ENGINEERING Material Specification
9984120
STANDARDS
Electrodeposition Primer – Cathodic ELPO for Small Parts
1 Scope
This specification covers the pretreatment, paint
materials and some processing requirements for
waterborne, black, cathodic electrodeposition
primers (ELPO or e-coat) generally used on small
parts. Paint durability requirements are also
included. Exterior body metal referenced to this
specification must meet the provisions outlined
under section 1.2, Typical Applications. These
requirements apply to ELPO coating applications
that require low, medium and high film thickness.
1.1 Material Description. This specification is
intended to assure that the ELPO materials used
on parts supplied to General Motors are high
quality and environmentally acceptable. Materials
containing lead or hexavalent chromium are no
longer acceptable on parts referenced to this
specification.
1.2 Typical Applications. This specification
covers parts that are ELPO coated outside of GM
Assembly Plants, including those parts that may
receive subsequent topcoats. These
requirements are primarily intended for parts that
would not be considered exterior body metal.
However, in some instances, replacement body
metal may be referenced to this standard. When
this occurs, the exterior body panels must be
coated using ELPO materials that are equivalent
to OEM body products. These ELPO’s will be
identified in the Comments section of materials
approved to, and listed in, MATSPC.
2 References
Note: Only the latest approved standards are
applicable unless otherwise specified.
2.1 External Standards/Specifications.
ASTM D523 SAE J2334
2.2 GM Standards/Specifications.
9984006 GM9511P
9984123 GM9535P
9984303 GM9540P
GM4350M GMW3001
GM9102P GMW3059
© Copyright 2005 General Motors Corporation All Rights Reserved
February 2005 Originating Department: North American Engineering Standards
Paint
3 Requirements
3.1 Pretreatment Requirements. Parts must be
cleaned and receive a phosphate pretreatment
using approved materials as shown in the GM
Corporate Materials File for spray or immersion
processes. Only phosphate materials approved to
GM Engineering Standard 9984123 (zinc
phosphate) or 9984006 (iron phosphate) may be
used. All requirements of 9984123 or 9984006
must be met. Processing parameters should
conform to those recommended by the chemical
suppliers. De-ionized (DI) or reverse osmosis
(RO) water rinses must be included and properly
maintained in order to meet the processing
performance requirements of this specification.
Alternate processes must receive Engineering
approval.
Note: Pretreatment systems that use primary
processing chemicals provided by more than one
supplier are unacceptable.
Note: All ELPO painted parts, both new and
carryover, must use a phosphate sealer /
passivation material approved to 9984303.
3.2 Repair Requirements. The baked ELPO
shall present a smooth, uniform surface. No
blisters, run-outs, rinsing residues, etc., are
acceptable. Defects in the ELPO coating that
require a repair must be moist sanded with P400
grit sandpaper. In the event of a cut-through to
bare metal or other signs of incomplete coating,
the repair area must be scuff sanded and then
rerun through the phosphate and ELPO system.
If a defect is present after the repair, the part
must be stripped completely to bare metal (if
applicable) or scrapped. Any other repair
procedure must receive Engineering approval
prior to use.
Craters are undesirable and indicate
contamination of the ELPO application and/or
cure process. When craters are evident, efforts
must be made to identify the source and mitigate
the contamination. Refer to the following
guidelines, Tables 1 and 2, when dealing with
craters. Each requirement relates to an area less
than or equal to 1 ft2.
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9984120 GM ENGINEERING STANDARDS

critical surfaces or as designated on the

Table 1: Cured ELPO Only Panels/Parts applicable engineering part drawing.
3.4.1 Appearance. The visual appearance of the
Number Size ELPO may be an indication of its durability.
<= 10 Small: <= 0.5 mm Visual inspection shall be performed in a well-lit
area prior to additional surface finishing.
<= 2 Large (or Fisheye): > 0.5 mm
3.4.1.1 Color. The color must be black unless
Table 2: Panels/Parts to be Subsequently otherwise designated on the engineering part
Topcoated drawing.
Number Size 3.4.1.2 Gloss. If a particular gloss is required, it
should be specified on the engineering part
<= 5 Small: Capable of being drawing. Reference ASTM D523.
covered by subsequent 3.4.1.3 Surface Quality. On finished
coating. panels/parts, the baked ELPO shall present a
0 Large (or Fisheye): Visible smooth, uniform surface.
under subsequent coating. 3.4.2 Film Thickness. The required thickness
range should be called out on the appropriate
Note: Large or fisheye craters must be sanded or
engineering part drawing. However, if it is not,
leveled prior to subsequent coating.
refer to Table 3 below.
3.3 Performance Requirements. Unless
Table 3: Film Thickness Requirements
otherwise noted, all generic approvals are to be
completed using multiple substrate materials: hot Application Film Thickness
rolled steel, cold rolled steel, galvanneal, (microns)
aluminum, and either electrogalvanized steel or
hot dipped galvanized steel. Interior and Lower Target: 15, Minimum:
Performance Area 10
3.3.1 Finish Durability. Parts shall meet the
requirements shown in GM4350M, Class A336, Underbody, Underhood, Target: 20, Minimum:
unless otherwise noted on the engineering part Exterior 15
drawing.
Exterior Body Panel Target: 20, Minimum:
3.3.2 Throw Box, GM9535P. Test panels must 17.5, Maximum: 30
exhibit a minimum of 300 mm of throw measured
as the distance from the immersed opening to the Interior Cavities Minimum: 10
first point where 2.54 microns of dry film ELPO is Note: High build ELPO materials should be used
present. This test is to be done during the initial when high film thickness is required.
material approval process.
3.3.3 Cyclic Corrosion. Field correlative cyclic 4 Manufacturing Process
corrosion testing is required. Test parts or test
panels are to be scribed following GM9102P and Not Applicable
then GM9540P or SAE J2334 may be used to
determine the predictive general corrosion 5 Rules and Regulations
performance of test samples. Materials must 5.1 All materials supplied to this specification
pass duration C of GM9540P when tested to this must comply with the requirements of GMW3001,
specification. Unless otherwise noted, pass Rules and Regulations for Material
criteria is to be 6 mm maximum creepback on Specifications.
cold rolled steel (CRS) and cast iron panels/parts. 5.2 All materials supplied to this specification
Pass criteria is 3 mm maximum creepback for all must comply with the requirements of GMW3059,
other panel/part substrates after duration C of Restricted and Reportable Substances for
GM9540P or 5 year equivalent SAE J2334. SAE Parts.
J2334 can be used provided GM9540P coupon
mass loss requirements are met.
3.4 Painted Product Requirements. When
applied over cleaned and phosphated surfaces of
production parts, properly cured cathodic ELPO
shall meet the following requirements on all
© Copyright 2005 General Motors Corporation All Rights Reserved

Page 2 of 3 February 2005

GM ENGINEERING STANDARDS 9984120

6 Approved Sources 8 Release and Revisions

Engineering qualifications of an approved source 8.1 Release. The specification was first approved
is required for this specification. Only sources and released in November 1989.
listed in the GM Materials File (i.e., MATSPC) 8.2 Revisions
under this specification number have been
qualified by engineering as meeting the Rev Approval Description (Organization)
requirements of this specification. Date
6.1 Source Shipment Responsibility. It will be H APR 2002 Revisions to section 3 and 6
the responsibility of the supplier to insure that the (Applied Parts Specialist
material is not exposed to temperatures during Team)
shipment that would cause the material to fail to
meet any of the requirements of this specification. I JAN 2005 Complete Revision (Applied
Parts Specialist Team)
7 Coding System
This material specification shall be referenced in
other documents, drawings, VTS, CTS, etc. as
follows:
Cathodic ELPO per 9984120, minimum 15
microns film thickness.

© Copyright 2005 General Motors Corporation All Rights Reserved

February 2005 Page 3 of 3