General Information On Body Repair - AH60.00-P-0001-01FF
MODEL 451.3/4, 453, 454.0
Basic requirements
Basis for correct execution of all body work is:
- Use of original replacement parts.
- Strict observance of guidelines for body work.
- Workshop equipped with suitable special tools and workshop equipment.
Notes on repair method
Repair of damaged body panels is one of the most economical and time-saving measures and is preferable to replacing assemblies.
A precise check should always be made to determine which repair procedure is most economical.
Repair should always be considered to be the "first choice", because this has the least effect on the strength, dimensional accuracy and corrosion resistance, etc. achieved at the factory.
Corrosion protection
After painting, treat areas affected by repair with appropriate corrosion protection measures (e.g. wax, cavity preservation agent, underbody protection, etc.).
Labor protection
Observe legal accident prevention regulations of professional societies and appropriate safety precautions contained in the applicable service literature strictly.
Labor protection equipment
In addition to personal occupational clothing, cap and safety shoes also wear work gloves, eye protection, ear protection, dust protection mask, etc. during the work as required for the conditions.
Battery
Before performing any type of welding work or other work causing sparks in the area of the starter battery, always remove the battery and store in a protected location.
Components
During repair work following accidents, visually check electronic components, steering and seat belts.
Drilling, sawing
Remove electronic cables and lines installed in hollow cavities as well as reservoirs located in concealed locations (e.g. battery) or electronic components from hazard area before drilling or sawing.
Vehicles
Shield vehicles located in the body repair area against possible damage to paint and glass surfaces as well as fire hazard from flying sparks using dividing walls or cover with fire-resistant tarp.
Lifting platform
The vehicle can fall off the lifting platform due to weight displacement caused by removed parts (e.g. engine, shafts, etc.). Secure vehicle or add sand bags to compensate the weight.
Air conditioning (on vehicles with code (I01) Air conditioning Plus)
Do not weld or perform similar types of work on components in the closed air conditioning system or in its immediate vicinity.
Metal chips
Do not blow away metal chips produced during and after chip producing bodywork with compressed air; remove with vacuum cleaner.
Engine and auxiliary assemblies
Before performing any type of machining work on the body (e.g. with ball cutter), cover engine, including all additional equipment (e.g. alternator, solenoids, etc.) to prevent damage from metal chips.
Straightening work
When performing straightening work never stand in a direct line in front of the pulling chains when introducing straightening forces to the frame or body.
Secure pull chains with catch cables or chains to prevent it from snapping away.
Check notes on straightening and reshaping work as well as locating holes. If necessary, detach body from straightening bench and realign.
Welding and related work
During all welding work, observe accident prevention regulations for welding, cutting and related types of work.
Before performing electric welding work, also observe safety precautions for electronic control units.
Moreover, remove easily combustible and flammable materials and liquids from the hazard area.
Use shields to protect against flying sparks and heat radiation and protect electric cables and piping installed in cavities.
When spot welding, maintain a spot weld interval of approx. 20 mm. Clean, smooth electrode tips are required. Set the current time or power according to the sheet metal thickness (new part) on the spot welder.
Sectional repairs
We recommend the following procedure for repairing body sections or sectional repairs:
Do not grind down flat or smooth inert gas welds not located in the immediate visible area or covered by assembly parts or after completing vehicle due to reasons of durability and costs.
Welding vapors
Evacuate noxious gases, vapors, dust and welding smoke in the area where these occur.
Welding procedures, connections and symbols
- MAG welding
- Continuous weld
- Continuous weld interrupted
- Tack weld
- Plug weld
- Continuous weld
- Brazing
- Resistance spot welding
- Single-row spot weld
- Double-row spot weld
- Double-row spot weld offset
Assembly examples for spot welding fittings