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This Technical Information Bulletin replaces TI -
C - 61, B - 34 dated June 1995.
Time allowances and text have been changed (marked with
"C")
Subject:
Stone Chip Damage to the Outside Paint with 2 - coat
Metallic Paints and 2 - coat Pearlescent Paint in the Areas of the
Bonnet, Wing and Roof Panel.
Vehicles:
Vectra / Cavalier, Calibra, Omega - B
Condition:
Chipping of base coat in diameters of more than
2 mm / 0.08 in., allowing the light - coloured filler
coat under the base coat to become visible.
Remedy: C
Painting of the affected parts with stone chip damage of diameter
more than 2 mm / 0.08 in. Approval from the responsible
Field personnel must be obtained before commencing painting.
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Affected paint numbers / shades
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Paint number shade
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Veh. Ident. No.
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Veh. Ident. No.
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Z 96L *)
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Smoke grey
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Z 140 *)
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R1 050 119
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to
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S1 094 772
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Z 46L
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Jungle green
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Z 359
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R1 108 432
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to
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S1 092 471
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Z 69L
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Rioja red
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Z 568
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R1 108 432
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to
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S1 091 743
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Z 72L
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Marseilles red
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Z 549
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R1 050 119
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to
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S1 091 250
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Z 37L
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Neptune turquoise
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Z 357
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R1 050 119
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to
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S1 149 275 *)
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*) 2 - digit (1) or 3 - digit (2) paint
number on vehicle identification plate.
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Preparation of wing
Note:
I Calibra
II Vectra / Cavalier
III Omega - B
· Remove
attaching parts
· Remove
nameplate (A) (only Vectra / Cavalier, Calibra)
· Remove turn
signal lamps / headlamps (B) (only Vectra / Cavalier,
Omega - B)
· Cover or tape
over adjacent part / attaching parts before painting
Surface Sanding procedure
1 Sand off clear coat and base coat down to filler coat
2 Sand - flat clear coat and base coat in the
transitional areas
3 Sand - flat remaining surface (remove high spots)
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Preparation of roof panel
Note:
I Calibra
II Vectra / Cavalier
· Remove
attaching parts
· Remove root
antenna (A)
· Remove spoiler
roof (B)
· Remove roof
strips (C)
· Lift up trim
strips at windscreen and rear screen using Installer MKM - 847
· Cover or tape
over adjacent surfaces
Surface Sanding procedure
1 Sand off clear coat and base coat down to filler coat
2 Sand - flat clear coat and base coat in the
transitional areas
3 Sand - flat remaining surface (remove high spots)
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Preparation of roof panel
Note:
III Omega - B, Omega - B Estate
· Remove
attaching parts
· Remove roof
antenna (A)
· Remove rear
rain gutter trim strip (D)
· Remove C pillar
moulding (E)
· Remove roof
railing (F)
· Lift up trim
strips at windscreen and rear screen using Installer MKM - 847
· Cover or tape
over adjacent surfaces
Surface Sanding procedure
1 Sand off clear coat and base coat down to filler coat
2 Sand - flat clear coat and base coat in the
transitional areas
3 Sand - flat remaining surface (remove high spots)
On Saloon:
up to C pillar moulding (E)
On Estate:
up to upper edge of side panel window (D pillar)
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Procedure: C
(based on Paint System No. 2, according to current
"Paint Repair Systems" brochure)
· Clean parts with
silicone remover
· Prepare bonnet: On
entire bonnet, sand off clear coat and base coat down to light -
coloured filler coat
· Prepare roof panel and wing: see
pages 3 to 5
· Apply filler (for
bonnet, complete surface)
Apply filler to surfaces 1 and 2 (roof panel and wing)
Material: 2 -
C - priming filler CF (2 coats / setting time 3 minutes
each) or 2 - C - high build filler.
Filler coat thickness 50 to 80 %om
m
· Sand filled
surfaces
· Clean parts with
silicone remover
· Apply top
2 - coat base metallic (for bonnet, complete surface)
Apply top 2 - coat base metallic (roof panel and
wing on surfaces 1 and 2, mist coat on surface 3).
Application: pre -
spray 1 layer, finish with 2 further layers. Setting time: 15 minutes
before applying clear coat.
· Apply 2 - C
super clear coat (complete surface for all parts)
Application: pre -
spray 1 layer. Setting time 3 to 5 minutes. Finish with 2 further
layers.
Setting time before forced drying: 8 minutes.
· Install attaching
parts
Time Allowance
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Op. No.
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Operation
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Time Allow.
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W 1000 00 *)
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Vehicle from Parking Place to Workplace and Back
TC: 99
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.2
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001
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Add:
Conversion and distribution time supplement for attaching
parts (once only)
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.2
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*) Separate main operation, to be entered once per vehicle
with each placing of an order.
Vehicle type: Vectra / Cavalier
C
Time allowances for two - coat metallic
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TC: 92
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Main Operation
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Adjacent
Part **)
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Non- adjacent- Part **)
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Position No.
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Part Description
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Operation No.
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Model
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1
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Bonnet, outer
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T 03 66 00
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2.6
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1.5
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1.7
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6
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Wing
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T 03 65 00 r
T 03 65 10 l
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2.2
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1.2
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1.3
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19
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Vehicle roof
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T 03 67 00
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3.5
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-
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2.7
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**) Combined operations
Supplementary operations Vectra / Cavalier C
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Position No.
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Operation Number
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Operation
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Time Allow.
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Code
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1
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B - Bonnet
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40
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Total time allowance
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.1
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42
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R+R spray nozzles
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.1
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45
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R+R ornament
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.1
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6
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W - Wing
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40
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Total time allowance
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.1
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42
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R+R rubber buffer
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.1
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49
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R+R turn signal lamps
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.1
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54
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R+R protective trim strip
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.1
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44
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R+R nameplate
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[.1]
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19
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VR - Vehicle Root
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40
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Total time allowance
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.2
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86, 87
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.2
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88, 89
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44
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Lift rubber lip of windscreen and rear screen
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.2
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42
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Lift rubber lip of windscreen
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.2
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Vehicle type: Calibra C
Time allowances for two - coat metallic
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TC: 92
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Main Operation
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Adjacent
Part **)
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Non- adjacent- Part **)
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Position No.
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Part Description
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Operation No.
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Model
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1
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Bonnet, outer
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T 03 66 00
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2.8
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1.7
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1.9
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6
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Wing
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T 03 65 00 r
T 03 65 10 l
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2.0
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.9
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1.1
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19
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Vehicle roof
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T 03 67 00
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2.8
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-
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1.9
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**) Combined operations
Supplementary operations Calibra C
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Position No.
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Operation Number
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Operation
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Time Allow.
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Code
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1
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B - Bonnet
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40
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Total time allowance
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.1
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42
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R+R spray nozzles
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.1
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45
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R+R ornament
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.1
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6
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W - Wing
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40
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Total time allowance
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.1
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42
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R+R rubber buffer
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.1
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54
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R+R protective trim strip
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.1
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69
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R+R guide rail and support
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.1
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19
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VR - Vehicle Root
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40
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Total time allowance
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.4
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44
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Lift rubber lip of windscreen and rear screen
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.1
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47
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R+R cover strips
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.1
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61
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R+R antenna
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.3
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62
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R+R steel sun roof cover
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[.2]
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Vehicle type: Omega - B C
Time allowances for two - coat metallic C
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TC: 92
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Main Operation
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Adjacent
Part **)
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Non- adjacent- Part **)
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Position No.
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Part Description
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Operation No.
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Model
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1
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Bonnet, outer
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T 03 66 00
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2.8
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1.7
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1.8
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6
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Wing
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T 03 65 00 r
T 03 65 10 l
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2.1
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.8
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1.1
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19
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Vehicle roof
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T 03 67 00
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25, 26, 27
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4.8
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-
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3.9
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19
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Vehicle roof
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T 03 67 10
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21, 22, 23
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5.6
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-
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4.6
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**) Combined operations
Supplementary operations Omega - B C
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Position No.
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Operation Number
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Operation
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Time Allow.
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Code
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1
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B - Bonnet
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40
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Total time allowance
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.1
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42
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R+R spray nozzles
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.1
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6
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W - Wing
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40
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Total time allowance
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.2
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42
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R+R rubber buffer
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.1
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54
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R+R protective trim strip
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.1
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69
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R+R guide rail
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.1
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72
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Partially R+R gas spring
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.1
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51
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R+R headlamp
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[.2]
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19
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VR - Vehicle Root
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40
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Total time allowance
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.3 *)
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43
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Lift rubber lip of rear screen
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.1
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44
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Lift rubber lip of windshield
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.1
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52
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R+R drip rail trim strip
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.2
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25, 26, 27
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59
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R+R roof railing
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[1.2]
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21, 22, 23
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*) -: With model 21, 22, 23
R+R of side windows and drip
rail drim strip (not necessary)
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