For 1990-2009 cars

# 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.

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