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| Preface | |
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| About the Book | |
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| Features of the Text | |
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| Supplements | |
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| About I-CAR | |
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| Acknowledgments | |
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| Fundamentals | |
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| Industry Overview and Careers | |
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| History Note | |
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| Collision Repair Technician | |
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| Other Personnel | |
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| The Professional | |
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| What is Collision Repair? | |
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| What is a Collision? | |
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| Vehicle Construction Basics | |
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| Shop Operations | |
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| Collision Repair Facilities | |
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| Summary | |
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| Technical Terms | |
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| Review Questions | |
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| ASE-Style Review Questions | |
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| Activities | |
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| Safety and Certification | |
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| What Causes Accidents? | |
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| Types of Accidents | |
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| Textbook Safety | |
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| Overall Shop Safety | |
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| Shop Layout and Safety | |
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| In Case of an Emergency | |
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| Work Area Safety | |
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| Fire Safety | |
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| Avoiding Falls | |
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| Avoiding Electrocution | |
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| Avoiding Asphyxiation | |
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| Avoiding Eye Injuries | |
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| Avoiding Chemical Burns | |
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| Personal Safety | |
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| Tool and Machine Safety | |
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| Paint Shop Safety | |
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| Respirators | |
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| Dustless Sanding Systems | |
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| Air Bag Safety | |
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| Manufacturer's Warnings | |
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| Right-to-Know Laws | |
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| Employer Responsibilities | |
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| Waste Disposal | |
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| Liability | |
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| Technician Liability | |
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| ASE Certification | |
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| I-CAR | |
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| Don't Be Foolish! | |
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| Summary | |
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| Technical Terms | |
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| Review Questions | |
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| ASE-Style Review Questions | |
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| Activities | |
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| Vehicle Construction | |
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| Crash Testing | |
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| Vehicle Classifications | |
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| Vehicle Construction | |
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| Joining Parts | |
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| Major Body Sections | |
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| Panel and Assembly Nomenclature | |
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| Front Section Parts | |
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| Center Section Parts | |
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| Rear Section Parts | |
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| Gaskets and Seals | |
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| Anticorrosion Materials | |
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| Sound-Deadening Materials | |
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| Engine Locations, Drive Lines | |
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| Vehicle Sizes | |
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| Roof Designs | |
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| Vans and Trucks | |
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| Summary | |
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| Technical Terms | |
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| Review Questions | |
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| ASE-Style Review Questions | |
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| Activities | |
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| Hand Tools | |
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| Purchase Quality Tools | |
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| Tool Storage | |
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| General Duty Hammers | |
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| Body Hammers | |
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| Dollies and Spoons | |
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| Holding Tools | |
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| Punches and Chisels | |
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| Wrenches | |
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| Wrench Types | |
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| Pry Bars | |
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| Screwdrivers | |
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| Pliers | |
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| Sheet Metal Tools | |
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| Files | |
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| Saws | |
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| Cleaning Tools | |
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| Creepers, Covers | |
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| Hydrometers | |
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| Fluid Handling Tools | |
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| Tire Tools | |
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| Pullers, Picks | |
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| Miscellaneous Collision Repair Tools | |
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| Summary | |
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| Technical Terms | |
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| Review Questions | |
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| ASE-Style Review Questions | |
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| Activities | |
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| Power Tools and Equipment | |
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| Air Supply System | |
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| Air Compressor | |
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| Air Lines | |
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| Air Pressure Regulator and Filter | |
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| Air Tools | |
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| Grinders | |
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| Polishers | |
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| Pneumatic Tool Maintenance | |
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| Blasters | |
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| Spray Guns | |
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| Spray Booths | |
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| Paint Drying Equipment | |
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| Measuring Systems | |
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| Straightening Systems | |
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| Lifts | |
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| Electric Tools | |
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| Battery Charger | |
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| Multimeter | |
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| Scan Tools | |
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| Engine Analyzer | |
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| Personal Computer | |
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| Soldering Gun | |
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| Plastic Welder | |
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| Air Conditioning Tools | |
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| Other Equipment | |
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| Summary | |
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| Technical Terms | |
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| Review Questions | |
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| ASE-Style Review Questions | |
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| Activities | |
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| Basic Measurement and Service Information | |
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| SAE and Metric Systems | |
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| Conversion Charts | |
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| Linear Measurements | |
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| Scales | |
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| Dividers and Calipers | |
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| Micrometers | |
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| Dial Indicators | |
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| Feeler Gauges | |
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| Pressure and Flow Measurements | |
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| Angle Measurements | |
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| Temperature Measurements | |
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| Paint-Related Measurements | |
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| Paint Mixing Sticks | |
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| Viscosity Cup Measurement | |
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| Paint (Material) Thickness Measurement | |
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| Vehicle Identification Number (VIN) | |
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| Collision Repair Publications | |
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| Computerized Service Information | |
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| Color Matching Manuals | |
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| Summary | |
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| Technical Terms | |
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| Review Questions | |
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| ASE-Style Review Questions | |
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| Activities | |
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| Fasteners | |
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| Bolts | |
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| Nuts | |
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| Thread Repair | |
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| Washers | |
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| Screws | |
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| Nonthreaded Fasteners | |
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| Replacing Fasteners | |
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| Hose Clamps | |
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| Adhesives | |
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| Summary | |
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| Technical Terms | |
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| Review Questions | |
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| ASE-Style Review Questions | |
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| Activities | |
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| Collision Repair Hardware and Materials | |
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| Refinishing Materials | |
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| Undercoats and Topcoats | |
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| Paint Types | |
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| Original Equipment Manufacturer (OEM) Finishes | |
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| Contents of Paint | |
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| Drying and Curing | |
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| Primers and Sealers | |
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| Sealers | |
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| Primer-Surfacers | |
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| Use a Complete System! | |
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| Other Paint Materials | |
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| Body Fillers | |
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| Glazing Putty/Finishing Fillers | |
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| Masking Materials | |
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| Abrasives | |
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| Grinding Discs | |
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| Sandpapers | |
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| Scuff Pads | |
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| Compounds | |
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| Adhesives | |
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| Epoxies | |
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| Sealers | |
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| Hazardous Materials | |
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| Waste Disposal and Recycling | |
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| Summary | |
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| Technical Terms | |
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| Review Questions | |
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| ASE-Style Review Questions | |
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| Activities | |
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| Welding, Heating, and Cutting | |
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| |
| What is Welding? | |
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| Weld Terminology | |
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| Welding Categories | |
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| Metal Inert Gas (MIG) Welding | |
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| Welding Positions | |
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| Welding Safety | |
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| Welding Surface Preparation | |
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| Holding Parts | |
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| Weld-Through Primer | |
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| Using the MIG Welder | |
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| MIG Burnback | |
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| Wire Speed | |
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| Shielding Gas Flow Rate | |
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| Heat Buildup Prevention | |
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| Clean After Welding | |
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| Resistance Spot Welding | |
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| Weld Problems | |
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| Welding Aluminum | |
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| Oxyacetylene Welding | |
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| Plasma Arc Cutting | |
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| Summary | |
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| Technical Terms | |
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| Review Questions | |
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| ASE-Style Review Questions | |
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| Activities | |
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| Minor Repairs | |
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| Straightening Fundamentals | |
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| Sheet Metal | |
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| Steel Strength | |
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| Physical Structure of Steel | |
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| Effect of Impact Forces | |
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| Work Hardening | |
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| Kinds of Damage | |
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| Using Body Hammers | |
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| Straightening with Dollies | |
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| Hammer-on-Dolly | |
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| Hammer-off-Dolly | |
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| Straightening with Spoons | |
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| Straightening with Picks | |
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| Pulling Damaged Areas | |
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| Shrinking Metal | |
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| Identifying Stretched Metal | |
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| Filing the Repair Area | |
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| Working Aluminum | |
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| Using Body Filler | |
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| Preparing Surface for Filler | |
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| Summary | |
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| Technical Terms | |
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| Review Questions | |
| |
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| ASE-Style Review Questions | |
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| Activities | |
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| Plastic and Composite Repair | |
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| Types of Auto Plastics | |
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| Plastics Safety | |
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| Plastic Identification | |
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| Plastic Part Removal | |
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| Principles of Plastic Welding | |
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| Hot-Air Plastic Welding | |
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| Airless Plastic Welding | |
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| Plastic Welding Methods | |
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| Hot-Air Plastic Welding Procedure | |
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| Plastic Tack Welding | |
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| Welding a Plastic V-Groove | |
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| Plastic Speed Welding | |
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| Airless Melt-Flow Plastic Welding | |
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| Plastic Stitch-Tamp Welding | |
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| Single-Sided Plastic Welds | |
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| Two-Sided Plastic Welds | |
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| Repairing Vinyl Dents | |
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| Welding Vinyl-Foam Cuts | |
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| Heat Reshaping Plastic Parts | |
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| Plastic Bumper Tab Replacement | |
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| |
| Plastic Adhesive Repair Systems | |
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| Use the Correct Adhesive! | |
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| Two-Part Plastic Adhesive Repairs | |
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| Two-Part Adhesive Dash Repair | |
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| Reinforced Plastic Repairs | |
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| |
| Reinforced Plastic Adhesives | |
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| Reinforced Plastic Fillers and Glass Cloth | |
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| |
| Reinforced Plastic, Single-Sided Repairs | |
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| Two-Sided Repairs of Reinforced Plastic | |
| |
| |
| Using Molded Cores | |
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| |
| Repairing RRIM | |
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| |
| Spraying Vinyl Paints | |
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| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
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| Replacing Hoods, Bumpers, Fenders, Grilles, and Lids | |
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| |
| How are Parts Fastened? | |
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| |
| Refer to Estimate | |
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| Where to Start | |
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| Hood Removal and Replacement | |
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| Bumper Removal, Replacement, and Adjustment | |
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| Fender Removal, Replacement, and Adjustment | |
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| Grille Removal and Replacement | |
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| Deck Lid Removal, Replacement, and Adjustment | |
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| Panel Alignment | |
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| Truck Bed Removal and Replacement | |
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| Installing Sound-Deadening Pads | |
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| Summary | |
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| Technical Terms | |
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| Review Questions | |
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| ASE-Style Review Questions | |
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| Activities | |
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| Servicing Doors, Glass, and Leaks | |
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| Doors | |
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| Door Construction | |
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| Door Adjustments | |
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| Glass | |
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| Air and Water Leaks | |
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| Rearview Mirror Service | |
| |
| |
| More Information | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
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| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
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| Activities | |
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| Prepainting Preparation | |
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| Vehicle Surface Preparation | |
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| Vehicle Cleaning | |
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| Surface Evaluation | |
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| Chemical Stripping | |
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| |
| Blasting Paint | |
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| Removing Paint | |
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| Bare Metal Treatment | |
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| |
| Preparing Metal Replacement Parts | |
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| Sanding | |
| |
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| Featheredging | |
| |
| |
| Undercoat Systems | |
| |
| |
| Using Spot Putty | |
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| |
| Using a Guide Coat | |
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| Masking | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
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| Activities | |
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| Shop and Equipment Preparation | |
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| Painting Environment | |
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| Preparing Spray Booth | |
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| Mixing and Storage Area Prep | |
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| Preparing Spray Equipment | |
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| Mixing Paint and Solvent | |
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| Viscosity | |
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| |
| Paint Temperature | |
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| |
| Captive Spray Gun System | |
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| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
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| Refinishing | |
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| |
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| Painting and Refinishing Fundamentals | |
| |
| |
| Preparation Review | |
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| |
| Review of Topcoats | |
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| |
| Determining Type of Finish | |
| |
| |
| Spray Gun Application Stroke | |
| |
| |
| Paint/Material Thickness Measurement | |
| |
| |
| Gun Handling Problems | |
| |
| |
| Types of Spray Coats | |
| |
| |
| Paint Blending | |
| |
| |
| Refinishing Methods | |
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| |
| Spot Repairs | |
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| |
| Panel Repairs | |
| |
| |
| Overall Refinishing | |
| |
| |
| Applying Basecoat-Clearcoat | |
| |
| |
| Applying Tri-Coat Finishes | |
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| |
| Refinishing Rules | |
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| |
| Removal of Masking Materials | |
| |
| |
| Finishing Rigid Exterior Plastic Parts | |
| |
| |
| Finishing Polypropylene Parts | |
| |
| |
| Finishing Urethane Bumpers | |
| |
| |
| Cleaning the Spray Gun | |
| |
| |
| Spray Gun Cleaning Steps | |
| |
| |
| VOC Tracking | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| |
| Color Matching | |
| |
| |
| Color Theory | |
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| |
| Lighting | |
| |
| |
| Color Blindness | |
| |
| |
| Dimensions of Color | |
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| |
| Metamerism | |
| |
| |
| Plotting Color | |
| |
| |
| Color Matching | |
| |
| |
| Paint Formulas | |
| |
| |
| Spectrophotometer | |
| |
| |
| Computerized Color Matching Systems | |
| |
| |
| Color Variance Programs | |
| |
| |
| Spray Methods Affect Color | |
| |
| |
| Matching Solid Colors | |
| |
| |
| Matching Metallic Finishes | |
| |
| |
| Matching Multi-Stage Finishes | |
| |
| |
| Zone Concept | |
| |
| |
| Color Flop | |
| |
| |
| Checking Color Match | |
| |
| |
| Blending Clearcoats | |
| |
| |
| Fluorine Clearcoat Repairs | |
| |
| |
| Tri-Coat Spot Repair | |
| |
| |
| Tri-Coat Panel Repair | |
| |
| |
| Blending Mica Coats | |
| |
| |
| Matching Mica Colors | |
| |
| |
| Why a Color Mismatch? | |
| |
| |
| Tinting | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| |
| Paint/Refinish Problems and Final Detailing | |
| |
| |
| Surface Imperfections | |
| |
| |
| Surface Finish Measurements | |
| |
| |
| Paint Problems | |
| |
| |
| Final Detailing | |
| |
| |
| Get Ready | |
| |
| |
| Caring for New Finish | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| |
| Decals, Custom Painting, and Trim | |
| |
| |
| Overlays and Tape Stripes | |
| |
| |
| Painted Pinstripes | |
| |
| |
| Custom Painting | |
| |
| |
| Moldings and Trim | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| |
| Major Repairs | |
| |
| |
| |
| Measuring Vehicle Damage | |
| |
| |
| Why is Measurement Important? | |
| |
| |
| Damage Diagnosis | |
| |
| |
| Safety | |
| |
| |
| Impact Effects | |
| |
| |
| Analyzing Collision Forces | |
| |
| |
| Types of Frame Damage | |
| |
| |
| Unibody Vehicle Damage | |
| |
| |
| Dimensional References | |
| |
| |
| Vehicle Measuring Basics | |
| |
| |
| Types of Measuring Equipment | |
| |
| |
| More Information | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| |
| Straightening Full-Frame and Unibody Vehicles | |
| |
| |
| Alignment Basics | |
| |
| |
| Straightening Equipment | |
| |
| |
| Measure As You Pull! | |
| |
| |
| Part Removal | |
| |
| |
| Planning the Straightening | |
| |
| |
| Straightening Safety | |
| |
| |
| Straightening Basics | |
| |
| |
| Anchoring Procedures | |
| |
| |
| Wheel Clamps | |
| |
| |
| Attaching Pulling Chains | |
| |
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| Executing a Planned Straightening Sequence | |
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| Straightening Directions | |
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| Overpulling | |
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| Aligning Front End Damage | |
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| Rear Damage Repairs | |
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| Straightening Side Damage | |
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| Straightening Sag | |
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| Straightening Diamond Damage | |
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| Stress Relieving | |
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| Stress Concentrators | |
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| Final Straightening/Alignment Checks | |
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| Summary | |
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| Technical Terms | |
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| Review Questions | |
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| ASE-Style Review Questions | |
| |
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| Activities | |
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| Other Operations | |
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| |
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| Replacing Structural Parts and Corrosion Protection | |
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| Repair or Replace Guidelines | |
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| Types of Structural Replacements | |
| |
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| Determining Spot Weld Locations | |
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| |
| Separating Spot Welds | |
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| Separating Continuous Welds | |
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| Preparing Vehicle for New Panel | |
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| Preparing Replacement Panel/Part | |
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| Positioning New Panels | |
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| |
| Welding New Panels/Parts | |
| |
| |
| Sectioning | |
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| |
| Corrosion | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| |
| Interior Repairs | |
| |
| |
| Seat Service | |
| |
| |
| Carpeting Service | |
| |
| |
| Headliner Service | |
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| |
| Instrument Panel Service | |
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| Instrument Cluster Service | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| |
| Mechanical Repairs | |
| |
| |
| Powertrain | |
| |
| |
| Engine Support Systems | |
| |
| |
| Drivetrain | |
| |
| |
| Steering Systems | |
| |
| |
| Suspension Systems | |
| |
| |
| Air Conditioning Systems | |
| |
| |
| Emission Control Systems | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| |
| Wheel Alignment | |
| |
| |
| Wheel Alignment Basics | |
| |
| |
| Prealignment Checks | |
| |
| |
| Diagnostic Checks | |
| |
| |
| Wheel Alignment Procedures | |
| |
| |
| Alignment Equipment Variations | |
| |
| |
| Road Test After Alignment | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| |
| Electrical Repairs | |
| |
| |
| Electrical Terminology | |
| |
| |
| Diagnostic Equipment | |
| |
| |
| Wiring Diagrams | |
| |
| |
| Electric Components | |
| |
| |
| Circuit Protection Devices | |
| |
| |
| Fuses | |
| |
| |
| Fuse Links | |
| |
| |
| Circuit Breakers | |
| |
| |
| Electrical-Electronic Systems | |
| |
| |
| Electrical Problems | |
| |
| |
| Batteries | |
| |
| |
| Lighting and Other Electric Circuits | |
| |
| |
| Repairing Wiring and Connections | |
| |
| |
| Solder Repair | |
| |
| |
| Electrical Connector Service | |
| |
| |
| Computer Systems | |
| |
| |
| Scanning Computer Problems | |
| |
| |
| Protecting Electronic Systems | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| |
| Restraint System Repairs | |
| |
| |
| Active and Passive Restraints | |
| |
| |
| Seat Belt Systems | |
| |
| |
| Child Restraint Systems and Air Bag Safety | |
| |
| |
| Air Bag Systems | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| |
| Estimating and Entrepreneurship | |
| |
| |
| |
| Estimating Repair Costs | |
| |
| |
| Damage Analysis | |
| |
| |
| Direct and Indirect Damage | |
| |
| |
| Vehicle Inspection | |
| |
| |
| Interior Inspection | |
| |
| |
| Damage Quick Checks | |
| |
| |
| Dimension Manuals | |
| |
| |
| Collision Estimating Guides | |
| |
| |
| Damage Report Terminology | |
| |
| |
| Part Costs | |
| |
| |
| Writing Estimates | |
| |
| |
| Estimating Sequence | |
| |
| |
| Flat Rate Operations | |
| |
| |
| Labor Costs | |
| |
| |
| Refinishing Time | |
| |
| |
| Total Labor Costs | |
| |
| |
| Totaling the Estimate | |
| |
| |
| Computerized Estimating | |
| |
| |
| Front Clips | |
| |
| |
| Sectioning | |
| |
| |
| Total Loss | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| |
| Entrepreneurship and Job Success | |
| |
| |
| Collision Repair Technician | |
| |
| |
| Related Professions | |
| |
| |
| Entrepreneurship | |
| |
| |
| Cooperative Training Programs | |
| |
| |
| Keep Learning! | |
| |
| |
| Use a Systematic Approach | |
| |
| |
| Work Traits | |
| |
| |
| Summary | |
| |
| |
| Technical Terms | |
| |
| |
| Review Questions | |
| |
| |
| ASE-Style Review Questions | |
| |
| |
| Activities | |
| |
| |
| Glossary | |
| |
| |
| |
| Abbreviations Used by Collision Repair Technicians | |
| |
| |
| |
| Measurement Equivalents | |
| |
| |
| |
| Tap and Drill Bit Data | |
| |
| |
| |
| Reference Tables | |
| |
| |
| |
| Torque Values | |
| |
| |
| Index | |