CRR 655 - Advanced Collision Repair

1. Examine necessary precautions with hazardous operations and materials according to federal, state and local regulations (HP-I)
   1. Determine safety and personal health hazards according to OSHA guidelines and the “Right to Know Law” (HP-I)
   2. 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 regulation (HP-I)
   3. Select personal safety equipment, hand, eye, ear, and respiratory protection
   4. Use recommended proper protective clothing and footwear                   
2. Evaluate the extent of the direct and indirect damage and the direction of impact; document the methods and sequence of repair (HP-I)
   1. Measure structural damage using tram and self-centering gauges (HP-I)
   2. Inspect the locations of all suspension, steering and powertrain component attaching points on the vehicle (HP-G)
   3. Measure unibody vehicles using a dedicated (fixture) measuring system (HP-G)
   4. Measure unibody vehicles using a universal measuring system (mechanical, electronic, and laser) (HP-G)
   5. Demonstrate removal of corrosion protection, undercoatings, sealers, and other protective coatings necessary to perform repairs (HP-I)
   6. Demonstrate ability to remove and replace repairable plastics and other components that are recommended for off-vehicle repair (HP-I)
3. Determine structural components on unibody and full frame structures
   1. 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. Demonstrate proper cold stress relief methods (HP-I)
   8. Explain heat limitations in unibody vehicles (HP-I)
   9. Explain heat limitations in structural components (HP-I)
4. Evaluate repairs and replacement of structural components on unibody and full frame structures
   1. Demonstrate attaching anchor devices to vehicle; remove or reposition components as necessary (HP-I)
   2. Explain straightening and aligning front-end sections (aprons, strut towers, upper and lower rails, steering, and suspension/powertrain mounting points etc.) (HP-G)
   3. Explain straightening and aligning quarter panels, wheelhouse assemblies, and rear body sections (including rails and suspension/powertrain mounting points) (HP-G)
   4. Explain removal and replacement of damaged sections of structural steel body panels (HP-G)
   5. Explain removal and replacement of damaged structural components (HP-G)
   6. Apply corrosion protection to repaired or replaced frame areas (HP-I)
   7. Apply corrosion protection to repaired or replaced unibody structural areas   (HP-I)
   8. Apply 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. Demonstrate ability to 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. Assess proper repair of non-structural misalignment of body panels
   1. Explain straightening and alignment of cowl assembly (HP-G)
   2. Explain straightening and alignment of roof rails/headers and room panels (HP-G)
   3. Explain straightening and alignment of hinge and lock pillars (HP-G)
   4. Explain straightening and alignment of vehicle openings, floor pans, and rocker panels (HP-G)
   5. Demonstrate repair of damage using power tools and hand tools to restore proper contours and dimensions (HP-I)
   6. Explain replacement procedure of door skins (HP-G)
   7. Explain panel bonding process (HP-G)
   8. Choose correct sound deadeners and foam materials (HP-I)
   9. Analyze the extent of damage to aluminum body panels; repair or replace (HP-G)
6. Evaluate proper preparation and welding procedures
   1. Demonstrate the correct GMAW (MIG) welder type, electrode, wire type, wire diameter, and gas to be used in a specific welding situation (HP-I)
   2. Demonstrate work clamp (ground) location and attach (HP-I)
   3. Demonstrate protection of adjacent panels, glass, vehicle interior, etc. from welding and cutting operations (HP-I)
   4. Demonstrate protection of computers and other electronic control modules during welding procedures (HP-I)
   5. Demonstrate cleaning and preparation of the metal to be welded, assure good metal fit-up, apply weld through primer if necessary, and clamp as required (HP-I)
   6. Identify correct joint type (butt weld with backing, lap etc.) for weld being made (HP-I)
   7. Identify correct type of weld (continuous, butt weld with backing, plug, etc.) for each specific welding operation (HP-I)
   8. Analyze weld damage or torn steel body panels; repair broken welds (HP-I)
   9. Identify different methods of attaching structural components (squeeze type resistance spot welding (STRSW), riveting, structural adhesive, silicon bronze, etc.) (HP-G)
   10. Analyze, weld and cut high-strength steel and other steels (HP-I)
   11. Explain welding and cutting aluminum (HP-G)
   12. Show restoration of corrosion-resistant coatings; caulking; and seam sealers to repaired areas (HP-I)
7. Determine 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. Demonstrate proper protection of panels, glass, and parts adjacent to the repair area (HP-I)
8. Inspect, remove and replace bolted, bonded, and welded steel panel or panel assemblies (HP-I)
9. Determine 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, reinforcements, 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. Analyze and repair water leaks, dust leaks, and wind noises; inspect, repair, and replace weather-stripping (HP-G)
   8. Show restoration of corrosion protection (HP-I)
10. Determine proper procedures for aligning and replacement of structural and non-structural glass
    1. Explain removal and reinstallation or replacement of fixed glass (heated and non-heated) using recommended materials (HP-G)
    2. Explain removal and reinstallation or replacement of modular glass using recommended materials (HP-G)
    3. Identify, adjust, repair or replace window regulators, run channels, glass, power mechanisms, and related controls (HP-I)
    4. Identify, repair or replace, and adjust removable, manually or power operated roof panel(s) and hinges, latches, guides, handles, retainers, and controls of sunroofs   (HP-G)
11. Complete I-CAR Non-Structural Pro level 1 Classes
    1. Complete Movable and Stationary Glass Program 1 (GLA01) online
    2. Complete Removing and Installing Hardware Interior Trim (TRM02) online
    3. Complete Automotive Lighting (LSC04) online

 
Competencies Revised Date: 2019