CRT 1030 - Non-Structural Analysis and Damage Repair

NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR (BODY COMPONENTS)

A.  Safety Precautions

1. Select and use proper personal safety equipment; take necessary precautions with hazardous operations and materials in accordance with federal, state, and local regulations.  HP-I
2. Locate OEM procedures to identify material and composition of the vehicle being repaired (mild steel, high strength steel, ultra-high strength steel, aluminum, etc.). HP-I
3. Locate procedures and precautions that may apply to the vehicle being repaired.  HP-I
4. Identify vehicle system precautions and/or inspections to include but not limited to supplemental restraint system (SRS), advanced driver assistance systems (ADAS), hybrid/electric/alternative fuel vehicles), locations and recommended procedures before inspecting or replacing components.  HP-I
5. Perform vehicle clean-up; complete quality control using a checklist on operations performed.   HP-I

B. Preparation

1. Review damage report and analyze damage to determine appropriate methods for overall repair; develop and document a repair plan.  HP-I
2. Inspect, remove, protect, label, store, inventory, and reinstall exterior trim and moldings.  HP-I
3. Inspect, remove, protect, label, store, inventory, and reinstall interior trim and components.  HP-I
4. Inspect, remove, protect, label, store, inventory, and reinstall body panels and components that may interfere with or be damaged during repair.  HP-I
5. Inspect, remove, protect, label, store, inventory, and reinstall vehicle mechanical and electrical components that may interfere with or be damaged during repair.  HP-G
6. Protect panels, glass, interior parts, and other vehicles adjacent to the repair area.  HP-I
7. Soap and water wash entire vehicle; complete pre-repair inspection checklist.  HP-I
8. Prepare damaged area using water-based and solvent-based cleaners. HP-I
9. Remove corrosion protection, under coatings, sealers, and other protective coatings as necessary to perform repairs.  HP-I
10. Inspect, remove, and reinstall repairable plastics and other components for off-vehicle repair. HP-I

C. Outer Body Panel Repairs, Replacements, and Adjustments

1. Inspect/locate direct, indirect, or hidden damage and direction of impact. HP-I
2. Inspect, remove and replace welded steel panel or panel assemblies.  HP-G
3. Determine the extent of damage to aluminum body panels; repair or replace.  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, latches, hinges, and related hardware.  HP-I
7. Inspect, remove, replace and align tailgates, hatches, liftgates and sliding doors.     HP-G
8. Inspect, remove, replace, overhaul and align bumpers, covers, reinforcements, guards, impact absorbers, and mounting hardware.  HP-I
9. Inspect, remove, replace and align fenders, and related panels. HP-I
10. Restore corrosion protection during and after the repair.  HP-I
11. Replace door skins. HP-G
12. Restore sound deadeners and foam materials. HP-G
13. Perform panel bonding and weld bonding.  HP-G
14. Diagnose and repair water leaks, dust leaks, and wind noise.  HP-G
15. Identify one-time use fasteners.  HP-G
16. Weld damaged or torn steel body panels; repair broken welds.  HP-G
17. Inspect, identify labels/decals and replace as necessary. HP-G        

D. Plastics, Adhesives, and Welding

1. Identify the types of plastics; determine repairability.  HP-I
2. Clean and prepare the surface of plastic parts; identify the types of plastic repair procedures.  HP-I
3. Repair rigid, semi-rigid, and flexible plastic panels.  HP-I
4. Remove, replace, or repair damaged areas of rigid exterior composite panels.  HP-G
5. Replace bonded rigid exterior composite body panels; straighten or align panel supports.  HP-G 
6. Repair plastic parts by welding (nitrogen airless) HP-G
7. Perform a single sided adhesive bonded cosmetic repair. HP-I
8. Perform a double sided adhesive bonded repair. HP-I
9. Perform an adhesive bonded or welded tab repair.  HP-I
10. Shape and reform damaged plastic. HP-G