CRR 655 - Advanced Collision Repair

1. Identify and take necessary precautions with hazardous operations and materials according to federal, state, and local regulations (HP-I).
   1. Identify safety and personal health hazards according to OSHA guidelines and the “Right to Know Law” (HP-I).
   2. Select and use the NIOSH approved personal sanding respirator. Inspect condition and ensure fit and operation. Perform proper maintenance in accordance with OSHA Regulation 1910.134 and applicable state and local regulations (HP-I)
   3. Select and use personal safety equipment, hand, eye, ear, and respiratory protection.
   4. Select and use recommended proper protective clothing and footwear
2. Determine the extent of the direct and indirect damage and the direction of impact; document the methods and sequence of repair (HP-I).
   1. Diagnose and measure struct6ural damage using tram and self-centering gauges (HP-I).
   2. Determine and inspect the locations of all suspension, steering and powertrain component attaching points on the vehicle (HP-G).
   3. Diagnose and measure unibody vehicles using a dedicated (fixture) measuring system (HP-G).
   4. Diagnose and measure unibody vehicles using a universal measuring system (mechanical, electronic, and laser) (HP-G).
   5. Remove corrosion protection, undercoatings, sealers, and other protective coatings necessary to perform repairs (HP-I).
   6. Inspect, remove, and replace repairable plastics and other components that are recommended for off-vehicle repair (HP-I)
3. Analyze structural components on unibody and full frame structures.
   1. Analyze and identify crush/collapse zones (HP-I).
   2. Analyze, straighten and align mash (collapse) damage (HP-G).
   3. Analyze, straighten and align sag damage (HP-G).
   4. Analyze, straighten and align side sway damage (HP-G).
   5. Analyze, straighten and align twist damage (HP-G).
   6. Analyze, straighten and align diamond frame damage (HP-G).
   7. Identify proper cold stress relief methods (HP-I).
   8. Identify heat limitations in unibody vehicles (HP-I).
   9. Identify heat limitations in structural components (HP-I).
4. Repair and replace structural components on unibody and full frame structures
   1. Attach anchor devices to vehicle, remove or reposition components as necessary (HP-I).
   2. Straighten and align front-end sections (aprons, strut towers, upper and lower rails, steering, and suspension/powertrain mounting points etc.) (HP-G)
   3. Straighten and align quarter panels, wheelhouse assemblies, and rear body sections (including rails and suspension/powertrain mounting points) (HP-G).
   4. Remove and replace damaged sections of structural steel body panels (HP-G).
   5. Remove and replace damaged structural components (HP-G).
   6. Restore corrosion protection to repaired or replaced frame areas (HP-I).
   7. Restore corrosion protection to repaired or replaced unibody structural areas (HP-I).
   8. Restore structural foam (HP-G).
   9. Determine the extent of damage to aluminum structural components; repair, weld, or replace (HP-G).
   10. Identify cutting process for different materials and locations; perform cutting operation (HP-I).
   11. Straighten and rough-out contours of damaged panels to a suitable condition for body filling or metal finishing using power tools, hand tools, and weld-on pull attachments (HP-I).
5. Demonstrate proper repair of non-structural misalignment of body panels.
   1. Attach vehicle to anchoring devices (HP-I).
   2. Straighten and align cowl assembly (HP-G).
   3. Straighten and align roof rails/headers and room panels (HP-G).
   4. Straighten and align hinge and lock pillars (HP-G).
   5. Straighten and align vehicles openings, floor pans, and rocker panels (HP-G)
   6. Repair damage using power tools and hand tools to restore proper contours and dimensions (HP-I).
   7. Replace door skins (HP-G).
   8. Perform panel bounding (HP-G).
   9. Restore sound deadeners and foam materials (HP-I).
   10. Determine the extent of damage to aluminum body panels; repair or replace (HP-G).
6. Demonstrate proper preparation and welding procedures
   1. Determine the correct GMAW (MIG) welder type, electrode, wire type, diameter, and gas to be used in a specific welding situation (HP-I).
   2. Determine work clamp (ground) location and attach (HP-I)
   3. Protect adjacent panels, glass, vehicle interior, etc, from welding and cutting operations (HP-I).
   4. Protect computers and other electronic control modules during welding procedures (HP-I).
   5. Clean and prepare the metal to be welded, assure good metal fit-up, apply welding through primer if necessary, and clamp as required (HP-I)
   6. Determine the joint type (butt weld with backing, lap etc.) for weld being made (HP-I).
   7. Determine the type of weld (continuous, butt weld with backing, ;lug, etc.) for each specific welding operation (HP-I).
   8. Weld damaged or torn steel body panels; repair broken welds (HP-I).
   9. Identify different methods of attaching structural components (squeeze type resistance sport welding (STRSW), riveting, structural adhesive, silicon bronze, etc.) (HP-G).
   10. Weld and cut high-strength steel and other steels (HP-I).
   11. Weld and cut aluminum (HP-G).
   12. Restore corrosion-resistant coatings; caulking; and seam sealers to repaired areas (HP-I).
7. Practice proper handling and storage of vehicle components
   1. Inspect, remove, store, and replace non-structural body panels and components that may interfere with or be damaged during repair (HP-I).
   2. Inspect, remove, store, and replace exterior trim and moldings (HP-I)
   3. Inspect, remove, store, and replace interior trim and components (HP-I).
   4. Inspect, remove, store and replace all vehicle mechanical and electrical components that may interfere with or be damaged during repair (HP-G)
   5. Protect panels, glass, and parts adjacent to the repair area (HP-I).
   6. Inspect, remove and replace bolted, bonded and welded steel panel or panel assemblies (HP-I).
8. Demonstrate correct procedures for outer body panel alignment
   1. Inspect, remove, replace, and align front fenders, headers, and other panels (HP-I).
   2. Inspect, remove, replace, and align bumper bars, covers, reinforcement, guards, isolators, and mounting hardware (HP-I).
   3. Inspect, remove, replace, and align doors, tailgates, hatches, lift gates, latches, hinges, and related hardware (HP-I)
   4. Inspect, remove, replace, and align deck lid, lid hinges, and lid latch (HP-I).
   5. Inspect, remove, replace, and align hood, hood hinges, and hood latch (HP-I).
   6. Inspect, remove, reinstall, and align convertible top and related mechanisms (HP-G).
   7. Diagnose and repair water leaks, dust leaks, and wind noises; inspect, repair, and replace weather-stripping (HP-G
   8. Restore corrosion protection (HP-I).
9. Demonstrate proper procedures for aligning and replacement of structural and non-structural glass
10. Remove and reinstall or replace fixed glass (heated and non-heated) using recommended materials (HP-G).
11. Remove and reinstall or replace modular glass using recommended materials (HP-G).
12. Inspect, adjust, repair or replace window regulators, run channels, glass, power mechanisms, and related controls (HP-I).
13. Inspect, repair or replace, and adjust removable, manually or power operated roof panel and hinges, latches, guides, handles, retainer, and controls of sunroofs (HP-G)
14. Replace mechanical parts
15. Demonstrate a knowledge of and importance of restoring corrosion protection
    1. Describe methods used
    2. Describe chemicals used
    3. Tell why manufacturer’s specifications are important