Remove, Repair, And Install Metal Panels And Components Flashcards
The typical measurement standard for panel gaps and flushness is:
- 12-18mm for panel gaps and 0-2mm for flushness
- 8-12mm for panel gaps and 0-2mm for flushness
- 3-8mm for panel gaps and 0-2mm for flushness
- 0-2mm for panel gaps and 3-8mm for flushness
3-8mm for panel gaps and 0-2mm for flushness
An incorrect panel gap can cause all of these EXCEPT:
- poor fuel economy
- water leaks
- wind noise
- damage to the finish
Poor fuel economy
What is the proper sequence for aligning a hood?
- Aligning the doors to the quarter panel, then align the fenders to the doors followed by aligning the hood to the fenders
- align the hood to the left fender, then to the right fender
- align fenders to bumper then align the hood to fenders
- align the fenders to the doors then align the hood to the fenders
Align the doors to the quarter panels, then align the fenders to the doors followed by aligning the hood to the fenders
When fitting a bolted panel, a helpful tip is to:
- align for flushness and then for correct panel gaps
- tighten the front bolts first
- tighten on old placement marks first.
- tighten the rear bolts first
Tighten on old placement marks first
When aligning a series of bolted panel, start with:
- the forward most panel
- the panel closet to the nearest undamaged welded panel
- the panel closet to the damaged area
- the first panel damaged in the collision
The panel closest to the nearest undamaged welded panel
All can be used to protect adjacent panels and glass from damage when removing a panel EXCEPT:
- liquid masking
- spark deflection
- duct tape
- blankets
Liquid masking
Tech A says that fasteners that are removed and can be reused for installation can be labelled and stored in clear plastic
Tech B says that damaged fasteners should replaced with the same size and shapes fastener as the original.
- A
- B
- Both
- Neither
Both
Replacement parts should be checked upon delivery for all EXCEPT:
- same design and mounting location
- same holes and openings
- shipping damaged
- galvanic coating application
Galvanic coating application
Recycled parts should be inspected for corrosion, minor damage, and improper previous repairs upon delivery of the part
True
False
True
What is the ideal method for bolted on panel alignment
- bending
- adjusting
- shimming
- jacking
Adjusting
When is it acceptable to use shims on unibody vehicle
- when adjusting the radiator core support
- never
- when replacing OEM shims
- whenever required
When replacing OEM shims
Where do manufacturers often use caged plates for adjustments
- Door strikers
- Seat belts anchor
- Seat tracks
- Fender bolts
Door strikers
What panel is NOT adjustable
- fender
- rockers
- door
- hood
Rockers
What way will the back of a door move if a block of wood is placed in the crotch of the lower hinge and pressure is applied
- out
- in
- up
- down
Up
A bumper reinforcement may be constructed with all of these materials EXCEPT:
- plastic composite
- high density wood
- steel
- aluminum
High density wood
Tech A says bumper energy absorbers are only located between the bumper reinforcement and the vehicle structure.
Tech B says energy absorbers are designed to ensure the vehicle does not sustain noticeable damage when impacted at less than 4 KPH ( 2.5mph ).
- A
- B
- Both
- Neither
B
Tech A says face bar type bumpers where ONLY used on full frame vehicle.
Tech B says plastic bumper covers are not used on full frame vehicles.
- A
- B
- Both
- Neither
Neither
All are consideration when adjusting a steel bumper EXCEPT:
- inspect the gaps from the bumper to the fenders, headlamps and grill
- it may be necessary to adjust a bolted radiator core support for proper bumper alignment
- an assistant may be helpful for raising and lowering the bumper while tightening
- filler or closeout panels should be removed for access during the installation
Filler or closeout panels should be removed for access during the installation
All of these are designs of energy absorbers EXCEPT:
- piston type
- plastic egg crate
- rigid foam
- pneumatic
Pneumatic
Tech A says crush boxes are designed to return to their original shape after an impact
Tech B says bumper energy absorbers are part of the vehicles energy management and safety restraint systems
- A
- B
- Both
- Neither
B
Tech A says bumper reinforcements that are visible through the bumper cover or fascia may require refinishing
Tech B says a bumper cover should be permanently installed on the vehicle prior to refinishing
- A
- B
- Both
- Neither
A
Tech A says that the fenders should be protected when installing a steel front bumper.
Tech B says that help from an assistant will help prevent damage to adjoining panel when removing a bumper
- A
- B
- Both
- Neither
Both
A negative flushness condition between a front fender and a door would mean the fender is:
- higher than the door
- in from the door
- sticking out from the door
- lower than the door
In from the door
Tech A says that the gaps on the undamaged opposite side of the vehicle should be used from comparison.
Tech B says that gaps will NOT affect the appearance of the vehicle
- A
- B
- Both
- Neither
A
The fender to hood gaps on a body over frame vehicle are wide at the front on both sides of the vehicle. In order to correct this condition the technician should:
- move the radiator core support until the fender gaps are consistent
- move the hood latch toward the centre of the vehicle
- adjust both fenders in until the gaps are consistent
- adjust the hood until the gaps are consistent
Adjust both fenders in until the gaps are consistent
Tech A says that labels on the inside of a hood should be removed and applied to the new hood.
Tech B says that new labels should be applied to match the ones on the damaged part
- A
- B
- Both
- Neither
B
The safety stops on a hood are used to
- keep the hood from hitting the fenders
- make adjustment easier
- prevent the hood from entering the passenger compartment.
- raise the hood for correct panel flushness
Prevent the hood from entering the passenger compartment
When the latch is installed, the front fender to hood gaps get tight on the driver side and wide on the passenger side. The likely cause is the
- hood is too far forward to the passenger side
- latch is positioned too far to the driver side
- radiator core support needs adjustment
- latch is positioned too far to the passenger side.
Latch is positioned too far to the driver side
When replacing a composite body panel, all of these should be considered EXCEPT:
- install the fasteners in the correct sequence
- use the correct fastener
- torque the fasteners with torque wrench
- use an air power ratchet
Use an air powered ratchet
Tech A says that a door check strap is used to hold a door open.
Tech B says that’s a door check strap will prevent a door from opening too far
- A
- B
- Both
- Neither
Both
Door adjustments on a pillar-mounted hinge include all of these EXCEPT:
- Upward or downwards
- for consistent gaps
- forward or rearward
- inward or outward
Inward or outward
Door adjustment on a door mounted hinge include all of these EXCEPT:
- Inward or outward
- for consistent flushness
- forward or rearward
- upward or downward
Forward or rearward
Tech A says that riveted hinges can be repaired by replacing the pin and bushing
Tech B says that riveted hinges should be replaced when worn
- A
- B
- Both
- Neither
B
Tech A says that a door handle may be connected to the latch with steel linkages.
Tech B says that’s the lock cylinder may be in the door handle
- A
- B
- Both
- Neither
Both
The purpose of a plunger pin is to
- carry electricity to the sliding door
- retain the lock cylinder
- align the panel
- retain the door handle
Carry electricity to the sliding door
The sliding door on a can is attached to the body with
- rollers
- rivets
- welds
- adhesive
Rollers
Tech A says that a child lock mechanism is used to prevent the door from opening from the outside of the vehicle
Tech B says that’s a door latch usually has two positions, pre latch and latched,
- A
- B
- Both
- Neither
B
Moving a door striker can be used to
- adjust the flushness
- raise the door
- move the door forward
- lower the door
Adjust the flushness
Tech A says that masking tape can be used to protect adjacent panels when removing door shell.
Tech B says that’s paint chipping at the edge of panel may be caused by panel misalignment
- A
- B
- Both
- Neither
Both
When replacing a bolted on composite quarter panel, use
- rivets
- seam sealer
- shouldered bolts
- adhesive
Shouldered bolts
Typically, all are used to hold open deck lids EXCEPT:
- springs
- torsion spring
- piston type struts
- prop rods
Prop rods
A tailgate on an early model SUC may have torsion spring to
- keep the gate close
- make it easer to open and close
- keep the gate open
- aid in the alignment of the movable glass
Make it easier to open and close
Straps or cables are used on pickup tailgate to
- make it easier to open and close
- keep the gate closed
- secure cargo
- keep the tailgate from opening too far
Keep the tailgate from opening too far
Tech A says that a tailgate may have a latch on both side
Tech B says that’s tailgates contain stationary glass
- A
- B
- Both
- Neither
A
Tech A says that a water leak can be simulated with a high pressure washer
Tech B says that when performing a water hose test, the water should be sprayed starting on the roof of the car and working down
- A
- B
- Both
- Neither
Neither
A suds test uses soapy water to
- clean the area of the suspected leak
- wash the vehicle
- identify where the air is leaking
- lubricate the weatherstripping
Identify where the air is leaking
All are done when performing an air pressure test EXCEPT:
- using the vehicle’s ventilation fan to create positive air pressure
- masking the air pressure relief valve
- using a listening device to hear air escape
-using an air pressure to spray air at the suspected leak area
Using an air blower to spray air at the suspected leak area
An ultrasonic leak detector uses
- infrared light to locate leaks
- laser beam to locate leaks
- sound waves to locate leaks
- ultraviolet light to locate leaks
Sound waves to locate leaks
Tech A says that an air leak may be located with a paper test
Tech B says that the paper should have some resistance when removed from between the panel body structure
- A
- B
- Both
- Neither
Both
An example of corrosive hot spot is an area
- where the finish has been broken
- where corrosion protection has been reapplied
- with excessive paint build
- with excessive clearcoat
Where the finish has been broken
Which of these is applied at the steel mill to provide corrosion protection
- zinc
- aluminum
- phosphate
- copper
Zinc
Tech A says that not restoring corrosion protection could result in a repair comeback
Tech B says that not restoring corrosion protection could result in failure of the vehicle structure
- A
- B
- Both
- Neither
Both
Which of these is considered to be “self-sacrificing “?
- e coat
- undercoating
- galvanized zinc
- cured primer
Galvanized zinc
E coat is applied at the steel mill
True
False
False
Weld through primer
- melts and is drawn to coat the welded joint as it cools
- used to fill minor scratches prior to topcoating
- is applied to hot welds to ensure weld defects do not corrode
- is used yo protect exposed interior surface from corrosion
Melts and is drawn to coat the welded joint as it cools
All describes adhesive bonding materials EXCEPT:
- provide adhesion between the metal and topcoat
- contain corrosion inhibitors
- used for structural and non-structural components
- used to join mating flanges
Provide adhesion between the metal and topcoat
All describe purpose for joint and seam sealers EXCEPT:
- seal out moisture and contaminants
- provide protection from UV light.
- prevent fumes from entering the passenger compartment
- reduce wind and road noise
Provides protection from UV light
Which one of these following corrosion protection materials spreads after it is applied
- weld through primer
- spray able seam sealer
- Anti corrosion compound
- textured undercoating
Anti corrosion compound
All describe OEM warranties EXCEPT
- cover surface corrosion for OEM finish
- cover collision repaired parts
- may not not cover underbody corrosion
- are time limited
Cover collision repaired parts
Repair shop are obligated to provide warranties for repairs and may be backed by limited lifetime warranties from paint manufacturers
True
False
True
Typically, the point of impact ( POI )
- is the most difficult to analyze
- is the highest point of the damage
- is described as indirect damage
- is described as direct damage
Is described as direct damage
Tech A says that a crease is an example of compressed metal
Tech B says that displaced metal is an area of direct damage
- A
- B
- Both
- Neither
Neither
Tech A Says that a cloth placed over a hand can used to help identify high and low spots
Tech B says that a body file can used to help identify high identify high and low spots
- A
- B
- Both
- Neither
Both
Newton’s law of motion explains that interim is often causes secondary or indirect damage to occur
True
False
True
All are general guideline to follow when using a body hammer EXCEPT:
- begin by striking softly, using increasingly stronger blows
- keep the face of the hammer flush with the surface of the panel
- space the blow about 10-13mm ( 3/8-1/2” ) apart
- swing with the whole arm and shoulder
Swing with the whole arm and should
Tech A says a body hammer can be used to strike a spoon when indirect hammer blows are needed
Tech B says marks on the face of the hammer can imprint on the sheet metal when it is struck with the hammer
- A
- B
- Both
- Neither
B
All should be considered when selecting which dolly to use EXCEPT:
- the weight of the dolly
- the brand of the dolly
- the contour of the panel
- the ability to balance the dolly to distribute the weight properly
The brand of the dolly
Tech A says a dolly can be used to deliver moderate blows during initial straightening
Tech B says a dolly should only be used on the back side of the panel
- A
- B
- Both
- Neither
A
Tech A says hammer and dollying may include hammer on dolly and hammer off dolly technique
Tech B says a combination of hammer on dolly and hammer off dolly techniques may be needed to return the panel to its original contour
- A
- B
- Both
- Neither
Both
All apply when using the hammer off dolly technique EXCEPT:
- should create a high pitched “ping” sounds
- the pressure that is used to hold the dolly against the panel affects the amount that the metal will move
- high spots are lowered and low spots are raised at the same time
- the hammer is used to strike the opposite side of the panel in an area adjacent to the dolly
Should create a high pitch “ping” sound
Tech A says a spoon should not be used like a hammer
Tech B says when a spoon is struck with a hammer it is called spring hammering
- A
- B
- Both
- Neither
B
Tech A says when using a spoon to remove buckles, start at the point of the most distortion
Tech B says when using a spoon to remove buckles, uses a series of blows while zigzagging along the buckle.
- A
- B
- Both
- Neither
B
A slapping file is a spoon with a serrated face used for straightening or shrinking
True
False
True
Typically, first in, last out is the general rule for applying repair force
True
False
True
All are considerations when determine the damage removal sequence EXCEPT:
- Straightening panel edges or feature lines first
- shrink stretch area first
- identify the high and low spots
- choose a sequence that will do as little additional damage to panel as possible
Shrink stretched area first
All describe stretched metal EXCEPT:
- is thinner
- typically found along ridges, channels and buckles
- has a larger surface area
- typically found indirect damage areas
Typically found indirect damage areas
The application of heat causes metal to shrink
- in the surrounding cold area
- by compression between hot and cold area
- at the point where the heat is applied
- where it is struck between a hammer and dolly
By compression between hot and cold area
All describe picking EXCEPT
- lifting low spots to be level with the contour or the panel
- slightly stretches the metal
- done using only a pick
- allows access to hard to reach areas
Done using only a pick
Tech A says that body file should be stroked in the direction of the highest crown
Tech B says that the first stroke of the body filler should contact at least half of the damage
- A
- B
- Both
- Neither
B
Tech A says that a pick and filing is used to identify and level high and low spots
Tech B says a body file may be called a Vixen File
- A
- B
- Both
- Neither
Both
All describe the heat shrinking process EXCEPT:
- over shrinking can be corrected with a hammer on dolly blow
- heat source may include open flame, stud gun or induction heater
- hold the flame at a 45 angle to the panel
Hold the flame at a 45 angle to the panel
Compressed metal may appear as metal that is stretched
True
False
True
All are consideration when removing a cease EXCEPT:
- start applying heat to the area with the largest amount of damage
- uses the hammer on dolly technique
- the stretched metal spread over a wider area if not heated
- creases tend to shrink more lengthwise than across the width
Start applying heat to the area with largest amount of damage
When using a stud gun to remove damage:
- a pin is inserted into the tip
- depress the trigger for about 10 seconds
- coatings on the backside should be left intact
- the paint should be left intact
A pin is inserted into the tip
Tech A says that dents may be removed using adhesive disc
Tech B says that dents can be removed using a suction cup
- A
- B
- Both
- Neither
Both
