Part One
1st Year Intermediate Technology
Table of Class and Practical Course Contents
COLLISION REPAIR AND REFINISH STUDY GUIDE
A. Preparation
1. Review damage report and replacement parts for accuracy; analyze damage to determine appropriate methods for overall repair. Inspect for prior damage and verify proper systems operation.
2. Identify potential health, safety, and environmental concerns associated with vehicle components and systems, i.e. ABS, air bags (SRS), refrigerants, hybrid electric vehicles, coolants, etc.
3. Determine repair procedures in accordance with the vehicle manufacturers’ specifications and industry procedures.
4. Position vehicle to perform repairs; lift or raise if necessary.
5. Remove damaged or undamaged interior and exterior trim and moldings as necessary; document missing or broken parts/fasteners, store removed parts/fasteners.
6. Remove undamaged, non-structural body panels and components that may interfere with or be damaged during repair.
7. Remove all vehicle mechanical and electrical components that may interfere with or be damaged during repair. Retrieve codes and settings, disconnect battery if necessary.
8. Protect panels and parts adjacent to repair area to prevent damage during repair.
9. Remove dirt, grease, wax, and other contaminants from areas to be repaired.
10. Remove pinstripes, emblems and decals (transfers/overlays, wood grains), if necessary.
11. Remove corrosion protection, undercoating, sealers, and other protective coatings as necessary to perform repairs.
12. Remove repairable plastics and other parts that are recommended for off-vehicle repair.
13. Identify safety considerations: Eye protection, proper clothing, respiratory protection, shock hazards, fumes, material safety data sheet (MSDS), etc. before beginning any repair operation.
B. Outer Body Panel Repairs, Replacements, and Adjustments
1. Determine the extent of the direct (Primary) and indirect (Secondary) damage and the direction of impact; plan the methods and order of repair.
2. Remove and replace bolted, riveted, adhesive/bonded, and welded panels or panel assemblies.
3. Determine the extent of damage to substrate (aluminum, magnesium, and composite) body panels; repair or replace.
4. Remove, replace, and align hood, hood hinges, and hood latch/lock.
5. Remove, replace, and align deck lid, lid hinges, and lid latch/lock.
6. Remove and replace doors, tailgates, hatches, lift gates, latch/lock assemblies, and hinges.
7. Remove, replace, and align bumpers, reinforcements, guards, absorbers, isolators, and mounting hardware.
8. Check and adjust clearances of front fenders, headlight mounting panel, and other panels.
9. Check door fit and function, adjust or replace as necessary, and adjust door clearances.
10. Restore contours of damaged panel to a surface condition suitable for metal finishing or body filling.
11. Weld cracked or torn metal body panels.
12. Apply protective coatings and sealants to restore corrosion protection.
13. Remove damaged sections of metal body panels; weld, adhesively-bonded, rivet, in replacements.
14. Repair door frame, repair or replace door skins; inspect intrusion beams.
15. Restore sealers, mastic, sound deadeners, and foam fillers.
16. Diagnose and repair water leaks, dust leaks, wind noise, squeaks, and rattles.
17. Install interior and exterior trim and moldings.