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Body shell complaint on door frame - AF72.00-P-2009B

MODEL 202, 203, 210 

MODIFICATION NOTES

20.2.06 op. no. 025242 completed and op. step 9 to 11 updated    
OPERATION NO. OF OPERATION TEXTS OR STANDARD TEXTS AND FLAT RATES

Category Op. no. Operation text
P 024773 Expose all window frames for test work
P 024774 Corrosion on window frame of the 1st door location: Eliminate (window frame exposed) repair stage 1
P 024775 Corrosion on window frame of the 2nd door location: Eliminate (window frame exposed) repair stage 1
P 024776 Corrosion on window frame of the 1st door location: Eliminate (window frame exposed) repair stage 2
P 024777 Corrosion on window frame of the 2nd door location: Eliminate (window frame exposed) repair stage 2
P 024778 Window frame of 1st door location: Paint
P 024779 Window frame of 2nd door location: Paint
P 024780 Corrosion on window frame of the 1st door location: Eliminate (window frame exposed) repair stage 3
P 024781 Corrosion on window frame of the 2nd door location: Eliminate (window frame exposed) repair stage 3
P 024782 Window frame of 1st door location: Paint above the strip
P 024783 Window frame of 2nd door location: Paint above the strip
P 024784 1st door location: Replace, modify with parts
P 024785 2nd door location: Replace, modify with parts
P 024836 Perform preparatory work for applying two-coat finish to fitted body panels
P 024835 Eliminate preparatory work for corrosion
P 024837 Carry out preparatory work for two-coat painting of removed body panels
P 024786 Paint 1st door stage 1-M (new part)
P 024787 Paint 2nd door stage 1-M (new part)
P 025242 Carry out addition for preparing body panels which have been removed in combination with body panels which have been installed
Damage code Cause Remedy  
60163 47 Corrosion on door frame. 1 Open the door to be checked.
IMPORTANT All the doors should be checked for signs of corrosion in the event of a customer complaint.
IMPORTANT Use Op. no. 024773.		  
    2 Detach rubber seal from door frame.  
    3 Clean rubber seal.  
    4 Carry out visual inspection for corrosion in the area (A and B).
IMPORTANT Select remedy as per the damage profile.		  
    5 Check for corrosion in area (C) using a mirror.
IMPORTANT Select remedy as per the damage profile.		  
60228 47   6 Carry out preparatory work for corrosion.
IMPORTANT Use Op. no. 024835.
Only in the case of remedy 1 to 3!
IMPORTANT Corrosion in the non-visible area (B and C) under the rubber seal:
Remedy 1:  ↓		  
72A01 DC (LF door)
72N01 DC (right front door)
73A01 DC (left rear door)
73N01 DC (right rear door)		   7.1 Eliminate bodyshell complaint on window frame (repair stage 1).
IMPORTANT Use Op. no. 024774, 024775.		 AR97.00-P-1001F
    IMPORTANT Corrosion also in visible area (A) which can be touched up:
Remedy 2:  ↓
IMPORTANTThe preparatory time is the same for all damaged parts and can be only be applied once per job. 		  
72A01 DD (LF door)
72N01 DD (right front door)
73A01 DD (left rear door)
73N01 DD (right rear door)
60162 47 (preparation time)		   7.2 Eliminate bodyshell complaint on window frame (repair stage 2).
IMPORTANT Op. no. 024776, 024778, 024777, 024779 and 024836.		 AR97.00-P-1002F
    IMPORTANT Corrosion also in the visible area (A) which can no longer be touched up:
Remedy 3:  ↓
IMPORTANTThe preparatory time is the same for all damaged parts and can be only be applied once per job. 		  
72A01 47 (LF door)
72N01 47 (right front door)
73A01 47 (left rear door)
73N01 47 (right rear door)
60162 47 (preparation time)		   7.3 Eliminate bodyshell complaint on window frame (repair stage 3).
IMPORTANT Op. no. 024780, 024782, 024781, 024783 and 024836.		 AR97.00-P-1003F
    IMPORTANT Replacing the door is only justified if:
  1. After separating the fold corrosion occurs in area (E)
  2. Corrosion also occurs at other points on the door and the costs of repair exceed that of replacement.

Remedy 4:  ↓
IMPORTANTThe preparatory time is the same for all damaged parts and can be only be applied once per job. 		  
72A01 DA (LF door)
72N01 DA (right front door)
60162 47 (preparation time)		   7.4 Replace front door.
IMPORTANT Use Op. no. 024784, 024786 and 024837.		  
    Model 202 AR72.10-P-0500E
    Model 203 AR72.10-P-0500P 
    Model 210 AR72.10-P-0500F
73A01 DA (left rear door)
73N01 DA (right rear door)
60162 47 (preparation time)		   8 Replace rear door.
IMPORTANT Use Op. no. 024785, 024787 and 024837.		  
    Model 202 AR72.12-P-0600E
    Model 203.0/2 AR72.12-P-0600P 
    Model 210 AR72.12-P-0600F
    9 Wax inner door frame.
IMPORTANT Not with remedy 1 to 3		  
    Preservation agent *BR00.45-Z-1011-05A 
    10 Install rubber seal in door frame.
IMPORTANT Not with remedy 1 to 3		  
    11 Wax window frame
IMPORTANT Not with remedy 1 to 3		  
    Wax bottle set for door frame *BR00.45-Z-1010-05A 
    Preservation agent *BR00.45-Z-1015-05A 

Cross-section of window frame 

Fig 1: Cross-Section Of Window Frame
G04737773

Fold on window frame 

Fig 2: Identifying Area Between Door Frame
G04737774
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1015-05A Preservation agent A 000 989 72 70 10
BR00.45-Z-1010-05A Wax bottle set for door frame Volker Farbspritztechnik GmbH
Bahnhofstr. 14
79194 Gundelfingen
Germany
Order no.: B63600000
BR00.45-Z-1011-05A Preservation agent A 000 986 72 70 10
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