The engine hood, trunk lid, doors, and front fenders are bolted on and can be easily replaced. In addition to removing body parts, this chapter also covers the removal and installation of interior trim, seats, and trim parts and assemblies. Since many of these parts are secured with slotted head screws, a screwdriver with replaceable slotted heads is required to perform the operations.
Safety precautions when performing bodywork
Before carrying out welding or other work during which sparks are generated, the battery must be removed.
Neither welding nor soldering of parts of a filled air conditioning system is permitted. This also applies to welding and soldering work on a vehicle when there is a risk of heating of parts of the air conditioning system.
Caution: The air conditioning system coolant circulation circuit must not be opened.
Galvanized steel sheet is used for the production of the body parts most susceptible to corrosion. Do not remove the zinc layer at the welding site before welding (remove only when performing hard soldering). Increase the welding current by approximately 10%.
Caution: When galvanized steel sheets are polished, toxic zinc oxide is formed, so it is necessary to ensure good ventilation of the workplace.
Remove the PVC coating of the bottom in the repair area with a rotating brush or heat the area with an air heater to a temperature of no more than +180°C and remove the coating with a spatula. If the PVC coating ignites or overheats to a temperature above +180°C, hydrochloric acid is formed, which causes severe corrosion, and, in addition, harmful vapors are released.
When repairing the varnish coating, it is permissible to heat the car in the drying chamber or in the area in front of the chamber to a temperature not exceeding +80°C. Otherwise, the electronic control units of the car will fail.