Nova
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Body and chassis sheet metal parts
General Instructions
Before beginning work on body sheet metal parts, remove body attaching parts, assemblies or fittings which interfere with the work. Disconnect battery ground strap.
After carrying out repair work on the body, ensure that the ground connections are correct. Poor ground connections lead to faults in the system and, in extreme cases, to destruction of control units.
The appropriate guidelines and regulations related to fire prevention are to be followed in connection with welding or grinding work on the body.
The same attention is to be devoted to following the environmental protection and health regulations.
Important: Since legal provisions differ in individual countries, it is not possible to provide details in the workshop literature. Obtainment and observance of the respective requirements are therefore an individual responsibility.
The sectional repairs described in the operations are the result of extensive tests.
The welding procedures appearing in the various operations are identified with welding symbols.
There is basically no difference between welding untreated deep drawn sheet metal panels and alloy galvanized panels. It is preferable to spot weld alloy galvanized panels.
Remove all paint and spot welding flanges.
Corrosion protection measures and materials from the "Parts and Accessories" range are contained in the current brochure "CORROSION PROTECTION, SAFETY, VALUE PRESERVATION, ECONOMY" from "European Service".
Appropriate equipment for vapour extraction is to be provided for all separating, grinding and welding operations.
Working procedures described and illustrated here apply mainly to left-hand drive vehicles. Working procedures for right-hand vehicles are usually a mirror image of these. The functioning of the systems described is the same for left-hand and right-hand drive vehicles. Where basic differences exist, appropriate information will be given.
The illustrated cutting sections and/or cutting lines are the result of comprehensive crash tests and examinations of vehicles which have been involved in accidents. Body sheet metal parts and body members (underbody) are made of cold-workable, deep drawn sheet steel in standard production. Consequently damaged parts must be cold when restoring them to their original shape.
All labour operations are shown to a great extent in the form of illustrations. Explanatory text has only been added at points where instructions are important to proper and appropriate repair. The sequence of the illustrations and the text occasionally included between them gives the sequence of labour operations.
No reference is made in these labour operations to continually recurring standard operations, such as separation of parts or grinding mating surfaces, as these should be known sufficiently well in the service workshops.
If the degree of damage does not permit restoration of the original shape, first straighten the mating surfaces. The damaged body section can then be replaced.
The repair methods specified in this group must be used in those areas where both cutting and joining would have an effect on the strength and safety of the body.
When delivered to the paint shop, the surface of the body parts must be satisfactorily prepared for painting. The surface is paintable when damaged sheet metal parts have been repaired (dents removed, seams welded and soldered, overlapping seams in cases of partial replacement) in such a way that the paint shop does not need to apply more than 3 fine putty layers. These operations belong to the sheet metal worker's duties and should be included in his specified repair time.
After accidents indicating considerable stress on the chassis, the following components in particular should be checked, independently of checking axle alignment, which should be carried out in all cases: Check steering and steering linkage for correct operation through the complete turning circle, check visually for deformation and cracks. Check all components of the chassis for deformation and cracks, including steering, spring strut, stabilizer, axle assembly and their fastening parts. Test wheel rims and tyres for damage, true running and balance. Examine tyres for cuts in the tread and the side walls.
Safety Measures:
- Disconnect battery from vehicle electrical system.
- Install ground cable of welding equipment immediately beside the area to be welded.
- Control units may be damaged at temperatures above 60 °C/140 °F.
- When removing and installing the engine and transmission, ensure that all ground connections are properly routed. If the engine is started although ground connections are missing, the control units will be destroyed.
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