Body repairs

BODY REPAIRS

General

Body shells are of monocoque construction. Front and rear sections of the shell are designed as ’energy absorbing’ zones. This means they are designed to deform progressively when subjected to impact in order to minimise the likelihood of injury to vehicle occupants.

It is essential that design dimensions and strength are restored in accident rectification. It is important that neither structural weakness nor excessive local stiffness are introduced into the vehicle during body repair.

Repairs usually involve a combination of operations ranging from straightening procedures to renewal of individual panels or panel assemblies. The repairer will determine the repair method and this decision will take into account a balance of economics between labour and material costs and the availability of repair facilities in both equipment and skills. It may also involve considerations of vehicles’ downtime, replacement vehicle availability and repair turn-around time.

It is expected that a repairer will select the best and most economic repair method possible, making use of the facilities available. The instructions given are intended to assist a skilled body repairer by expanding approved procedures for panel replacement. The objective is to restore the vehicle to a safe running condition by carrying out a repair which is close as feasible to original standards. The result will not advertise to the experienced eye the fact that the vehicle has been damaged, although the repair will not necessarily be identical in all respects to original factory build. Commercial bodyshop repair facilities cannot always duplicate methods of construction used during production.

Operations covered in this Manual do not include reference to testing the vehicle after repair. It is essential that work is inspected and suspension geometry checked after completion. A road test of the vehicle should be carried out, particularly where safety-related items are concerned.

Where major units have been disconnected or removed it is necessary to ensure that fluid levels are checked and topped up where necessary. It is also necessary to ensure that the repaired vehicle is in a roadworthy condition in respect of tyre pressures, lights, washers fluid etc.

Body repairs often involve the removal of mechanical and electrical units and associated wiring. Where necessary, refer to the relevant section of the Workshop Manual for removal and refitting instructions. Body trim and SRS sections with remove and refit operations are also included in this Manual.

Body Components

Taking into consideration the differences in body styles, steering and suspension systems and engine and transmission layouts, the location of the following components as applicable to a particular vehicle is critical:

• Front suspension upper damper mountings.
• Front suspension or sub frame mountings.
• Engine mounting on RH and LH valances.
• Rear suspension upper damper mountings.
• Rear suspension mountings or lower pivots.
• Steering rack mountings.

Additional points which can be used to check alignment and assembly are:

• Inner holes in crossmember - side - main floor.
• Holes in front longitudinals.
• Holes in extension - side member - front.
• Holes in rear longitudinals.
• Holes in rear lower panels or extension rear floor.
• Petrol tank mountings.

Apertures for windscreen, backlight, bonnet and doors can best be checked by offering up an undamaged component as a gauge.

Follow basic alignment measurements for relevant model. See INFORMATION, General data.