Field Remedy: 2761

Remedy:

In case of customer complaint grind the paint in the area of corrosion 
down to the uncoated metal sheet and perform a paint repair stage III 
(as described in TIS2Web). See Working Procedure “Paint Stages”, 
Group “B – Paint/Painting Repair System”, Service Instruction Corsa-D.

Note:
If the listed chemical products are not available in your country, 
use usual equivalent available products (same specification) 
(egg. Sikkens 2K Primer Surfacer EP II).

Working Procedure:

Note:
If there are several corrosion dots in the lower aera at the tailgate 
(arrow) grind and repair the complete lower tailgate area (Picture I).

Note:
Picture I shows body style L68.

Important:
Remove the original sealing at the lower inner area at the tailgate 
(arrow) only if there are corrosion dots present (Picture II)!

 1. Clean outer repair area at tailgate

    Warning:
    Pay attention to the safety regulations!
    Arrange appropriate inhalation protection!

    - Use antistatic/Silicon remover (93165067 / 15 30 040)
    - Post-clean using degreaser – solvent-free –
      (93165312 / 65 30 017)

 2. Grind outer repair area at tailgate

    - Remove paint including zinc coat using an orbital grinder 
      and grinding disc (P40-P120)

 3. Grind lower/inner repair area at tailgate (Picture II, arrow)

    Warning:
    Pay attention to the safety regulations!
    Arrange appropriate inhalation protection!

    Important:
    This work step is only required if there are corrosion dots at 
    the lower/inner tailgate area!
    If there are NO corrosion dots in this area, the original sealing
    may NOT be removed!

    - Remove paint and zinc coat completely at border edges, folding,
      swage lines, edges, sealing seams, sealing compounds using an
      angle grinder and a pigtail steel brush, Roloc Bristle Disc or
      something comparable

    - Rework repair area using an orbital grinder and grinding
      disc (P120)

 4. Clean repair area using degreaser – solvent-free –
    (93165312 / 65 30 017)

 5. Filler repair area

    Important:
    For the filler coat the lower specified 2K EP priming filler 
    MUST be used !

    - Priming filler with 2K EP
      93165239 / 15 30 121,
      93165240 / 15 30 122,
      90009260 / 15 30 181 or
      90369080 / 15 30 172

    - Mixture ratio: Grinding version
      100 parts by volume 2K EP priming filler
       50 parts by volume hardener for 2K EP priming filler
       40 parts by volume general-purpose thinner V85/long

    - Apply 3 running single coats
    - Nozzle size: 1.8 – 2.0 mm
    - Injection pressure: According to the manufacturer specifications

    Note:
    Flash off time 5 – 10 Min. at 20°C

 6. Dry repair area

    Note:
    To guarantee a complete drying process medium till short wave
    infrared devices should be used.
    Alternatively an oven drying of 40 Min. at 60°C may be performed.

    Important:
    At temperatures below 15°C drying MUST be performed with an oven
    respectively with an infrared heating element!

 7. Grind repair area (dry)

    - Using grinding disc (P400 – P500)

    Important:
    Do NOT grind trough the edges!
    After grinding a dry coat thickness of at least 80 µm MUST be
    present!

    Note:
    Check folding and edges for too thin grinded areas.
    If required repeat step “4” to “6”.

 8. Apply sealing compound to border edges

    - 90093639 / 15 04 520

 9. Clean repair area using degreaser – solvent-free –
    (93165312 / 65 30 017)

10. Painting

    - Water-based paint and clear coat or
    - VOC finish paint

Spare-Parts:                            Part-No.:      Catalogue-No.:

Remover, Anti-static/Silicone           93165067       15 30 040
Cleaner, 5 Litre                        93165312       65 30 017
2K EP Filler, 3 Litre                   93165239       15 30 121
Hardener, 1 Litre                       93165240       15 30 122
Thinner, 2K, 1 Litre                    90009260       15 30 181
Thinner, Long, 5 Litre                  93165381       15 30 130
Compound, Sealing, 310 ml,              90093639       15 04 520
Vehicle outer side, white (Cartridge)

Labour Times:

A) Grinding – Tailgate:

                                                TC:      Hours:

U3 276 10      Grinding Paint and Zinc Coat –   90       0.2
               Tailgate (outside only)
U3 276 10 001  Tailgate (additional only)                0.4

B) Painting (Paint Stage III):

                                                TC:      MO   AP   NAP

B 0018 31      Tailgate Below Exterior -        20       1.4  0.2  0.3
               Handle, Outer – L08
               (One-coat Paint)

B 0018 31      Tailgate Below Exterior -        20       1.5  0.2  0.4
               Handle, Outer – L08
               (Two-coat Paint)

B 0018 31      Tailgate Below Exterior -        20       1.3  0.2  0.3
               Handle, Outer – L68
               (One-coat Paint)

B 0018 31      Tailgate Below Exterior -        20       1.4  0.3  0.4
               Handle, Outer – L68
               (Two-coat Paint)

B 0018 26      Tailgate Below Exterior -        20       1.5  0.2  0.4
               Handle, Outer Including
               Inner Side – L08
               (One-coat Paint)

B 0018 26      Tailgate Below Exterior -        20       1.6  0.3  0.5
               Handle, Outer Including
               Inner Side – L08
               (Two-coat Paint)

B 0018 26      Tailgate Below Exterior -        20       1.4  0.2  0.3
               Handle, Outer Including
               Inner Side – L68
               (One-coat Paint)

B 0018 26      Tailgate Below Exterior -        20       1.5  0.2  0.4
               Handle, Outer Including
               Inner Side – L68
               (Two-coat Paint)

Abbreviations:

TC:    Trouble Code
MO:    Major Operation
AP:    Adjacent Part
NAP:   Non-Adjacent Part

The costs for this repair will be covered during warranty and policy.
For policy please refer to the Policy Guideline (WebPG/Kuugel).
The regular Warranty Procedure will apply.