Paint - Identification/Repair of Colorcoat Delamination
BULLETIN NUMBER: 92-1O-134ASECTION: 10 Body
NUMBER: 4
CORPORATE REFERENCE NUMBER: 231054R
DATE: July 1993
SUBJECT:
SERVICE PROCEDURES FOR IDENTIFICATION AND REPAIR OF PAINT COLORCOAT DELAMINATION FROM ELPO PRIMER
MODELS:
1988-92 TRUCKS
THIS BULLETIN CANCELS AND REPLACES TRUCK SERVICE BULLETIN 92-10-134 (CORP # 231054R), DATED OCTOBER 1992. IT IS BEING REVISED TO REMOVE THE COVER LETTER PORTION AND SUBJECT STATEMENT NOW INCLUDES NOTE FOR TRUCKS AND REVISES THE MONOCOAT MATERIAL ALLOWANCES ON "G", "S/T" AND SOME "R/V" MODELS. THE ALLOWANCE FOR "ADD FOR TWO-TONE" ON G AND S/T TRUCKS HAS BEEN CHANGED. ALL COPIES OF 92-10-134 SHOULD BE DISCARDED.
The revisions are the result of changes to the MONOCOAT (ENAMEL) material allowance charts published in June, 1993.
Six (6) of the "G" model revisions use Basecoat/Clearcoat material allowance codes. THESE ARE TO BE USED AS DOLLAR REFERENCES ONLY, AND ARE MARKED WITH A # INDICATOR. Continue to repair these vehicles with monocoat materials. DO NOT repair these vehicles with Basecoat/Clearcoat products.
Use the latest (June, 1993) material allowance charts when submitting claims.
SUBJECT:
Service procedures for the repair of paint colorcoat delamination from elpo primer (repaint entire body above the body side moldings, except trucks as noted).
APPLICATION:
1988-1992 LIGHT DUTY TRUCKS (C/K, R/V, S/T, M/L AND G)
This bulletin cancels and supersedes service procedures and time allowances on all previous bulletins regarding paint DELAMINATION. Due to the use of new procedures, add times for optional equipment, and designating specific hardware items for removal, the published labor times will not be the same as previously published.
CONDITION
This bulletin is being issued to assure that the correct procedure is followed to repair a condition known as DELAMINATION. Some of the above listed passenger cars, light duty trucks, and vans may have DELAMINATION (peeling) of the paint color-coat from the ELPO primer depending upon variable factors including prolonged exposure to sunlight and humidity.
Blues, Grays, Silvers and Black Metallics are the colors that have the highest potential for this condition. On rare occasions, other colors may be involved.
Important
DELAMINATION is different than other paint conditions and/or damage. A proper problem identification is necessary, and the service procedure that follows is specific to the proper repair of DELAMINATION and must be followed. The information in this bulletin covers Paint DELAMINATION of the colorcoat from the ELPO primer ONLY. It does not address any other paint conditions. Procedures for the repair of other paint conditions (stone chips, scratches, environmental damage, clearcoat peeling, runs, dirt, fading, etc.) will not effectively repair DELAMINATION and customer dissatisfaction will result.
CAUSE
This condition may occur on vehicles produced in plants where the paint process does not call for application of a primer surfacer. Under certain conditions, ultraviolet light can penetrate the colorcoat, sometimes causing a reaction and separation of portions of the colorcoat from the ELPO (electrocoat) primer.
PROBLEM IDENTIFICATION:
On a clean surface, at or above room temperature, firmly apply a 2" wide piece of masking tape and pull upward quickly. DO NOT USE duct tape, cloth backed tape or other aggressive tapes. If the colorcoat flakes or peels away from the ELPO (leaving the ELPO intact) the colorcoat is delaminating and the vehicle should be repaired using the "Paint Repair Procedure" contained in this bulletin. This test SHOULD ONLY BE APPLIED TO A VEHICLE SHOWING THE CONDITION, (peeling/delamination) and NOT in areas of stone chipping or other obvious damage. These "other" conditions should be repaired following standard paint repair procedures.
CORRECTION
Refinish the ENTIRE BODY ABOVE THE BODY SIDE MOLDINGS using the following repair procedure. It is important that ALL surfaces above the body side moldings (including recessed areas around door handles) be refinished, as these surfaces may show the same DELAMINATION (peeling) condition at a later date.
Note:
Many vehicles have some type of plastic exterior body panels (cowl vent grilles, fascias, front end panels, rear fenders, etc.). These panels are not subject to DELAMINATION and therefore do not require refinishing. If painting of these panels is required for color uniformity, scuff sand and color- coat only (and clearcoat if basecoat/clearcoat system is used).
Note:
Two tone lines, feature lines or body side molding treatments near mid-door height are appropriate break lines. If no such convenient break lines are present, the entire panel above the next lower break line must be refinished and the portion of the panel below that break line should be COLOR- COATED ONLY (and clearcoated if basecoat/clearcoat system is used) for color uniformity of the repair.
Note:
Pickup boxes which are covered by caps, bedliners or tonneau covers do not receive direct exposure to sunlight, and normally would not be repaired under this procedure. However, if the inside of the box has been uncovered and experienced DELAMINATION, use the appropriate Labor Operation Number.
Note:
Certain two tone applications on trucks using the high potential colors (Blues, Grays and Silvers) may require that only portions of the vehicle surface be refinished. Examples would be:
Example 1.
Blues, Grays and Silvers as "insert colors" on vertical surfaces with other, non-high potential colors above the insert (or break line).
Action:
Refinish the "insert color" only, between the break line and body side molding (or to the lower feature line on certain vehicles).
Example 2.
Blues, Grays and Silvers on surfaces above the break line with other, non-high potential colors as "insert colors".
Action:
Refinish the surfaces above the "insert color" or break line only.
Example 3.
Blues, Grays and Silvers used as both the primary and "insert colors".
Action:
Refinish both high potential color surfaces above the body side moldings (or to the lower feature line on certain vehicles).
Vehicles should be repaired with the same type materials they were manufactured with; repair basecoat/clearcoat with basecoat/clearcoat materials and monocoat with monocoat.
PAINT REPAIR PROCEDURE
1. Some vehicle components will be removed from the vehicle while others will require masking. The list located at the end of this bulletin will establish the removal items. Items not found on the list and non-repair areas are to be masked.
2. Prior to removing the paint finish, clean the area to be refinished with an appropriate wax and grease remover to remove any contaminants.
3. Remove the original finish of paint down to the ELPO primer surface using an orbital D.A. sander, leaving the ELPO surface intact. This can be done in "stages" using 80 grit (or finer) discs to remove the majority of coating, followed with 180 grit (or finer) discs to remove the remainder of material down to the ELPO surface and any chalky residue or degraded ELPO that may remain. Avoid sanding through ELPO to bare metal in order to retain maximum corrosion protection.
- An alternative in some geographic areas may be plastic media blasting such as may be provided by members of: - Dry Stripping Facilities Network 1-800-634-9185 *
* We believe these sources and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources.
Important
Additional time or payment beyond established allowances in this bulletin will not be allowed.
- The use of a razor blade on large flat surfaces is not recommended because of the potential to chip. gouge or otherwise damage the primer surface. If razor blade technique is used, the application of a "guide coat" prior to wet sanding should also be used.
Note:
Chemical stripping is not recommended because of negative impact to moldings, non-metal components, ELPO and environmental concerns.
4. Blow off with air to remove all dirt and sanding residue from cracks and vehicle surface.
5. Clean sanded surface with an appropriate wax and grease remover.
6. Tack wipe entire area to be primed.
7. Spray entire prepared area with a coat of anti-corrosion primer to ensure maximum adhesion and corrosion resistance. Be sure to cover any bare metal surfaces exposed during the sanding operations. Follow manufacturer's instructions and recommended dry times.
Typical materials for this application would be: DuPont 615S/616S, BASE DE17/PR8O/DA18, PPG DP4O/DP401, or equivalent.
V.O.C. materials would be: DuPont 615S/616S, BASF DE15/PA16/PRB0, PPG DCP21/DCX211 or equivalent.
8. Apply two to three medium wet coats of primer surfacer to the primed surface of the vehicle, following the manufacturer's instructions for application and film build requirements.
Important
Failure to apply primer surfacer will likely result in future delamination.
Typical materials for this application would be: DuPont 1120S/1130S/1125S, BASF DP20/PR80/PH36, PPG K36/DT870/K201, or equivalent.
V.O.C. materials would be: DuPont 210S, BASF HP400, PPG DCP21/DCX211, or equivalent.
9. After allowing adequate drying time, wet sand with 400 grit (or finer) or dry sand with 320 grit (or finer) sandpaper.
10. Repeat steps 4 through 6.
11. Apply a medium coat of corrosion resistant primer sealer (tintable base) to the entire surface to be refinished. This will provide maximum adhesion, uniform color coating and corrosion protection to areas "sanded through" during wet sanding. Follow manufacturer's instructions and recommended dry times.
Typical materials for this application would be: DuPont 2610S/2605S, BASF DP21/DH6O/PR80, PPG DP40/DP402 or equivalent.
V.O.C. materials for this application would be: DuPont 21255, PPG DPW1834 or equivalent.
12. Apply two to three medium wet coats of color (or until primer color is hidden). Follow manufacturer's instructions and recommended dry times.
13. If vehicle has basecoat/clearcoat paint, apply clearcoat. Follow manufacturer's instructions and recommended dry times.
14. After sufficient air or force dry time, unmask the vehicle.
15. Finesse/polish as required.
16. Reinstall all previously removed items.
17. Wash and prepare the vehicle for delivery.
HARDWARE ITEMS REMOVAL LIST
Note:
Some technicians may apply a small cord (wire, plastic tube, etc.) behind or underneath moldings that remain on the vehicle to improve sanding and painting. If the vehicle paint system is baked with cord in place, damage to some moldings may occur. If this technique is used, DO NOT BAKE PAINT air dry only
Note:
Only items marked with an asterisk are "add" conditions to the Major Operation being performed. Removal time for all other items listed is included in the refinish time.
LIGHT DUTY TRUCKS
C/K TRUCKS
Grille Front bumper filler
panel
Antenna Tail lamps
Door edge guards Metal wheel opening moldings
*Roof marker lamps "Luggage rack
*West coast style mirrors "Stripes
Emblems/decals if necessary Swing out windows/seals
Tail gate handle bezel
S/T TRUCKS
Windshield molding Bumper filler panels, Ft./Rr.
Wiper arms Antenna
Wheel opening moldings Cowl vent grille
Door edge guards Side view mirrors
Tail lamps *Wind deflector
Rear Window (Jimmy) *Luggage rack
*Stripes Emblems/decals if necessary
Swing out windows/seals
*Spare tire carrier and latch-external mount (Jimmy)
M/L VANS
Windshield molding Wheel opening moldings
Headlamp bezels Antenna
Tail lamps Door edge guards
*Luggage rack *Stripes
Emblems/decals if necessary
R/V TRUCKS
Wiper arms Cowl vent grille
Antenna Tail lamps
Hood ornaments Wheel opening moldings
Side view mirrors Grille and headlamp bezels
Door edge guards Bumper filler panel, Frt./Rr.
Front side marker lamps *Roof marker lamps
*West coast style mirrors *Stripes
Emblems/decals if necessary
G VANS
Wiper arms Cowl vent grille
Grille and headlamp bezels Front bumper filler panel
Antenna Side view mirrors
Side marker lamps Tail lamps
Door edge guards Wheel opening moldings
*Roof marker lamps *West coast style mirrors
*Stripes Emblems/decals if necessary
Swing out windows/seals
WARRANTY INFORMATION
For vehicles repaired under warranty. and for customer satisfaction. use:
Labor Op (Labor Operations include mix time)
A6100 Refinish the entire exterior body surface ABOVE THE BODY SIDE MOLDING AND INSERT COLOR on two tone vehicles if equipped.
A6101 Refinish the entire exterior body surface INSERT COLOR only.
A61O2 Refinish the PICKUP BOX LOAD FLOOR AND INNER FENDERS when applicable.
A61O3 On units with an insert color, included is the entire exterior body surface ABOVE THE BREAKLINE. (If the insert color and the entire body surface above the break-line requires refinishing, use A6100).
Time Allowance: See Chants
NOTE:
The time allowances provided on the chart include the hardware removal and installation (as indicated by the list guidelines), the masking and unmasking of the vehicle, stripping of the surface (as indicated by the guidelines), the refinish (and colorcoat when required), mix time for primer/paint (and clearcoat when required), finesse/polish where required, washing and preparing the vehicle for delivery.
OPERATION DESCRIPTION:
PAINT COLORCOAT DELAMINATION FROM ELPO PRIMER, REFINISH ENTIRE BODY ABOVE BODY SIDE MOLDINGS.
PAINT TERM DEFINITIONS
Following are definitions of paint repair terms used in this bulletin:
Basecoat: A color topcoat that requires a clear topcoat over it.
Break line: A natural dividing line on
panel(s) that can be used as a starting/
stopping point when making a repair.
Clearcoat: A clear topcoat required to cover a color basecoat.
DELAMINATION: Loss of adhesion between
one coat of paint to succeeding coats or
coatings. Ultraviolet DELAMINATION is between
the E coat (ELPO) and color topcoat(s).
ELPO: (Electrocoating or "E" coat):
The process by which electrically
charged primer is plated on conductive
surfaces of an opposite charge. This
process provides outstanding corrosion
resistance.
Guidecoat: A light coat (almost overspray)
of color applied over primer
surfacer prior to wetsanding to
highlight any low spots.
Insert Color: The secondary two-tone color between the break
line and body side molding.
Monocoat: A color topcoat that does not require a clearcoat.
Primer: The coating applied to a properly
prepared substrate (bare
metal) to give adhesion, corrosion
and chemical resistance.
Primer Sealer: An undercoat that provides
maximum adhesion. color coating
and corrosion protection.
Primer Surfacer: An undercoat used to fill imperfections,
with primer qualities, that must
be sanded.
Refinish: The act of replacing a painted
surface, usually undercoat and
topcoat.
Scuff Sand: A method of sanding a painted
surface using a fine grit sandpaper
to promote paint adhesion.
Topcoat: A finish material over an undercoat
material.
Ultraviolet Light: The portion of the spectrum of
light which can cause fading of
paint. It is located below the visible
part of the spectrum.
V.O.C.: "Volatile Organic Compound"
or "Volatile Organic Content"
relates to certain emission
requirements in specific areas
of the country.