CEG P-Pages - Mitchell WorkCenter

CEG P-Pages - Mitchell WorkCenter
Estimating Information
Parts General Information
Parts Illustrations
The linking of detailed, exploded diagrams and text in each section helps
you note all of the affected parts. Those parts most likely to be damaged
together are displayed together.
Part Numbers
Part numbers are included to facilitate estimating. It is recommended, however, that the year, make, model and VIN or model code information be
given to dealership personnel for verification of application and most current
pricing. There are often non-interchangeable right-hand and left-hand parts
which have the same price and are similar in format. Those right and left
part numbers are combined on one line, always listing the right part first
(example: 4016306-7). This means the right number is 4016306 and the left
number is 4016307. This applies whether the right number is the higher or
the lower. If the right and left numbers differ widely, each is listed on a separate line.
Discontinued Parts
Occasionally parts are discontinued by manufacturers. Any discontinued
parts that Mitchell can identify will continue to be carried in the Guide, but
will be identified by a "d" preceding the part price. Any part number and part
price listed with a preceding "d" should be considered to be the last available factory information.
P1
Special Pricing
As described below, certain replacement parts are included in the General
Motors Goodwrench Service Merchandising Parts (GSMP) Program or the
Mopar Competitive Crash Parts Program. These parts are designated by
either a “black box” or the “§” symbol in the parts price column.
General Motors Goodwrench Service Merchandising Parts (GSMP)
Program: Parts included in this program may not have a manufacturer’s
suggested retail price. The price, if any, following this symbol is an approximation that you may find helpful. The actual price may be higher or lower,
and can be determined by contacting your local dealer.
Mopar Competitive Crash Parts Program: Parts included in this program may be available with special pricing. Additional purchase discounts
may apply. See your Chrysler Corporation dealership for availability and
participation. Dealers are not required to adhere to suggested prices and
are free to set their own prices for parts.
Glass Prices
There are instances where the vehicle manufacturer does not provide
replacement glass. Therefore, both the manufacturers’ and National Auto
Glass Specifications (NAGS) prices are listed throughout the Guide. NAGS
part numbers and prices are produced under license from NAGS INTERNATIONAL—All rights reserved.
Remanufactured Parts
Database Inquiries/Toll-Free Number
Where possible, remanufactured parts are listed by vehicle manufacturer.
From time to time, however, the manufacturer may supersede a new part to
a remanufactured part and/or not identify a part as being remanufactured.
Therefore, care should be exercised when ordering parts that are often
remanufactured, including, but not limited to alternators, water pumps, starters, brake calipers, control modules, A/C compressors, air flow meters, ignition distributors, axle shafts, power steering pumps, radios, steering racks,
and turbochargers. All known remanufactured parts will be identified by a
"R" preceding the part price. Any part number and part price listed with a
preceding "R" should be considered to be the last available factory information. These remanufactured parts may have a core charge in addition to the
part price listed. Often, collision damage makes a core ineligible for return.
Contact the dealer for policy clarification before remanufactured parts are
purchased.
Your comments and suggestions are appreciated and invaluable to us. Call
us toll-free at 800-854-7030 or 858-368-7000. You can also fax us toll-free
at 888-256-7969 or 858-549-0629. Inquiries via email may also be sent to
[email protected] You will receive a prompt response
to each inquiry.
OEM Refinished Parts
Mitchell lists as many colors of OEM pre-painted, high impact parts as is
practical. The manufacturer will sometimes, without notice, replace a prepainted part with a part that requires refinishing. Dealer contact may be
required for these items.
Non-Reusable Parts
Some attachment components may not be suitable for reuse (examples:
plastic clips, fasteners, suspension bolts). Caution should be taken when
estimating removal and/or replacement. It should be agreed upon as to
what parts may require replacement even though not noticeably damaged.
Federal Motor Vehicle Theft Prevention Act
Federal Motor Vehicle Theft Prevention Action of 1984 mandates that high
theft vehicles carry a VIN identification sticker on major components. This
law also mandates replacement parts must carry this identification in the
form of an R-DOT (Replacement-Department of Transportation) label. Penalties may apply to their removal or alteration. Contact NHTSA or the part
manufacturer for further information.
Price General Information
Parts Prices
Each issue of the Guide reflects the latest pricing activity available from the
vehicle manufacturers at time of printing. The prices shown in each issue
are MANUFACTURERS’ SUGGESTED RETAIL PRICES. PRICES AND
AVAILABILITY OF PARTS VARY FROM TIME TO TIME AND BY GEOGRAPHICAL AREA, AND ARE SUBJECT TO CHANGE WITHOUT
NOTICE.
Symbols
The following symbols are used throughout Mitchell
Estimating information and are explained in detail in
each section.
d — Discontinued Part:
nation.
Refer to Parts General Information for full expla-
§ or “black box” — Special Pricing:
for full explanation.
Refer to Price General Information
¶ — Part Footnote: Special part situations or requirements are denoted
with a footnote symbol. The explanation follows as closely as possible to the
part referenced.
(P) — Paint to Match: A designation that appears immediately after a
part description or application to identify components that must be painted
to match the exterior/interior color of the vehicle.
(R) — Remanufactured Part:
explanation.
Refer to Parts General Information for full
# — Labor Footnote: Special labor situations or requirements are denoted with a footnote symbol. The explanation follows as closely as possible to
the time referenced.
m — Mechanical Operation: A designation that appears in a separate
text column to the left of the labor time column to identify components for
which R&I or R&R is commonly considered to be a mechanical operation
when performed in a collision repair environment.
s — Unibody Structural Component: A designation that appears in a
separate text column to the left of the labor time column to identify unibody
structural components—those which support the weight of the vehicle and
absorb the energy of the impact as well as road shock.
P2
Estimating Information
Guide Layout Sequence
Identify the Vehicle
Models are often combined in one service because there is enough similarity between them that a separate service for each is not necessary. Record
all model identification information on the damage report. Paint code locations are found in the front of the Guide and/or the beginning of each service. This will save time in searching for refinish codes or touchup paint.
Use the Layout as a Guide
An alphabetized Section Index can be found at the beginning of each service. Arranged from front to rear and from outside the vehicle inward are
about 30 sections for each service (example: grille, quarter panel, luggage
lid). Most have illustrations in which the components are identified and
described, and part numbers, part prices, and labor times are shown. The
descriptions are carefully arranged to depict the most frequent kinds of collision damage.
Overlap
If adjoining parts are being replaced (example: quarter and rear body panels), there is an overlap in that both individual operations include common
welded surfaces or parts attached to both panels. A deduction must, therefore, be made from the total of the individual operations to compensate for
the two or more repeated operations in each sub-task. Similarly, if a part has
already been removed, it makes access to other parts easier.
Remove and Install (R&I)
Remove a part or assembly, set it aside and reinstall it later. The time shown
includes the alignment that can be done by shifting the part or assembly.
Remove and Replace (R&R)
Remove a part or assembly identified as included within the Procedure
Explanation and replace the part or assembly with a new one. The time
shown includes the alignment that can be done by shifting the part or
assembly.
Work Through the First Section
Underhood Dimensions
From the outside inward, note each part that is damaged and its attachments. For each part, list the part number, the price and the labor time.
Engine compartment views are shown as if you are above the vehicle looking down. A centerline is provided for measuring strut widths. The illustration
is an exact view of the engine compartment showing all bolts, holes, supports and other structural components. Measurements can be duplicated
with tape measure or with tram bar pointers set at equal lengths. Dimensions are given, whether symmetrical or non-symmetrical. All round holes
are measured to center. Oval holes are usually measured to the front or rear
center. Measurements are shown in millimeters. These dimensions are for
estimating purposes only. See Vehicle Dimension topic in the Mitchell Information Center.
Work Through Each Section
Use the sequence in the book as a guide and a reminder, and observe the
notes that apply to specific situations. For the first few damage reports it is
well worth reading through the Procedure Explanations to become thoroughly familiar with the approach used, and to know which parts and operations are included and which are not.
Complete the Damage Report
Add up all the labor times and calculate the total. Add up total part prices
and material costs. Total, and you have a complete and accurate damage
report.
Definitions
Bolted Parts and Assemblies
Refers to items bolted to inner structures, radiator supports, cowl and dash,
etc., that may need to be removed for access. Due to the variety of these
items and vehicles, time to remove and install or replace them is not
included. Refer to the specific Procedure Explanation for examples of these
items.
Disconnect & Connect
Disconnect a part or assembly by unbolting and/or unplug, and set it aside
without physically removing it from the vehicle to gain access or removal of
an adjacent part. The disconnected part or assembly is then reconnected
during the assembly process.
High Strength Steels
Complete HSS information is not available from the vehicle manufacturers.
When information is available, the components will be called out by the
appropriate acronym (HSS/UHSS etc.) within the text after the name of the
part identified. See Abbreviations in Reference Information for a list of acronyms and their definitions.
Order by Application
Many parts vary in usage according to differences in colors, materials,
engines, transmissions, VIN, year and other factors. Where there are occasional variations regarding the part price, a representative part number at
times is selected and the phrase "Order By Application" is footnoted to the
part’s description. Consult the dealer parts department for exact price and/or
part number information.
Labor General Information
IMPORTANT REMINDER: Labor related notes in the text portion override
the Procedure Explanation pages.
Aluminum
The labor times shown for aluminum panel R&R represent replacement
according to the manufacturer’s recommended procedures and guidelines.
Within the published labor times Mitchell has also taken into consideration
these commonly asked about items; Remove and Replace: Rivets, Drill
and de-burr rivet holes, EMC screws, Flow drill screws, Body pretreatment: Flame coat treatment, Application of bonding adhesives, Welding (if
applicable): Welding equipment set-up, "Run-on" or "Cold start" tabs.
NOTE: In addition, Aluminum panel replacement follows the guidelines outlined in specific applicable panel P-Pages. e.g. Aluminum Quarter Panel
replacement follows Procedure 20, Quarter Panel R&R.
New Undamaged Part
IMPORTANT REMINDER: The cost of aluminum panel replacement materials is not included in panel replacement R&R times. (example: Rivets, Panel
bonding, Adhesives, Bonding primer, EMC screws, Flow drill screws etc.).
Refers to a replacement part from the vehicle manufacturer without exterior
or interior trim or attached parts.
Labor Times
Overhaul (O/H)
Remove an assembly, disassemble, clean and visually inspect it, replace
needed parts, reassemble and reinstall on the vehicle making any necessary adjustments. Items which can only be changed by using the overhaul
operation are shown by placing "IOH" (Included in Overhaul) in the column.
There are other items which are included in the overhaul operation that may
be replaced individually. These will have a time assigned for a stand-alone
operation. For verification, refer to the Procedure Explanation for the operation being performed.
THE LABOR TIMES SHOWN IN THE GUIDE ARE IN HOURS AND
TENTHS OF AN HOUR (6 MINUTES) AND ARE FOR REPLACEMENT
WITH NEW, UNDAMAGED PARTS FROM THE VEHICLE MANUFACTURER ON A NEW, UNDAMAGED VEHICLE. Any additional time needed
for collision DAMAGE ACCESS, ALIGNMENT PULLS, NON-ORIGINAL
EQUIPMENT or USED PARTS should be agreed upon by all parties. Times
for some operations are applicable after necessary bolted, attached or
related parts have been removed. Exceptional circumstances, including all
the sub-operations or extra operations, are indicated as notes throughout
the text or are identified in the Procedure Explanations. The actual time
taken by individual repair facilities to replace collision damaged parts can be
expected to vary due to severity of collision, vehicle condition, equipment
used, etc.
Estimating Information
P3
Labor Categories
Comprehensive Labor Time
The labor times shown in the Guide fall into various categories (for example,
body, frame, mechanical) as determined by the repair facility’s operating
procedures. As a guide, components for which R&I or R&R is commonly
considered to be a mechanical operation when performed in a collision
repair environment are designated with the letter "m" in the text. These designations are only a guide. They are not necessarily all inclusive, nor do
they suggest the application of a labor rate.
While completeness is strived for in each Guide, there will be instances,
however, in which a labor time has not been established for an operation at
the time of publication. If an item requires replacement and can be replaced
as an individual item but shows no time, a time should be agreed upon
among all parties and recorded on the damage report. It also should not be
inferred that a component with no established Mitchell labor time has been
included in another component’s replacement allowance.
Welded Panels
Procedure Reference
Replacement labor times for new panels that are joined by welding include
the necessary use of inserts and accepted sectioning guidelines developed
by OEMs, I-CAR, and TECH-COR. The labor times for welded panels
include grinding, filling and final sanding with up to 150 grit sandpaper to
match the original panel contour. Labor times do Not-Include the Feather,
Prime and Block refinish operation. See Procedure 28 in Procedure Explanation section, for information on Feather, Prime and Block.
Throughout each vehicle "service" there are Procedure Explanation reference notes located immediately following the main section headings. Example: BUMPER/FRONT PANEL is followed by, "Use Procedure Explanations
1, 3 and 28 with the following text." This indicates that the text portion and
the Procedure Explanations for Front Bumper, Front Panel and Refinish
should be used in conjunction with one another when writing a damage
report. LABOR RELATED NOTES IN THE TEXT PORTION OVERRIDE
THE PROCEDURE EXPLANATION PAGES.
Adhesive Panel Bonding
Replacement labor times for panel bonding include all necessary weld applications identified by adhesive material manufacturers and OEM guidelines.
Users should reference best practices procedures from bonding material
manufacturers and/or OEM guidelines before selecting this replacement
method option.
Shop Material
The labor times shown in the Guide do not take into account the cost of any
materials, or the cost of hazardous materials recycling or disposal.
Disable and Enable Air Bag System
The labor times shown in the Guide represent the procedures necessary to
disable and enable the air bag system in order to replace air bag system
components and/or to perform repairs not related to the air bag system,
e.g., welding. This procedure includes visually monitoring the air bag warning light to verify proper system functionality. The allowance does not
include troubleshooting of the system if proper system functionality is not
present.
Diagnose Air Bag System
The labor times shown in the Guide to diagnose air bag systems include
system disable and enable, removal and installation of air bag module(s)
(where required), installation of appropriate simulators, and retrieving and
clearing of trouble codes. Time for specific troubleshooting of Diagnostic
Trouble Codes (DTCs) is not included.
Glass Labor Times
The labor times shown in the Guide for glass listed with the NAGS part numbers are Mitchell times, not times from NAGS. Glass labor times are for
remove and replace (R&R), i.e., removal of the existing glass and its
replacement with new glass. Some glass labor times are also shown for
removal and the later installation (R&I) of the same glass.
Procedures
The Procedure Explanations on the following pages outline the operations
which are or are not included in the labor time listed in each vehicle "service." You are encouraged to become familiar with these procedure pages
to be sure you have a thorough understanding of the Mitchell approach to
collision estimating.
The left Included Operations column means that the labor time shown in
the Mitchell Collision Estimating Guide text includes that particular operation
or operations.
The right Not Included Operations column means that the labor time in the
text does not include that particular operation or operations. Performance of
one or more of these operations may or may not be necessary as determined by the individual job requirements. If an add-on time has been established for any of these operations it will be shown in the text. If a time has
not been established or if the add-on time is dependent on conditions that
vary due to collision damage (example: access time, free up parts), the
additional time should be recorded on the damage report. Labor times relating to the repair of a damaged panel or the use of used parts would come
under this category.
Additions to Labor Times
Due to the wide range of collision damage and vehicle conditions, labor
times for the following operations are not included in the Guide.
Access Time
Remove extensively damaged parts by cutting, pushing, pulling, etc.
Anti-Corrosion Rust Resistant Material
Remove and/or apply weldable zinc primers, wax, petroleum based coatings, undercoating or any type of added conditioning.
Stripes, Decals and Overlays
Broken Glass Clean Up
The labor times shown in the Guide for these items refer to installation only.
Clean vehicle of all broken glass.
TECH-COR Repair Information
Detail
The labor times shown in the Guide for TECH-COR repair procedures are
supplied by Mitchell. TECH-COR does not endorse, sanction or otherwise
approve such times. TECH-COR publications are copyrighted material.
However, reproduction of TECH-COR bulletins is permitted as long as the
bulletin is reproduced in its entirety, including source attribution. TECH-COR
bulletins may be obtained by contacting: TECH-COR, Inc., Technical Communications Dept., 100 East Palatine Road, Wheeling, IL 60090; Phone:
847-667-2341.
Clean vehicle to pre-accident condition.
Base Model Vehicle
Vehicle with the minimal level of equipment available from the manufacturer.
Types of Vehicles
The types of vehicles covered are regular production models only.
Drain & Refill
Fuel (see fuel tank)
Electronic Components
•
•
•
Time to remove and install as necessary; includes wiring and/or wiring
harness and computer module.
Time to reset memory code function (example: seat position, radio presets) when battery has been disconnected to perform repairs.
Time to complete computer relearn procedures for proper operation of
vehicle systems (example: power sunroof, power window) when battery
has been disconnected to perform repairs.
Estimating Information
P4
Fabrication
Rework Parts
Fabrication of reinforcements or inserts (new component not cut or manufactured from existing or new part, but from raw stock).
To fit a particular year or model (example: cutting holes for lamps, modifying
a radiator support).
Free Up Parts
Tar and Grease
Time necessary to free up parts frozen by rust or corrosion.
Removal of these or any other materials that would interfere with operation.
Measure and Identify
Transfer Time
Structural damage by comparing vehicle underbody, underhood, and upperbody reference points to accepted, OEM-based dimension specification to
identify damage to unibody vehicles.
For welded, riveted or bonded brackets, braces or reinforcements from old
part to new part.
Plug and Finish Holes
Time to plug and finish unneeded holes on parts being installed.
Repair or Align
Parts or adjacent to parts being replaced.
Fig. 1:
Unibody Structural Components
Unibody structural components are parts which support the weight of the
vehicle and absorb the energy of the impact as well as road shock. These
components are designated with the letter "s" in the text. The components
are the radiator support, front and rear unirails, apron and wheelhouse (strut
type) assemblies, rocker panel assemblies and suspension crossmembers.
Body pillars, while not primary load-bearing structures, also require special
treatment and are considered structural components.
Component Identification & Illustration—Courtesy of TECH-COR, Inc.
Rev. 2-10
Procedure Explanation
Procedure 1—Front Bumper
Procedure 3—Front Panel
Bumper Assembly R&I
Front Panel R&R
Included Operations
Included Operations
•
•
•
•
•
•
Remove assembly from frame, impact absorbers or mounting arms
Reinstall assembly
Adjust alignment to vehicle
Not Included Operations
•
•
Refinish bumper
Remove and install optional accessories (example: auxiliary lamps,
brush guard, fog lamps, headlamp washer systems, laser/radar cruise
control sensors, parking aid sensors, spoilers)
Bumper Assembly O/H
Included Operations
•
•
•
•
•
Remove assembly from frame, impact absorbers or mounting arms
Disassemble and replace damaged parts
Assemble and install
Adjust alignment to vehicle
Remove and install or replace: License plate/bracket, Parklamp if so
equipped
•
•
Remove and replace panel assembly
Replace or transfer attached bolted parts
Remove and install or replace: Grille, Headlamps as an assembly,
Parklamp if so equipped
Loosen fender(s) for access, if necessary
Replace clip type moulding for base model vehicle
Not Included Operations
•
•
•
•
•
•
•
Refinish front panel
Aim lamps
Overhaul or replace headlamp parts
Remove and install: Front bumper unless noted otherwise, Fender(s)
unless noted otherwise, Adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Procedure 4—Hood
Not Included Operations
Hood Panel R&R
•
•
•
Included Operations
•
•
•
Refinish bumper
Remove and replace impact absorbers or mounting arms
Remove and install or replace optional accessories (example: auxiliary
lamps, brush guard, fog lamps, headlamp washer systems, laser/radar
cruise control sensors, parking aid sensors, spoilers)
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Procedure 2—Front Bumper & Grille
Bumper/Grille Assembly R&I
Included Operations
•
•
•
Remove assembly from frame, impact absorbers or mounting arms
Reinstall assembly
Adjust alignment to vehicle
Not Included Operations
•
•
•
Refinish cover
Aim lamps
Remove and install optional accessories (example: auxiliary lamps,
brush guard, fog lamps, headlamp washer systems, laser/radar cruise
control sensors, parking aid sensors, spoilers)
•
•
•
•
•
•
•
•
•
•
Remove assembly from frame, impact absorbers or mounting arms
Replace or transfer parts attached except those listed in Not Included
Section
Disassemble and replace damaged parts
Assemble and install
Adjust alignment to vehicle
Remove and install or replace: Grille, Headlamps as an assembly,
License plate/bracket, Parklamp if so equipped
•
•
•
Refinish bumper
Aim lamps
Overhaul or replace headlamp parts
Remove and replace impact absorbers or mounting arms
Remove and install or replace optional accessories (example: auxiliary
lamps, brush guard, fog lamps, headlamp washer systems, laser/radar
cruise control sensors, parking aid sensors, spoilers)
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Refinish hood panel
Remove and install or replace: Hinges, Gas prop rod
Remove and install adhesive insulator
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Procedure 5—Cooling
Radiator Support R&R
Included Operations
•
Remove and install or replace: Shroud when support is serviced by manufacturer as a one piece unit, Radiator assembly when support is serviced by manufacturer as a one piece unit, Impact absorbers or mounting
arms if necessary to perform operation.
Not Included Operations
•
•
•
•
•
•
Not Included Operations
•
•
•
•
•
Remove and replace hood assembly
Remove and install or replace: Parts attached to hood except those listed
in Not Included Section
Replace clip type moulding for base model vehicle
Replace caulking for standard factory application if necessary
Not Included Operations
•
•
•
•
•
•
•
Bumper/Grille Assembly O/H
Included Operations
P5
Refinish radiator support
Aim lamps if attached to support
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Front bumper, Hood panel if necessary, Front
header panel, Front fenders, Wiring and/or wiring harness
Remove and replace: Radiator hoses, Fan, pulley, fan clutch or belts,
Decals (example: EPA, body identification, caution/danger)
Remove and install or replace: Suspension assemblies, Bolted parts and
assemblies (example: fluid reservoirs and coolers, vapor canister, cruise
control, air conditioning components)
IMPORTANT REMINDER: Labor times for inner panels, rails or reinforcements are with outer panels removed.
NOTE: For Unibody type vehicles see Procedure 8—Front Inner Structure Unibody.
Radiator R&R
Included Operations
•
•
Remove and install or replace: Shroud, Electric fan if necessary
Disconnect and connect: Hoses at radiator, Transmission coolant lines
P6
•
•
Procedure Explanation
Drain, refill and check coolant
Visual check for leaks
Not Included Operations
•
•
Remove and install or replace: Fan, Pulley, Fan clutch, Belts, Hoses if
necessary; add .1 hour for one, .2 hour for all hoses
Pressure test system if necessary (example: check for damage due to
collision); add .3 hour
Procedure 6—Air Conditioning
Air Conditioning R&R
Included Operations
•
Each operation identified in the text is considered to be a stand-alone
operation.
Not Included Operations
•
•
•
•
Evacuate and recharge system
Refrigerant recovery
Remove and install or replace: Receiver drier
Leak check
IMPORTANT REMINDER: If all refrigerant has been lost by collision damage, or if refrigerant lines have been opened and not immediately sealed,
the receiver drier should be replaced. Replacement of collision damaged
parts on a system that is still pressurized should not require replacement of
receiver drier.
NOTE: Refrigerant recovery is the removal of refrigerant from the vehicle
A/C system as specified by SAE standard J-2209 and its transfer to a holding tank. The recovery operation does not include recycling of the used
refrigerant.
Procedure 7—Front Fender
•
•
•
•
IMPORTANT REMINDER: Labor times for inner panels, rails or reinforcements are with outer panels removed.
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
Radiator R&R
Included Operations
•
•
•
•
•
•
Remove and install or replace: Headlamp assembly if attached to fender,
Cornering lamp if so equipped, Side marker lamp if so equipped, Turn
indicator if so equipped, Parts attached to fender except those listed in
Not Included Section
Replace clip type moulding for base model vehicle
Not Included Operations
•
•
•
•
•
•
•
•
Refinish front fender
Aim lamps
Remove and install front bumper
Remove and install or replace: Front header panel, Skirt or liner, Wheel,
Antenna, Rocker moulding
Remove and install adhesive exterior trim; add to clean and retape
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Cut holes for installing lamps
Remove and install or replace: Shroud, Electric fan if necessary
Disconnect and connect: Hoses at radiator, Transmission coolant lines
Drain, refill and check coolant
Visual check for leaks
Not Included Operations
•
•
Remove and install or replace: Fan, Pulley, Fan clutch, Belts, Hoses if
necessary; add .1 hour for one, .2 hour for all hoses
Pressure test system if necessary (example: check for damage due to
collision); add .3 hour
Radiator Support R&R
Included Operations
•
Front Fender R&R
Included Operations
Remove and install: Front bumper, Hood panel, Front header panel,
Front fenders, Engine, Wiring and/or wiring harness
Remove and replace: Radiator hoses, Fan, pulley, fan clutch or belts,
Decals (example: EPA, body identification, caution/danger)
Remove and install or replace: Suspension assemblies, Bolted parts and
assemblies (example: fluid reservoirs and coolers, vapor canister, cruise
control, air conditioning components), Instrument panel and center console, Seat assemblies, Windshield and mouldings, Air safety bag
Wheel alignment
•
Remove and install or replace: Shroud when support is being replaced as
a complete unit, Radiator assembly when support is being replaced as a
complete unit, Impact absorbers or mounting arms if necessary to perform operation
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
•
•
Refinish radiator support
Aim lamps
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Front bumper, Hood panel if necessary, Front
header panel, Front fenders, Wiring and/or wiring harness
Remove and replace: Radiator hoses, Fan, pulley, fan clutch or belts,
Decals (example: EPA, body identification, caution/danger)
Remove and install or replace: Bolted parts and assemblies (example:
fluid reservoirs and coolers, vapor canister, cruise control, air conditioning components)
IMPORTANT REMINDER: Sectioning of a panel may or may not be performed by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
Procedure 8—Front Inner Structure Unibody
Apron Panel and/or Front Rail R&R
Inner Structure Assembly R&R
•
•
Included Operations
•
•
•
•
Remove and install: Cowl trim
Remove and install or replace: Shroud and radiator assembly, Impact
absorbers or mounting arms if necessary to perform operation, Cowl top
panel if assembly includes dash panel
Loosen and pull back carpet and insulation as required
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
Refinish radiator support, apron and/or front rail
Aim lamps
Remove and/or apply: Anti-corrosion rust resistant materials
Included Operations
•
•
Remove and install: Cowl trim
Remove and install or replace: Impact absorbers or mounting arms if
necessary to perform operation
Loosen and pull back carpet and insulation as required
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
Refinish apron support and/or front rail
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Engine, Wiring and/or wiring harness
Remove and install or replace: Front bumper, Front header panel, Front
fender, Hood panel and Cowl top panel, Suspension assemblies, Upper
reinforcement, Bolted parts and assemblies (example: fluid reservoirs
and coolers, vapor canister, cruise control, air conditioning components),
Procedure Explanation
•
Decals (example: EPA, body identification, caution/danger), Instrument
panel and center console, Seat assemblies
Wheel alignment
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
Engine Subframe/Crossmember R&R
Included Operations
•
•
•
Suspend/Support assemblies (except if required to R&I for access):
Engine, Suspension
Remove and install assemblies: Exhaust, Hood, Steering gear
Remove and install or replace: Engine mounts/absorbers (mounted on
subframe), Engine undercovers, Stabilizer bar and brackets
Not Included Operations
•
•
•
Remove and install assemblies: Engine, Suspensions
Overhaul or replace: Exhaust system components, Hood, Steering gear
components, Suspension components, Wheel alignment
Bleed brakes if necessary
Procedure 9—Frame
Frame Assembly R&R
Included Operations
•
•
Remove and install: Front and rear bumpers, Front sheet metal as an
assembly, Hood, Body assembly, Pickup bed, Spare tire (when attached
to frame), Mechanical assemblies (example: engine, transmission, suspension, fuel tank, differential and components)
Remove and install or replace: Radiator, Wiring and/or wiring harness if
necessary, Exhaust system, Fluid lines, Engine mounts/absorbers, Vapor
canister, Clips and bolted brackets attached to frame
Not Included Operations
•
•
•
•
•
•
•
•
•
•
Overhaul assemblies or replace parts of assemblies that are transferred
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Seats, Interior trim if necessary
Remove and install or replace: Welded or riveted assemblies of the frame
(see Note), Optional accessories (example: auxiliary lamps and fuel
tanks, brush guard, trailer hitch, trailer connector)
Wheel alignment
Adjust control linkage
Bleed brakes if necessary
Evacuate and recharge Air Conditioning if so equipped and necessary
Refrigerant recovery if necessary
Pull back carpet as required
NOTE: Frame Assembly R&R requires planning. Proper preparation and job
sequencing are key to performing this operation. Also, special equipment,
additional work space and manpower may be needed.
NOTE: It may be necessary to transfer parts from the damaged frame or
order new parts to use on the new frame. This cannot be determined until
you see the new frame. The needed additional time for this operation must
be estimated.
Front Suspension Crossmember R&R
Included Operations
•
•
Remove and/or disconnect necessary attaching bolts and components to
frame and raise front sheet as an assembly
Loosen or remove and install: Suspension assemblies as necessary
Not Included Operations
•
•
•
•
•
•
Remove and install front bumper
Remove and install or replace: Steering gear
Remove and install or suspend: Engine assembly
Overhaul and replace suspension parts
Wheel alignment
Bleed brakes if necessary
P7
Rear Crossmember R&R
Included Operations
•
Remove and install: Rear gravel shield if necessary, Tailpipe or rear muffler if necessary
Not Included Operations
•
•
Remove and install rear bumper
Remove and replace fuel tank
Procedure 10—Wheel/Wheel Alignment
Wheel and Tire R&I
Included Operations
•
•
•
Jack up and support vehicle
Remove and install wheel and tire assembly on hub
Remove and install or replace: Wheel cover or hub cap
Not Included Operations
•
•
•
Refinish wheel
Remove and install or replace: Valve stem, Locking type lugs, Locking
type wheel covers
Mount and balance tire
IMPORTANT REMINDER: Labor times with part numbers shown in the text
are for Remove and Install (R&I) of the Wheel and Tire Assembly. When
necessary to R&I a damaged Wheel and Tire Assembly for repair or sublet
and substitute with the vehicle’s existing spare wheel and tire for temporary
mobility, an additional .2 hour is provided in the Wheel Section headnotes.
Adjust Front Alignment
Included Operations
•
•
•
•
•
•
•
•
•
Position vehicle on alignment rack and check/adjust tire pressure
Check ride height and adjust to vehicle manufacturer specifications
Set-up gauges on all 4 wheels and check wheel run out and front suspension for wear
Determine vehicle tracking by checking thrust angle to vehicle center line
Center steering wheel
Adjust front caster, camber and toe-in where applicable
Perform vehicle manufacturer recommended shimming procedures if
necessary
Remove vehicle from alignment equipment
Verify alignment by road test
Not Included Operations
•
•
•
•
•
•
•
Diagnostic road test to determine if alignment operations are necessary
Straighten or replace suspension parts and/or structural components
Shift or align engine subframe/crossmember and/or axle housing
Remove and install steering wheel
Non-vehicle manufacturer shimming
Adjust wheel bearings
Adjust rear wheel alignment
NOTE: Labor times for Wheel Alignment are based on the use of Four
Wheel Alignment equipment to ensure that a minimum Thrust Angle Alignment is provided in all instances where a Four Wheel Alignment cannot be
performed. If other than Four Wheel Alignment equipment is used, some
adjustment in labor times may be appropriate.
Adjust Four Wheel Alignment
Included Operations
•
•
•
•
•
•
•
•
•
Position vehicle on alignment rack and check/adjust tire pressure
Check ride height and adjust to vehicle manufacturer specifications
Set-up gauges on all 4 wheels and check wheel run out and front suspension for wear
Determine vehicle tracking by checking thrust angle to vehicle center line
Center steering wheel
Adjust front and rear caster, camber and toe-in where applicable
Perform vehicle manufacturer recommended shimming procedures if
necessary
Remove vehicle from alignment equipment
Verify alignment by road test
P8
Procedure Explanation
Not Included Operations
•
•
•
•
•
•
Diagnostic road test to determine if alignment operations are necessary
Straighten or replace suspension parts and/or structural components
Shift or align engine subframe/crossmember and/or axle housing
Remove and install steering wheel
Non-vehicle manufacturer shimming
Adjust wheel bearings
•
•
•
Remove and install: Radiator if necessary, Any parts on engine if necessary
Adjust linkage if adjustable type
Evacuate and recharge air conditioning if so equipped and necessary
NOTE: Labor times shown in the text are only to remove and install the
engine and/or transmission assembly in order to facilitate other work. The
times are not for engine or transmission replacement.
Adjust Rear Alignment
Fuel Tank R&R
Included Operations
Included Operations
•
•
•
•
•
•
•
•
Position vehicle on alignment rack and check/adjust tire pressure
Check ride height and adjust to vehicle manufacturer specifications
Set-up gauges on all 4 wheels and check wheel run out and front suspension for wear
Determine vehicle tracking by checking thrust angle to vehicle center line
Adjust rear caster, camber and toe-in where applicable
Perform vehicle manufacturer recommended shimming procedures if
necessary
Remove vehicle from alignment equipment
Verify alignment by road test
Not Included Operations
•
•
•
•
•
•
•
Diagnostic road test to determine if alignment operations are necessary
Straighten or replace suspension parts and/or structural components
Shift or align rear suspension axle assembly carrier and/or housing
Remove and install, or center steering wheel
Non-vehicle manufacturer shimming
Adjust wheel bearings
Adjust front wheel alignment
NOTE: If Front Wheel Adjustment is necessary, cancel Adjust Rear Alignment procedure and use Adjust Four Wheel Alignment procedure.
•
•
Disconnect & Connect: Fuel Lines at tank, Wiring at tank
Remove and install or replace: Fuel pump (tank mounted), Interior trim (if
necessary), Sending unit, Stone shields/protectors, Tank straps
Not Included Operations
•
•
Drain & Refill
Remove & install or replace: Exhaust system, Suspension/drive train,
Skid plates or specialty equipment
Procedure 13—Windshield
Windshield R&R
Included Operations
•
•
•
•
•
Remove and replace: Reveal mouldings, Garnish mouldings, Wiper
arms, Rear view mirror
Replace weatherstrip if so installed
Replace necessary adhesive/urethane
Clean up old adhesive in opening area
Test for leaks
Not Included Operations
Procedure 11—Front Suspension
•
•
Front Suspension Component R&R
IMPORTANT REMINDER: Urethane set glass may typically be considered
a structural component. Refer to OEM replacement procedures for installation methods and materials necessary to restore structural integrity.
Included Operations
•
•
Each operation identified in the text is considered to be a stand-alone
operation unless noted otherwise
Remove and install wheel
Not Included Operations
•
•
Wheel alignment
Bleed brakes if necessary
Front Suspension O/H
Included Operations
•
•
•
•
•
Remove and install wheel
Disassemble and clean parts
Visual check for damage
Replace needed parts
Assemble
Not Included Operations
•
•
•
•
Replace steering linkage parts
Remove and replace: Torsion or stabilizer bar, Drive axle parts
Bleed brakes if necessary
Wheel alignment
IMPORTANT REMINDER: Due to the design of suspension on unibody
vehicles, it may be necessary to perform four wheel alignment.
Procedure 12—Engine/Fuel Tank
Engine & Transmission R&I
Included Operations
•
•
Disconnect and connect: Necessary components to remove and install
engine/transmission as an assembly
Remove and install hood assembly
Not Included Operations
Remove and replace: Aftermarket window tint
Broken glass clean up
IMPORTANT REMINDER: No windshield or flush mounted reveal mouldings can be removed without the possibility of breakage or damage that will
require replacement. Unintentional damage to glass that is considered a
structural member by the vehicle manufacturer may occur when attempting
alignment pulls to correct unibody collision damage. Agree beforehand who
will incur the charge for damage occurring during normal R&R and R&I
operations.
Procedure 14—Cowl & Dash
Hinge and/or Windshield Pillar R&R
Included Operations
•
•
•
•
Remove and install: Front door
Remove and install or replace: Sun visor, if replaced at roof, Sill plates,
Jamb switches
Loosen and pull back: Front area of cloth type headliner, Carpet and
insulation as required
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
•
•
Refinish pillar
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Front fender
Remove and install or replace: Windshield and mouldings, Instrument
panel assembly, Door hinges, Air conditioning and heater parts that interfere, Wiring and/or wiring harness
Remove and install preformed or molded type headliner
Broken glass clean up
IMPORTANT REMINDER: No windshield or flush mounted reveal mouldings can be removed without the possibility of breakage or damage that will
require replacement. Unintentional damage to glass that is considered a
structural member by the vehicle manufacturer may occur when attempting
alignment pulls to correct unibody collision damage. Agree beforehand who
Procedure Explanation
will incur the charge for damage occurring during normal R&R and R&I
operations.
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
NOTE: FULL PANEL REPLACEMENT PROCEDURE - Labor times are for
replacement at factory seams if feasible. However, many windshield pillars
cannot be replaced at roof seams because the roof panel overlaps the pillar.
If a windshield pillar is designed in this manner and a section time is not
listed, the time in the text represents replacement of the panel at the most
practical area—usually below the roof seam. This method is considered a
full panel replacement.
Cowl & Dash R&R
Included Operations
•
•
•
Remove and install or replace: Cowl top panel, Cowl trim, Weathercords
and weatherstrips
Loosen and pull back carpet and insulation as required
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
•
Refinish cowl and dash
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Engine, Front door assemblies, Front fender assemblies
Remove and install or replace: Windshield and mouldings, Air safety bag,
Instrument panel assembly, Air conditioning and heater parts that interfere, Wiring and/or wiring harness, Bolted part and assemblies (example:
wiper components, master cylinder)
Broken glass clean up
Instrument Panel R&R
Included Operations
•
•
•
•
•
Disconnect and connect: Necessary wiring, hoses and cables
Remove and install: Instrument cluster, Standard gauges, switches and
lamps, Trim and attached parts (example: glove box), Heater/Air Conditioning controls if so equipped, Release levers (example: brake, hood,
fuel door, trunk)
Remove and install or replace: Passenger air bag, Crash pad, Standard
audio system, Attached brackets and reinforcements (non-welded type)
Loosen steering column for access
Test all necessary functions of electrical components for correct operation and reset as required
Not Included Operations
•
•
•
•
•
•
Refinish instrument panel or crash pad
Remove and install: Front seats, Steering column, Main wiring harness
Remove and install or replace: Windshield, Optional equipment (example: electronic components, center console, cruise control), Control
cables (example: hood release, remote mirrors), Remote mirrors
Repair/Rework parts (example: cut holes for modification)
Drill holes for installing trim
Broken glass clean up
Center Console R&R
•
•
•
Included Operations
•
•
•
•
Included Operations
•
•
•
Refinish console or compartment door
Remove and install: Main wiring harness
Remove and install or replace: Clockspring, Steering wheel, Driver air
bag module
Not Included Operations
•
•
•
•
Remove and install or replace: Impact sensors, Control modules, Wire
harness, Steering column
Disable and enable air bag system
Diagnose air bag system
Deployed air bag residue clean-up
Passenger Air Bag Module R&R
Included Operations
•
Remove and install or replace: Passenger air bag module, Instrument
panel, if necessary, Glove box, if necessary
Not Included Operations
•
•
•
•
Remove and install or replace: Impact sensors, Control modules, Wire
harness, Windshield
Disable and enable air bag system
Diagnose air bag system
Deployed air bag residue clean up
Knee Air Bag Module R&R
Included Operations
•
Remove and replace: Knee air bag module
Not Included Operations
•
•
•
•
Remove and install or replace: Impact sensors, Control modules, Wire
harness, Glove box assembly, Instrument panel grilles, Instrument panel
trim panels
Disable and enable air bag system
Diagnose air bag system
Deployed air bag residue clean up
Seat Air Bag Module R&R
Included Operations
•
Not Included Operations
Remove and install or replace: Impact sensors, Control modules, Wire
harness, Steering column
Disable and enable air bag system
Diagnose air bag system
Deployed air bag residue clean-up
Clockspring R&R
•
•
•
Remove and install or replace: Driver air bag module, Switches attached
to steering wheel, if necessary
Not Included Operations
•
•
•
Remove and install or replace: Optional equipment (example: electronic
components, air cond. ducts)
Repair/Rework parts (example: cut holes for modification)
Drill holes for installing trim
Driver Air Bag Module R&R
Included Operations
Disconnect and connect: Necessary wiring, hoses and cables
Remove and install: Shift lever if necessary (includes adjust neutral
safety switch), Standard gauges, switches and lamps, Front seats if necessary, Trim and attached parts, Heater/Air Conditioning controls if so
equipped, Release levers (example: seat belt)
Remove and install or replace: Standard audio system if so equipped,
Attached brackets and reinforcements (non-welded type)
Test all necessary functions of electrical components for correct operation and reset as required
P9
Remove and replace: Seat air bag module
Not Included Operations
•
•
•
Remove and install or replace: Impact sensors, Control modules, Wire
harness, Seat assembly, Seat cover
Disable and enable air bag system
Diagnose air bag system
Deployed air bag residue clean up
Door Air Bag Module R&R
Included Operations
•
Remove and replace: Door air bag module
Not Included Operations
P10
•
•
•
•
Procedure Explanation
Remove and install or replace: Impact sensors, Control modules, Wire
harness, Door glass, Trim panel
Disable and enable air bag system
Diagnose air bag system
Deployed air bag residue clean up
Side Curtain Air Bag Module R&R
Included Operations
•
•
•
•
Not Included Operations
Not Included Operations
•
•
•
•
•
•
•
•
•
Remove and replace: Side curtain air bag module
Remove and install or replace: Impact sensors, Control modules, Wire
harness, Headliner
Disable and enable air bag system
Diagnose air bag system
Deployed air bag residue clean up
IMPORTANT REMINDER: Vehicle manufacturer’s recommended service
and repair procedures must be followed when servicing any Supplemental
Restraint/Air Bag System. Certain safety precautions and disabling procedures must be observed when performing repairs.
Procedure 15—Rocker Panel/Side Body
Panel/Center Pillar
Rocker Outer Panel R&R
Included Operations
•
•
•
•
Remove and install: Quarter trim at sill
Remove and install or replace: Cowl trim, Center pillar trim, Sill plates,
Rear seat cushion
Loosen and pull back carpet and/or insulation as required
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
•
•
•
Refinish rocker panel
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Front or rear doors
Remove and replace: Hinge pillar, Center pillar, Lock pillar, Quarter panel
Remove and install or loosen rear edge of front fender
Remove and install or replace: Rocker moulding, Wiring and/or wiring
harness, Control cables (example: latch release), Fluid lines
Drill holes for installing trim
NOTE: FULL PANEL REPLACEMENT PROCEDURE - Labor times are for
replacement at factory seams if feasible. However, many rocker panels cannot be replaced at factory seams because the hinge pillar, center pillar, lock
pillar and/or quarter panel overlaps the rocker panel. If a rocker panel is
designed in this manner and a section time is not listed, the time in the text
represents replacement of the panel at the most practical area. This
reduces repair damage to overlapping panels and is considered a full panel
replacement.
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
IMPORTANT REMINDER: Labor times for inner panels, rails or reinforcements are with outer panels removed.
NOTE: Deduct 1.0 hour each for hinge, center and lock pillar if these items
are also replaced.
Side Body Panel R&R
Included Operations
•
•
Remove and install: Front door, Rear door, Front seat, Rear seat, Parcel
shelf trim, Quarter trim, Plastic wheelhouse liner, Luggage compartment
trim, Rear lamp assemblies, Rear bumper, Filler panel, stone deflector, or
rear lower valance
Remove and install or replace: Non urethane set glass (Windshield and
moulding, Back window and moulding), Quarter window and moulding,
Sun visor, if replaced at roof, Roof rail moulding, if replaced at roof, Cowl
top panel, Cowl trim, Weathercords and weatherstrips, Pillar trim, Sill
plates, Jamb switches, Lock striker, Bolt-on extension
Remove and replace urethane set glass: Windshield and mouldings,
Back window and moulding, Quarter window and moulding
Loosen and pull back: Cloth type headliner as required, carpet and/or
insulation as required
Remove and replace caulking for standard factory application
Replace clip type moulding for base model vehicle
•
•
•
•
•
•
•
•
•
Refinish side body panel
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Front fender, Preformed or molded type headliner,
Fuel tank
Remove undamaged urethane set glass: Windshield and moulding,
Back window and moulding, Quarter window and moulding
Remove and install or replace: Instrument panel assembly, Door hinges,
Air conditioning and heater parts that interfere, Wiring and/or wiring harness, Control cables (example: latch release), Fluid lines, Decals (example: EPA, body identification, caution/danger), Rocker moulding, Wheel,
Antenna
Remove and replace inner panels
Replace sound deadening
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing trim
Cut holes for installing lamps
Broken glass clean up
IMPORTANT REMINDER: Labor times for inner panels, rails or reinforcements are with outer panels removed. Also, no windshield, back or quarter
glass (if applicable), or flush mounted reveal mouldings can be removed
without the possibility of breakage.
Side Body Sectioning Explanation: See Procedure 20—Quarter Panel.
SPECIAL NOTE: Procedure Number 15 includes removal of damaged urethane set glass and replacement with new glass. The Procedure does not
include allowances for necessary precautionary measures to remove
undamaged urethane set glass, nor clean up of the old adhesive on the
glass. If the existing urethane set glass is undamaged and will be reused,
the labor time difference between the glass R&R and R&I represents the not
included allowance.
Example: A Side Body Panel allowance includes a Back Glass R&R of 2.0
hr. The R&I of the back glass is 2.3 hr. The difference of .3 hr. between Back
Glass R&R (2.0 hr.) and R&I (2.3 hr.) has not been factored into the Side
Body Panel allowance.
Door Opening Panel R&R
Included Operations
•
•
•
•
•
Remove and install: Front door, Rear door, Front seat, Rear seat, Quarter
trim
Remove and install or replace: Sun visor, if replaced at roof, Roof rail
moulding, if replaced at roof, Cowl top panel, Cowl trim, Weathercords
and weatherstrips, Pillar trim, Sill plates, Jamb switches, Lock striker
Remove and replace urethane set glass: Windshield and mouldings
Loosen and pull back: Cloth type headliner as required, Carpet and/or
insulation as required
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
•
•
•
•
•
•
•
•
Refinish door opening panel
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Front fender, Preformed or molded type headliner
Remove undamaged urethane set glass: Windshield and moulding
Remove and install or replace: Instrument panel assembly, Door hinges,
Air conditioning and heater parts that interfere, Wiring and/or wiring harness, Control cables (example: latch release), Fluid lines, Decals (example: EPA, body identification, caution/danger), Rocker moulding, Antenna
Remove and replace inner panels
Replace sound deadening
Remove and install adhesive exterior trim: add to clean and retape
Replace new adhesive exterior trim: deduct one half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Broken glass clean up
Procedure Explanation
IMPORTANT REMINDER: Labor times for inner panels, rails or reinforcements are with outer panels removed. No windshield, back or quarter glass
(if applicable), or flush mounted reveal mouldings can be removed without
the possibility of breakage or damage that will require replacement. Unintentional damage to glass that is considered a structural member by the
vehicle manufacturer may occur when attempting alignment pulls to correct
unibody collision damage. Agree beforehand who will incur the charge for
damage occurring during normal R&R or R&I operations.
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
•
•
P11
Remove and install or replace: Door hinges, Wiring and/or wiring harness, Rocker moulding, Decals (example: EPA, body identification, caution/danger), Control cables (example: latch release), Fluid lines
Drill holes for installing trim
NOTE: FULL PANEL REPLACEMENT PROCEDURE - Labor times are for
replacement at factory seams if feasible. However, many center pillars/rocker panels cannot be replaced at factory seams because the hinge
pillar, lock pillar, quarter panel and/or roof overlaps the panel. If a panel is
designed in this manner and a section time is not listed, the time in the text
represents replacement of the panel at the most practical area. This
reduces repair damage to overlapping panels and is considered a full panel
replacement.
SPECIAL NOTE: Procedure Number 15 includes removal of damaged urethane set glass and replacement with new glass. The Procedure does not
include allowances for necessary precautionary measures to remove
undamaged urethane set glass, nor clean up of the old adhesive on the
glass. If the existing urethane set glass is undamaged and will be reused,
the labor time difference between the glass R&R and R&I represents the not
included allowance.
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
Example: A Door Opening Panel allowance includes a windshield R&R of
2.0 hr. The R&I of the windshield is 2.3 hr. The difference of .3 hr. between
windshield R&R (2.0 hr.) and R&I (2.3 hr.) has not been factored into the
Door Opening Panel allowance.
NOTE: Deduct 1.0 hour each for hinge pillar, lock pillar and roof if these
items are also replaced.
Procedure 16—Front/Rear or Back Door
Center Pillar R&R
Door Shell R&R
Included Operations
Included Operations
•
•
•
•
•
•
•
Remove and install: Rear door, Front seat
Remove and install or replace: Pillar trim, Lock striker, Sill plates
Loosen and pull back: Carpet and/or insulation as required, Cloth type
headliner at pillar
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
•
Refinish center pillar
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install preformed or molded type headliner
Remove and install or replace: Door hinges, Wiring and/or wiring harness, Decals (example: EPA, body identification, caution/danger)
Drill holes for installing exterior trim
NOTE: Deduct 1.0 hour if roof also replaced.
NOTE: FULL PANEL REPLACEMENT PROCEDURE - Labor times are for
replacement at factory seams if feasible. However, many center pillars cannot be replaced at factory seams because the roof panel overlaps the center
pillar. If a center pillar is designed in this manner and a section time is not
listed, the time in the text represents replacement of the panel at the most
practical area - usually below the roof seam. This method is considered a
full panel replacement.
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
Center Pillar & Rocker Panel R&R
Included Operations
•
•
•
•
Remove and install: Rear door, Front seat, Quarter trim at sill
Remove and install or replace: Cowl trim, Pillar trim, Lock striker, Sill
plates, Rear seat cushion
Loosen and pull back: Carpet and/or insulation as required, Cloth type
headliner at pillar
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
•
Refinish center pillar and rocker panel
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Front door, Preformed or molded type headliner
Remove and replace: Hinge pillar, Lock pillar, Quarter panel
Remove and install or loosen rear edge of front fender
IMPORTANT REMINDER: Labor times for inner panels, rails or reinforcements are with outer panels removed.
•
•
Remove and install trim panel
Remove and install or replace: Lock cylinder, Water/dust barrier
Replace or transfer parts attached to door (example: outside handle,
glass, run channels, regulator, vent assembly, weatherstrip)
Replace caulking for standard factory application if necessary
Replace clip type moulding for base model vehicle (example: window
surround moulding, belt moulding)
Not Included Operations
•
•
•
•
•
Refinish door panel
Replace channels attached to glass; add .2 hour for lower and .3 hour for
upper and lower
Replace sound deadening
Remove and install or replace: Rear view mirror, Hinges, Hinge anchor
plates, Decals (example: EPA, body identification, caution/danger)
Recode lock cylinder
Remove and install adhesive exterior trim: deduct one-half of R&R time
Install stripes, decals, transfer or overlays
Drill holes for installing trim
Broken glass clean up
•
•
•
IMPORTANT REMINDER: Labor times for reinforcements are with outer
panels removed.
Door Repair Panel R&R
Included Operations
•
•
•
•
Remove and install: Door assembly, Trim panel
Remove and replace caulking for standard factory application
Remove and install or replace: Outside handle, Lock cylinder, Water/dust
barrier, Weatherstrip on door edge, Belt moulding/weatherstrip
Replace clip type moulding for base model vehicle
Not Included Operations
•
•
•
•
•
•
•
•
•
•
Refinish door panel
Remove and/or apply: Anti-corrosion rust resistant materials
Replace sound deadening
Remove and install or replace: Glass, hardware, mirror and channels
Recode lock cylinder
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing trim
Broken glass clean up
P12
Procedure Explanation
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
Door Glass R&R
Included Operations
•
•
•
•
•
•
•
Remove and install: Trim panel, Garnish mouldings
Remove and install or replace: Belt moulding if necessary, Outside rear
view mirror if necessary, Parts attached to glass, Water/dust barrier
Replace weatherstrip if so attached
Replace necessary adhesive/urethane
Clean up old adhesive in opening area
Align glass
Test for leaks
Not Included Operations
•
•
•
Remove and install or replace: Glass regulator and motor
Remove and replace: Aftermarket window tint
Broken glass clean up
Procedure 17—Roof
Roof Panel R&R
Included Operations
•
•
•
•
•
Remove and install: Rear or lift gate, Front and rear seats (Passenger/Pickup vehicles), Front seats (Van/Utility vehicles), Quarter trim
Remove and replace: Windshield and mouldings, Back window and
mouldings, Quarter windows and mouldings if necessary, Sunroof
assembly
Remove and install or replace: Headliner (all types), sun visors, dome
lamps, grip handles and coat hooks
Replace clip type moulding for base model vehicle (example: roof rail,
drip rail)
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
•
•
Refinish roof panel
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install or replace: Luggage rack, Roof cap and/or vinyl
cover, Wiring and/or wiring harness, Sound deadening material, Nonbase model interior trim and/or rear seating (Van/Utility vehicles)
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Broken glass clean up
IMPORTANT REMINDER: No windshield, back or quarter glass (if applicable), or flush mounted reveal mouldings can be removed without the possibility of breakage or damage that will require replacement. Unintentional
damage to glass that is considered a structural member by the vehicle manufacturer may occur when attempting alignment pulls to correct unibody collision damage. Agree beforehand who will incur the charge for damage
occurring during normal R&R or R&I operations.
Headliner R&R
Included Operations
•
Remove and install or replace: Rear seat, Sun visors, dome lamp, grip
handles and coat hooks, Inside mouldings that interfere
Procedure 18—Pickup Cab Panels
Lock Pillar, Side or Corner Panel
Included Operations
•
•
•
•
•
•
Remove and install: Sill plates, Front and/or rear seats
Remove and replace urethane set glass: Quarter window and moulding
Remove and install or replace: Non urethane set glass (Quarter window
and moulding), Lock striker
Remove and replace caulking for standard factory application
Loosen and pull back carpet and/or insulation as required
Replace clip type moulding for base model vehicle
Not Included Operations
•
•
•
•
•
•
•
•
•
•
•
Refinish pillar, side or corner panel
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install bed assembly
Remove and install or replace: Back window and moulding, Interior trim
Remove undamaged urethane set glass: Quarter window and moulding
Replace sound deadening
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Broken glass clean up
IMPORTANT REMINDER: No back or quarter glass (if applicable), or flush
mounted reveal mouldings can be removed without the possibility of breakage or damage that will require replacement. Agree beforehand who will
incur the charge for damage occurring during normal R&R and R&I operations.
Side or Corner Panel Sectioning Explanation: See Procedure 20—Quarter Panel.
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
Quarter Glass R&R
Included Operations
•
•
•
•
•
•
•
Remove and install: Rear Seat if necessary
Remove and install or replace: Parts attached to glass
Replace weatherstrip if so attached
Replace necessary adhesive/urethane
Clean up old adhesive in opening area
Align glass
Test for leaks
Not Included Operations
•
•
•
Remove and install: Trim panel
Remove and replace: Aftermarket window tint
clean up
Back Panel R&R
Included Operations
•
•
•
•
•
Remove and install: Front and/or rear seats
Remove and replace urethane set glass: Back window and moulding
Remove and install or replace: Non urethane set glass (Back window and
moulding)
Remove and replace caulking for standard factory application
Loosen and pull back carpet and/or insulation as required
Not Included Operations
•
•
•
•
•
•
•
•
•
•
•
•
Refinish back panel
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install bed assembly
Remove and replace: Interior trim
Remove undamaged urethane set glass: Back window and moulding
Remove and install or replace: Headliner (all types)
Replace sound deadening
Remove and install adhesive exterior trim; add to clean and retape
Remove and install adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Broken glass clean up
Procedure 19—Back Window
Back Window R&R
Included Operations
•
•
•
•
Remove and replace: Reveal mouldings, Garnish mouldings, Wiper arm
if so equipped
Replace weatherstrip if so installed
Replace necessary adhesive/urethane
Clean up old adhesive in opening area
Procedure Explanation
•
Test for leaks
Not Included Operations
•
•
•
Remove and install or replace: High mount stop lamp
Remove and replace: Aftermarket window tint
Broken glass clean up
IMPORTANT REMINDER: Urethane set glass may typically be considered
a structural component. Refer to OEM replacement procedures for installation methods and materials to restore structural integrity.
IMPORTANT REMINDER: No back glass or flush mounted reveal mouldings can be removed without the possibility of breakage or damage that will
require replacement. Unintentional damage to glass that is considered a
structural member by the vehicle manufacturer may occur when attempting
alignment pulls to correct unibody collision damage. Agree beforehand who
will incur the charge for damage occurring during normal R&R and R&I
operations.
P13
damage. Agree beforehand who will incur the charge for damage occurring
during normal R&R or R&I operations.
FULL PANEL REPLACEMENT PROCEDURE: Labor times are for replacement at factory seams if feasible. However, many quarter panels cannot be
replaced at roof seams because the roof panel overlaps the quarter. If a
quarter panel is designed in this manner and a section time is not listed, the
time in the text represents replacement of the panel at the most practical
area - usually below the roof seam. This method is considered a full panel
replacement provided the back glass and, if applicable, the quarter glass is
removed for splicing in the pillar/sail areas.
Quarter Panel Section
The time for this operation is for a horizontal cut at belt and below quarter
and back window unless described otherwise. The Included and Not
Included operations are the same as for a full panel except the removal and
installation or replacement of the quarter and back glass is not included.
Quarter Outer Panel R&R
Important Reminder: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
Included Operations
Quarter Glass R&R
Procedure 20—Quarter Panel
•
•
•
•
•
•
•
Remove and install: Rear seat, Parcel shelf trim, Quarter trim, Plastic
wheelhouse liner, Luggage compartment trim, Weatherstrip attached to
panel, Rear lamp assemblies, Rear bumper, Filler panel, store deflector
or rear lower valance
Remove and replace urethane set glass: Back window and moulding,
Quarter window and moulding
Remove and install or replace: Non urethane set glass (Back window and
moulding, Quarter window and moulding), Water/dust barrier, Lock
striker, Sill plates, Bolt-on extension
Loosen and pull back: Cloth type headliner as required, Carpet and/or
insulation as required
Loosen convertible top at quarter
Remove and replace caulking for standard factory application
Replace clip type moulding for base model vehicle
Not Included Operations
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Refinish quarter panel
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Preformed or molded type headliner, Fuel tank
Remove undamaged urethane set glass: Back window and moulding,
Quarter window and moulding
Remove and replace inner panels
Remove and install or replace: Wheel, Antenna
Replace sound deadening
Replace channels attached to glass; add .2 hour for lower and .3 hour for
upper and lower
Remove and install adhesive exterior trim; add to clean and retape
Remove and install adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Cut holes for installing lamps
Broken glass clean up
IMPORTANT REMINDER: Procedure Number 20 includes removal of damaged urethane set glass and replacement with new glass. The Procedure
does not include allowances for necessary precautionary measures to
remove undamaged urethane set glass, nor clean up of the old adhesive on
the glass. If the existing urethane set glass is undamaged and will be
reused, the labor time difference between the glass R&R and R&I represents the not included allowance.
Included Operations
•
•
•
•
•
•
•
Remove and install: Trim panel, Rear Seat if necessary
Remove and install or replace: Parts attached to glass, Water/dust barrier
Replace weatherstrip if so attached
Replace necessary adhesive/urethane
Clean up old adhesive in opening area
Align glass
Test for leaks
Not Included Operations
•
•
Remove and replace: Aftermarket window tint
Broken Glass clean up
Important Reminder: Urethane set glass may typically be considered a
structural component. Refer to OEM replacement procedures for installation
methods and materials necessary to restore structural integrity.
Procedure 21—Pickup Bed
Bed Assembly R&R
Included Operations
•
•
•
Remove and install: Rear lamp assemblies, Plastic wheelhouse liners,
Fuel door, Rear bumper, Tailgate
Remove and replace: Rear fender, Running board, Fuel filler pipe
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
•
•
•
Refinish bed assembly
Remove and install or replace: Wheel, Optional accessories (example:
bed liner, camper shell, fender flare)
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Cut holes for installing lamps
IMPORTANT REMINDER: Labor times for inner panels, rails or reinforcements are with outer panels removed.
Example: A Quarter Panel allowance includes a Back Glass R&R of 2.0 hr.
The R&I of the back glass is 2.3 hr. The difference of .3 hr. between Back
Glass R&R (2.0 hr.) and R&I (2.3 hr.) has not been factored into the Quarter
Panel allowance.
Side Panel R&R
IMPORTANT REMINDER: Labor times for inner panels, rails or reinforcements are with outer panels removed. No back, quarter glass (non-movable)
or flush mounted reveal mouldings can be removed without the possibility of
breakage or damage that will require replacement. Unintentional damage to
glass that is considered a structural member by the vehicle manufacturer
may occur when attempting alignment pulls to correct unibody collision
•
•
Included Operations
•
Remove and install: Rear lamp assemblies, Plastic wheelhouse liner,
Fuel door, Rear bumper, Tailgate, Bed assembly
Remove and replace: Rear fender, Running board, Fuel filler pipe
Remove and replace caulking for standard factory application
Not Included Operations
•
•
Refinish side panel
Remove and/or apply: Anti-corrosion rust resistant materials
P14
•
•
•
•
•
•
Procedure Explanation
Remove and install or replace: Wheel, Optional accessories (example:
bed liner, camper shell, fender flare)
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Cut holes for installing lamps
Not Included Operations
•
•
•
Remove and install: Trim panel, Rear seat
Remove and replace: Aftermarket window tint
Broken glass clean up
Important Reminder: Urethane set glass may typically be considered a
structural component. Refer to OEM replacement procedures for installation
methods and materials necessary to restore structural integrity.
Procedure 22—Van Utility Vehicle Side
Panel
Procedure 23—Rear Suspension
Side Panel R&R
Rear Suspension Component R&R
Included Operations
•
•
•
•
•
Remove and install: Side door, Rear door or tailgate, Rear bumper, Rear
lamp assemblies, Plastic wheelhouse liner, Filler panel, stone deflector or
rear lower valance
Remove and replace urethane set glass: Side windows and mouldings
Remove and install or replace: Non urethane set glass (Side windows
and mouldings), Water/dust barrier, Lock striker, Sill plates
Loosen and pull back cloth type headliner as necessary
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
•
•
•
•
•
•
•
•
Refinish side panel
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Preformed or molded type headliner, Interior trim,
Fuel tank
Remove undamaged urethane set glass: Side windows and mouldings
Remove and install or replace: Wheel, Seat assemblies, Inner panels
Replace sound deadening
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Cut holes for installing lamps
Broken glass clean up
SPECIAL NOTE: Procedure Number 22 includes removal of undamaged
urethane set glass and replacement with new glass. The Procedure does
not include allowances for necessary precautionary measures to remove
undamaged urethane set glass, nor clean up of the old adhesive on the
glass. If the existing urethane set glass is undamaged and will be reused,
the labor time difference between the glass R&R and R&I represents the not
included allowance.
Included Operations
•
•
Not Included Operations
•
•
Included Operations
•
•
•
•
•
Procedure 24—Luggage Lid
Luggage Lid R&R
Included Operations
•
•
•
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
•
•
•
•
Remove and install or replace: Parts attached to luggage lid except those
listed in Not Included section
Replace clip type moulding for base model vehicle
Replace caulking for standard factory application if necessary
Not Included Operations
Refinish luggage lid
Remove and install or replace: Hinges, Gas prop rod, Luggage rack,
Spoiler, Decals (example: jacking instructions, caution/danger)
Recode lock cylinder
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Procedure 25—Rear/Lift Gate
Gate Shell R&R
Included Operations
•
•
Included Operations
Remove and install or replace: Parts attached to glass, Water/dust barrier
Replace weatherstrip if so attached
Replace necessary adhesive/urethane
Clean up old adhesive in opening area
Align glass
Test for leaks
Replace rear axle parts
Remove and replace stabilizer bar
Bleed brakes if necessary
Wheel alignment
Important Reminder: Due to the design of suspension on unibody vehicles,
it may be necessary to perform four wheel alignment.
SIDE PANEL SECTIONING EXPLANATION: See Procedure 20—Quarter
Panel.
•
•
•
•
•
•
Remove and install wheel
Disassemble and clean parts
Check parts
Replace needed parts
Assemble
Not Included Operations
•
•
•
•
•
•
Quarter Glass R&R
Wheel alignment
Bleed brakes if necessary
Rear Suspension O/H
Example: A Side Panel allowance includes a Quarter Glass R&R of 1.5 hr.
The R&I of the quarter glass is 1.7 hr. The difference of .2 hr. between Quarter Glass R&R (1.5 hr.) and R&I (1.7 hr.) has not been factored into the Side
Panel allowance.
IMPORTANT REMINDER: Labor times for inner panels, rails or reinforcements are with outer panels removed. No quarter glass (non-movable) or
flush mounted reveal mouldings can be removed without the possibility of
breakage or damage that will require replacement. Agree beforehand who
will incur the charge for damage occurring during normal R&R or R&I operations.
Each operation identified in the text is considered to be a stand-alone
operation
Remove and install wheel
•
•
•
•
Remove and install trim panel
Remove and install or replace: Non urethane set glass and mouldings,
Lock cylinder, Water/dust barrier, Lamp assemblies and wiring harness
attached to gate
Replace urethane set glass and mouldings
Replace or transfer parts attached to gate (example: outside handle,
glass run channels, regulator, weatherstrip, license plate/bracket, lamp
assemblies)
Replace caulking for standard factory application if necessary
Replace clip type moulding for base model vehicle
Procedure Explanation
Not Included Operations
•
•
•
•
•
•
•
•
•
Refinish gate
Remove undamaged urethane set glass
Remove and install or replace: Wiper and washer, Hinges, Hinge anchor
plates, Gas prop rod, Spoiler
Recode lock cylinder
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Broken glass clean up
IMPORTANT REMINDER: No back glass or flush mounted reveal mouldings can be removed without the possibility of breakage or damage that will
require replacement. Agree beforehand who will incur the charge for damage occurring during normal R&R or R&I operations.
Gate Repair Panel R&R
Included Operations
•
•
•
•
•
•
Remove and install: Gate assembly, Trim panel
Remove and install or replace: Non urethane set glass and mouldings,
Lock cylinder, Water/dust barrier
Replace or transfer parts attached to gate (example: outside handle,
glass run channels, regulator, weatherstrip, license plate/bracket, lamp
assemblies)
Remove and replace: Urethane set glass and mouldings
Remove and replace caulking for standard factory application
Remove clip type moulding for base model vehicle
Not Included Operations
•
•
•
•
•
•
•
•
•
•
Refinish gate
Remove and/or apply: Anti-corrosion rust resistant materials
Remove undamaged urethane set glass
Remove and install or replace: Wiper and washer, Spoiler
Recode lock cylinder
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Broken glass clean up
Glass R&R
Included Operations
•
•
•
•
•
•
•
Remove and install: Trim panel, Garnish mouldings
Remove and install or replace: Belt moulding if necessary, Parts attached
to glass, Water/dust barrier
Replace weatherstrip if so attached
Replace necessary adhesive/urethane
Clean up old adhesive in opening area
Align glass
Test for leaks
Not Included Operations
•
•
•
Remove and install or replace: Glass regulator and motor
Remove and replace: Aftermarket window tint
Broken glass clean up
Procedure 26—Rear Body
Rear Body Lower Panel R&R
•
•
•
•
•
•
•
Remove and install or replace: Quarter panel interior trim, Wiring and/or
wiring harness
Recode lock cylinder
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Drill holes for installing exterior trim
Cut holes for installing lamps
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
IMPORTANT REMINDER: Labor times for inner panels, rails or reinforcements are with outer panels removed.
Rear Rail R&R
Included Operations
•
•
•
Remove and install or replace: Impact absorbers or mounting arms if
necessary to perform operation
Loosen and pull back carpet and/or insulation as required
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
•
Refinish rear rail
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Rear bumper, Wiring and/or wiring harness, Fuel
tank
Remove and install or replace: Suspension assemblies, Seat assemblies, Luggage compartment trim
Wheel alignment
IMPORTANT REMINDER: Labor times for inner panels, rails or reinforcements are with outer panels removed.
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
Rear Floor Pan R&R
Included Operations
•
•
Loosen and pull back: Carpet and/or insulation as required
Remove and replace caulking for standard factory application
Not Included Operations
•
•
•
•
Refinish floor plan
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install: Rear bumper, Fuel tank, Wiring and/or wiring harness
Remove and install or replace: Suspension assemblies, Seat assemblies, Luggage compartment trim
IMPORTANT REMINDER: Labor times for inner panels, rails or reinforcements are with outer panels removed.
IMPORTANT REMINDER: Sectioning of a panel may or may not be recommended by vehicle manufacturer. This procedure should only be performed
when a qualified and knowledgeable technician has determined that the
operation does not jeopardize the integrity of the vehicle.
Included Operations
Procedure 27—Rear Bumper
•
Bumper Assembly R&I
•
•
•
Remove and install: Rear bumpers, Filler panel, applique/finish panel,
stone deflector or lower valance, Weatherstrip attached to panel, Rear
lamp assemblies
Remove and install or replace: Impact absorbers or mounting arms if
necessary to perform operation, Lock cylinder attached to panel, Latch
attached to panel, Lock striker attached to panel, Rear body interior trim
Remove and replace caulking for standard factory application
Remove clip type moulding for base model vehicle
Not Included Operations
•
•
•
Refinish rear body panel
Remove and/or apply: Anti-corrosion rust resistant materials
Remove and install fuel tank assembly
P15
Included Operations
•
•
•
Remove assembly from frame, impact absorbers or mounting arms
Reinstall assembly
Adjust alignment to vehicle
Not Included Operations
•
•
Refinish bumper
Remove and install or replace optional accessories (example: trailer
hitch, trailer connector)
P16
Procedure Explanation
Bumper Assembly O/H
Included Operations
•
•
•
•
•
•
Remove and install assembly
Disassemble and replace damaged parts
Replace or transfer parts attached except those listed in Not Included
Section
Remove and install or replace: License plate/bracket
Assemble and install
Adjust alignment to vehicle
Not Included Operations
•
•
•
•
•
•
Refinish bumper
Remove and replace impact absorbers or mounting arms
Remove and install or replace optional accessories (example: trailer
hitch, trailer connector)
Remove and install adhesive exterior trim; add to clean and retape
Replace new adhesive exterior trim; deduct one-half of R&R time
Install stripes, decals, transfers or overlays
Procedure 28—Refinish Procedure
Refinish General Information
Complete Refinish
Refinish times in this Guide pertain to NEW, UNDAMAGED PARTS and are
not intended for calculating complete vehicle refinish—single- or multistage. An estimate of this nature would suggest all new panels have been
fitted to the vehicle.
Lifetime Refinish Warranty/Clear Coat
The major paint manufacturers listed below have provided the following
information: "Major refinish paint manufacturers recommend that when performing refinish warranty repairs on an OEM multi-stage or
basecoat/clearcoat finish, you must extend the application of clear to the
nearest panel edge or breakpoint to qualify for lifetime warranty." AKZO —
DuPont — Sherwin Williams — BASF — PPG
Repaired/Used Panels
Labor times related to repaired and/or used panels—example: Remove and
install or masking of glass, outside handles or exterior trim, feather prime &
block, masking for primer surfacer application—are not included in refinish
time. The steps required for refinishing a repaired and/or used panel may
vary from those required for a new panel depending on the condition of the
repaired and/or used panel.
BACK, QUARTER, PICKUP BED FRONT, PICKUP BED SIDE, VAN SIDE,
VAN REAR CORNER, ENGINE LID, LUGGAGE LID, LIFT GATE, REAR
RATE, TAIL GATE, REAR BODY
Overlap
Deduct .4 hour from refinish time for each ADJACENT MAJOR PANEL and
deduct .2 hour from time for each NON-ADJACENT MAJOR PANEL. There
is no overlap deduction taken for the first major panel.
Adjacent major panel example: Right front fender 2.5 hours (full time) and
right front door 2.5 hours minus .4 hour overlap for a total of 4.6 hours.
Non-adjacent major panel example: Right front fender 2.5 hours (full time)
and left front fender 2.5 hours minus .2 hour overlap for a total of 4.8 hours.
No overlap deductions for valance panel, pillars, door jambs, underside of
hood, underside of luggage lid or underside of gate, inner panels, filler panels, soft bumper covers or bolt-on finish panels.
NOTE: Refinish times are for outside surfaces only unless stated otherwise
in text (example: add for underside, add to edge).
Included Operations
•
•
•
•
•
•
•
•
•
Not Included Operations
•
•
•
•
•
•
•
•
•
•
Feather, Prime & Block
Is the Not-Included refinish operation that completes bodywork repair from
150 grit smoothness to the condition of a new undamaged panel, and the
point at which refinish labor time begins. The labor and materials associated
with feather, prime and block may vary depending upon the size of the
repair area, and should be evaluated when determining the work to be performed. See Welded Panels under Estimating Information.
SPOT REPAIR/BLEND ADJACENT PANEL
Spot Repair
Spot repair is defined as applying color to the repaired area of a damaged
panel to obtain full coverage of undercoats, and blending that color into the
original panel finish so that no transition can be detected. The goal is to
keep the actual repair as small as possible to avoid having newly applied
color directly next to an undamaged adjacent panel(s). Clear coat is then
applied to the entire panel. This refinish process minimizes color mismatch.
Blend for Color Match
Blending is defined as applying color, without necessity to cover undercoats,
to less than the full surface area of an adjacent undamaged panel. Paint
manufacturers recommend blending adjacent panels when a panel is
replaced, or repaired and color applied to the full surface areas, or to the
area that borders the adjacent undamaged panel(s). Clear coat is then
applied to the entire blended panel.
Major Panels
Major panels are those listed: FRONT HEADER, FENDER, HOOD, COWL
TOP, DOOR, ROCKER, ROOF, PICKUP CAB CORNER, PICKUP CAB
Solvent wash
Scuff panel and clean
Mask adjacent panels up to 36 inches or substitute with cover vehicle
(bag) complete
Prime or seal as required
Final sanding and clean
Mix materials
Adjust spray equipment
Apply color
Clean equipment
•
Blending into adjacent panel and/or panels, or nearest breaking point
Color match or tinting
Applying anti-corrosion rust resistant materials
Additional application of soft chip primers or anti-chip undercoats
Finish sand and buff
Subsequent vehicle bagging when required: add .2 hour for each application & removal
Mask interior to prevent overspray damage
Removal of protective coatings
Removal of release agent from OEM raw plastic components (example:
non-primed bumper covers) See formula under Raw Substrate Prep
Feather, Prime & Block paint damage to adjacent panel and/or panels
joined by welding due to burn damage (see Feather, Prime & Block definition under Refinish General Information)
Gravel guard refinish; add .5 hour for the first major panel and .3 hour for
each additional panel.
NOTE: The included operation of mask adjacent panels is inclusive of any
necessary back tape masking to prevent overspray.
IMPORTANT REMINDER: Refinish times are for NEW, UNDAMAGED
PARTS without exterior or interior trim or attached components. Refinish
times may vary depending on individual procedures, product and/or weather
conditions.
A small percentage of colors are identified by the paint manufacturers as
highly transparent. These colors may require additional application coats to
achieve visual hiding. In instances where four or more color coats are necessary to achieve adequate hiding, some adjustment in refinish times may
be appropriate.
IMPORTANT REMINDER: The cost of paint and materials is not included in
refinish time.
NOTE: Gravel Guard application and appropriate refinish may be necessary
beyond the actual replacement area to achieve a "texture" match.
It may be necessary to tint or otherwise modify non-exterior colors applied
to undersides, edges and/or jambs for which there is no paint color formula
to achieve a color match. When necessary, reference "color match or tinting" listed above in Not Included Operations.
Raw Substrate Prep
Allow .2 per refinish hour (20%) for plastic components that come from the
manufacturer/supplier in a raw/un-primed state.
Procedure Explanation
Included Operations
•
•
•
•
•
Detergent wash
Alcohol/plastic cleaner wash
Additional solvent wash
Application of specialized adhesion promoter
Clean Equipment
Clear Coat/Two Stage Refinish
First major panel or soft bumper/fascia cover: Add .4 per refinish hour
(40%), then add .4 per refinish hour for jamb, jamb and interior, edge panel,
and/or underside (when necessary).
Included Operations
•
•
•
•
Mix material
Clean and tack surface
Apply material
Clean equipment
NOTE: Some OEMs now utilize a matte clear coat on non-exterior colors
applied to undersides, edges, and/or jambs.
Additional panel(s) and/or other refinish area(s): Deduct overlap (if
applicable); add .2 per refinish hour (20%), then add .2 per refinish hour for
jamb, jamb and interior, edge panel, and/or underside (when necessary).
Included Operations
•
•
Clean and tack surface
Apply material
NOTE: For NEW, UNDAMAGED PARTS, a total of no more than 2.5 hours
should be necessary to perform the four Clear Coat Refinish Included Operations listed above. This calculation DOES NOT APPLY to bumper covers,
ground effects, special package equipment, interior edges, jambs, entryways, undersides and additional time that may be required for repaired
and/or used panels. It DOES NOT APPLY to complete vehicle refinish. It is
not intended to determine the quantity or cost of materials required for the
application of clear.
Three Stage Refinish
First major panel or soft bumper/fascia cover: Add .7 per refinish hour
(70%), after time has been added for jamb, jamb and interior, edge panel,
and/or underside (when necessary).
Included Operations
•
•
•
•
•
•
•
Mix pearl/mica toner
Apply toner to test panel
Mix clear
Clean and tack surface
Apply clear to test panel
Repeat application to surface being refinished
Clean equipment
Additional panel(s) and/or other refinish area(s): Deduct overlap (if
applicable); add .4 per refinish hour (40%), after time has been added for
jamb, jamb and interior, edge panel, and/or underside (when necessary).
Included Operations
•
•
•
Apply pearl/mica toner
Clean and tack surface
Apply clear
NOTE: With three stage paints, it may be necessary to blend into larger
areas of adjacent panels or complete sides of vehicles, otherwise known as
zone painting.
NOTE: Some OEMs now utilize a matte clear coat on non-exterior colors
applied to undersides, edges, and/or jambs.
Two Tone Refinish
First major panel: Add .5 per refinish hour (50%)
Included Operations
•
•
•
•
Mask panel
Scuff panel
Mix material
Apply material
•
P17
Clean equipment
Additional panel(s) and/or other refinish area(s): Deduct overlap (if
applicable); add .3 per refinish hour (30%)
Included Operations
•
•
•
Mask panel
Scuff panel
Apply material
Blend Adjacent Panel(s)
With some colors, it may be necessary to blend color into adjacent panels to
obtain an acceptable color match.
A blend labor time formula is provided should it be necessary to perform this
operation. The performance of this operation is NOT INCLUDED in the
Mitchell refinish labor time.
The blend times are for existing undamaged adjacent surfaces. The
blend labor time includes the application of clear coat to the entire panel on
which color is blended. On some panels, the clear may be stopped at natural body lines or be blended into acceptable design configuration areas.
Single Stage/Two Stage Colors
Blend adjacent panel(s): Allow .5 per refinish hour (50%) for each
panel(s)/refinish area(s) blended.
Included Operations
•
•
•
•
•
•
•
Detergent/solvent wash
Wet sand, scuff (ScotchBrite) or rubout (compound) panel and clean for
preparation
Mask existing adjacent panels to 36"
Apply bonding material - if required
Apply color
Clean and tack surface
Apply clear material
Not Included Operations
•
•
•
Repair existing surface imperfections
Remove and install or mask attached components, trim, stripes or decals
on blended panel/area
Finish, sand, and buff
NOTE: Blend labor time does not apply to two-tone refinish or custom nonOEM refinish. No overlap deduction applies to blended panel(s)/refinish
area(s).
NOTE: When calculated, the estimate will allocate 20% from the total blend
time and apply it to the clear coat line item. The total sum of the blend line
and the amount allocated to the clear coat line will total 50% of the exterior
refinish time for the panel being blended.
Example: A panel refinish time is 2.0 hrs. When blended, the refinish time
for that panel will be displayed as 1.0 (.5 per refinish hour). Once calculated,
the refinish blend line will be displayed as .8 and .2 (20%) will be allocated
to the clear coat line.
Three Stage Colors
Blend adjacent panel(s): Allow .7 per refinish hour (70%) for each
panel(s)/refinish area(s) blended.
Included Operations
•
•
•
•
•
•
•
•
•
Detergent/solvent wash
Wet sand, scuff (ScotchBrite) or rubout (compound) panel and clean for
preparation
Mask existing adjacent panels to 36"
Apply bonding material - if required
Apply color
Clean and tack surface
Apply pearl/mica toner
Clean and tack surface
Apply clear material
Not Included Operations
•
Repair existing surface imperfections
P18
•
•
Procedure Explanation
Remove and install or mask attached components, trim, stripes or decals
on blended panel/area
Finish, sand, and buff
NOTE: Blend labor time does not apply to two-tone refinish or custom nonOEM refinish. No overlap deduction applies to blended panel(s)/refinish
area(s).
NOTE: When calculated, the estimate will allocate 40% from the total blend
time and apply it to the three stage line item. The total sum of the blend line
and the amount allocated in the three stage line will total 70% of the exterior
refinish time for the panel being blended.
Example: A panel refinish time is 2.0 hrs. When blended, the refinish time
for that panel will be displayed as 1.4 (.7 per refinish hour). Once calculated,
the refinish blend line will be displayed as .8 and .6 (40%) will be allocated
to the three stage line.
Extension of Clear Coat
In some applications, it may be required to extend the application of clear to
the nearest panel edge or breakpoint.
The performance of this operation is NOT INCLUDED in the Mitchell refinish
labor time.
The extension of clear coat formula is intended to be calculated as a percentage of base refinish hours excluding overlap.
The performance of this operation is NOT INCLUDED in the Mitchell refinish
labor time.
The de-nib and finesse formula is intended to be calculated as a percentage
of the base refinish hours excluding overlap and clear coat. It DOES NOT
APPLY to edges, jambs, and undersides. For blended panels, the formula
should be applied to the full panel refinish time. No deduction for refinish
overlap should be taken.
De-nib and finesse outside surface area(s): Allow .2 per refinish hour
(20%) to de-nib and finesse each surface area(s).
Mask Vehicle to Prevent Overspray Damage
The following refinish information is provided should it be necessary to perform these operations as determined by individual job requirements:
MASK INTERIOR, ENTRYWAYS, ENGINE COMPARTMENT AND TRUNK
OPENINGS
Interior masking may be necessary when refinishing exterior surfaces to
stop overspray damage that is not prevented by adjacent panel perimeter
masking which includes back taping or application of foam tape. Interior
masking may also be used when exterior panels (door, hood, etc.) are
removed while applying refinish material. The performance of this operation
is NOT INCLUDED in the Mitchell refinish labor time.
Fig. 1:
IDENTIFYING INTERIOR MASKING LOCATIONS
It DOES NOT APPLY to edges, jambs, and undersides. No deduction for
overlap should be taken.
This formula DOES APPLY to the 2.5 hours maximum clear coat allocation.
Should this operation be necessary, the following formula is provided:
Extend Clear to Adjacent Panel(s)
Extend clear to adjacent panel(s): Allow .5 per refinish hour (50%) for each
panel(s)/refinish area(s) cleared.
Included Operations
•
•
•
•
•
•
Detergent/solvent wash
Wet sand, scuff (ScotchBrite) or rubout (compound) panel and clean for
preparation
Mask existing adjacent panels to 36"
Apply bonding material - if required
Clean and tack surface
Apply clear material
Not Included Operations
•
•
•
•
Repair existing surface imperfections
Remove and install or mask attached components, trim, stripes or decals
on extended clear panel/area
Finish, sand, and buff
Nib sand and finesse
Finish Sand & Buff
A labor time formula is provided should it be necessary to perform this
operation. This procedure includes the removal of orange peel and any
blemishes that affect paint texture in order to produce a smooth finish to the
entire panel surface. This process is not limited to "nib sanding" or "finessing" which is the removal of isolated dirt/dust particles only. The performance of this operation is NOT INCLUDED in the Mitchell refinish labor
time.
The finish sand and buff formula is intended to be calculated as a percentage of the base refinish hours excluding overlap and clear coat. It DOES
NOT APPLY to edges, jambs, and undersides. For blended panels, the formula should be applied to the full panel refinish time. No deduction for refinish overlap should be taken.
Finish sand and buff outside surface area(s): Allow .3 per refinish hour
(30%) to finish sand and buff each surface area(s).
De-nib & Finesse
A labor time formula is provided should it be necessary to perform this
operation. This procedure includes the removal of small isolated dust particles (nibs) and the application of a finishing glaze.
NOTE: The times shown in the illustration are for interior masking of that
panel and/or opening. Labor time includes all pillars, jambs, weatherstrips,
edges, entryways and openings as necessary. Deduct .1 hour overlap for
each interior masked adjacent panel and/or opening.
The Mitchell REFINISHING MATERIALS GUIDE has the Latest Available
Costs for Materials Used in Single and Multi-Stage Refinishing, and is an
Accurate Source for Determining Costs.
Procedure Explanation
Procedure 29—Special Caution
Computer Modules
When working with vehicles equipped with on-board computers, manufacturers recommend removal if temperatures are likely to exceed 176°F
(80°C). Do not apply heat from a torch or weld in the immediate vicinity of
computers without protecting them. Remove if necessary.
Many vehicles have multiple computers such as: Electronic Control Modules
(ECM), Body Control Modules (BCM), individual computers for Anti-Lock
Brake Systems and Electronic Suspension systems. All of these computers
should be protected or removed before exposing them to high heat. Never
connect or disconnect these units with ignition switch on, or charge a battery
with battery cables connected. Before servicing, ground yourself and
ground the work area to discharge stored static electricity.
Computer control information is listed in the Electrical Section of all Mitchell
Collision Estimating Guides. There is a footnote below the listing or an illustration describing the location of each unit.
Structural Glass
Windshields, back windows and other glass that was originally installed by
vehicle manufacturer utilizing urethane, should be reinstalled with urethane.
The urethane bonds the glass to the vehicle and makes the glass part of the
vehicle’s structure. Ensure that the vehicle manufacturer and/or I-CAR recommended installation is followed, and that the urethane is properly cured
before returning the vehicle to service.
Supplemental Restraint/Air Bag System
Vehicle manufacturer’s recommended service and repair procedures must
be followed when servicing any Supplemental Restraint/Air Bag System.
Certain safety precautions and disabling procedures must be observed
when performing repairs.
See Mitchell’s Air Bag Service & Repair Manual for system description and
operation checks, precautions, disabling and activating procedures, component removal and installation procedures, and diagnosis and testing information. Refer to Air Bag/SRS Component Inspection & Replacement
Tables.
Seat Belts
Many vehicle manufacturer’s advise replacement of seat belts when
stressed by occupants in a collision. Refer to vehicle manufacturer or service manual for specific clarification.
Rev. 02-10
P19
Reference Information
P20
Abbreviations
Table 1:
Identifying Abbreviations (continued)
Abbreviation
Table 1:
Identifying Abbreviations
Abbreviation
Description
1BC
1 Barrel Carburetor
2-4BC
2-4 Barrel Carburetors
2BC
2 Barrel Carburetor
2WD
2 Wheel Drive
2WS
2 Wheel Steering
3-2BC
3-2 Barrel Carburetors
4BC
4 Barrel Carburetor
4WD
4 Wheel Drive
4WS
4 Wheel Steering
6BC
6 Barrel Carburetor
A/C
Air Conditioning
AAM
All Active Module
AAS
Automatic Adjusting Suspension
ABC
Active Body Control
ABS
Antilock Braking System
ACE
Active Cornering Enhancement
Add’l
Additional
Adj
Adjust
ADS
Adaptive Damping System
AFS
Adaptive Front Lighting System
ALB
Antilock Braking System
ALD
Auto Locking Differential
Alt
Alternator
Alum
Aluminum
Alum/Steel
Aluminum/steel
Amp
Amperage
AOT
Automatic Overdrive Trans
AQCS
Air Quality Control System
ASC
Auto Stability Control
ASC&T
Auto Stability Control plus Traction Control
ASCD
Automatic Speed Control Device
ASR
Automatic Slip Control
Assy
Assembly
ATC
Automatic Temp Control
Auto
Automatic
Aux
Auxiliary
Description
AWD
All Wheel Drive
BAS
Brake Assist System
BBC
Bumper to Back of Cab
BC
Barrel Carburetor
BLIS
Blind Spot Information System
BOC
Back of Cab
Boron Stl
Boron Steel
BPMV
Brake Pressure Modulator Valve
BPT
Back Pressure Transducer
Brg
Bearing
Brkt
Bracket
Brkts
Brackets
BSC
Battery Safety Clamp
BTSI
Brake Trans Shift Interlock
Cast Alum
Cast Aluminum
CB
Citizens Band Radio
cc
Cubic Centimeters
CCC
Computer Command Control
CCT
Computer Controlled Timing
CD
Compact Disc
C Fiber
Carbon Fiber
CFI
Central Fuel Injection
Ch
Chassis
Cig
Cigarette
cm
Centimeter
CMBS
Collision Mitigation Braking System
CNG
Compressed Natural Gas
COE
Cab Over Engine
Com
Composite
Comb
Combination
Comp
Compressor
Compt
Compartment
Cond
Condenser
Cont
Control
Conv
Convertible
CPI
Central Port Injection
CRSSS
Cold Rolled Sheet Structural Steel
Ctr
Center
Reference Information
Table 1:
Identifying Abbreviations (continued)
Abbreviation
Table 1:
Description
P21
Identifying Abbreviations (continued)
Abbreviation
Description
CV
Constant Velocity
EHSS
Extra High Strength Steel
CVVT
Continuously Variable Valve Timing
Elec
Electric
CWBS
Collision Warning w/Brake Support
Elect
Electronic
Cyl
Cylinder
Eng
Engine
d
Discontinued
EPR
Evaporator Pressure Regulator
D&A
Disassemble & Assemble
EPS
Electrical Power Steering
D&C
Disconnect & Connect
Equip
Equipment
DEFI
Digital Electronic Fuel Injection
ESC
Electronic Stability Control
Defl
Deflector
ESP
Electronic Stability Program
DERM
Diagnostic Energy Reserve Module
EST
Electronic Spark Timing
Dia
Diameter
ETR
Emergency/Energy Tension Reactor
Diaph
Diaphragm
ETS
Electronic Traction System
Diff’l
Differential
Ev-Em
Evaporative Emission Control
Dist
Distribution
Evap
Evaporator
DME
Digital Motor Electronics
Exh
Exhaust
DOD
Displacement on Demand
Ext
Extension
DOHC
Dual Over Head Cam
FFV
Flex Fuel Vehicle
DOT
Department of Transportation
F-Glass
Fiber Glass
DPF
Diesel Particulate Filter
FI
Fuel Injection
DPMS
Driving Position Memory System
Frt
Front
DPS
Dual Phase Steel
FWD
Front Wheel Drive
DRL
Daytime Running Lights
Fwd
Forward
DSC
Dynamic Stability Control
g
Gram
DSTC
Dynamic Stability Traction Control
Galv Steel
Galvanized Steel
DVD
Digital Versatile Disc
GDO
Garage Door Opener
EATC
Electronic Auto Temperature Control
GPS
Global Positioning System
EATX
Electronic Automatic Transmission Control
Gskt
Gasket
EBCM
Electronic Brake Control Module
GVW
Gross Vehicle Weight
EBTC
Electronic Brake and Traction Control
H/Lamp
Headlamp
ECM
Electronic Brake and Traction Control
H/Lamps
Headlamps
ECS
Electronic Crash Sensor
H/Perf
High Performance
EDC
Electronic Dampening Control
HCU
Hydraulic Control Unit
EEC
Electronic Engine Control
HD
Heavy Duty
EFC
Electronic Fuel Control
HEI
High Energy Ignition
EFE
Early Fuel Evaporation
HFM
Hot Film Management
EFI
Electronic Fuel Injection
HFS
Hydroformed Steel
EGR
Exhaust Gas Recirculation
HICAS
High Capacity Suspension
EGS
Elect Trans Gear System
HID
High Intensity Discharge
Reference Information
P22
Table 1:
Identifying Abbreviations (continued)
Abbreviation
Description
Table 1:
Identifying Abbreviations (continued)
Abbreviation
Description
HO
High Output
LSM
Laminated Sheet Metal
Horiz
Horizontal
Lwr
Lower
HP
Horsepower
MAF
Mass Air Flow
Hsg
Housing
MAG
Magnesium
HSLA
High Strength Low Alloy Steel
Man
Manual
HSLA/Com
High Strength Low Alloy Steel Composite
MAP
Manifold Absolute Pressure
HSS
High Strength Steel
MAT
Manifold Air Temperature
HUD
Head Up Display
Mbr
Member
HVAC
Heater Ventilation Air Conditioning
MCU
Microprocessor Control Unit
Hvy
Heavy
MD
Medium Duty
Hyd
Hydraulic
MDM
Motor Drive Module
Hz
Hertz
Mech
Mechanical
ICC
Interstate Commerce Commision
Med
Medium
ID
Inside Diameter
Mfg
Manufacturer
Ign
Ignition
MFI
Multi-Fuel Injection
Illum
Illuminated
MHz
Megahertz
IMA
Integrated Motor Assisted
Mldg
Moulding
Info
Information
Mldgs
Mouldings
Inr
Inner
MHSS
Mega Hard Strength Steel
Inst
Instrument
mm
Millimeter
Inter
Intermediate
MMC
Manifold Mount Converter
IOH
Included in Overhaul
MPFI
Multi-Port Fuel Injection
IPU
Intelligent Power Unit
MPH
Miles Per Hour
ITS
Inflatable Tubular Structure
MPI
Multi-Port Injection
IVD
Interactive Vehicle Dynamics
MST
Manifold Surface Temperature
Kg
Kilogram
Mtd
Mounted
Kgs
Kilograms
Mtg
Mounting
KHz
Kilchertz
MTV
Manifold Tuning Valve
km
Kilometer
N.A.
Not Available
KPH
Kilometers Per Hour
Nav
Navigation
KW
Kilowatt
No
Number
L
Litre or Left
NOx
Nitrogen Oxide Emission Control
Lb
Pound
O/D
Overdrive
LCD
Liquid Crystal Display
O/H
Overhaul
LED
Light Emitting Diode
OBD
On-Board Diagnostics
LEV
Low Emission Vehicle
OCS
Occupant Classification System
Lic
License
OD
Outside Diameter
LSD
Limited Slip Differential
OE
Original Equipment
Reference Information
Table 1:
Identifying Abbreviations (continued)
Abbreviation
Table 1:
Description
P23
Identifying Abbreviations (continued)
Abbreviation
Description
OEM
Original Equipment Manufacturer
Resv
Reservoir
OHC
Over Head Cam
RPM
Revolutions Per Minute
OHV
Over Head Valve
RPO
Regular Production Option
OPDS
Occupant Position Detector Sensor
Rr
Rear
Opng
Opening
RTV
Room Temperature Vulcanized
Opt
Option
RWD
Rear Wheel Drive
OPVR
On-Board Refueling Vapor Recovery
SAM
Signal Acquisition Module
Otr
Outer
SBA
Set Back Axle
OVRS
Onboard Vapor Recovery System
SBEC
Single Board Engine Control
Ozs
Ounces
SCRS
Selective Catalyst Reduction System
P/S
Power Steering
SDM
Sesning & Diagnostic Module
PAIR
Pulse Air Injection Reactor
SEFI
Sequential Electronic Fuel Injection
Pass
Passenger
SFA
Set Forward Axle
PCM
Powertrain Control Module
SFI
Sequential Fuel Injection
PCU
Power Control Unit
SHO
Super High Output
PDCC
Porsche Dynamic Chassis Control
SIPS
Side Impact Protect System
PDU
Power Drive Unit
SIR
Supplemental Inflatable Restraints
Perf
Performance
SISM
Side Impact Sensing Module
Pkg
Package
SLS
Self-Leveling Suspension
Pnl
Panel
SMC
Sheet Molded Compound
Pos
Position
SOHC
Single Over Head Cam
PPD
Passenger Presence Detection
Spec
Specifications
PTO
Power Take Off
Speedo
Speedometer
PVC
Positive Ventilation Crankcase
SPI
Single Port Injection
Pwr
Power
SRS
Supplemental Restraints System
PZEV
Partial Zero Emission Vehicle
Stab
Stabilizer
Qtr
Quarter
STC
Stability Traction Control
Qty
Quantity
Std
Standard
R
Right
Stpd
Stamped
R&I
Remove & Install
SULEV
Super Ultra Low Emissions Vehicle
R&R
Remove & Replace
Strg
Steering
R/L
Right/Left
Supt
Support
Rad
Radiator
Susp
Suspension System
Rect
Rectangular
Sys
System
Refrig
Refrigeration
Tach
Tachometer
Reg
Regulator
TBI
Throttle Body Injection
Reinf
Reinforcement
TCS
Traction Control System
Reinfs
Reinforcements
TDC
Top Dead Center
Reference Information
P24
Table 1:
Identifying Abbreviations (continued)
Abbreviation
Description
TDI
Turbo Direct Injection
Temp
Temperature
TEMS
Toyota Electronic Modulated Suspension
TH
Turbo Hydra-Matic
THRU
Through
TLEV
Transitional Low Emission Vehicle
TP
Thermoplastic
TPI
Tuned Port Injection
Trac
Traction
Trans
Transmission
UHSS
Ultra High Strength Steel
ULEV
Ultra Low Emission Vehicle
Upr
Upper
Vac
Vacuum
Veh
Vehicle
Vert
Vertical
VHHS
Very High Strength Steel
VIN
Vehicle Identification Number
VTR
Valve in Receiver
VTEC
Valve Timing Electronic Control
VTM-4
Variable Torque Management -4WD System
w/
With
w/o
Without
W/S
Windshield
W/Strip
Weatherstrip
WB
Wheel Base
Whlhse
Wheelhouse
X-Cool
Extra Cooling
Xmbr
Crossmember
ZLEV
Zero Level Emissions Vehicle
Rev. 10-09
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