| : | Sep 22, 2004 |
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| 1 | Body | |
| 2 | Integral body Frame |
| Abbreviation | Steel type | Yield Point |
|---|---|---|
| SS | Soft Steel | Maximum Yield point of 220 MPa |
| DP | Dual Phase Steel | Steel With a Yield Point up tp 400 MPa |
| HS | High Strength Steel | Steel With a Yield Point 220 - 450 MPa |
| EHS | Extra High Strength Steel | Steel With a Yield Point 450 - 800 MPa |
| UHS | Ultra High Strength Steel | Steel With a Yield Point up to 1400 MPa |
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| 1 | Gap too wide | |
| 2 | Gap too small |
| It is preferable to repair body parts rather than to renew them, as this keeps the complete body-shell intact. |
| Check dimensions and gaps continuously during straightening. |
| Check dimensions and gaps continuously during straightening. |
: Ultra High Strength steel in the A-Pillar, B-Pillar and cantrail cannot
be straightened. |
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| All other parts like interior equipment, window glass etc. must be protected against flying sparks. |
| Ensure that the milling depth is set correctly to prevent the remaining flange from being weakened. |
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| Wear protective clothing. Protect any vulnerable body or glass areas against flying sparks. Remove explosive materials from the vicinity. |
| Wear protective clothing. Protect any vulnerable body or glass areas against flying sparks. Remove explosive materials from the vicinity. |
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| Underlying metal parts, wiring harnesses, hoses etc. must not be damaged - remove them beforehand if necessary. |
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| The severance cut should always be kept as short as possible on sectional replacement. Only cut at the severance lines shown in the repair chapters. Do not make any cuts near reinforcements or pre-determined folding lines. |
| Do not use a welding torch to remove paint residue (the heat could cause the metal to deform). |
| Do not use a welding torch to remove paint residue (the heat could cause the metal to deform). |
| When using aerosols, take care not to contaminate adjacent parts with spray mist. |
| The need for subsequent follow-on work can be significantly reduced if aligning and tack-welding are carried out with due care. |
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| 1 | Tack welds | |
| 2 | Using a suitable tool to align |
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| The increased application of heat during MIG welding destroys the welding primer/zinc layer over a much larger area than during resistance spot welding, as a result of which much more care needs to be taken when applying anti-corrosion protection afterwards. |
| A test weld should always be carried out to ensure that the welded joint is not just a surface connection. |
| The increased application of heat during MIG welding destroys the welding primer/zinc layer over a much larger area than during resistance spot welding, as a result of which much more care needs to be taken when applying anti-corrosion protection afterwards. |
| A test weld should always be carried out to ensure that the welded joint is not just a surface connection. |
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| 1 | Welding direction: circular pattern working from the inside outwards | |
| 2 | Welding starting point: centre of hole on lower panel |
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| 1 | Rubber strip | |
| 2 | Window frame | |
| 3 | Adhesive | |
| 4 | Window glass |
| Open the windows and doors while the window is left to dry and do not move the vehicle (slamming doors creates excess pressure which could cause the window to become loose). |
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: When preparing bumpers for painting, ensure the PDC sensors are not
damaged. Only remove the clear coat if possible. When painting the PDC
sensors, do not apply excessive layers of paint as this can hinder the
performance of the sensors. |
: When heat curing paint repairs, the temperature must not exceed 65°C
(149°F). Temperature above this figure will cause the reflective elements
within the headlamps and tail lamps to distort and may damage other
components. |