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GUIDE TO ESTIMATING - MOTOR Information Systems

1. G39 and takes precedence over information in the Guide to Estimating pages for the operation indicated NA TT ES dd m i 9 ES id se d E TT Ge GUIDE TO ESTIMATING Index TEXT EXPLANATION GUIDE G2 LABOR PROCEDURES MOLDINGS STRIPE TAPE amp r r GENERAL cont d DRILL TIMES cont d INFORMATION Cowl Hinge Pillar amp Dash Panel G18 Drilling Operation G33 Door Door Shell G20 21 Moldings Bolt or Clip on Type G33 Bolted On Parts iss De Dae Ee anaes G3 Door Outer Panel G21 Moldings Nameplates amp Estimating Sequence G3 Engine Transaxle G15 Emblems Adhesive Type G33 FOOUIOIES saab me iia a rada G3 Fender Front Rails GIS Overlays 1 suivant cee acia G33 Part Prices records ne Pas ER n ata G3 Fender Inner Panel G14 Stripe Tapes ooooomoomoo G33 Part Quantities us ae tile ao ee die ee ares G3 Fender Outer Panel G14 Technical Information GS Frame nsscteceetecatauce sents ches G12 REFINISHING Underhood Diagrams G4 Fuel lank ss SEE ESE SEE ARE Ee EE G26 PROCEDURES GEES su ae ELS REDES MEE ar Wo ees G20 INDUSTRY Eie sis diera rara dr os Sa a G13 Bagging Cover Entire Vehicle G36 DEFINITIONS Header Panel or Headlamp Basic Color Coat Application G35 Mounting Panel
2. ADHESIVE TYPE MOLDINGS without mounting holes pre drilled 6 NAMEPLATES amp EMBLEMS Time to drill holes is listed in parentheses next to the part ee 3 ml o description or in an add if required operation For example d 2 sr INCLUDED indicates 0 2 for drilling This time should be added to the estimate a z e Clean heat when it is determined a drilling operation is required Time shown surfaces is for round holes only Estimate time accordingly if holes must be E o a shape other than round CONSIDERED e If new parts are used on a new panel component add drilling time and one half the only replacement time e If old parts are used on a new panel DOES NOT INCLUDE add drilling time and entire replace e Adhesive backing removal clean up and replace ment time e Damage panel repair e Door hardware REV 5 11 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to G33 and takes precedence over information in the Guide to Estimating pages for the operation indicated a N izd o gt a Rd Y 2 oe a O x wt Z ra kid c GUIDE TO ESTIMATING REFINISH TIME LISTINGS All refinish times are listed in hours and tenths of an hour A time in parentheses adjacent to the part name such as p3 5 indicates three and one half hours Replacement operation time does not include time necessary to refinish the component Operation times for th
3. Transfer steering gear and linkage as an assembly Steering gear gear assembly R8R R8d Suspension assemblies R amp l Transfer lines to new assembly DOES NOT INCLUDE e Auxiliary fuel tank second tank Brackets weld on Brakes adjust amp bleed Exhaust systems Fluids top off Heat shields Interior trim carpet Parking brake adjust Power steering cooler Pulling or straightening time Seats Shift amp throttle linkage adjust Special equipment transfer FRAME CONVENTIONAL FRAME VEHICLES Continued Steering gear individual components R amp R R amp I Suspension wheel alignment Trailer hitch Transfer fuel hold tank if necessary Transmission cooler Wheels FRAME CROSSMEMBERS FRONT REAR or SUSPENSION MOUNT BOLTED TYPE INCLUDED e Crossmember R amp R e Attached parts R amp l DOES NOT INCLUDE e Attached parts R amp R Brakes bleed or adjust Suspension wheel alignment Exhaust system components Fuel tank FRAME CROSSMEMBERS FRONT REAR or SUSPENSION MOUNT WELDED TYPE INCLUDED e Attached parts R amp l e Welding as necessary DOES NOT INCLUDE e Attached parts R amp R e Brakes adjust amp bleed e Suspension wheel alignment G12 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING GRILLE INCL
4. ROOF HEADLINER R amp R INCLUDED e Coat hooks e Grab handles e High mounted stop lamp if attached to headliner e Lamp dome read ing e Reveal amp interior moldings trim e Sunvisor e Sunvisor bracket DOES NOT INCLUDE e Overhead console e Seats Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to G19 and takes precedence over information in the Guide to Estimating pages for the operation indicated p Y Mu x a TT a O a a s Q 3 E tr GUIDE TO ESTIMATING WINDSHIELD GLASS SPECIAL NOTATION Glass moldings mounting studs or mounting flange may be damaged or broken during normal service procedures on some applications MOTOR advises that these factors be considered before performing glass operations in the event unavoidable damage occurs Time for the removal of old ure thane clean and preparation of sealing surfaces vehicle and or glass should be estimated after an on the spot evalu ation INCLUDED e Cowl vent panel screen if overlapping glass e Rear view mirror support attached to glass e Reveal amp interior mold ings trim e Rubber channel R amp I if installed j e Test for leaks e Urethane adhesive appli AN cation JA Hh i N e Wiper arms i EO DOES NOT INCLUDE e Clean up of broken glass e Cost of installation material or Kit e Refinish glass pinchweld epoxy primer
5. e Adjacent panels Air inlet system if necessary Attached standard items Battery Bolted on parts Bumper assembly Carpet insulation or seat R amp l Cruise control Dash panel Decals labels G14 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING FENDER INNER PANEL ENGINE TRANSAXLE ASSEMBLY R amp I Welded Apron amp Rails Continued 6 INCLUDED Electrical wiring e Air cleaner JS Energy absorber e Hoist or lift attach Wh ee Engine N AL Front suspension assembly Hood hinges amp support cylinder Horns Outer sheet metal Pulling or straightening time Reservoir Set up on frame machine amp diagnosis Steering components Suspension wheel alignment Washer Coolant reservoir Welded brackets amp braces transfer FENDER FRONT RAILS DOES NOT INCLUDE Splash shields aw if necessary A A C condenser Drain amp replace oil and fluids Evacuate amp recharge A C system Linkage adjustments Radiator gt A Replacement of any AA parts Road test vehicle INCLUDED e Adhesive application if required all types e Carpet insulation turn back e Caulk seam sealer ROAD WHEEL R amp R e Cowl trim e Cutting amp welding as necessary SPECIAL NOTATION D OES eed ie ie E When requ
6. mix is required if the underside color is a different color than the exterior body color Clear coat gloss or matte will be required for base color coat applications INCLUDED e Refer to specific vehicle text for estimated time allowance e Use full refinish ing time without deduction for overlap DOES NOT INCLUDE e Clear coat e Color tinting e Mixing a different underside color G38 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING WELD ZONE ADJACENT PANEL SPECIAL NOTATION Suggested refinish operation times do not include additional time for repair of damage to adjacent panels resulting from normal cutting welding and grinding procedures The amount of damage can vary considerably depending upon process and technique used by the servicing technician and there fore is impractical to anticipate in this publication MOTOR recommends these factors be considered before finalizing any repair cost estimate Typical areas to be considered are illustrated below DE NIB amp POLISH SPECIAL NOTATION Refinished panels may or may not require a varying amount of de nibbing a process used to remove small particles in final finish surface The clear coat contains ultraviolet screen ers and reducing the clear coat th
7. Correction of pre existent surface imperfections Damage repair De nib wet sand and or buff for polishing Masking of attached parts Material costs R amp l of attached parts COLOR BLEND Adjacent Panels SPECIAL NOTATION Calculations for blending are based upon the outer surface only and should not include additions for underside inside or edges of the blend panel There should be no overlap deduc tion between blend panel s and or refinished panel s This formula is not applicable to SINGLE STAGE 3 STAGE 4 STAGE or TWO TONE type finishes Finishes of this type should be negotiated after an on the spot evaluation Estimation of material cost should be based upon the full blended panel s Blending may be necessary for adjacent body components to avoid noticeable color variation between newly applied paint and the existing paint of adjacent components or areas The following formula may be considered in the event this type of procedure is required on an UNDAMAGED panel e Each blended adjacent panel or area 50 of blend panel s base refinish time INCLUDED e Back tape opening handle lock cylinder mirror Blend coat application Bonding adhesion coat application Clean component solvent detergent wash Clean in preparation for material application Clear coat application full blend panel if required Initial wet sand or scuff when required Mask adjacent panels three foot perimeter Mask close gap between adjacen
8. Instrument panel e Straightening inner pan els brackets or braces e Sunvisors ROOF ROOF PANEL R amp R SPECIAL NOTATION This section applies to passenger cars trucks and vans INCLUDED e Adhesive applica tion if required all types e Back glass amp moldings e Caulk seam seal Y er e Cutting 4 welding NAT as necessary e Flutter material e Glass run channels Grind fill amp smooth welded seams up to 150 grit sandpa per Headliner coat hooks amp grab handles High mounted stop lamp if attached to roof Lamp dome reading Liftgate R amp l Moldings OEM sunroof or T top Quarter glass and reveal moldings if overlapping roof Rear view mirror support R amp l attached to roof Reveal amp interior moldings trim Sunvisor Upper quarter trim panels Weatherstrips amp retainers Windshield glass ROOF ROOF PANEL R amp R Continued DOES NOT INCLUDE e Electrical wiring and components R amp l Emblems amp nameplates GPS Antenna Header panels Lamp Luggage racks Rear package tray trim Roof covers Roof rails Stripe tape decals ROOF CONVERTIBLE TOP R amp R INCLUDED e Boot well e Fabric cover R amp R e Frame assembly R amp R e Quarter trim panels e Weatherstrips amp p NA T Gs sd TT Y Q BE Ek Gs Q oa el i retainers DOES NOT INCLUDE e Deck lid e Frame assembly alignment Ornamentation Power cylinder Roll bar Windshield frame
9. Lamp aiming License plate bracket Reinforcement impact bar if mounted to frame rail Stripe tape decals or overlays Valance panel spoiler when not mounted to bumper VALANCE PANEL INCLUDED e Brackets braces e Lamps e Grilles DOES NOT INCLUDE e Air dam e Bumper assembly f e Emblems amp nameplates Z e Moldings O Spoilers amp flares and takes precedence over information in the Guide to Estimating pages for the operation indicated G11 Y N Mu as sd E TT Y Q BE Ee Gs Q oa el i p Y Mu x a TT a O a a s Q 3 E tr GUIDE TO ESTIMATING FRAME UNITIZED FRAME VEHICLES INCLUDED e Caulk seam sealer e Welding as neces sary DOES NOT INCLUDE e Adjacent panels e Body sheet metal e Bolted on parts brackets amp braces Brakes adjust amp bleed Drive train assembly Floor mats insulation amp trim Pulling or straightening time Set up on frame machine amp diagnosis Suspension wheel alignment FRAME CONVENTIONAL FRAME VEHICLES INCLUDED eS e Bed assembly R amp l ad truck e Body assembly R amp l e Brackets bolted on A e Bumper assemblies Q front rear R amp l Bushings Clips Drive shaft Drivetrain as assembly R amp l Engine amp transmission R amp l Front sheet metal R amp I as an assembly when practical Fuel tank primary R amp l independent rear suspension LT amp RT side assem blies axles and housing Stabilizer bar
10. Phone 847 667 2340 http www tech cor net I CAR Created by the collision industry in 1979 I CAR the Inter Industry Conference on Auto Collision Repair conducts extensive collision repair research to develop and deliver quality technical educational programs to professionals in the insurance and colli sion repair industries which increases the common understanding of required repair methods The international not for profit training organization works toward its vision that every person in the colli sion industry has the necessary technical knowledge and skills rel evant to their position to achieve a complete and safe repair Ultimately benefiting the vehicle owner information on I CAR train ing is available at http www i car com NASTF The National Automotive Service Task Force is a not for profit no dues task force established to facilitate the identification and correction of gaps in the availability and accessibility of automotive service information service training diagnostic tools and equip ment and communications for the benefit of automotive service professionals NASTF is a voluntary cooperative effort among the automotive service industry the equipment and tool industry and automotive manufacturers See their website http www nastf org for information on NASTF programs and activities ASA The Automotive Service Association ASA advances profes sionalism and excellence in the automotive repair industry th
11. R amp l of attached parts Wet sand and or buff for polishing Test spray out panel STONE CHIP GUARD Protective Material SPECIAL NOTATION The following items or operations were not considered during the development of any published basic refinish operation times If any of these items or operations are required they should be considered by the estimator e First panel Add 0 5 per panel e Each additional panel Add 0 3 per panel INCLUDED S e Uptoa12 height EN a DOES NOT INCLUDE Ss e Texture matching TWO TONE REFINISHING Second Color Tone Application SPECIAL NOTATION The following items or operations were not considered during the development of any published basic refinish operation times If any of these items or operations are required on exterior interior or undersides they should be considered by the estimator The following formula may be superseded by information published in specific parts text Calculations should be made after deductions for overlap and additions for edges if required e First panel Add 40 to refinish time e Each additional panel Add 30 to refinish time UNDERSIDE OF HOODS LIDS OR GATES SPECIAL NOTATION The following items or operations were not considered during the development of any published basic refinish operation times If any of these items or operations are required they should be considered by the estimator An additional paint
12. RAIL STRUCTURAL COMPONENT IDENTIFICATION Continued Welded structural parts of the body on a body over frame vehi cle typically include APRON ASSEMBLY CAB CORNER PICK UP CAB BACK PANEL PICK UP CENTER PILLARS CORNER PILLARS FRONT RAIL HINGE PILLARS LOCK PILLARS RADIATOR CORE SUPPORT REAR RAIL ROCKER PANELS UPPER RAIL Some parts that are bolted bonded or welded may add struc tural integrity to a vehicle s body These parts may be made from different types of materials and vehicle dimensions must be correct before replacement If improperly repaired road performance and or crashworthiness of the vehicle may be affected Air bag deployment may also be affected Parts that may add structural integrity to a vehicle s body may include COWL ASSEMBLIES DASH PANEL ENGINE CRADLE bolt on FLOOR PANEL IMPACT BAR bolt on PERIMETER FRAME QUARTER PANEL RADIATOR CORE SUPPORT bolt on REAR BODY PANEL ROOF PANEL STATIONARY GLASS urethane bonded G6 REV 5 11 GUIDE TO ESTIMATING ACOUSTICAL AND STRUCTURAL FOAM FILLERS This type of product is used by some OEMs to control NVH noise vibration and harshness or add structural integrity to the vehicle body Acoustical foam is a soft to firm pliable product while structural foam is a hard dense rigid product Acoustical and or structural fillers may be found internally on vehicle panels there fore identification of foam type and lo
13. Stripe tape decals or overlay e Stripe tape decals or overlay e Windshield glass and moldings e Windshield glass and moldings REV 5 11 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to G29 and takes precedence over information in the Guide to Estimating pages for the operation indicated XY NA T Gs sd TT Y Q BE Ek Gs Q oa el i XY Y Mu x a TT a a a s Q 3 E tr GUIDE TO ESTIMATING PICKUP TRUCK CAB SIDE CORNER BACK PANEL INCLUDED e Adhesive application if required all types e Carpet insu lation turn back e Caulk seam sealer e Cutting amp welding as necessary e Grind fill amp smooth welded seams up to 150 grit sand paper Rear Seat R amp l extended or crew cabs Seat R amp l regular cab Side glass amp moldings Sill plate Seatbelt anchor Shoulder harness Weatherstrips DOES NOT INCLUDE e Back glass Body side moldings Box set back Carpet amp insulation R amp l Emblems amp nameplates Exterior lamp Foam Headliner Interior trim Stripe tape decals or overlays PICKUP TRUCK BOX SET BACK SPECIAL NOTATION Pick up box set back is considered by MOTOR to be the removal of the fasteners securing the box to the frame of the vehicle D amp R necessary wiring D amp R fuel neck and moving the box rearward This operation is generally used for accessing the cab back or
14. Whenever touching any high voltage part insulated gloves rated for 5000 volts certified to 1000 volts or class OO and meet all of the American Society for Testing and Materials ASTM standards must be worn Follow OEM service repair information for disabling the high voltage electrical system before beginning any repairs OEM COLLISION REPAIR NETWORK Some OEM s manufacture aluminum vehicles that have an established repair network for these vehicles and require collision repairs to be performed at an OEM authorized aluminum repair center Manufacturers with collision repair networks covered in MOTOR s guide are Audi BMW Jaguar and Mercedes Benz Refer to the OEM for complete information on collision repair network program G7 wi 4 9 ja ad ef Y pr os N mal lt Y LH a A v ps 9 el Y Ed me n pen lt V tu 6 A GUIDE TO ESTIMATING PANEL BONDING Metal Adhesives OEM labor procedures for panel bonding requires different procedural steps versus welding such as panel vehicle prepara tion sectioning insert sleeve additional panel fit and adhesive application unless otherwise specified in a footnote attached to the sectioning operation MOTOR published welded panel replace ment labor times may be applied for panel bonding and would include all the necessary procedure steps as outlined by the OEM Refer to the Guide to Estimating pages for specific INCLUDED NOT INCLU
15. a component are the same proce dure steps required to R amp I a component For example bolt or clip on moldings ornamentation mirrors trim door handles locks cylinders latches and many single piece components In addition an equal sign printed after an R amp R time indicates MOTOR has evaluated an operation and determined that the R amp R time may be used as the R amp l time G5 Y d 9 a E Z a Ee Y a z 2 A Es 9 di E kid Y a 2 GUIDE TO ESTIMATING R amp R Remove amp Replace Remove old part transfer necessary items to new part unless otherwise noted in Labor Procedure pages replace and align Does not include Suspension Wheel alignment STRUCTURAL COMPONENT IDENTIFICATION Structural component identification information as presented in I CAR Enhanced Delivery programs Welded structural parts can be made from different types of metal Identification is not based on metal type Replacement requires specific measuring equipment and vehicle dimensions must be correct If improperly repaired road performance and or crashworthiness of the vehicle may be affected Airbag deploy ment may also be affected Welded structural parts on a unibody vehicle typically include APRONS STRUT TOWER CENTER PILLAR CORNER PILLAR FRONT RAIL HINGE PILLAR LOCK PILLAR RADIATOR CORE SUPPORT REAR RAIL REAR STRUT TOWER ROCKER PANEL SUSPENSION CROSSMEMBER UPPER
16. any given procedure have not been considered in the estimated work time development for that procedure unless specified by a footnote All included not included items for labor procedures listed between pages G10 and G33 are for component R amp R and R amp l procedures unless otherwise indicated in operation heading OPERATION TIMES LISTED ARE BASED ON NEW UNDAM AGED PARTS INSTALLED ON NEW UNDAMAGED VEHICLES AS INDIVIDUAL OPERATIONS TIME HAS NOT BEEN CONSIDERED FOR ALIGNMENT PULLS DAMAGE RELATED ACCESS TIME DAMAGED USED REMANUFACTURED OR AFTERMARKET PARTS SOME OPERATION TIMES ARE APPLICABLE AFTER BOLTED ATTACHED OR RELATED PARTS HAVE BEEN REMOVED REFER TO SPECIFIC FOOTNOTES ATTACHED TO OPERATION TIME LISTING LABOR TIME DOES NOT INCLUDE SPECIAL NOTATION The items listed below apply to all labor procedures LABOR TIME PREMISE Continued e Reset electronic memory functions after battery disconnect e Road test vehicle e Rusted frozen broken or corrosion damaged components or fasteners Scan tool clear reset electronic module Scan tool diagnostics Straighten or align used reconditioned or non OEM parts Structural damage diagnosis and vehicle set up time Structural foam removal or application Test panel spray caulk Undercoating tar or grease removal Unprimed bumpers removal of mold release agents Waste disposal fees all types Weld through primer Welded seam surface finishing finer than 150 grit sandpaper Wh
17. e ABS sensor Air bag components Back glass and moldings Carpet amp insulation R amp l Control cables Doors Door hinge Foam Electrical wiring Emblems amp nameplates Fender Fluid lines Headliner Instrument panel Quarter glass and moldings Road wheel Roof cover Stripe tape decals or overlay Windshield glass and moldings Wiring G22 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING UNISIDE WITH GUARTER PANEL SPECIAL NOTATION When replacing welded door hinges add one half of the Door Hinge R amp R time to Uniside R amp R time Included and Not Included items also apply to sectioning below roof lower uniside and sectioning roof rail upper uni side When sectioning other areas of uniside follow GTE page for portion of uniside being sectioned INCLUDED Adhesive application if required all types Back glass amp mold ings Carpet amp insulation turn back Caulk seam sealer Center pillar trim four door models Cutting and welding as necessary QUARTER PANEL WITHOUT CONVERTIBLE ROOF SPECIAL NOTATION Quarter panel R amp R times are generally based upon replace ment at the factory seams On some vehicles it is not practi cal to repla
18. e Body side moldings e Foam e Carpet amp insulation R amp l e Fuel tank e Control cables e Glass regulator assembly e Doors e Headliner R amp I e Door hinge e Lamp R amp I optnl equip e Electrical wiring e Mud guard e Emblems amp nameplates e Panels inward of quarter e Fender e Road wheel Foam e Roof cover R amp I or roll back e Fluid lines e Spoilers amp flares optnl equip e Headliner e Stripe tape decals or overlays e Instrument panel e Trunk lid lift gate or tail gate R amp I e Road wheel e Roof cover e Stripe tape decals or overlay e Windshield glass and moldings e Wiring REV 5 11 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to G23 and takes precedence over information in the Guide to Estimating pages for the operation indicated XY N Mu as sd E TT Y Q BE Ee Gs Q oa el i p Y Mu x pa TT a O a a s Q a i GUIDE TO ESTIMATING QUARTER PANEL CONVERTIBLE ROOF MODELS INCLUDED e Adhesive applica tion if reguired all oor types A e Belt moldings e Bolt on extensions amp fillers e Carpet amp insulation turn back e Caulk seam sealer e Cutting amp welding as necessary e Door striker e Fuel door e Grind fill amp smooth welded seams up to 150 grit sandpaper Lamp Quarter glass amp regulator assembly Quarter interior trim Rear lamp assemblies R amp l Rear seat R am
19. removed with new OEM glass It is MOTOR s position that removal of the glass from the damaged part panel for reuse is a process best reserved for the judgment of an estimator appraiser following a thorough review of vehicle manufacturer guidelines G9 v 4 9 ad ef W Ea os N sal lt Y LH Ek A p Y Mu x TT df O a a s Q 3 E tr GUIDE TO ESTIMATING LABOR TIME LISTINGS All operation times are listed in hours and tenths of an hour A time listed as 3 5 indicates three and one half hours LABOR TIME PREMISE The times reported in this publication are to be used as a GUIDE ONLY Reported times include normal align procedure to insure proper fit of the individual new part being replaced Reported times include tube paddled application of OEM caulking and seam seal ers on welded replacement panels Sprayable seam sealer equip ment requires preparation and adjustment before application and is NOT INCLUDED IN LABOR TIME Times do not apply to vehicles with equipment other than that supplied by the vehicle manufacturer as standard or regular pro duction options lf other equipment is used the time may be adjusted to compensate for the variables Removal and replace ment of exchanged or used parts is not considered If additional aligning or repair must be made such factors should be consid ered when developing the estimate ltems not listed under the INCLUDED DOES NOT INCLUDE heading for
20. starting from the outside of the vehi cle and working inward list everything attached to it which is dam aged By following this procedure you will make a more thorough inspection For instance on an estimate involving front fender damage inspect as shown Fender molding nameplate emblem Fender Liner FOOTNOTES Footnotes are used to present information specific to the indi cated component or operation Footnotes are not intended to be used in place of service repair information PART PRICES Prices used in MOTOR Crash Estimating Data are factory sug gested list prices as supplied to us by the manufacturer Dealers may not be required to sell at this price and may be free to deter mine their own prices When a price is prefixed by the letter D it indicates that this part has been discontinued by the manufactur er and for your convenience we continue to publish the last avail able price When a part is prefixed by the letter C this indicates a core value assigned by the manufacturer has been deducted from the manufacturer s suggested retail price When a price is prefixed by the letter A it indicates a Special Marketing Program part General Motors Target Marketing Program This program has been discontinued by GM Parts indicated with the letter A rep resent components included in the program These parts do not have a suggested list price supplied by General Motors The price shown following t
21. support vehicle one time Road wheel e Splash shield e Stabilizer bar e Stabilizer bar end link e Steering gear or linkage e Steering arm e Suspension wheel alignment e Strut radius rod amp bushing e Strut cartridge assembly e Strut seat DOES NOT INCLUDE e Brake calipers R amp I Brake pad or shoes Brakes adjust bleed Crossmember Drivetrain components Road wheel Stabilizer bar Steering linkage Steering gear Suspension wheel alignment Wheel cylinders G16 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING FRONT SUSPENSION OVERHAUL STEERING COLUMN I BEAM TUBE TYPE OVERHAUL OPERATIONS 0 INCLUDED o SPECIAL NOTATION Oo a a a ABS sensor Air bag considerations are included in all steering column eek overhaul operations unless an ADD IF REQUIRED heading e Bearing seal R amp R is listed in the text e Bearing INCLUDED e Ww e Brake rotor e Column housing f TT e Coil spring seat e Column lower shroud f pe e Coil spring e Column internal parts e Coil spring insula e Column upper shroud a tor e Cruise control parts TT e Control arms attached to column U e Hub e Ignition lock cylinder O e Knuckle spindle e Ignition switch e Overhaul procedure as defined e Levers Pa e Raise amp support v
22. surfaces vehicle e Appliqu e and or glass should be estimated after an on the spot evalu e Belt Molding ation e Door check e Glass fixed moveable eS ee TE EE Hinge halves bolted to door ings trim e Inside handles amp bezels e Rubber channel if ee gas installed e Internal mechanisms e Test for leaks aten ES Urethane adhesive appli License Lamp if attached to door canon e License plate if attached to door DOES NOT INCLUDE ee EN Ad assembly if necessary e Outside handle e Clean up of broken glass e Regulator e Cost of installation mate N e Trim panel R amp I rial or kit e Vents y e Water shield f e Weatherstrips if attached to door e Window run channel G20 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING DOOR DOOR SHELL R amp R HINGED TYPE Continued DOES NOT INCLUDE Back glass wiper or washer Body side moldings Emblems amp nameplates Hinge halves bolted to pillar DOOR HINGED AND SLIDING TYPE OUTER PANEL R amp R SPECIAL NOTATION Some cutting or welding processes may require the door glass to be removed prior to replacing outer panel This fac tor should be considered prior to finalizing any repair cost e Hinge welded type as e Lock cylinder recod
23. A 23 03 03 79104 7800 08 11 LA 23 03 03 79104 7810 5 Body side mida OB HR 3208 0 3 79116 1360 08 11L 3763 03 79116 4376 7 Wheel opng d 2 O08 11R 5380 03 79116 5080 mldg d 2 8 11 L 53 80 0 3 791165090 PARTS Order by model amp color 1 LABOR Time includes R amp I quarter glass G2 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING Operation times reported herein are compiled from available manufacturer data as well as our own evaluation of shop data and are published only as an estimating guide This Guide to Estimating provides the guidelines that apply to MOTOR Crash Estimating Data Knowledge and application of these guidelines will assist the estimator in developing a clear esti mate reflecting as accurately as possible the requirements to per form operations listed To maintain accuracy estimators must fre quently refer to these pages throughout the estimating process BOLTED ON PARTS The phrase BOLTED ON PARTS referenced in this publication are mechanically fastened parts such as braces brackets mounts shields extensions etc ESTIMATING SEQUENCE Listed under each basic assembly are the related and compo nent parts List the damage according to the basic assembly tak ing the basic item first Then
24. ATES AND TAIL GATES Refinish times listed on the parts detail line for these new com ponents include exterior surface edges and interior sides unless otherwise noted in text REFINISH TIME PREMISE Continued DOOR SHELLS LIFT GATES AND TAIL GATES Continued Refinish times listed under the Refinishing Notes heading for door outer panel only operations do not include time for refinish ing the door frame edge or interior side Where possible MOTOR will publish time for those areas under a Refinishing Notes head ing within that group FENDERS HOODS AND OTHER MAJOR BOLTED PANELS Refinish times listed on the parts detail line for these new pan els do not include time for refinishing the edge or underside Where possible MOTOR will publish time for those areas under a Refinishing Notes heading within that group QUARTER PANELS AND OTHER MAJOR WELDED PANELS Refinish times listed on the parts detail line for these new pan els include exterior side recessed edges gutters and pockets unless otherwise noted in text Refinish times listed under the Refinishing Notes heading for quarter panels or other major welded panels exterior surface only operations do not include time for refinishing recessed edges gut ters and pockets Where possible MOTOR will publish time for these areas under the Refinishing Notes heading within that group NEW UNDAMAGED PANEL A component manufactured to th
25. DED operations An adjustment in time may or may not apply after an on the spot evaluation of required procedures Refer to OEM for specific repair recommendations procedures and replacement product s PARTS SUPPLIED IN COLOR Some replacement components such as instrument panels trim panels and moldings can be ordered in various colors and there fore may not require painting In some instances specific colors may no longer be available from the manufacturer and therefore would require painting MOTOR recommends the availability of appropriate replacement colors be confirmed before finalizing any estimate of repairs Refinishing time should be added if needed color is not available NOTE Air bag components should never be refinished Refinishing these components will alter the original design and change deployment characteristics REFINISH CLEAR COAT APPLICATION Most major paint manufacturers recommend that when per forming refinish repairs on an OEM base coat clear coat or multi stage finishes the application of clear coat must be extended to the nearest panel edge or breakpoint to qualify for their lifetime refinish warranties RESTRAINT SYSTEM Air Bag NOTE RESTRAINT SYSTEMS REPLACEMENT COMPO NENTS and INSPECTION COMPONENTS are FOR ESTIMATING PURPOSES ONLY Wiring repairs should only be performed in accordance with vehicle manufacturer specifications Air bag com ponents should never be refinished Refinishing these compo
26. G15 and takes precedence over information in the Guide to Estimating pages for the operation indicated N Mu as sd E TT Y Q BE Ee Gs Q oa el i XY N Mu a a TT df Q G a s Q 3 E tr GUIDE TO ESTIMATING FRONT SUSPENSI N INDIVIDUAL FRONT SUSPENSI N OPERATIONS OVERHAUL S L A TYPE INCLUDED SPECIAL NOTATION S L A is defined as short upper control arm and long lower control arm This includes Ball Joint and Torsion Bar Systems e Raise amp support vehicle one time DOES NOT INCLUDE e Brake calipers R amp I INCLUDED e Brake pads or shoes A ABS sensor e Brakes adjust amp Ball joint bleed e Road wheel a eco e Suspension wheel Bearing alignment e Brake rotor e Coil spring components e Hub FRONT SUSPENSION a Naud OVERHAUL STRUT TYPE e Lower control arm INCLUDED components e ABS sensor e Overhaul e Air suspension procedure as defined components e Radius rod amp bushing e Ball joint e Raise amp support vehicle one time e Bearing e Shock absorber e Bearing seal e Splash shield e Brake rotor e Steering arm e Coil spring amp e Torsion bar components e Upper control arm components Pole pang cap DOES NOT INCLUDE e Hub e Axle or carrier assy FWD or AWD e Knuckle e Brake calipers R amp l e Lower control arm e Brake pad or shoes e Lower control arm bushing e Brakes adjust amp bleed e Overhaul procedure as defined Crossmember e Raise amp
27. GED PANEL SPECIAL NOTATION Calculations for clear coating an undamaged panel are based upon the outer surface only and should not include additions for underside inside or edges of the clear coated panel There should be no overlap deduction between refinished or clear coated panel s nor should this procedure be applied towards the maximum clear coat allocation Clear coating may be necessary for adjacent body panel s to nearest break point see G 8 The following formula may be considered in the event this type of procedure is required on an undamaged panel e Each clear coated panel s 40 of panel s Base Refinish Time G36 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING CLEAR COAT UNDAMAGED PANEL Continued INCLUDED e Back tape opening handle lock cylinder mirror e Bonding adhesion coat application if required e Clear coat application e Clean component solvent detergent wash e Clean in preparation for material appli cation e Initial wet sand or scuff e Mask adjacent panels three foot perimeter e Mask close gap between adjacent pan els up to foam tape overspray Mask glass opening Mask protect grille radiator opening overspray Remove masking Tack wipe surface when required DOES NOT INCLUDE e
28. INFORMATION SYSTEMS INDUSTRY DEFINITIONS i CED GUIDE TO ESTIMATING LABOR 3 PROCEDURES 7 MOLDINGS STRIPE a TAPE amp DRILL TIMES MOTOR Collision Estimating Data GUIDE TO ESTIMATING Text Explanation Guide ide PERIA aton D Discontinued R amp R Operation Time L Left C Part price is less core charge B Both A Special marketing program Component Classification eee s structural Right or Left m mechanical O E M Part Number Part Description Tie rod end ees sesse essens DO 1 1 D 25 96 22348963 QUARTER PANEL REFINISHING NOTES Add for stone guard if required See Guide to Estimating Refn quarter panel exterior surface only 08 11 p1 7 edges amp pockets 08 11 p 3 lock pillar 08 11 p 5 OVERLAP OPERATIONS R amp R quarter panel with roof off ojo se 08 11 B 4 0 R amp l OPERATIONS R amp I trim panel 08 11 B 0 4 SECTIONING OPERATIONS Sctn qtr panel cut in window opening 08 11R p2 5 119 08 11 L p2 5 17 5 PARTS AND R amp R OPERATIQNS QUARTER PANEL amp COMPONENTS Outer panel p 2 5 08 11 R 19998 140 75142 8990 2 5 08 11L 19998 14 75144 1008 2 Lower pilla p 5 08 11 R 5448 3 5 75143 4360 P 5 08 11L 54 48 3 5 9143 4370 3 Fueldoor p 5 08 11 17 00 03 75760 1050 Belt Molding 4 atwindow 08 11R 332 03 79106 7000 08 11L 3642 03 79106 7010 Molding 5 rear vertical 08 11 R
29. INGE PILLAR amp DASH PANEL Continued DOES NOT INCLUDE Air bags Air conditioning parts Bolted on parts Carpet insulation 4 seat R amp I Door Door hinge Electrical wiring and components Engine Fender Foam Headliner Hinge plate transfer Instrument panel or crash pad Interior moldings Parking brake assembly Roof rail molding Windshield glass Windshield reveal moldings INSTRUMENT PANEL SPECIAL NOTATION Air bag considerations are included in all Instrument Panel operations unless an Add If Required heading is listed in text INCLUDED Crash pad R amp I p Emblems amp name a ed plates Glove box R amp l Heater amp A C controls Instrument cluster R amp l Lamps amp switches Metal reinforcement Moldings amp ornamen tation R amp l Fe Radio EP dd mn DOES NOT INCLUDE if Console Inner cowl support braces amp brackets Remote control mirrors Steering column Straightening inner panels 618 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING CONSOLE FLOOR OR OVERHEAD INCLUDED e Console e Emblems amp nameplates e Gauges e Moldings amp ornamenta tion e Shift lever if necessary DOES NOT INCLUDE e Front seat R amp l if neces pe sary A e Headliner R amp I e
30. R ASSEMBLY R amp R COVER TYPE SPECIAL NOTATION The removal of mold release agents from and preparation priming of unprimed bumpers is required and is NOT INCLUDED Where the OEM has provided information regarding the availability of unprimed bumper covers an Add if Required labor operation has been added to the bumper group INCLUDED e Align to vehicle REAR BUMPER ASSEMBLY OVERHAUL COVER TYPE SPECIAL NOTATION The removal of mold release agents from and preparation priming of unprimed bumpers is required and is NOT INCLUDED Where the OEM has provided information regarding the availability of unprimed bumper covers an Add if Required labor operation has been added to the bumper group INCLUDED e Align to vehicle e Disassemble complete assembly e Emblem amp nameplate e Energy absorber e Lamps mounted in bumper e License plate bracket if attached e Molding amp impact strip e Reassemble complete assembly e Replace damaged parts DOES NOT INCLUDE e Bumper brackets frame rail extensions if mounted to frame Reinforcement impact bar if mounted to frame rail Reverse sensor Stripe tape decals or overlays Trunk trim liner Valance panel spoiler PICKUP TRUCK CAB ASSEMBLY SKELETON e Emblem amp name INCLUDED plate e Cab R amp R e Energy absorber e Carpeting e Lamps mounted in e Doors R amp l bumper e Electrical wiring in cab e License plate R amp l bracket if e Glas
31. STATIONARY SIDE GLASS Doors or Quarter Panel SPECIAL NOTATION Glass moldings mounting studs or mounting flange may be damaged or broken during normal service procedures on some applications MOTOR advises that these factors be BACK GLASS SPECIAL NOTATION Glass moldings mounting studs or mounting flange may be damaged or broken during normal service procedures on some applications MOTOR advises that these factors be considered before performing glass operations in the event unavoidable damage occurs Time for the removal of old ure thane clean and preparation of sealing surfaces vehicle and or glass should be estimated after an on the spot evalu ation INCLUDED e Reveal amp interior moldings trim e Rubber channel if installed e Test for leaks e Urethane adhesive application e Wiper arm DOES NOT INCLUDE ha ME N e Clean up of broken ii EE glass AE AA e Cost of installation ea material or kit e High mounted stop lamp DOOR DOOR SHELL R amp R HINGED TYPE SPECIAL NOTATION Some replacement components may or may not be supplied with duplicated OEM caulk seam sealer This is not included in R amp R time and requires an on the spot evaluation Disconnect at hinges unless otherwise noted in text considered before performing glass operations in the event INCLUDED unavoidable damage occurs Time for the removal of old ure e Align to vehicle thane clean and preparation of sealing
32. UDED e All components clear coated during a single continuous procedure Apply clear coat Clean sprayer one time Mix clear coat one time Tack wipe surface when required DOES NOT INCLUDE e Any component clear coated as a separate procedure e Any operation previously excluded in Refinish time Premise and or Basic Color Coat Applications groups e Material costs THREE STAGE FINISHES Base Mica Clear Coat SPECIAL NOTATION The following items or operations were not considered during the development of any published basic refinish operation times If any of these items or operations are required they should be considered by the estimator Calculations should be made after deduction for overlap and additions for under side and edges if required if three stage finish from factory e First major panel Add 70 to refinish time e Each additional panel Add 40 to refinish time INCLUDED e Back tape open ing handle lock cylinder mirror e Mask close gap between adja cent panels up to foam tape overspray e Mask glass opening e Mask protect grille radiator opening overspray e Retrieve accurate color information including paint chip DOES NOT INCLUDE e Any component clear coated as a separate procedure e Any operation previously excluded in Refinish Time Premise and or Basic Color Coat Application groups e Material costs e Test spray out panel CLEAR COAT UNDAMA
33. UDED e Emblems amp nameplates e Grille e Lamp in grille e Moldings amp ornamentation DOES NOT INCLUDE e Adjacent panels or components e Lamp aiming e Stripe tape decals HEADER PANEL OR HEADLAMP MOUNTING PANEL INCLUDED Align to vehicle y Bolt on extensions 4 fillers HL Emblems 8 nameplates AAA Grille EZ e Lamp A Moldings o Ornamentation DOES NOT INCLUDE e Bumper assembly e Lamp aiming e Stripe tape decals or overlays RADIATOR SPECIAL NOTATION If R amp R of a coolant hose connected to both the radiator and water pump is combined with removal of the radiator and water pump then no additional time should be estimated for R amp R or R amp I of that coolant hose INCLUDED e Drain check and refill fluids e Electric fan assembly R amp l e Purge air from system DOES NOT INCLUDE e Belts e Cost of coolant e Electric fan assembly O H or R amp R e Mechanical fan e Pulley RADIATOR SUPPORT XY SPECIAL NOTATION Operations components included with R amp R radiator support are listed in FOOTNOTES in each chapter and below as INCLUDED INCLUDED e Caulk seam sealer e Included parts are listed in footnote in each chap ter e Welding as necessary DOES NOT INCLUDE e See LABOR TIME PREMISE DOES NOT INCLUDE N Mu as sd E TT Y Q BE Ee Gs Q oa el i HEATER ee INCLUDED TA SR e R amp R time is listed with parts Se DOES NOT INCLUDE Mi AA e Cost of cool
34. ant A e Drain and refill fluids AIR CONDITIONER SPECIAL NOTATION A Refrigerant Recovery procedure should be considered prior to any repair necessitating a refrigerant line disconnect from an A C system containing refrigerant Published recov ery time is for a service technician to operate and periodically monitor typical refrigerant recovery amp recycling equipment as the vehicle s existing refrigerant is transferred out of the vehi cle and into the machine 0 3 and reprocessed by the machine 0 1 Recovery time does not include overall recycling machine processing time nor does it include A C Service which is the evacuation recharge and testing of an A C system fol lowing repairs INCLUDED e R amp R time is listed with parts DOES NOT INCLUDE e Cost of refrigerant amp oil Cost of seals or O rings Refrigerant recovery Test for leaks Retrofit for 134a Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to G13 and takes precedence over information in the Guide to Estimating pages for the operation indicated p Y Mu x a TT a O a a s Q 3 E tr GUIDE TO ESTIMATING SPECIAL NOTATION Some replacement components may or may not be supplied with duplicated OEM caulk seam sealer This is not included in R amp R time and requires an on the spot evaluation Disconnect hood at hinges INCLUDED e Air inlet syst
35. c information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING REAR SUSPENSION OVERHAUL INDEPENDENT TYPE INCLUDED e ABS sensor e Ball joint e Bearing e Bearing seal R amp R e Brake drum rotor Coil spring compo nents if equipped Hub e Knuckle e Lower control arm components e Overhaul procedure as defined Radius rod amp bushing Raise amp support vehicle one time Shock absorber Splash shield Stabilizer link Strut Torsion bar if equipped Upper control arm components DOES NOT INCLUDE e Axle or carrier assy Brake pad or shoe Brakes adjust amp bleed Crossmember Road wheel Stabilizer bar Suspension wheel alignment REAR SUSPENSION OVERHAUL REAR TRAILING TYPE INCLUDED e ABS sensor Axle stub spindle Axle beam Axle mounting pads Bearing Bearing seals R amp R Brake rotor Coil spring or leaf spring components Control arms R amp l e Overhaul procedure as defined e Radius rod amp bushing Raise amp support vehi cle one time REAR SUSPENSION OVERHAUL REAR TRAILING TYPE Continued DOES NOT INCLUDE e Axle or carrier assy Brake pad or shoes Brakes adjust amp bleed Drive axles Road wheel Stabilizer bar Suspension wheel alignment REAR BUMPER ASSEMBLY R amp I ALL TYPES INCLUDED e Align to vehicle DOES NOT INCLUDE e Emblem
36. cation may require an inspection after vehicle disassembly Foam products must be removed if within six inches of an open flame excessive heat 600 degrees or welding operation Any foam damaged or removed during the repair process must be replaced SPECIAL NOTATION Not all vehicles contain foam fillers others may contain foam fillers in one or more locations Refer to OEM for specific repair recommendations procedures and replacement product s AIR CONDITIONER REFRIGERANT Reported refrigerant capacities are FOR ESTIMATING PUR POSES ONLY ALWAYS refer to the vehicle A C label or manufac turer s service manual for recommended repair procedures and system capacity DAMAGED OR NON REUSABLE MOLD INGS AND FASTENERS Some moldings may be damaged or broken during normal R amp l procedures Additionally some plastic or metal fasteners may be damaged and their ability to be reused jeopardized because of sin gle use design age or exposure to the elements Moldings emblems and trim attached using a heat stake method are consid ered to be non reusable Caution should be taken while removing all fasteners both metal and plastic MOTOR recommends these factors be considered and mutually agreed upon before finalizing any repair cost estimate ELECTRONIC SYSTEMS amp ON BOARD COMPUTERS Special caution should be taken when servicing vehicles due to the wide use of computer modules electronic sensors and printed circuit boards T
37. cc cc Ee crac G38 Acoustical And Structural Uniside cera daa aa G29 Weld Zone Adjacent Panel G39 Foam Fillers a4 resp wed E ties PER ba G7 Quarter Panel Wet Sand Rub Out amp Buff G39 Air Conditioner Refrigerant G7 Convertible Roof Models G24 Damaged or Non Reusable w o Convertible Roof G23 Moldings and Fasteners Gf Radiator cicecew dead DE tren ex dues G13 Electronic Systems amp On Board Radiator Support G13 Computers AA PERE bere ee G7 Rear Body Floor Pan Rails G26 Hazardous Materials G7 Rear Body Lower Body Panel G25 Hybrid Vehicles G7 Road Wheel G15 OEM Collision Repair Network G7 Rocker Panel G21 Panel Bonding 5 e s0e PER EE aki ss GG ROO O EE N G19 Parts Supplied In Color G8 Roof Headliner G19 Refinish Clear Coat Application G8 SIEN 2s i uie n Ee RE dn die RE G17 Restraint System Air Bag G8 Suspension Front G16 17 Restraint System Seat Belt G8 Suspension Rear G26 27 Sectioning 234 bravas oa G8 Tail Gate Passenger Special Substrate Metals G8 Cars WagonS oooooooooo G25 Steering Column o o o oocooooooo G9 Tail Gate Outer Panel G25 Stone Chip Guard G9 Trunk Lid oe ia ee ae MR De ad G24 St
38. ce at the factory roof seam If a sectioning opera tion is not listed then the R amp R time on the parts line repre sents the time to splice at the best area GTE page includes Quarter panel sectioning INCLUDED Adhesive applica tion if required all types Back glass amp mold ings Bolt on extensions amp fillers Carpet amp insulation turn back Caulk seam sealer Cutting amp welding e Door striker as necessary e Front seat R amp l e Door striker e Fuel Door e Fuel door e Grind fill amp smooth e Grind fill amp smooth welded seams up to welded 150 grit sandpaper seams up to 150 grit sandpaper e High mounted stop lamp if necessary e Interior molding e Hinge pillar trim e Quarter glass amp reveal e Jamb switches moldings unless noted e Package tray trim e Quarter interior trim e Quarter panel trim e Rear seat R amp l e Quarter glass amp moldings e Rear lamp assemblies R amp I std equip e Rear bumper R amp l e Rear bumper assembly and or e Rear lamp cover R amp I if necessary e Rear seat R amp I e Rear package tray trim e Roof drip rail moldings e Sill plates Seat belt anchor e Trunk compartment trim e Sill plates e Weatherstrips e Trunk compartment trim e Wheelhouse liner plastic e Weatherstrips e Wheelhouse liner plastic AE NONE AE e Antenna DOES NOT INCLUDE e Body side moldings Ab sensor e Carpet amp insulation R amp I e Air bag components e Emblems amp nameplates
39. ces e Straightening of door frame sary e Stripe tape decals or overlays e Outside handle e Regulator ROCKER PANEL e Trim panel R amp l e Vents INCLUDED Watershield e Adhesive application if required all types e Weatherstrips if attached to door e Carpet amp insulation turn back e Window run channel e Caulk seam sealer DOES NOT INCLUDE e Cutting amp welding as necessary e Body side moldings e Grind fill amp smooth welded seams up to 150 grit sandpa e Emblems and nameplates per e Lock cylinder recoding e Interior trim panels R amp l e Moldings e Sill plates e Remove bonded glass from damaged door shell e Weatherstrips pull back e Stripe tape decals or overlays DOES NOT INCLUDE e Carpet insulation or seat R amp l e Control cables e Door e Emblems amp nameplates e Fender e Foam e Fuel lines REV 5 11 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to G21 and takes precedence over information in the Guide to Estimating pages for the operation indicated p N Mu as sd E TT Y Q BE da es Q ma q tr p N Mu BE TT df Q G a s Q E tr GUIDE TO ESTIMATING ROCKER PANEL Continued e Moldings e Stripe tape decals CENTER PILLAR SPECIAL NOTATION When replacing welded rear door hinges add one half of the Hinge R amp R time to Center Pillar R amp R time INCLUDED e Adhesive applica tion if
40. ct BASIC COLOR COAT APPLICATION INCLUDED Mad e Back tape ad opening handle lock cylinder mirror e Clean component solvent wash e Clean sprayer Color coat application Initial dry sand as recommended by paint manufacturer Light buff lacquer paint only Load sprayer Mask adjacent panels three foot perimeter Mask close gap between adjacent panels up to foam tape overspray Mask glass opening Mask protect grille radiator opening overspray Mix paint color and necessary solvents Primer sealer coat application Primer sealer coat final clean Primer sealer coat final application Remove masking Retrieve accurate color information including paint chip DOES NOT INCLUDE e Adhesion promoter unprimed flexible component Backside refinishing Blending into adjacent panels Cover mask engine compartment to prevent overspray Color matching to adjacent panels Cover mask for prime and block Cover mask for cut in Cover mask recessed edges jambs weatherstrips and takes precedence over information in the Guide to Estimating pages for the operation indicated G35 NA TT ES dd m i O ES id se d E TT Ge N bid o gt a Rd Y Q oe a O T wt Z E kid o GUIDE TO ESTIMATING BASIC COLOR COAT APPLICATION Continued DOES NOT INCLUDE continued e Cover mask trunk compartment to prevent overspray e Cover mask entire exterior of vehicle to prevent overspray dama
41. cturer OVERHAUL Remove an assembly from the vehicle disassemble clean inspect replace parts as needed reassemble install and adjust except wheel suspension alignment Overhaul time should be used only if the time for individual parts less overlap is more than the overhaul time Overhaul operations include component R amp R procedure steps and inclusions unless otherwise noted OVERLAP When replacing two or more components the duplication of included labor procedures is known as overlap Labor procedures R amp R R amp I D amp R that create overlap include but are not limited to mechanical attachment welding bonding and or technician preparation For example when replacing a quarter panel and rear body panel on the same vehicle the common required labor procedures necessary to remove and replace or reinstall these components is known as overlap When a labor overlap condition exists less time is required to replace adjoining components collectively than is required when they are replaced individually Overlap labor information is generally included at the beginning of each group or subgroup within each chapter R amp I Remove amp Reinstall tem is removed set aside and later reinstalled and aligned for proper fit does not include Suspension Wheel alignment Generally used to gain access to another part If an R amp I time is not available published R amp R times can be used when the steps required to R amp R
42. d and when the flexible component is refinished during the same procedure with major or minor components then flexible components should be considered the same designation as major or minor components for the purpose of calculating refinish over lap deductions and or multi stage refinishing additions INDIVIDUAL PROCEDURE ITEMS AREAS Areas of a panel or component that are part of a main compo nent but are refinished during a procedure separate from the main component Example edges jambs hinges inside panels and the underside of hoods deck lids liftgates etc No overlap deduction should be taken when calculating refinish time for items from this category Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to DEDUCTIONS TO BASIC REFINISH TIMES Refinish Overlap OVERLAP NON ADJACENT PARTS e First major panel Use full published time e Each additional part Deduct 0 2 per part OVERLAP ADJACENT PARTS e First major panel Use full published time e Each additional part with a base time of 1 0 hour or greater Deduct 0 4 per part e Each additional part with a base time less than 1 0 hour Deduct 0 2 per part OVERLAP INNER PANEL COMPONENTS e First inner part Use full published time e Each additional inner part with a base time of 0 5 hour or greater Deduct 0 2 per part e Inner part with a base time less than 0 5 hour No dedu
43. d to tail gate REAR BODY LOWER BODY PANEL e Window run channel DOES NOT INCLUDE INCLUDED e Back glass wiper or washer e Adhesive application if 2 e Camera required all types e Electrical wiring R amp I e Bolt on extensions amp e Emblems amp nameplates fillers e Hinges e Bumper and or cover e Lock cylinder recoding assembly R amp l e Moldings except as listed above e Caulk seam sealer e Remove bonded glass from damaged tail gate e Cutting amp welding as e Spoiler flare or louver necessary e Stripe tape decals or overlays e Grind fill amp smooth welded seams up to 150 grit sandpaper REV 5 11 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to G25 and takes precedence over information in the Guide to Estimating pages for the operation indicated XY N T Gs sd TT Y Q BE Ek Gs Q oa el i p Y Mu x a TT a O a a s Q a i GUIDE TO ESTIMATING REAR BODY LOWER BODY PANEL Continued Lamp R amp I Latch or striker License plate bracket License plate Rear compartment trim as necessary Sill plate Weatherstrips DOES NOT INCLUDE e Electrical wiring Fuel tank R amp I Emblems amp nameplates Energy absorber Exhaust system Lock cylinder recoding Moldings Stripe tape decals or overlays Valance panel REAR BODY FLOOR PAN RAILS CROSSMEMBERS INCLUDED e Adhesive application if ae required a
44. e decals or overlays REV 5 11 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to G31 and takes precedence over information in the Guide to Estimating pages for the operation indicated Y NA T Gs sd TT Y Q BE Ek Gs Q oa el i GUIDE TO ESTIMATING VAN SUV SIDE AND CORNER PANELS VAN SUV SIDE AND CORNER PANELS 9 Continued SPECIAL NOTATION Side and corner panel R amp R times are generally based upon DOES NOT INCLUDE replacement at the factory seams On some vehicles it is not e ABS sensor practical to replace at the factory roof seam If a sectioning e Air bag components operation is not listed then the R amp R time on the parts line e Body side moldings represents the time to splice at the best area When a sec e Brackets braces amp supports transfer ui tioning operation time is listed it represents the time to e Carpet amp insulation R amp I rx splice at the most efficient location usually within the win e Emblems amp nameplates dow openings Both Full Panel R amp R operations and Partial e Foam st Panel Sectioning operations involve the same basic oa a INCLUDED and NOT INCLUDED procedure steps eaa ner TT e Panels inward of side panel U ee e Sliding door tracks welded o e Spare tire carrier pe e Stripe tape decals or overlays e SUV rear hinged door da e Tail gate lift gate se e Van sliding door O e Window aft
45. e decals or overlays e Cutting amp welding as necessary TAIL GATE PASSENGER CARS WAGONS e Finish panel e Finish plate e Finish molding SPECIAL NOTATION 3 Finchin Some replacement components may or may not be supplied e Flutter material appli with duplicated OEM caulk seam sealer This is not included cation if required in R amp R time and requires an on the spot evaluation e Grind fill and smooth welded seams up to 150 grit sand Disconnect at hinge amp support cylinder paper INCLUDED e Interior trim e Align to vehicle e Lamp e Appliqu panel e License plate if attached e Glass moveable e License pocket e Finish panel e Lock cylinder assembly if necessary e Finish plate e Outside handle e Finish molding e Tailgate R amp I e Finish trim e Trim panel R amp l e Inside release e Water shield e Install bonded e Weatherstrips if attached glass DOES NOT INCLUDE e Internal mecha e Back glass wiper or washer NISMS e Camera e Interior trim e Electrical wiring R amp I e Lamp e Emblems amp nameplates e Latch or striker attached to gate e Glass e License plate if attached e Hinge e License pocket e Moldings except as listed above e Lock amp cylinder assembly if necessary e Remove bonded glass from damaged tail gate e Outside handle e Reinforcement bar e Regulator e Spare tire carrier e Run channel e Straightening of frame e Trim panel R amp I e Stripe tape decals or overlays e Water shield e Weatherstrips if attache
46. e application of painted on stripes are not covered in this publication The time necessary to perform this type of operation should be estimated after an on the spot evaluation of required procedure REFINISH TIME PREMISE Published refinish times are for one color applied to new undamaged replacement components without exterior trim interi or trim or other attached components and applied in one continu ous process For damaged panel s published refinish times may be applied after the damaged panel has been returned to a NEW UNDAMAGED condition Refinish times do not include time which may be required to match color tints or defective finish textures on interior or exterior surfaces Nor do they include time which may be required to cor rect finish imperfections caused by improper weather conditions application or environmental contamination such as dust dirt grease etc MOTOR advises all parties consider these factors beforehand to determine mutually acceptable provisions in the event such conditions exist or occur ANTI THEFT LABELS R DOT Replacement part labels are coded with the letter R to show that it is a replacement part R Dot labels should not be removed from the part Use caution when refinishing rustproofing or under coating replacement components to avoid damaging the label BUMPER COVERS AND OTHER FLEXIBLE COMPONENTS Refinish times listed on the parts detail lines for these compo nents are based on th
47. e items being refinished prior to installation Refinish time listed on the parts detail line for an OEM bumper cover that has both body color and unpainted grained portion allows for the refinish of the body color only Masking the grained textured or non body color portions in preparation for body color application is an included operation It includes exterior surface and edges refinished during one continuous process If a separate edging procedure is utilized then the appropriate time should be estimated after an on the spot evaluation Refinish times do not include removal of mold release agent from new unprimed molded components Parts received from the OEM manufacturer without primer and some non OEM parts with or without primer should be tested for the presence of release agents that would cause paint adhesion problems and treated accordingly For unprimed bumper preparation time see Add If Required operation s Preparation time for all other unprimed components should be estimated after an on the spot evaluation DOOR OUTER REPAIR PANELS Refinish times listed on the parts detail line for new repair pan els i e door outer repair panel tail gate and lift gate repair panels include panel lip and immediate area It does not include time for refinishing the entire door frame edge or interior side Where pos sible MOTOR will publish time for those areas under a Refinishing Notes heading within that group DOOR SHELLS LIFT G
48. e same exacting standards as the parts installed on new vehicles when the car was built Exterior body panels are supplied with a smooth painted surface e coat UNDERSIDE COLORS Refinish times presented in this guide are developed under the premise that the underside and jamb color is the same as the exte rior body color Some vehicle manufacturers use a different color for the engine compartment trunk compartment and or jambs An additional paint mix is required if the underside and or jamb color is a different color than the exterior body color Clear coat gloss or matte will be required for base color coat applications This should be considered when developing the estimate PRIME amp BLOCK Prime amp block high build primer filler is a required procedure that restores a repaired panel surface including the joined areas of replaced welded panels from 150 grit finish to that of a NEW UNDAMAGED condition It is MOTOR s position that prime and block is a process best reserved for the judgment of an estimator appraiser following a thorough on the spot evaluation of the specific vehicle and damage in question REPAIRED PANEL REFINISHING MOTOR suggests using component s base refinish time for this type of procedure after the damaged panel is repaired to new undamaged condition Repaired surface preparation requires an on the spot evaluation for additional procedural steps such as featheredge and or prime and block not required fo
49. eel or hub cap locks R amp I FRONT BUMPER ASSEMBLY R amp I ALL TYPES INCLUDED e Align to vehicle e Face bar bumper cover assembly R amp l DOES NOT INCLUDE e Air bag sensor Battery Emblems amp nameplates Energy absorber all types Lamp aiming Lamps when not mounted in bumper Moldings amp impact strip Stripe tape decals or overlays Valance panel spoiler when not mounted to bumper FRONT BUMPER R amp R FACE BAR TYPE e A C System Evacuate and Recharge INCLUDED e Aftermarket amp OEM accessories e Align to vehicle f e Alignment check or straightening related parts e Emblem amp nameplate e Alignment check of front or rear suspension steering e Face bar R amp l e Anticorrosion material restoration application e Guard e Battery D amp R recharge e Guard cushions e Brackets amp braces transfer e Molding amp impact strip e Broken glass removal or clean up DOES NOT INCLUDE e Brakes bleed and adjust e Air bag sensor e Caulk non OEM sound insulate or paint inner areas e Battery e Clean up or detailing of vehicle prior to delivery e Distance sensor e Computer control module D amp R relearn e Energy absorber if mount e ao Vans special components equipment and ed to frame rail all types dae e Lamp aiming e Cutting pulling or pushing collision damaged parts for e Lamps when not mounted in bumper access e License plate bracket e ae a N replacement parts e Stripe tape decals or overlays Dra
50. efinish time Blending may be necessary for adjacent body components to avoid noticeable color variation between newly applied paint and the existing paint of adjacent components or areas The following formula may be considered in the event this type of procedure is required on an undamaged panel e Each blended adjacent panel or area 70 of blend panel s base refinish time INCLUDED e Back tape open ing handle lock cylinder mirror e Blend coat application Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to G37 and takes precedence over information in the Guide to Estimating pages for the operation indicated NA izd o gt a Rd Y 2 oe a x wt Z E kid e GUIDE TO ESTIMATING THREE STAGE COLOR BLEND Adjacent Panels Continued INCLUDED continued Bonding adhesion coat application Clean component solvent detergent wash Clean in preparation for material application Clear coat application full blend panel if required Cover mask recessed edges jambs Panel preparation when required Mask adjacent panels three foot perimeter Mask close gap between adjacent panels up to front tape overspray e Mask glass opening e Mask protect grille radiator opening overspray e Remove masking DOES NOT INCLUDE e Correction of pre existent surface imperfections Damage repair Masking of attached parts Material costs
51. ehicle one time e Lower coupling A e Radius rod amp bushing e Shift lever o e Shock absorber e Shift bowl e Splash shield e Steering shafts le e Steering arm e Steering shaft bearings 2A DOES NOT INCLUDE RE a lt e Axle or carrier assy 4WD R amp l e Brake caliper R amp I e Turn signal switch lever e Brake pad or shoes e Wiring e Brakes adjust amp bleed DOES NOT INCLUDE e Drive train parts e Lock cylinder recoding e Road wheel e Refinish column components e Stabilizer bar e Steering gear or linkage SUSPENSION WHEEL ALIGNMENT e Suspension wheel alignment SPECIAL NOTATION STEERING LINKAGE Operations outlined in the following section are based on INDIVIDUAL OPERATIONS four wheel sensor alignment equipment Alignment time includes normal wear diagnosis Alignment time does not INCLUDED include collision related damage diagnosis e Individual compo nent R amp R FRONT WHEEL ALIGNMENT DOES NOT INCLUDE INCLUDED e Brakes adjust amp e Align front wheels bleed e Center steering wheel e Road wheel e Check vehicle height amp thrust angle e Suspension wheel a e Check and adjust tire pressure alignment 4 e Check wheel size amp run out 7 e Remove vehicle from alignment Ek equipment Road test vehicle e Set up on alignment equipment amp normal wear diagnosis e Shimming as required DOES NOT INCLUDE e Adjust brakes e Adjust vehicle height e Align rear wheels e Alignment shim cost REV 5 11 Footnotes found in a chapter contain
52. em if necessary e Align to vehicle Grille if attached Hood lamp Hood panel R amp R Insulation Scoop Safety catch Striker Washer hoses amp nozzle mounted to hood e Weatherstrips amp seals mounted to hood DOES NOT INCLUDE e Emblems amp nameplates e Hinge e Hood lock e Moldings amp ornamentation Stripe tape decals or labels LAMPS Composite Type INCLUDED e Bulb s DOES NOT INCLUDE e Lamp aiming e Headlamp door bezel LAMPS Sealed Beam Type INCLUDED e Mount ring e Retainer ring i e Sealed beam OS DOES NOT INCLUDE e Lamp aiming ad dik EE e Headlamp door bezel i ee EE FENDER OUTER PANEL INCLUDED e Align to vehicle Fillers if mounted to fender Cornering lamps if mounted to fender Fender liner Scoop MA Side marker AA EN S Side repeater lamp if lt y J mounted to fender N DOES NOT INCLUDE e Antenna Bumper R amp I Battery Emblems amp nameplates Grille Header panel Hood Inner panels Lamp aiming Mirror Moldings Mud guard Road wheel Spoilers amp flares Stripe tape decals or overlays FENDER INNER PANEL Welded Apron amp Rails SPECIAL NOTATION Detach and weld at floor pan radiator support hinge pillar and cowl panel INCLUDED e Adhesive application if required all types e Battery tray e Carpet amp insulation turn back e Caulk seam sealer e Cowl trim e Cutting 4 welding as necessary DOES NOT INCLUDE
53. epaired panels Flex additive mixing time Flex prep application Material costs Mask inner panels ex apron cowl pillars rail floor etc Molding amp ornamentation Protective coating material application Protective coating removal Sound deadening application Spatter paint application time Stripe tape decal amp overlay Waste disposal fees all types PANEL and or COMPONENT DESIGNATION MAJOR PANELS COMPONENTS All panels or components with a base refinish time of 1 0 hour or greater are generally considered by MOTOR to be major panels Example grille header panel fender hood cowl top panel doors roof panel rocker panel quarter panel engine lid trunk lid lift gate rear gate rear body panel truck cab corner and back panel truck bed front and side panel and van side and corner panels MINOR PANELS COMPONENTS All panels or components with a base refinish time of less than 1 0 hour FLEXIBLE PANELS COMPONENTS All panels or components for which paint systems require a flex agent added to the paint mix Example fascia covers fillers exten sions spoilers etc No overlap deduction should be taken when calculating refinish time for a single item from this category A combination of items from this category refinished during a single continuous procedure should be subject to the appropriate Adjacent or Non Adjacent overlap formula deduction When a flex agent or a separate paint mix procedure is not require
54. ermarket E mel INCLUDED e Adhesive application if required all types e Bolt on extensions amp fillers e Bumper assembly R amp l e Carpet amp insulation turn back e Caulk seam sealer e Cutting amp welding as necessary e Detachable roof assemblies e Door striker e Fuel door e Grind fill amp smooth welded seams up to 150 grit sandpaper e Interior trim e Lamp e Side glass amp moldings e Sill plates e Sliding door tracks bolted e Weatherstrips amp seals e Wheelhouse liner G32 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING DECALS STRIPE TAPE amp OVERLAYS BOLT OR CLIP ON MOLDINGS INCLUDED i CONSIDERED e Clean heat ie e Drill time if required surfaces e If new parts are used on a new e Component align position e Installation of panel add one half the replace ment time e If old parts are used on a new e Component align position e Installation of component panel add entire replacement time a only DOES NOT kid INCLUDE en e Adhesive backing removal clean up and replace DRILLING OPERATIONS 7 ete eerie ad Service components may be inconsistently delivered by the 7 1 manufacturer with mounting holes drilled at the factory Drilling time should be added to the estimate if a component is received
55. fected after an on the spot evaluation of the vehicle s inner structure design The labor time premise included not included operations for a sectioned panel is considered to be the same as for the full panel replacement unless otherwise specified in a footnote attached to the sectioning operation SPECIAL SUBSTRATE METALS Some vehicle manufacturers use special or alternative metals in the construction of their vehicles When possible parts made from one of the seven listed metals will be identified using the abbrevi ations shown below It is not always possible or practical to identify where special or alternative metals are used on a vehicle Do not assume that a part NOT IDENTIFIED AS SPECIAL METAL ISN T ACTUALLY MADE OF SPECIAL METAL When in doubt it is recommended that you con tact the vehicle manufacturer for further information WHEN PER FORMING REPAIRS TO SPECIAL METAL SUBSTRATES REFER TO OEM RECOMMENDATIONS FOR SPECIFIC INFORMATION IMPROPER REPAIRS MAY ADVERSELY AFFECT THE STRUC TURAL INTEGRITY AND SAFETY OF THE VEHICLE ALUMINUM ALU Aluminum is lighter than steel and is non magnetic Aluminum is sensitive to galvanic corrosion Only use fasteners tools and materials that are designated for use on alu minum Heat limitations MUST be observed when working with this type of metal BORON STEEL BOR Boron steel has extremely high strength do not use heat on this type of metal It cannot be straightened because
56. ge e Cover mask interior of vehicle to prevent overspray dam age e Edge refinishing e Grind fill amp smooth welded seams up to 150 grit sandpa per Paint or material costs Prime amp block high build primer filler Test spray out panel Tinting Primer Sealer Tinting to achieve color match Underside refinishing Weld grind or sanding damage to adjacent panels Wet sanding BAGGING Cover Entire Vehicle Exterior Published refinish times include time necessary to mask exteri or surface adjacent to the refinish area to a perimeter of 36 inches or 3 feet When the process of perimeter masking is substituted for an entire vehicle bagging procedure then no additional time should be added If entire vehicle bagging is used along with perimeter masking then the following formula may be considered APPLY AND REMOVE VEHICLE COVER BAGGING e Add 0 2 each time a cover is applied and removed CLEAR COAT FINISHES Base Coat Clear Coat SPECIAL NOTATION The following items or operations were not considered during the development of any published basic refinish operation times If any of these items or operations are required they should be considered by the estimator Calculations should be made after deductions for overlap and additions for underside and edges if required e First major panel Add 40 to refinish time e Each additional panel Add 20 to refinish time e Maximum time allocation 2 5 hours INCL
57. h from chipping This type of coating may be named differently depending on manufacturer ex Stone Guard Soft chip Primer PVC Chipping Primer Chip Guard Gravel Guard etc This type of coating is designed to reduce paint chipping appearance varies from textured surface to a smooth surface Chip resistant coatings may be applied to the vehicle s lower body and or leading edges of the body Refer to OEM serv ice repair information for specific location repair recommendations and or replacement product s MOTOR recommends following OEM service repair information for replacement of these materials following a thorough on the spot evaluation of vehicle and damage in question STRUCTURAL GLASS Urethane bonded stationary glass such as windshields side quarter glass and back glass adds structural integrity to a vehicle s body and may be considered a structural component on some vehicles Therefore it is important to use proper materials and procedures when installing this type of glass CAR and some vehicle manufacturers recommend the use of epoxy primer on glass pinchweld where coating has been removed Utilization of incorrect methods or materials could result in a failure to restore the vehicle s original structural integrity Removal of some undam aged urethane bonded glass for reuse may not be possible due to damaging plastic locating studs and or attached moldings Some vehicle manufacturers recommend replacing glass that has been
58. he clear coat thickness mils may result in early paint failure Follow manufacturer s recommendations when performing this type of repair Calculations should be based upon the outer surface only and should not include additions for clear coat underside inside or edges Base refinish time does not include deduc tion for refinish overlap In the event that this type of opera tion will be performed MOTOR suggests the following formu la be considered Refinished panels may or may not require a varying amount of wet sanding compound rub out or buffing operations In the event this type of operation will be performed MOTOR suggests the fol lowing formula be considered e Each panel requiring wet sand rub out and or buff refinish or blend Add 30 of full base refinish time INCLUDED e Panel outer surface only e Wet sand full panel as required e Compound buff and or polish as required DOES NOT INCLUDE e Acid rain damage e Overspray removal e Removal of residual material from recessed edges and jambs if required e Wash clean wax or detail entire vehicle prior to delivery if required UNPRIMED BUMPER PREPARATION e 25 of the bumper s base refinish time e Maximum time allocation 1 0 hours INCLUDED e Removal of mold release agents as outlined by manufacturer e Masking if required e Application of adhesion promoter DOES NOT INCLUDE e Correction of pre existent surface imperfections e Material Costs
59. he letter A is an approximation which you may find helpful These prices are to be regarded as a GUIDE only The actual price which may be higher or lower than the published price can be determined by contacting the General Motors dealer in your area Mopar Competitive Crash Parts Program The prices for these parts may carry a special discount Actual price should be deter mined by calling the dealer in your local area Dealers are not required to participate in this program and are free to determine their own prices for these parts PART PRICES Continued Part prices do not include cost of state and local taxes bolts rivets screws nuts washers clips fasteners paint body repair materials and refinishing unless otherwise noted PART QUANTITIES Many procedures require replacement of parts such as fasten ers bolts rivets screws nuts clips for example or washers The applicable quantities for these parts are provided whenever possi ble This information will be provided as reported by the OEM TECHNICAL INFORMATION Labor times shown in reference to labor procedures contained in Tech Cor Bulletins are researched and developed by MOTOR While Tech Cor Bulletins are protected under copyright laws reproduction of these bulletins is permitted as long as the bulletin is reproduced in its entirety including source attribution Tech Cor LLC Technical Research Dept 110 East Palatine Road Wheeling Illinois 60090
60. his type of equipment is very sensitive to high tem peratures and voltage fluctuations including electrostatic dis charge A few safety tips you should consider are e Disconnect battery cable e Computer modules should not be exposed to tempera tures exceeding OEM recommendations e Remove component if necessary e Discharge static electricity before handling component s e Avoid touching electrical terminals of component I CAR s Uniform Procedures for Collision Repair states that electronic components should be removed from the vehicle if welding is to take place within 12 inches of the component Refer to manufacturer s specific recommendations for each vehicle HAZARDOUS MATERIALS Regulations and safety considerations may require protective clothing respirator protective eyeglasses and or ear plugs be worn in certain areas of collision repair facilities Caution must be exercised when dealing with isocyanates flammables fumes liq uids and airborne particles HYBRID VEHICLES Warning High Voltage Electrical System Some vehicles are equipped with a high voltage nickel metal hydride battery ranging from 144 397 volts Failure to use caution in the proper disconnection of this electrical system may result in injury For safety and ease of identification electrical cables carry ing the high voltage are colored orange Any orange colored cable should be avoided until the high voltage electrical system has been disabled
61. ickness mils may result in early paint failure Follow vehicle manufacturer s recommen dations when performing this type of repair Calculations should be based upon the base refinish time outer surface only and should not include additions for clear coat under side inside or edges In the event that this type of operation will be performed MOTOR suggests the following formula be considered Each panel requiring de nibbing refinish or blend HOOD ROOF TRUNK LID SPOILER First panel add up to 20 of full base refinish time each additional panel add up to 10 FENDER DOOR QUARTER PANEL BUMPER COVER First panel add up to 10 of full base refinish time each additional panel add up to 5 INCLUDED e Panel outer surface only e Paint nib removal as required spot only e Spot polish only DOES NOT INCLUDE e Acid rain damage e Full panel polish e Overspray removal e Removal of residual material from recessed edges and jambs if required Scratch damage e Wash clean wax or detail entire vehicle prior to delivery if required e Wet sand full panel Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to WET DRY SAND RUB OUT amp BUFF SPECIAL NOTATION Refinished panels may or may not require a varying amount of wet sanding compound rub out or buffing operations in order to match original finish texture The clear coat contains ultraviolet screeners and reducing t
62. in a ret tuel tan e Valance panel spoiler when not mounted to bumper e Drilling modification or fabrication of mounting holes e Fabricate templates reinforcing inserts sleeves or flanges e Filling plugging and finishing of unneeded holes in new parts e Information label installation e Material costs e Pinch weld clamp damage repair e Refinishing G10 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING FRONT BUMPER ASSEMBLY OVERHAUL FACE BAR TYPE INCLUDED e Align to vehicle e Disassemble com plete assembly e Emblem amp name plate Guards Guard cushions Lamps Molding amp impact strip e Reassemble com plete assembly e Replace damaged parts DOES NOT INCLUDE e Air bag sensor Battery Distance sensor Energy absorber if mounted to frame rail all types Lamp aiming Lamps optnl equip or when not mounted in bumper License plate bracket Stripe tape decals or overlays Valance panel spoiler when not mounted to bumper FRONT BUMPER R amp R COVER TYPE SPECIAL NOTATION The removal of mold release agents from and preparation priming of unprimed bumpers is required and is NOT INCLUDED Where the OEM has provided information regarding the availability of unprimed bumper covers an Add if Required labor operation ha
63. ined as follows M Mechanical Components that transform one form of motion or energy into another Mechanical components would like ly be serviced at a mechanical service facility rather than a body repair facility if that component failed during normal operation Mechanical components will likely require a specialized technician skill level and or specialized tools S Structural Components that provide a load bearing foun dation for the purpose of safety and or stability no classification Body Components that do not fall under the mechanical or structural classification D amp R Disconnect amp Reconnect Some labor procedures require disconnecting unplug and or unbolt of a component assembly at the point where it is attached to the subject part The component assembly is not completely removed from the vehicle The component is reconnected during the assembly procedure Due to various configurations and type of parts that may be involved in the D amp R operations and considering that the times involved are generally not definable in tenths of hours time for D amp R is not provided When D amp R is necessary to perform a labor operation it is included in that labor operation s time INCLUDED and or NOT INCLUDED LABOR OPERATIONS INCLUDED OPERATIONS When items or operations appear in the Guide to Estimating pages under the Included heading it means that the operation is performed in conjunction with another ope
64. ing INCLUDED e Mirror e Adhesive application if required all e Moldings types e Passive restraint system e Applique e Power lock option e Belt molding ff e Remove bonded glass from damaged door shell e Caulk seam sealer OB e Power window option e Cutting amp welding as necessary j e Spare tire carrier e Door R amp I im e Stripe tape decals or overlays e Flutter material application if required pe i e Grind fill and smooth welded seams Nf DOOR DOOR SHELL R amp R SLIDING TYPE up to 150 grit sandpaper e Inside handles amp bezels e Lock and cylinder assembly if necessary SPECIAL NOTATION e Outside ane handle d d Some replacement components may or may not be supplied e Trim panel R amp I with duplicated OEM caulk seam sealer This is not included e Water shield in R amp R time and requires an on the spot evaluation e Weatherstrips if attached to door Disconnect at hinges unless otherwise noted in text DOES NOT INCLUDE INCLUDED e Back glass wiper or washer e Access cover e Body side moldings e Align to vehicle e Clean up broken glass e Applique e Emblems amp nameplates e Belt molding e Glass e Glass fixed move e Hinge able e Lock cylinder recoding e Glass reveal moldings e Mirror e Inside handles and e Moldings bezels e Passive restraint system e Install bonded glass e Power lock option e Internal mechanisms e Power window option e Latch mechanisms e Regulator e Lock and cylinder e Reinforcement bar assembly if ne
65. ion Disconnect at hinge amp support cylinder INCLUDED e Align to vehicle Appliqu panel Glass moveable Glass moldings Finish panel Finish plate Finish molding Finish trim Inside release Install bonded glass Interior trim Internal mechanisms Lamps Latch or striker attached to gate License plate if attached License pocket Lock amp cylinder assembly if necessary Outside handle Trim moldings Trim panel R amp l Watershield Weatherstrips if attached to lift gate Window run channel G24 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING LIFT GATE Continued TAIL GATE OUTER PANEL R amp R DOES NOT INCLUDE SPECIAL NOTATION e Back glass wiper or washer Some cutting or welding processes may require the door i ranoni wirina R amp I glass to be removed prior to replacing the outer panel This g factor should be considered prior to finalizing any repair cost e Emblems amp nameplates l estimates e Hinges e Lock cylinder recoding INCLUDED e Moldings except as listed above e Adhesive application e Remove bonded glass from damaged lift gate if required all types e Spare tire carrier e Align to vehicle e Special interior trim e Applique panel e Spoiler flare or louver e Caulk seam sealer e Stripe tap
66. ir Bag Continued Estimated Work Times for disabling vehicle safety restraint sys tems have been developed for instances where the OEM recom mended procedure steps required to disable the system are in addition to steps required to de energize the vehicle by discon necting the battery and or removing a readily accessible fuse RESTRAINT SYSTEM Seat Belt Many automobile manufacturers recommend seat belt compo nents be replaced when subjected to stress by occupants in a col lision Check with the manufacturer for specific repair recommen dations and procedures SECTIONING Sectioning is an industry accepted procedure which involves replacing a vehicle s welded body panel quarter rocker rail etc onto the undamaged portion of a vehicle body at a location other than at a factory seam This may or may not be a factory recom mended procedure Special care and training is required when sec tioning any part due to the wide use of special steels and vehicle design Repairs of this type should only be performed in accor dance with the OEM service repair information if available When sectioning procedures are not available from the vehicle maker it may be possible to section a part using vehicle specific proce dures developed by research organizations such as Tech Cor and or general sectioning guidelines taught by I CAR Please visit http www i car com partialreplacement for more information The sectioning location may be af
67. ired an additional 0 3 hrs may be necessary to EE GEM pi remove a spare tire from its storage location and install it on e Battery Yj A the hub and to later remove the spare tire from hub and e Bolted on parts da ee j e Bumper assembly A a N ER return it to the original storage location gt sa In MANS e Carpet insulation A ee INCLUDED or seat R amp l e Raise amp support vehicle e Decals labels e Remove amp reinstall wheel tire assembly e Electrical wiring e Transfer tire e Energy absorber e Lower vehicle e Engine e TPMS sensor if attached to valve e Exhaust system stem e Front suspension e Valve stem e Outer sheet metal DOES NOT INCLUDE e Pulling or straightening time e Balancing e Set up on frame machine amp diagnosis e Cost of valve stems or weights e Steering components e Lock type lug nuts e Suspension wheel alignment e Lock type wheel covers e Welded bracket amp braces transfer e Scan tool clear reset e Tire disposal fee BLEED BRAKE HYDRAULIC SYSTEM SPECIAL NOTATION Bleed Brake System operation times are based upon other suspension and or brake work already being performed and the Bleed Brake System Operation performed in conjunction with those other operations INCLUDED e Bleed brake system e Add fluid to master cylinder reservoir DOES NOT INCLUDE e Brakes adjust e Cost of brake fluid REV 5 11 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to
68. ll types e Cutting amp welding as necessary e Caulk seam sealer e Rear body panel on floor pan only DOES NOT INCLUDE e Bolted on parts Electrical wiring Exhaust system Rear body panel on rails only Sound deadening pad FUEL TANK SPECIAL NOTATION Disconnect at fuel filler neck INCLUDED e Fuel pump if necessary e Sending unit REAR SUSPENSION INDIVIDUAL OPERATIONS INCLUDED e Raise amp support aw vehicle one time E DOES NOT INCLUDE e Bolted on parts e Brake calipers R amp I e Brake shoes or pads e Brakes adjust amp bleed e Road wheel e Suspension wheel alignment e Wheel cylinders REAR SUSPENSION OVERHAUL STRUT TYPE INCLUDED e ABS sensor Bearing seal R amp R Bearing Brake drum rotor Coil spring compo nents Hub Knuckle Lower control arm Lower control arm bushing e Overhaul procedure as defined e Radius rod amp bush ing Raise amp support vehicle one time Splash shield Stabilizer link Strut seat Strut radius rod amp bushing Strut cartridge assembly DOES NOT INCLUDE e Axle or carrier assy e Bolt on crossmember DOES NOT INCLUDE e Brake pad or shoes e Exhaust system e Brakes adjust amp bleed e Fuel tank drain amp refill e Rear drive axle carrier differential e Suspension amp drivetrain e Road wheel R amp l e Stabilizer bar e Suspension wheel alignment e Wheel cylinders G26 Footnotes found in a chapter contain vehicle specifi
69. n if required all types e Bolt on exten sions amp fillers e Bumper assembly R amp l e Caulk seam sealer e Cutting amp welding as necessary e Fuel door Grind fill amp smooth welded seams up to 150 grit sandpaper Lamp License plate bracket Tail gate R amp l Wheelhouse liner plastic DOES NOT INCLUDE e Body side moldings Box R amp l Box set back Brackets braces amp supports transfer Emblems amp nameplates Fuel tank Outer fender Panels inward of side panel Standard running boards amp step plates Stripe tape decals or overlays PICKUP TRUCK BOX FRONT PANEL INCLUDED e Adhesive applica tion if required all types e Bolt on extensions amp fillers e Caulk seam sealer e Cutting amp welding as necessary e Grind fill amp smooth welded seams up to 150 grit sandpaper PICKUP TRUCK BOX FRONT PANEL Continued DOES NOT INCLUDE e Body side moldings e Box Ral e Box set back e Standard running boards amp step plates Stripe tape decals or overlays PICKUP TRUCK BOX TAIL GATE SPECIAL NOTATION Some replacement components may or may not be supplied with duplicated OEM caulk seam sealer This is not included in R amp R time and reduires an on the spot evaluation Disconnect at hinge INCLUDED e All bolted on parts e Hinge bolted type DOES NOT INCLUDE e Align to vehicle Body side moldings Emblems amp nameplates Hinge welded type Stripe tap
70. nents will alter the original design and change deployment characteris tics Always refer to the vehicle manufacturer s recommended repair procedures when servicing any air bag system Before repairing any air bag system disconnect and isolate the battery cable so that any back up power supply is discharged for the time period stipulated by the manufacturer to prevent acciden tal deployment when working on the vehicle All system compo nents and mounting areas must be inspected before energizing the system On some vehicles the windshield is considered an integral com ponent of the overall system and has specific requirements regard ing materials and procedures used when replacing a windshield Factory recommended procedures must be followed when servic ing this type of system Some vehicles are equipped with dual stage air bags The air bags are deployed at different rates depending on the severity of the crash seat belt usage and driver position If a dual stage air bag has deployed it is possible that only one stage has deployed If both stages have not deployed there is a danger of the second stage deploying if the air bag is not properly handled On vehicles that are equipped with dual stage air bags ensure the air bag system is disabled before performing any repair procedures The air bag should then be properly disposed of Refer to the vehicle manufacturer s recommended procedures for air bag disposal RESTRAINT SYSTEM A
71. of the extremely high heat used in the form ing process The only solution for damage is replacement Boron steel can be cut with a cutoff wheel Drilling boron steel is very dif ficult and may be accomplished using a titanium drill bit combined with slow speed 490 rpm 68 REV 5 11 GUIDE TO ESTIMATING SPECIAL SUBSTRATE METALS Continued HIGH STRENGTH STEEL HSS Generally frame rails inner rocker panels Suspension crossmembers and upper apron rails are made of this material this varies by manufacturer Heat limita tions MUST be observed when working with this type of steel When in doubt most manufacturers recommend all steel be treat ed as HSS steel HYDROFORMED STEEL HYD Hydroformed parts may be sectioned depending on the vehicle manufacturer s recommenda tion Heat limitations MUST be observed when working with this type of steel MAGNESIUM MAG Magnesium is much lighter stronger and more resistant to corrosion than steel Magnesium has the tenden cy to crack or break either from collision damage or during straightening due to its quick work hardening characteristics Magnesium is also not weldable with common collision repair facil ity GMA MIG welding capabilities Do not use oxyacetylene equipment or plasma arc cutting equipment around this or any other magnesium part If magnesium catches on fire it requires a class D fire extinguisher SANDWICHED STEEL SAS This type of steel OEMs may have o
72. p l if necessary Rear bumper assembly and or cover R amp l if necessary Sill plates Trunk compartment trim Weatherstrips seal strip Wheelhouse liner plastic DOES NOT INCLUDE e Antenna Body side moldings Boot well Carpet amp insulation R amp l Convertible top alignment Emblems amp nameplates Foam Fuel tank Mud guard Panels inward of quarter Power cylinder Retractable roof alignment Road wheel Roll bar Spoilers amp flares Stripe tape decals or overlays Trunk lid R amp l TRUNK LID SPECIAL NOTATION Some replacement components may or may not be supplied with duplicated OEM caulk seam sealer This is not included in R amp R time and requires an on the spot evaluation Disconnect at hinge TRUNK LID Continued INCLUDED e Align to vehicle Appliqu panel Finish panel Finish plate Finish molding Finish trim Inside release Internal mechanisms Interior trim Latch or striker attached to lid License plate if attached License pocket Lock amp cylinder assembly if necessary Trim moldings Lamps Weatherstrips if attached to lid DOES NOT INCLUDE e Emblems amp nameplates Hinge Lock cylinder recoding Moldings except as listed above Spoilers amp flares Stripe tape decals or overlays LIFT GATE SPECIAL NOTATION Some replacement components may or may not be supplied with duplicated OEM caulk seam sealer This is not included in R amp R time and requires an on the spot evaluat
73. r new undam aged panels PARTIAL PANEL REFINISHING This is NOT a BLEND WITHIN procedure partial panel refinish ing is NOT a BLEND operation MOTOR defines partial panel refin ishing as refinishing a body panel with damage that is contained within a defined border or underneath body cladding after the panel has been repaired to that of a NEW UNDAMAGED PANEL It is MOTOR position that partial panel refinishing is a process best reserved for the judgment of an estimator appraiser following a thorough on the spot evaluation of the specific vehicle and refin ish requirements in question Refer to G T E BASIC COLOR COAT APPLICATION G34 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING REFINISH TIME PREMISE Continued SPECIAL NOTATION The items or operations below were not considered during the development of any published basic refinish operation times These operations may or may not be required depend ing upon the vehicle or process used If any of these items or operations are required they should be considered by the estimator and added to the estimate if necessary REFINISH WET DRY SAND DE NIB and or RUB OUT TIME DOES NOT INCLUDE e Anti corrosion material application Filling blocking featheredging r
74. ration For example Steering Wheel R amp l is an individual operation but when replacing a steering column steering wheel R amp l is also performed and there fore included in Steering Column R amp R If an item is listed without a qualifier it means all labor has been considered within the indicated labor procedure If a specific qual ifier such as R amp I appears it means only the specified qualifier applies INCLUDED and or NOT INCLUDED LABOR OPERATIONS Continued NOT INCLUDED OPERATIONS Items or operations listed under Does Not Include were not considered in the development of published labor operation times These operations may or may not be required depending upon the vehicle or repair process used If any of these items or operations are required they should be considered by the estimator If a spe cific qualifier such as R amp l appears it means only the specified qualifier applies NAGS GLASS PRICES Glass Prices We include when available both the vehicle man ufacturer and the NAGS benchmark prices as applicable to each make and model All NAGS part numbers and benchmark prices are provided from National Auto Glass Specifications a division of Mitchell International Inc Labor operation times listed on the line with the NAGS information are MOTOR suggested labor operation times NAGS labor operation times are not included OEM Original Equipment Manufacturer Used to define original vehicle manufa
75. required all types e Carpet amp insula tion turn back gt A e Caulk seam sealer Vi e Cutting amp welding Y as necessary e Door striker e Grind fill amp smooth welded seams up to 150 grit sandpaper Interior trim R amp I Seat belt anchor Sill plates Weatherstrips DOES NOT INCLUDE e ABS sensor Air bag components Carpet insulation or seat R amp l Door Door hinge Electrical wiring R amp l Emblems amp nameplates Foam Headliner Hinge plate transfer Lamp Roof cover UNISIDE APERTURE PANEL WITHOUT QUARTER PANEL SPECIAL NOTATION When replacing welded door hinges add one half of the Door Hinge R amp R time to Uniside R amp R time Included and Not Included items also apply to sectioning below roof lower uni side and sectioning roof rail upper uniside When sectioning other areas of uniside follow GTE page for portion of uniside being sectioned UNISIDE APERTURE PANEL WITHOUT QUARTER PANEL Continued INCLUDED e Adhesive application if required all types e Carpet amp insulation turn back e Caulk seam sealer e Center pillar trim 4 door models e Cutting and welding as necessary e Door striker e Front seat R amp l e Grind fill amp smooth weld ed seams up to 150 grit sandpaper Hinge pillar trim Jamb switches Package tray trim Quarter panel trim Rear seat R amp l Roof drip rail moldings Seat belt anchor Sill plates Weatherstrips DOES NOT INCLUDE
76. rough education representation and member services See their website http www asashop org for information on ASA s programs and activities or if you have any questions about membership please call the ASA Membership Services Department at 800 ASA SHOP ext 295 or send e mail to asainfo asashop org G3 9 lt Gs O r z TT TT O 9 lt 2 Q r z TT TT GUIDE TO ESTIMATING TECHNICAL INFORMATION Continued ASE The National Institute for Automotive Service Excellence ASE was established in 1972 ASE s mission is to improve the quality of vehicle repair and service through the testing and certification of repair and service professionals See their website http www ase com for information on ASE s programs and activ ities or e mail to webmaster asecert org AGRSS99 The Automotive Glass Replacement Safety Standards AGRSS99 Council Inc is a not for profit organization dedicated to the safe replacement of auto glass Stationary bonded auto glass replacement is important in maintaining the structural integri ty and safety features of the vehicle The AGRSS99 Standard ANSI 002 2002 is the North American standard detailing the steps and procedures to provide safer automotive glass replacement See their website http www agrss com for information on AGRSS99 programs and activities UNDERHOOD DIAGRAMS MOTOR includes underhood diagrams when available All mea
77. ructural Glass iss Rd ARK Re N GQ Uniside with Quarter Panel G23 Uniside without uarter Panel G22 LABOR PROCEDURES Valance Panel si sus abre We da G11 Van Truck SUV Liftgate G24 Labor Time Listings G10 ROOT AAR AA OO di OE N G19 Labor Time Premise G10 Side amp Corner Panels G32 Air Conditioner 005 G13 Wheel Alignment G17 18 Brake Bleed Hydraulic System G15 nee oe led Ed ETE a 11 MOLDINGS STRIPE TAPE amp umper Assembly Rear 271 28 Center Pilar vis Ed EER aaa G22 DRILL TIMES Console Floor or Overhead G19 Decals cocos G33 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 G40 and takes precedence over information in the Guide to Estimating pages for the operation indicated
78. s amp nameplate e Energy absorber all types e Molding amp impact strip e Stripe tape decals or overlays e Trunk trim liner Y NA T Gs sd TT Y Q BE Ek Gs Q oa el i REAR BUMPER ASSEMBLY R amp R FACE BAR TYPE INCLUDED Align to vehicle Emblem amp nameplate Face bar R amp R Lamps mounted in bumper e License plate bracket if attached e Molding amp impact strip DOES NOT INCLUDE e Energy absorber if mounted to frame rail all types e Reverse sensor e Stripe tape decals or overlays e Trunk trim liner e Valance panel spoiler e Shock absorber e Splash shield e Stabilizer link e Strut REV 5 11 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to G27 and takes precedence over information in the Guide to Estimating pages for the operation indicated p Y Mu a a TT v Q a a s Q 3 E tr GUIDE TO ESTIMATING REAR BUMPER ASSEMBLY OVERHAUL FACE BAR TYPE INCLUDED e Align to vehicle e Disassemble complete assembly e Emblem amp nameplate e Lamp e Lamps mounted in bumper e License plate bracket if attached e Molding amp impact strip e Reassemble complete assembly e Replace damaged parts DOES NOT INCLUDE e Energy absorber if mounted to frame rail all types Reverse sensor Stripe tape decals or overlays Trunk trim liner Valance panel spoiler REAR BUMPE
79. s fixed moveable attached e Headliner e Molding amp impact e Install bonded glass strip e Instrument panel R amp l e Rear bumper e Interior trim cover e Interior mirror DOES NOT INCLUDE Reveal moldings e Bumper brackets frame rail extensions if mounted to Seats R amp I frame rail e Steering column R amp I e Reinforcement impact bar if mounted to frame rail DOES NOT INCLUDE e Reverse sensor e Body side molding e Stripe tape decals or overlays e Brackets amp braces transfer e Trunk trim liner e Caulk seam sealer e Valance panel spoiler e Emblems amp nameplates e Exterior lamps e Foam e Front end sheet metal e Lock cylinder recoding e Pickup box set back e Remove bonded glass from damaged cab e Stripe tape decals or overlays e Sun roof G28 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING PICKUP TRUCK UNISIDE WITHOUT PICKUP TRUCK UNISIDE WITH SIDE OR CORNER PANEL SIDE OR CORNER PANEL SPECIAL NOTATION SPECIAL NOTATION When replacing welded door hinges add one half of the Door When replacing welded door hinges add one half of the Door Hinge R amp R time to Uniside R amp R time Hinge R amp R time to Uniside R amp R time INCLUDED INCLUDED e Adhesive application all
80. s been added to the bumper group INCLUDED e Align to vehicle e Emblem amp name plate e Energy absorber e Front bumper cover R amp R e Grille when mount ed to bumper e Lamp R amp I e Molding amp impact strip DOES NOT INCLUDE e Air bag sensor e Battery e Bumper brackets frame rail extensions if mounted to frame e Distance sensor e Lamp optnl equip e License plate bracket e Reinforcement impact bar if mounted to frame rail e Stripe tape decals or overlays Valance Panel spoiler when not mounted to bumper Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to FRONT BUMPER ASSEMBLY OVERHAUL COVER TYPE SPECIAL NOTATION The removal of mold release agents from and preparation priming of unprimed bumpers is required and is NOT INCLUDED Where the OEM has provided information regarding the availability of unprimed bumper covers an Add if Required labor operation has been added to the bumper group INCLUDED e Align to vehi cle e Disassemble complete assembly e Emblem amp nameplate e Energy absorber e Grille when mounted to bumper e Lamp Rel e Molding amp impact strip e Reassemble unit e Replace damaged parts DOES NOT INCLUDE e Aim lamps Air bag sensor Battery Bumper brackets frame rail extensions if mounted to frame rail Drill time Distance sensor
81. side panels or welds on the quarter panel INCLUDED e Disconnect and move box rearward e Move box forward and reconnect PICKUP TRUCK BOX ASSEMBLY SPECIAL NOTATION Some replacement components may or may not be supplied with duplicated OEM caulk seam sealer This is not included in R amp R time and requires an on the spot evaluation Be sure to itemize both outside and inside panel refinish times when applicable INCLUDED e Box R amp R e Bumper assembly R amp l Electrical wiring Fuel door Lamp License plate bracket Tailgate R amp l e Wheelhouse liner plastic DOES NOT INCLUDE e Accessory items Body side moldings Brackets braces amp supports transfer Emblems amp nameplates Fuel tank Stripe tape decals or overlays Undercoating amp sound insulation PICKUP TRUCK BOX FENDERS INCLUDED e Fender R amp R e Fuel door e Lamp e License plate bracket e Wheelhouse liner plastic DOES NOT INCLUDE e Body side moldings Brackets braces amp supports transfer Emblems amp nameplates Fuel tank Stripe tape decals or overlays DOES NOT INCLUDE e Fuel tank e Bumper R amp l G30 Footnotes found in a chapter contain vehicle specific information The content of footnotes is in addition to REV 5 11 and takes precedence over information in the Guide to Estimating pages for the operation indicated GUIDE TO ESTIMATING PICKUP TRUCK BOX SIDE PANELS INCLUDED e Adhesive applicatio
82. ss se ss we KEN G13 Clear Coat Finishes G36 Add If Required Go Healer secante G13 Clear Coat Undamaged Panel G36 Component Classification Ge MOOG cunnscsser sedas dan aba G14 Color Blend eee G37 A G5 Instrument Panel G18 De Nib amp Polish 639 Included and or Not Included Lamps Composite Type G14 Edges of New Parts G37 Ope ONS SEE OO cede G5 Lamps Sealed Beam Type G14 Panel and or Component NAGS oe Scot ER ETE AO IE G5 Lid Gale siese E WELEER ER Ad G24 Designation nunun G35 A obacccemecnandeeacnnsuseis G5 Pickup Truck Box Assembly G30 Refinish Overlap ooa aaaaa a G35 Overhaul ORE EE OR N EG G5 BOX Fonda sir AAR RE sees G30 Refinish Time Listings G34 at ep AA ER AE OR EE N GRS G5 BOX Front Panel See on HERE ES G31 Refinish Time Premise G34 si sons EE N OO EIE ET IE G5 Box Set Back isi snw AR EE sacs G30 Stone Chip Protective Material G38 SMS EE ER ONS N N EE G6 Box Side Panels sucesion G31 Three Stage Color Blend G37 Structural component identification G6 Box Vall Gates se AR ER RR eaves G31 Three Stage Finishes G36 Cab Assembly Skeleton G28 Two Tone Refinishing G38 SPECIAL PRECAUTIONS Cab Side Corner Back Panel G30 Undersides of Hoods Lids OOM su exe RE MOERASSE ee G19 or Gates c
83. surements are in millimeters Please refer to MOTOR Collision Repair Data manual or MOTOR E Frame Data on CD for complete vehicle dimension specifications All underhood illustrations used herein are copyrighted by Hein Werner Corporation Milwaukee Wisconsin and used with the permission of the copyright owner G4 REV 5 11 GUIDE TO ESTIMATING ADD IF REGUIRED MOTOR Collision Estimating Data is based on the base model vehicle configuration standard or regular production options and or standard replacement operations Add if required opera tions are for extra procedures necessitated by optional factory equipment or certain collision scenarios that may be encountered Add if required operations should be added to the estimate whenever applicable after an on the spot inspection of vehicle damage and or vehicle options COMPONENT CLASSIFICATION The purpose of classifying components is to describe physical properties of the component and classifications may inform the estimator that specialized technician skill levels and or tools may be required Indicators are not intended to determine labor rates charged or to be inclusive of all components Any additional com ponent classification s should be determined after an on the spot evaluation of required repair procedures CLASSIFICATION INDICATORS ARE PROVIDED FOR YOUR CONVENIENCE AND MUST ONLY BE CONSIDERED A HELPFUL GUIDE MOTOR component classifications are def
84. t panels up to foam tape overspray Mask glass opening e Mask protect grille radiator opening overspray e Remove masking COLOR BLEND Adjacent Panels Continued DOES NOT INCLUDE e Correction of pre existent surface imperfections Cover mask recessed edges jambs weatherstrips Damage repair Masking of attached parts Material costs R amp I of attached parts Wet sand and or buff for polishing EDGES OF NEW PARTS Edging SPECIAL NOTATION The following items or operations were not considered during the development of any published basic refinish operation times If any of these items or operations are required they should be considered by the estimator An additional paint mix is required if the edge color is a different color than the exterior body color Clear coat gloss or matte will be required for base color coat applications INCLUDED e Refer to specific parts text for estimated time allowance e Use full refinishing time NA TT ES dd m i 9 ES id se d E TT Ge without deduction for WN overlap N DOES NOT INCLUDE ss JY e Clear coat Uf e Color tinting SPY e Mixing a different edge color THREE STAGE COLOR BLEND Adjacent Panels SPECIAL NOTATION Calculations for blending are based upon the outer surface only and should not include additions for underside inside or edges of the blend panel There should be no overlap deduc tions between blend panel s r
85. ther names is being used on the dash panels floor panels and oil pans etc This product has an engineered non steel layer sandwiched between two cold rolled layers of steel do not use heat on this type of metal unless recommended by OEM It is used to help lower sound levels and vibration This product may or may not be weldable with common collision repair facility GMA MIG welding ULTRA HIGH STRENGTH STEEL UHS Generally door guard beams bumper reinforcements and other special purpose areas contain this type of steel These parts must not be repaired They are to be replaced only Contact the vehicle manufacturer for appli cable locations This information supersedes information pub lished in previous Guide to Estimating pages Note Due to space limitations special substrate metals information is not available in MOTOR CEG Online or DVD products STEERING COLUMN Many vehicle manufacturers use collapsible steering columns to absorb energy sustained from a collision impact These columns should be inspected for proper length binding and deformation among other specific considerations Failure to do so may prevent proper operation of steering column and or air bag deployment MOTOR recommends following vehicle manufacturer s guidelines for inspection and replacement of these components STONE CHIP GUARD Protective Material Vehicle manufacturers may apply a spray on chip resistant coating to protect the vehicle s finis
86. types e Adhesive application if required e Back panel trim all types E ge e Carpet amp insulation turn back e Back glass and moldings e Caulk seam sealer e Back panel trim e Center pillar trim four door models e Carpet amp insulation turn back e Cutting and welding as necessary e Caulk seam sealer E e Door striker e Center pillar trim 4 door models 5 e Front seat R amp I e Cutting and welding as necessary z e Grind fill amp smooth weld e Door striker Ss ed seams up to 150 grit e Front seat R amp l sandpaper e Grind fill amp smooth welded e Hinge pillar trim seams up to 150 grit e Jamb switches K J sandpaper e Rear seat R amp I e Hinge pillar trim e Roof drip rail moldings e Jamb switches e Seat belt anchor e Rear seat R amp l e Side panel trim e Seat belt anchor e Sill plates e Side glass amp moldings e Weatherstrips windlace e Side panel trim DOES NOT INCLUDE e Sill plates e Back glass and moldings e Weatherstrips e Body side moldings DOES NOT INCLUDE e Box set back e Body side moldings e Carpet amp insulation R amp l e Box set back e Control cables e Carpet amp insulation R amp l e Doors e Control cables e Door hinge e Doors e Electrical wiring e Door hinge e Emblems amp nameplates e Emblems amp nameplates e Fender e Fender e Fluid lines e Fluid lines e Foam e Foam e Instrument panel e Headliner e Road wheel e Instrument panel e Side glass amp moldings e Road wheel e
87. vehicle specific information The content of footnotes is in addition to G17 and takes precedence over information in the Guide to Estimating pages for the operation indicated XY Y Mu x a TT a O a a s Q 3 i GUIDE TO ESTIMATING SUSPENSION WHEEL ALIGNMENT Continued REAR WHEEL ALIGNMENT INCLUDED Align rear wheels Check and adjust tire pressure Check vehicle height amp thrust angle Check wheel size amp run out Remove vehicle from alignment equipment Road test vehicle Set up on alignment equipment amp normal wear diagnosis Shimming as required DOES NOT INCLUDE e Adjust vehicle height e Adjust brakes e Align front wheels e Alignment shim cost 4 WHEEL ALIGNMENT INCLUDED e Align front amp rear wheels Center steering wheel Check vehicle height amp thrust angle Check wheel size amp run out Check and adjust tire pressure Remove vehicle from alignment equipment Road test vehicle Set up on alignment equipment amp normal wear diagnosis Shimming as required DOES NOT INCLUDE e Adjust brakes e Adjust vehicle height e Alignment shim cost COWL HINGE PILLAR amp DASH PANEL INCLUDED e Adhesive application if required all types e Carpet amp mats turn back e Caulk seam sealer e Cowl side trim e Cutting amp welding as necessary e Grind fill amp smooth welded seams up to 150 grit sandpaper e Jamb switch e Sill plates e Weatherstrips COWL H

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