Field Remedy: 2334

Remedy:

In case of customer complaint the inset for tank filler neck in the 
side panel has to be replaced. Therefore ordering of a complete side 
panel is no more necessary. If the contact face of the inset on the
side panel is damaged through corrosion too it has to be replaced by 
a individual made repair panel. This repair panel has to be attached
by adhering and tack welding.

Working procedure:

 1. Paint inset for tank filler neck in body colour

    Note:
    Attend to specifications for paint repair in service literature.

 2. Remove inner panelling luggage compartment right side

    - see according working procedure in TIS,
      group "C", Service Instruction Astra-G.

 3. Mask side panel in outer area around tank filler neck with 
    protective foil.

 4. Release tank filler neck (picture I)

    - Unscrew 2x screw (2)
    - Remove lid tank filler neck (3)
    - Unscrew 2x screw (arrows) from latch lid tank filler neck
    - Remove latch (5)
    - Remove sleeve (4)
    - Unscrew upper tightening screw tank filler neck (1)

    - Raise vehicle up to half height
    - Remove rear wheel on right side
    - Raise vehicle up to whole height
    - Unscrew lower tightening screw tank filler neck (1, picture II)
    - Turn tank filler neck down and to the side.

 5. Lower vehicle.

 6. Remove inset tank filler neck

    - Cover tank filler neck with a fire-extinguishing blanket

      Note:
      Use flame-retardant material

    - Detach inset tank filler neck (3, picture III) with parting 
      grinder (1) on overlap (2) of outer side panel (4)

      Note:
      Do not damage shackles (arrows)

    - Remove inset with pliers

      Note:
      Inset is bonded to inner side panel and must be pulled off

    - Bend shackles (1, picture IV) outwards and detach tacking from
      rear side with grinder (2)

      Note:
      Carry out procedure in succession on all shackles

    - Heat up bonding for inset tank filler neck with hot-air blower 
      and remove rest of sheet panel
    - Deburr shackles.

 7. Inspect bracket tank filler neck (4, picture V) for corrosion. If
    massive signs for corrosion are visible, a partial replacement of
    the bracket has to be carried out (not on F67)

    - Part off old bracket on height of buckling point (3)
    - Face new bracket onto old bracket and apply a marking on heigth
      of line (1) onto new bracket

      Note:
      Both brackets must align flush on outer sides (arrows)

    - Part off new bracket on heigth of the applied marking and fix 
      with self-grip pliers on old bracket

      Note:
      Both brackets must align flush on outer sides (arrows)

    - Make two drillings (4,1 mm) centrally located (2) between line 
      (1) and and buckling point (3)
    - Detach self-grip pliers and grind surface of old bracket on both
      sides with grinding machine until they are bright
    - Clean old and new bracket with cleaner and tissue from adhesive 
      kit
    - Apply adhesive on surface of old bracket

      Note:
      Use protective gloves

    - Attach new bracket and tighten with 2x rivet

      Note:
      Use exclusive watertight steel rivets listed below

      Note:
      Both brackets must align flush on outer sides (arrows).

 8. Clean bonding points (picture VI)

    - Grind surface of bonding points (arrows) on inner side panel and
      on shackles with grinding machine (1) until they are bright.

 9. Match new inset tank filler neck (picture VII)

      Note:
      On bodystyle F67 step 9. is invalid. Continue with step 10

    - Insert inset from vehicle interior

      Note:
      On bodystyle F35 eventually the inner wheelhouse must be bend
      over. After completion of working procedures the wheelhouse
      must be brought in its original position

    - Bring shackles in original position
    - Align inset on shackles and check alignment. Both cutouts (2) of
      inset must respectively align flush (arrow) between shackles (1)

      Note:
      If alignment is not okay correct with suitable equipment

    - Make drillings (4,1 mm) for rivets on old tackings 
      (arrow, picture VIII)
    - Remove inset.

10. Bond in new inset tank filler neck

    - Clean all bonding points
    - Apply adhesive as shown onto inner side panel (arrows, 
      picture IX), inset (arrows, picture X) and rear sides of 
      shackles

      Note:
      Use protective gloves

    - Insert inset tank filler neck 
    - Align inset on shackles and check alignment. Both cutouts 
      (2, picture VII) of inset must respectively align flush 
      (arrow, picture VII) between shackles (1, picture VII)
    - Tighten rivets

      Note:
      Use exclusive watertight steel rivets listed below

    - Straighten shackles with hammer and align to inset for tank
      filler neck
    - Apply adhesive on outer side of shackles and contact faces of
      side panel to inset
    - Smear all bonding points even with brush (smear adhesive also
      between inset and side panel)

      Note:
      Smear inner bonding point from wheelhousing

    - Clean drillings for tightening screws from adhesive.

      Note:
      Implicitly wait at least 2h to let adhesive harden before 
      starting further working procedures.

11. Make corrosion protection for inset tank filler neck (picture XI)

    - Mask area around inset on contact areas to side panel with tape
      (arrows)
    - Apply sprayable seam seal on whole surface of inset (1)
    - Paint inset in body colour

      Note:
      Attend to specifications for paint repair in service literature.

12. Apply sealing wax on bonding point on inner side panel

      Note:
      From vehicle interior.

13. Raise vehicle.

14. Apply sealing wax on bonding point on inner and outer side panel

      Note:
      From wheelhousing.

15. Insert tank filler neck into inset and screw in lower tightening
    screw and tighten.

16. Lower vehicle to half height.

17. Install rear wheel on right side.

18. Lower vehicle.

19. Screw in upper tightening screw for tank filler neck and tighten.

20. Insert sleeve tank filler neck.

21. Install latch for lid tank filler neck

    - Insert latch
    - Screw in 2x screw and tighten.

22. Install lid tank filler neck

   - Insert lid
   - Screw in 2x screw and tighten.

23. Install inner panelling luggage compartment right side

    - see according working procedure in TIS,
      group "C", Service Instruction Astra-G.

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

Inset for tank filler neck               90521303       08 06 332
Astra-G Limousine, Coupe, Cabrio

Inset for tank filler neck               90559333       08 06 331
Astra-G Caravan

Bracket for tank filler neck             90572653       90 98 059
Astra-G Limousine, Coupe

Bracket for tank filler neck             90572654       90 98 060
Astra-G Caravan

Adhesive kit                             93160535       15 05 000

Rivet                                    93184033       01 84 983

Sprayable seam seal                      90543279       15 03 176

Labour Times:                            TC:            Hours:

U3 233 40      Replacement tank          75             3,5
               filler neck

         001   Replacement bracket       75             0,2
               tank filler neck

         002   Make repair panel         75             SA

The costs for this repair will be covered during the normal corrosion 
warranty. The regular warranty procedure should be used for claiming
Set-up-time.