For every task in Non-Structural Analysis and Damage Repair, the following
safety requirement must be strictly enforced:
Comply with personal and environmental safety practices associated with clothing;
respiratory protection; eye protection; hand tools; power equipment; proper
ventilation; and the handling, storage, and disposal of chemicals/materials in
accordance with local, state, and federal safety and environmental regulations.
| II. NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR |
|
A. Preparation |
|
| 1. |
Review damage report and analyze damage to determine appropriate methods
for overall repair; develop repair plan. |
HP-G |
| 2. |
Inspect, remove, store, and replace exterior trim and moldings. |
HP-I |
| 3. |
Inspect, remove, store, and replace interior trim and components. |
HP-G |
| 4. |
Inspect, remove, store, and replace non-structural body panels and components
that may interfere with or be damaged during repair. |
HP-I |
| 5. |
Inspect, remove, store, and replace all vehicle mechanical and electrical
components that may interfere with or be damaged during repair. |
HP-G |
| 6. |
Protect panels, glass, and parts adjacent to repair area. |
HP-I |
| 7. |
Soap and water wash entire vehicle; use appropriate cleaner to remove
contaminants from those areas to be repaired. |
HP-I |
| 8. |
Remove corrosion protection, undercoatings, sealers, and other protective
coatings necessary to perform repairs. |
HP-I |
| 9. |
Inspect, remove, and replace repairable plastics and other components that are
recommended for off-vehicle repair. |
HP-G |
| 10. |
Apply safety procedures associated with vehicle components and systems such
as ABS, air bags, refrigerants, batteries, tires, oil, anti-freeze, engine coolants,
etc. |
HP-G |
| 11. |
Apply environmental practices associated with vehicle components and systems
such as substrates, fluids, refrigerants, batteries, etc. |
HP-G |
| II. NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR |
|
B. Outer Body Panel Repairs, Replacements, and Adjustments |
|
| 1. |
Determine the extent of direct and indirect damage and direction of impact;
develop repair plan. |
HP-I |
| 2. |
Inspect, remove and replace bolted, bonded, and welded steel panel or panel
assemblies. |
HP-I |
| 3. |
Determine the extent of damage to aluminum body panels; repair, weld or
replace in accordance with manufacturer's specifications. |
HP-G |
| 4. |
Inspect, remove, replace, and align hood, hood hinges, and hood latch. |
HP-I |
| 5. |
Inspect, remove, replace, and align deck lid, lid hinges, and lid latch. |
HP-I |
| 6. |
Inspect, remove, replace, and align doors, tailgates, hatches, lift gates, latches,
hinges, and related hardware. |
HP-I |
| 7. |
Inspect, remove, replace, and align bumper bars, covers, reinforcement guards,
isolators, and mounting hardware. |
HP-I |
| 8. |
Inspect, remove, replace and align front fenders, headers, and other panels. |
HP-I |
| 9. |
Straighten and rough-out contours of damaged panel to a surface condition for
body filling or metal finishing using power tools, hand tools, and weld-on pull
attachments. |
HP-I |
| 10. |
Weld cracked or torn steel body panels; repair broken welds. |
HP-I |
| 11. |
Restore corrosion protection. |
HP-I |
| 12. |
Cut out damaged sections of sheet steel body panels and weld in replacements
according to manufacturer/industry specifications. |
HP-I |
| 13. |
Replace door skins according to manufacturer's procedures. |
HP-G |
| 14. |
Replace or repair rigid, semi-rigid, and flexible plastic panels according to
manufacturer's/industry specifications. |
HP-I |
| 15. |
Restore sealers, sound deadeners, and foam fillers. |
HP-I |
| 16. |
Perform panel bonding. |
HP-G |
| 17. |
Diagnose and repair water leaks, dust leaks, and wind noise. |
HP-G |
| II. NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR |
|
C. Metal Finishing and Body Filling |
|
| 1. |
Remove paint from the damaged area of a body panel. |
HP-I |
| 2. |
Locate and reduce surface irregularities on a damaged body panel. |
HP-I |
| 3. |
Demonstrate hammer and dolly techniques. |
HP-I |
| 4. |
Heat shrink stretched panel areas to proper contour. |
HP-G |
| 5. |
Cold shrink stretched panel areas to proper contour. |
HP-G |
| 6. |
Mix body filler. |
HP-I |
| 7. |
Apply body filler; shape during curing. |
HP-I |
| 8. |
Rough sand cured body filler to contour; finish sand. |
HP-I |
| II. NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR |
|
D. Moveable Glass and Hardware |
|
| 1. |
Inspect, adjust, repair or replace window regulators, run channels, glass, power
mechanisms, and related controls. |
HP-G |
| 2. |
Diagnose and repair water leaks, dust leaks, and wind noises; inspect, repair, and
replace weather-stripping. |
HP-G |
| 3. |
Inspect, repair or replace, and adjust removable, manually or power operated
roof panel and hinges, latches, guides, handles, retainer, and controls of
sunroofs. |
HP-G |
| 4. |
Inspect, remove, reinstall, and align convertible top and related mechanisms. |
HP-G |
| II. NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR |
|
E. Metal Welding and Cutting |
|
| 1. |
Identify weldable and non-weldable materials used in collision repair. |
HP-I |
| 2. |
Weld and cut high-strength steel and other metals using manufacturer's
procedures. |
HP-I |
| 3. |
Determine the correct welder type, electrode, wire type, diameter, and gas to be
used in a specific welding situation. |
HP-I |
| 4. |
Set up welding equipment. |
HP-I |
| 5. |
Adjust the welder to "tune" for proper electrode stickout, voltage, polarity, flow
rate, and wire-feed speed required for the material being welded. |
HP-I |
| 6. |
Store, handle, and install high-pressure gas cylinders. |
HP-I |
| 7. |
Determine work clamp (ground) location and attach. |
HP-I |
| 8. |
Use the proper angle of the gun to the joint and the direction of the gun travel
for the type of weld being made in the flat, horizontal, vertical, and overhead
positions. |
HP-I |
| 9. |
Protect adjacent panels, glass, vehicle interior, etc. from welding and cutting
operations. |
HP-G |
| 10. |
Protect computers and other electronic control modules during welding
procedures according to manufacturer's specifications. |
HP-G |
| 11. |
Clean and prepare the metal to be welded, assure good metal fit-up, apply weld-
through primer if necessary, and clamp as required. |
HP-I |
| 12. |
Determine the joint type (butt weld with backing, lap, etc.) for weld being made
according to manufacturer's/industry specifications. |
HP-I |
| 13. |
Determine the type of weld (continuous, butt weld with backing, plug, etc.) for
each specific welding operation according to manufacturer's/industry
specifications. |
HP-I |
| 14. |
Perform the following welds: continuous, stitch, tack, plug, butt weld with
backing, and lap joints. |
HP-I |
| 15. |
Perform squeeze-type resistance spot welding according to
manufacturer's/industry specifications. |
HP-G |
| 16. |
Perform destructive tests on each weld type. |
HP-I |
| 17. |
Identify the causes of spits and sputters, burn through, lack of penetration,
porosity, incomplete fusion, excessive spatter, distortion, and waviness of bead;
make necessary adjustments. |
HP-I |
| 18. |
Identify cause of contact tip burn-back and failure of wire to feed; make
necessary adjustments. |
HP-I |
| 19. |
Identify cutting process for different materials and locations in accordance with
manufacturer's procedures; perform cutting operation. |
HP-G |
