Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Contents
1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Working on the alignment frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Disassembly of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.6 Paintwork, glass, upholstery, trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.7 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.8 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.9 Fuel tanks and fuel-carrying lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.10 Safety instructions when performing repair work in bodyshells and liquefied petroleum gas
systems (LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.11 Safety measures when performing paint work on vehicles with a liquefied petroleum gas
system (LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.12 Electronic control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.13 Paintwork, glass, upholstery, trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.14 Airbag system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.15 Safety instructions for belt tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.16 Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Diagnosis of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Delivery condition of the bodyshell or individual parts for the paintshop . . . . . . . . . . . . . . 7
2.4 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Separation cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Welding of galvanized body panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Repairing higher-strength body panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.8 High-strength/ultra-strength, warm-formed body panels . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.9 Body Work - Glued joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.10 Removing underbody protection and sealing seams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.11 Bodyshell offcut sections and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.12 Original welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Explanation of drawings for welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Explanation of drawings for work procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Repairing the thread for the attachment of the assembly carrier . . . . . . . . . . . . . . . . . . . . 15
4.1 Repairing the thread for the attachment of the assembly carrier . . . . . . . . . . . . . . . . . . . . 15
4.2 Contents of the thread repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Drilling thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Cutting the thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5 Inserting the threaded insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 List of tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Contents i
General InformationBody Repairs, General Body Repairs - Edition 07.2014
ii Contents
General InformationBody Repairs, General Body Repairs - Edition 07.2014
1 Safety measures
(SKAH000002; Edition 07.2014)
⇒ “1.1 Safety instructions”, page 1
⇒ “1.2 Safety measures”, page 1
⇒ “1.3 Working on the alignment frame”, page 1
⇒ “1.4 Disassembly of parts”, page 1
⇒ “1.5 Battery”, page 1
⇒ “1.6 Paintwork, glass, upholstery, trims”, page 2
⇒ “1.7 Welding work”, page 2
⇒ “1.8 Air Conditioning”, page 2
⇒ “1.9 Fuel tanks and fuel-carrying lines. ”, page 3
⇒ “1.10 Safety instructions when performing repair work in body‐
shells and liquefied petroleum gas systems (LPG)”, page 3
⇒ “1.11 Safety measures when performing paint work on vehicles
with a liquefied petroleum gas system (LPG)”, page 4
⇒ “1.12 Electronic control units”, page 4
⇒ “1.13 Paintwork, glass, upholstery, trims”, page 4
⇒ “1.14 Airbag system”, page 4
⇒ “1.15 Safety instructions for belt tensioners”, page 4
⇒ “1.16 Warning signs”, page 5
1.5 Battery
The battery must be removed before performing welding work.
The battery must always be removed before performing any work
which induces sparking.
1. Safety measures 1
General InformationBody Repairs, General Body Repairs - Edition 07.2014
Note
Caution
Note
Note
An Air Conditioning unit which has been emptied may can only
be filled by a A/C service station. For this reason only empty the
Air Conditioning when required by the safety measures.
2 1. Safety measures
General InformationBody Repairs, General Body Repairs - Edition 07.2014
WARNING
WARNING
1. Safety measures 3
General InformationBody Repairs, General Body Repairs - Edition 07.2014
WARNING
4 1. Safety measures
General InformationBody Repairs, General Body Repairs - Edition 07.2014
WARNING
Note
1. Safety measures 5
General InformationBody Repairs, General Body Repairs - Edition 07.2014
2 Basic instructions
⇒ “2.1 Basic instructions”, page 6
⇒ “2.2 Diagnosis of accident vehicles”, page 6
⇒ “2.3 Delivery condition of the bodyshell or individual parts for
the paintshop”, page 7
⇒ “2.4 Alignment”, page 7
⇒ “2.5 Separation cuts”, page 7
⇒ “2.6 Welding of galvanized body panels”, page 7
⇒ “2.7 Repairing higher-strength body panels”, page 8
⇒ “2.8 High-strength/ultra-strength, warm-formed body panels”,
page 9
⇒ “2.9 Body Work - Glued joints”, page 9
⇒ “2.10 Removing underbody protection and sealing seams”,
page 10
⇒ “2.11 Bodyshell offcut sections and parts”, page 11
⇒ “2.12 Original welding”, page 11
⇒ “4.1 Repairing the thread for the attachment of the assembly
carrier”, page 15
6 2. Basic instructions
General InformationBody Repairs, General Body Repairs - Edition 07.2014
2.4 Alignment
The bodyshell and the body platform are manufactured from cold-
formed deep-drawing panels in series production. For this reason,
the reverse deformation must be done in the same way.
Note
When aligning kinks with sharp edges, there is a risk that the
panel will suddenly tear.
WARNING
Spot welding only results in the zinc layer burning off slightly in
the centre of the welding point and the protective zinc ring around
the welding point, which arises at the same time, protects against
corrosion. For this reason, this method is preferred to insert gas
seam welding.
2. Basic instructions 7
General InformationBody Repairs, General Body Repairs - Edition 07.2014
8 2. Basic instructions
General InformationBody Repairs, General Body Repairs - Edition 07.2014
Note
Painting
When a higher-strength panel is warmed too quickly by drying
radiation waves, it will expand. However, if the panel is firmly
connected with the trim panels underneath it by welding points or
bonding, dents arise at this points which continue to remain visible
after the panel has cooled down. For this reason, heat radiators
must only be brought slowly to max. heating level. Drying in the
drying booth can proceed without risk.
Note
2. Basic instructions 9
General InformationBody Repairs, General Body Repairs - Edition 07.2014
Note
10 2. Basic instructions
General InformationBody Repairs, General Body Repairs - Edition 07.2014
WARNING
2. Basic instructions 11
General InformationBody Repairs, General Body Repairs - Edition 07.2014
3 Explanation of symbols
⇒ “3.1 Explanation of drawings for welding work”, page 12
⇒ “3.2 Explanation of drawings for work procedures”, page 13
Gas arc quilting seam (where necessary, must be ground off flush
to the bodyshell contour)
Gas arc full seam (where necessary, must be ground off flush to
the bodyshell contour)
Brazing
Note
12 3. Explanation of symbols
General InformationBody Repairs, General Body Repairs - Edition 07.2014
3. Explanation of symbols 13
General InformationBody Repairs, General Body Repairs - Edition 07.2014
Glueing
Precision sealing
14 3. Explanation of symbols
General InformationBody Repairs, General Body Repairs - Edition 07.2014
Caution
Note
Note
Caution
Note
♦ Use for example the drilling machine - VAS 6267- for drilling
and milling.
♦ The drilling machine must be held by a second person with the
additional handle when drilling.
♦ Do not tilt the drill.
Caution
Wear safety goggles when cutting the thread and blowing out
the threaded bush.
Note
– Screw the threaded insert into the threaded plate until the
threaded insert is flush with the threaded plate on the outside
(visual inspection).
– Subsequently turn the threaded insert a further 1/4 turn to‐
wards the inside.
– Unscrew the installation spindle.
– Use the pin breaker for breaking the driver pin of the threaded
insert.
– Install assembly carrier (subframe) (tightening torques) ⇒
Axles, steering; Rep. gr. 40 .
5 Tools
⇒ “5.1 List of tools”, page 21
5. Tools 21