File Name:
QMS - UndercoatingChecklist r0.doc
ApprovedBy: ZK
DateCreated: October 2004
Last Revised:
RevApproval:
Master List of Controlled Documents
Page1 of 1
Current revisions are indicated.
Undercoating–CheckList
þ
Indicatescritical itemhasprocesscontrol
Unit #
___________
Box#
___________
Date
___________
Description
................................................................................................................................................................................................
Initials
1.
þ
If welding is required, disconnect PCM, batteries, connectors C210, C211, and C212 and RCM.........
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2. Prior to lifting unit - remove rivet studs (re: hinge installation) fromO2, side door and ECC door.............
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3. Ensure that frame grounds are tight, spray undercoating over these areas. ..........................................
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4. Tape A/C connections between cab and box (Prestige Tape) ...............................................................
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5.
þ
Install heat shield to cover wire loom from exhaust, front passenger side of box ................................
_____
6.
þ
Install spare tire carrier (if required) ...............................................................................................
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7.
þ
Install sway bar as per instructions (if required) ..............................................................................
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8. Silicone holewhere harnesses pass through the floor
þ
Undercoat Instructions
......................................................................................................................................................................
Initials
1. Mask off box accordingly: ..................................................................................................................
_____
2. Sides, gaps on running boards, gap between bumper and body, back-up alarm ....................................
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3. Sides of cab and wheel wells..............................................................................................................
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4. All areas of box floor excluding heat shields ........................................................................................
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5. Exposed bolts in conversionwheel well area.......................................................................................
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6. Stay away from exhaust & tailpipe (floor not to be undercoated in these areas) ....................................
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7. Inspect for thin or missed areas ..........................................................................................................
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8. When complete pull off tape and lower vehicle ....................................................................................
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9. Remove undercoat overspray from critical items (i.e. exhaust, drive shaft, etc)......................................
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COMPLIANCE
InspectionCriteria
(RecorddeficienciesonaNCR)
YES
NO
NA
1. Heater hosesaft of catalytic converter –minimum12 inchesof clearance+heat shield+ loom............... ........... ...........
2. Battery cablesaft of catalytic converter –minimum12 inchesof clearance+heat shield+ loom.............. ........... ...........
3. Box is visually squareon the chassis.................................................................................................................... ........... ...........
4. Rear tires are centered in thewheel well (+/- 2 inches front tobackand+/- 1 inch side to side)............... ........... ...........
5. Rear bumper issquare to thebody (+/-¼ inch toleranceallowed).................................................................. ........... ...........
6.
Make sure all mounting pucks are tight and compressed (torque to published requirements)
.. ........... ...........
7.
Check fuel tankmounting bolts installed and tight (torque to published requirements)
............... ........... ...........
8.
Verify no bolts/screws are over/pointed toward the fuel tank(s), fuel filler(s), or vent hoses
...... ........... ...........
9.
Inspect for any screw holes and loose fasteners in the floor of frame
................................................ ........... ...........
10.
Make sure all tubing ends and screw holes are sealed
........................................................................... ........... ...........
11.
Ensure that all door pin cover plates are installed
..................................................................................... ........... ...........
12.
Ensure that all wires are cable tied
................................................................................................................. ........... ...........
Undercoating InspectedBy
...................................................................................................................
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