Field Remedy: 1699

Subject: Front doors of Antwerp built vehicles - Cracks in door frame

Models:	Engines:	Option:
Astra-G 1998...2000	All

Complaint:	Cracks are causing corrosion in the area front door to front door window frame.
Cause:	The radius in the critical area of the door frame is too small.
Production:	As of VIN Y5323762 problem is solved in production.

Remedy:

In case of customer complaint carry out the following instruction.

 1. Disconnect battery.

 2. Remove interior trim

    -see Working procedure "Interior trim, remove and reinstall", 
    unit "C" of Service-Instruction Astra-G.

 3. Remove window channel seal outer with plastic wedge.

 4. Remove retaining clip window channel seal.

 5. Remove rubber sash window guide rear.

 6. Mask adjacent surface for protection against damages.

 7. Remove airbag sticker.

 8. Remove paint and sealing in work area.

 9. Drill hole at tear ends with 3mm drill.

10. Put wet spange from inside in soldering area (heat conduction).

11. Solder cracks.

12. Sand and clean working area.

13. Fill and sand working area.

14. Ground working area.

15. Apply sealant.

16. Repaint the working area.

17. Apply cavity protection.

18. Install rubber sash window guide rear.

19. Install retaining clip window channel seal.

20. Install interior door trim

    -see Working procedure "Interior trim, remove and reinstall", 
    unit "C" of Service-Instruction Astra-G.

21. Connect battery.

22. Reprogramm volatile memories.