A. Preparation (7 questions)
1. Review damage report and replacement parts for accuracy. Inspect for prior damage and repairs. Inspect for 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. Research and determine repair plan, procedures, and methods of overall repairs in accordance with the vehicle manufacturer’s specifications and accepted industry procedures (including calibration/initialization of advanced vehicle systems).
4. Position vehicle to perform repairs; lift, raise, or support if necessary.
5. Remove damaged or undamaged interior and exterior trim and moldings/claddings as necessary; document missing or broken one-time use parts/fasteners/components, store removed parts/fasteners/components.
6. Remove and store undamaged, non-structural body panels and components and mechanical/electrical components that may interfere with or be damaged during the repair process.
7. Check for malfunction indicator lamp (MIL) illumination; scan all computer systems and retrieve codes and settings; identify battery disconnect procedures.
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 and other paint protection accessories); remove adhesives if necessary.
11. Remove corrosion protection, undercoatings, sealers, and other protective coatings as necessary to perform repairs.
12. Remove repairable plastics and other parts for off-vehicle repair.
13. Identify safety considerations: Personal Protection Equipment (PPE), shock hazards, fumes, safety data sheet (SDS), etc. before beginning any repair operation.
B. Outer Body Panel Repairs, Replacements, and Adjustments (17 questions)
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. Identify the body panel substrate (high-strength steel, aluminum, magnesium, composite, etc.), determine the extent of damage for reparability or replacement.
4. Remove, reinstall or replace, and adjust/align hood, hood supports, hood hinges, and hood latch/lock.
5. Remove, reinstall or replace, and adjust/align deck lid, lid hinges, supports, and lid latch/lock.
6. Remove, reinstall or replace and adjust/align doors, tailgates, hatches, supports, liftgates, latch/lock assemblies, handles, and hinges.
7. Remove, reinstall or replace, and adjust/align bumpers, brackets, reinforcements, guards, absorbers, isolators, and mounting hardware.
8. Remove, reinstall or replace and adjust/align front fenders; check and adjust gaps and clearances.
9. Remove, reinstall or replace and adjust/align exterior lighting and mounting panels.
10. Check outer body panel function, adjust as necessary for proper operation.
11. Restore contours of a damaged panel to a surface condition suitable for metal finishing or body filling.
12. Weld cracked or torn metal body panels.
13. Apply protective coatings to restore corrosion protection.
14. Remove damaged body panels; replace panels using a weld, weld-bond, adhesively-bonded, rivet, rivet-bond, or other fastening procedures.
15. Repair door frame, repair or replace door skins; inspect intrusion beams.
16. Restore seam sealers, mastic, sound deadeners, and foam fillers.
17. Diagnose and repair water leaks, dust leaks, wind noise, squeaks, rattles, and vibrations.
18. Install interior and exterior trim, pinstripes, emblems, decals (transfers/overlays, vapor barriers), and protective film.
19. Scan computer systems and verify proper system operation followng outer body panel repair, replacement or adjustment.
C. Metal Finishing and Body Filling (8 questions)
1. Remove paint and other coatings from the damaged area of a body panel.
2. Heat-shrink stretched panel areas to proper contour.
3. Cold-shrink stretched panel areas to proper contour
4. Metal-finish the damaged area of a body panel to eliminate surface irregularities.
5. Prepare surface for application of body filler material.
6. Mix, apply and shape body filler material.
7. Sand cured body filler material to contour.
D. Glass and Hardware (5 questions)
1. Inspect, adjust, remove and/or replace moveable, electrically-heated, stationary, mechanically-fastened, bonded, and hinged glass.
2. Inspect, adjust, repair, or replace window regulators, run channels, power mechanisms, and related controls. Reset automatic features and clear stored codes if necessary.
3. Inspect, adjust, repair, remove or replace power glass roof panels and related controls. Reset automatic features and clear stored codes if necessary.
4. Inspect, adjust, repair, remove, or replace removable, manually-operated glass roof panels and hardware.
5. Diagnose and repair water leaks, dust leaks, wind noises; rattles, and vibrations; inspect, repair, or replace weatherstripping.
6. Inspect, adjust, and install convertible or retractable roof and related mechanisms. Reset automatic features and clear stored codes if necessary.
7. Scan computer systems and verify proper system operation following stationary glass removal or replacement.
E. Welding, Cutting, and Removal (12 questions)
1. Identify weldable and non-weldable materials used in vehicle construction.
2. Identify the considerations for cutting, removing, and welding various types of steels, aluminum and other metals.
3. Determine the correct welding process to be used in specific welding situations: [compression/inverter/squeeze type resistance spot (STRSW), GTAW (TIG), GMAW (MIG), MIG-brazing]; determine settings, electrode, wire type, diameter, gas and bonding material to be used in specific welding processes.
4. Adjust the welding equipment for proper operation.
5. Perform test welds. Visually inspect, perform destructive test, and make adjustments as necessary.
6. Determine proper work clamp (ground) location.
7. Use the proper gun-to-joint angle, distance, speed, and direction of gun travel for welds being made in all positions.
8. Select proper STRSW arm set, electrode type and diameter, and settings based on the location and material to be welded.
9. Protect vehicle components (adjacent components, hybrid components, computers and other electronic modules) from possible damage caused by welding and cutting.
10. Clean or prepare the metal to be welded; ensure proper weld joint fit-up; apply weld through primer if required.
11. Select and prepare the correct joint type (butt, lap, etc.) for the repair.
12. Identify and perform the correct type of weld (continuous, stitch, tack, plug, spot, slot, etc.) for each specific welding operation.
13. Identify the causes of weld defects; perform required equipment maintenance and/or make necessary adjustments.
F. Plastic Repair (6 questions)
1. Identify the types of plastic(s) or composite(s); determine repairability.
2. Identify the proper plastic or composite repair/cleaning procedures; clean and prepare the surfaces of plastic or composite parts for repair.
3. Repair plastic parts by welding or using adhesive repair materials; repair composite parts using adhesive repair materials; use reinforcing materials as required.
4. Reshape plastic parts.
5. Perform single or two-sided repairs in plastic or composite panels.
6. Replace bonded plastic or composite body panels; straighten or align mounting locations.
7. Replace mechanically fastened plastic or composite body panels; straighten or align mounting locations if necessary; torque fasteners to specifications.