984

3M® General Purpose Adhesive Cleaner

51135-08946

3M® Silicone Paste

CLAIM INFORMATION

To receive credit for this repair, submit a claim through the Saturn Dealer System as follows:

--

Case Type

Description

Labor Operation Code

Time

--

VW

Repair and Refinish One Door 1996-1999 Sedans/Wagons

T9749

2.60 hrs GF

--

VW

Repair and Refinish One Door 1997-1999 Coupes

T9749

1.80 hrs GF

--

VW

Repair and Refinish Two Doors 1996-1999 Sedans/Wagons

T9750

3.50 hrs GG

--

VW

Repair and Refinish Two Doors 1997-1999 Coupes

T9750

2.70 hrs GH

--

VW

Repair and Refinish Three Doors 1996-1999 Sedans/Wagons

T9751

4.40 hrs GH

--

VW

Repair and Refinish Four Doors 1996-1999 Sedans/Wagons

T9752

5.30 hrs GI