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Undercoating –CheckList
Indicates critical itemhasprocess control
Unit # ___________ Box # ___________ Date ___________
Description.............................................................................................................................................................................................. Initials
1. Install rear door pin cover............................................................................................................................._____
2. ClampA/C and heater lines (Chev) ............................................................................................................._____
3. Drill holes and install rear bolts inbumper (Chev) ......................................................................................._____
4. Drill holes and install puck bolts by gas tank (Chev) ..................................................................................._____
5. Ifwelding is required, disconnect PCM, batteries, connectorsC210, C211, andC212andRCM _____
6. Ensure that framegrounds are tight, spray undercoatingover theseareas................................................_____
7. TapeA/C connections between cabandbox (PrestigeTape) ...................................................................._____
8. Install spare tirecarrier (if required)...................................................................................................._____
9. Install swaybar asper instructions (if required) ..............................................................................._____
10. Siliconeharness hole, seat baseholes and door pin covers......................................................................._____
11. Ensure all electrical connections arehookedup.........................................................................................._____
Undercoat Instructions .................................................................................................................................................................... Initials
1. Mask off outer edgeof box and cab: ..........................................................................................................._____
2. Mask off driveshaft andexhaust .................................................................................................................._____
3. Mask off rearmud flaps, areaaround tailpipeand fuel fill hoses................................................................._____
4. Tapeoff back –upalarm, battery box and gaps..........................................................................................._____
5. Sprayall areas of box floor excluding heat shields......................................................................................_____
6. Inspect for thinormissedareas..................................................................................................................._____
7. When complete pull off tapeand lower vehicle............................................................................................_____
8. Sprayexposedareas andbolts insidewheel wells ....................................................................................._____
9. Removeundercoat overspray from critical items (i.e. exhaust, drive shaft, exterior walls…etc) ................_____
COMPLIANCE
InspectionCriteria (Record deficiencies on aNCR) YES NO NA
1. Heater hoses aft of catalytic converter –minimum12 inches of clearance + heat shield+ loom............. .......... .........
2. Battery cables aft of catalytic converter –minimum12 inches of clearance + heat shield+ loom........... .......... .........
3. Box is visually square on the chassis....................................................................................................... .......... .........
4. Rear tires are centered in thewheel well (+/- 2 inches front to back and +/- 1 inch side to side)............. .......... .........
5. Rear bumper is square to thebody (+/-¼ inch tolerance allowed).......................................................... .......... .........
6. Make sure all mounting pucks are tight and compressed (torque topublished requirements)................. .......... .........
7. Check fuel tankmounting bolts installedand tight (torque topublished requirements)............................ .......... .........
8. Verify no bolts/screws areover/pointed toward the fuel tank(s), fuel filler(s), or vent hoses .................... .......... .........
9. Inspect for any screwholes and loose fasteners in the floor of frame...................................................... .......... .........
10. Make sure all tubing ends and screwholes are sealed............................................................................ .......... .........
11. Ensure that all door pin cover plates are installed.................................................................................... .......... .........
12. Ensure that all wires are cable tied .......................................................................................................... .......... .........
13. Ensureno kinks in fuel lines/filler hoses................................................................................................... .......... .........
NOTE: If a step is incomplete circle O the initial blank in red pen.
Thiswill be thenotification to thedownstreamwork center(s) that this stepstill needs tobe completed.