Remove, Repair, And Install Metal Panels And Components Flashcards by Anthony Almazan

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

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An incorrect panel gap can cause all of these EXCEPT:

poor fuel economy
water leaks
wind noise
damage to the finish

Poor fuel economy

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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

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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

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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

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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

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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

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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

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Recycled parts should be inspected for corrosion, minor damage, and improper previous repairs upon delivery of the part

True
False

True

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What is the ideal method for bolted on panel alignment

bending
adjusting
shimming
jacking

Adjusting

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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

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Where do manufacturers often use caged plates for adjustments

Door strikers
Seat belts anchor
Seat tracks
Fender bolts

Door strikers

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What panel is NOT adjustable

fender
rockers
door
hood

Rockers

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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

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A bumper reinforcement may be constructed with all of these materials EXCEPT:

plastic composite
high density wood
steel
aluminum

High density wood

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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

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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

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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

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All of these are designs of energy absorbers EXCEPT:

piston type
plastic egg crate
rigid foam
pneumatic

Pneumatic

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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

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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

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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

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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

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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

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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

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

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

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

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

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

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

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

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

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

Acts as fulcrum against the panel

Leverage bar

Requires pressure to contact ground collar to part

Stud gun

Attaches to panel at multiple points to distribute pull force

Wiggle wire

Requires a ground plate be attached to the part

Dedicated dent removal tool

Tech A says that some body fillers may applied over epoxy primer. Tech B says that some body fillers may be applied over clear coat. A B Both Neither

Tech A says that sanding discs are stiffer than grinding discs. Tech B says that a grinder should be moved in a circular motion to removed coatings A B Both Neither

Neither

Tech A says that metal temperature affects body fillers application Tech B says that fiberglass body filler absorbs moisture A B Both Neither

Polyester glazing putty - can be substituted for primer-surface - is usually sanded with 80-grit sandpaper - is used for filling large dents - can be applied over scuffed paint

Can be applied over scuffed paint

Tech A says that equal parts of body fillers may applied and hardener are required for a proper mixture Tech B says that body fillers may and hardener should be mixed on a non porous surface A B Both Neither

Tech A says that the final coat of body fillers may applied should be applied below the level surface of the panel. Tech B says that road shock can cause body filer to crack A B Both Neither

Tech A says that P120 grit is coarser than 80 - grit sandpaper. Tech B says that a sandpaper maker may use more than one grading system A B Both Neither

After initial sanding of body fillers, a bare metal spot appears in the middle of the filler. Tech A says that the bare area indicate improper body fillers may applied application Tech B says that the bare area may indicate a high spot A B Both Neither

A guide coat is used for - a base for the body fillers - shrinking stretched metal - better adhesion of topcoat - identifying high and low spots

Identifying high and low spots

All describe parrafins EXCEPT - disappears as filler cures - prevents oxygen absorption from the atmosphere - carried to the surface by evaporating solvents - must be removed before re coating

Disappears as filler cures

Tech A says that fiber glass filler may be required when repairing a paint scratch Tech B says that the finish may require feather edging to repair a nick A B Both Neither

Tech A says that masking tape may be used to help apply body fillers to feature lines. Tech B says that when one method of applying body fillers to a complex area Is to apply it in stages according to the shape of the panel A B Both Neither

Tech A says that masking tape may be used to help sand feature lines Tech B says that a flat panel is considered a complex area A B Both Neither

Tech A says that some vehicle makers recommend using plastic tips on the PDR pick Tech B says that the vehicle makers recommend using may recommend against using PDR to repair damage. A B Both Neither

Both

Tech A says that the depth of the dent affects whether the damage should be repaired using PDR Tech B says that the shape of the dent affects whether the damage should be repaired using PDR A B Both Neither

Both