UPPER DOOR FRAME DISCOLOR./ CORROSION (REFINISH PROC.). Saturn Saturn 1991

For 1990-2009 cars

# UPPER DOOR FRAME DISCOLOR./ CORROSION (REFINISH PROC.)

#### SUBJECT: Discoloration of Upper Door Frames and Surface Corrosion on Inside and Outside Surface Edges of Upper Door Frames (Refinish Upper Door Frames)

Due to revisions in the affected model years and to the addition of a paint material allowance code under "CLAIM INFORMATION" this bulletin supersedes bulletin 91 - T - 49, which should be discarded.

#### MODELS AFFECTED: 1991 - 1992 Saturn Coupes and Sedans

CONDITION: Discoloration or surface corrosion on upper door frames.

CAUSE: Insufficient paint application to upper door frames and open seam on inside of door frame behind primary seal at rear of rear door.

CORRECTION: Perform the following procedures to remove the discoloration and/or surface corrosion.

#### PROCEDURE:

--------- 1. Lower door glass, remove primary and secondary seal from door frame (remove primary seal above belt line only as outlined in the "Doors" section of the "Body/Collision Repair Service Manual."

2. Remove outside mirror and outer beltline weatherstrip as outlined in the "Doors" section of the "Body/Collision Repair Service Manual."

3. Pull glass seal and door molding out of door frame as outlined in the "Doors" section of the "Body/Collision Repair Service Manual."

4. On rear doors, remove outer panel, door glass, and stationary vent window assembly as outlined in the "Doors" section of the "Body/Collision Repair Service Manual."

5. Wash entire upper door frame completely with a degreasing cleaner such as PPG DX-330 (or equivalent).

6. Thoroughly sand corroded areas to remove surface rust using 3M ROLOC (#07485) Surface Conditioning Discs (or equivalent). Clean seam inside of upper door frame with 3M Clean 'N Strip (#07460) Disc attached to a die grinder or drill motor.

7. Scuff sand remaining surface of upper door frame.

8. Inspect corners of door frame for cracks. If cracks or open edges are detected, note their location for further reference in step 11.

9. Treat exposed steel areas with a metal conditioner such as PPG DX-579 (or equivalent) followed by conversion treatment such as PPG DX-520 (or equivalent).

10. Mask off adjacent areas and apply PPG DP-90 Epoxy Prime (or equivalent) to door frame covering entire upper door frame.

11. Apply 3M DRIP-CHECK Sealer(#8531) (or equivalent) over epoxy primer to full length of seam in seal area and to any cracks detected in step 8.

12. Apply two to three coats of semi-gloss black code #19 DAU Urethane Enamel (or equivalent) to entire upper door frame.

#### NOTE: Prior to installation of door frame weatherstrips, refer to Bulletin No. 91-T-41 (Corp. No. 181512) for proper installation procedures.

13. Install rear door fixed vent window, glass seals, rear door glass, door moldings, primary and secondary seals as outlined in the "Doors" section of the "Body/Collision Repair Service Manual."

14. Install rear door outer panel, beltline weatherstrips and front door outside mirror as outlined in the "Doors" section of the "Body/Collision Repair Service Manual.

#### MATERIALS CHART:

PAINT METAL PAINT PAINT TYPE AND PAINT COMR MGF CONDITIONER PRIMER CODE STOCK # (PAINT) ------------------------------------------------------------------------- PPG DX-579 DP-90 19N 9640 and 858 DAU ACRYLIC DX-520 Urethane Enamel DuPont 244 S 615 S 19N 99J Alternate J 858 using 305 Low - Gloss Black-Cronar R-M 801 (R-M) DE-15 19N -Diamont Solo (Semi) Diamont or 858 DE-17

CLAIM INFORMATION: To receive credit for this repair, submit a claim through the Saturn Dealer System as follows: Labor Case Operation Type Description Code Time ----------------------------------------------------------- VW Repair and Refinish Left Front T9563 1.0 hrs Door Frame (All SL and SC) GD VW Repair and Refinish Right T9564 1.0 hrs Front Door Frame GD (All SL and SC) VW Repair and Refinish Left Rear T9565 1.0 hrs Door Frame GD

VW Repair and Refinish Right Rear T9566 1.0 hrs Door Frame GD

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.