Ford Kuga

 Service Manual

Body Repairs - General Information
Impact of Insufficient Repair Quality

Body repairs usually require a significant level of intervention in the existing body shell structure.

The corrosion protection, seals and NVH components are destroyed and must be replaced.

To prevent the vehicle quality from being reduced due to a poor quality repair, all repairs carried out in all repair sections must be inspected during and after the accident repair.

Simply checking the vehicle at the time of delivery is not sufficient to guarantee the repair quality.

Rather, continuous checking of the work carried out is recommended.

NOTE: Logs of the acceptance of individual operations are a useful tool for quality assurance.

A comprehensive final inspection can be carried out based on a final acceptance log.

In the process, the entire repair sequence must be split into meaningful sections, with the creation of check points to which particular attention must be paid.

The following are some possible sections:

• During and after body work.
• Final assembly, ancillary components, functional tests.
• Vehicle delivery.

NOTE: The following points offer an indication of possible test logs. They can be combined and supplemented differently, depending on the individual operating procedures.

During and after body work the following areas should be checked:

After completion of the body repairs, the following areas should be checked:

• Manufacturing inspection for functionality and originality in the accident area.
• Check snug fitting of metal panel parts (welding and screw connections).
• Check snug fitting of ancillary components (doors, hoods, glazing).
• Check surface condition of the welded seams.
• Check seals, blanking plugs, NVH components
• Check corrosion prevention measures
• Check that the repair work is in the correct condition for painting.

Final assembly, ancillary components, functional tests

After final assembly, not only a visual inspection is required, but also the functionality of many components must be checked:

• Check repair area for originality.
• Check ancillary components for correct installation.
• Check precision fitting of all parts.
• Check that the doors and flaps are working correctly.
• Check that all mechanical parts, such as the window winder are working correctly.
• Check for leaks in the repair area.

Vehicle delivery

Vehicle delivery again offers the opportunity of checking the repair quality. In the process, the following points are to be checked again:

• Corrosion protection, sound damping matting and rubber seals.
• Check for traces of leftover paint.
• Check the cleanliness of the vehicle.
• Functional check of the mechanical and electrical components.
• Road test the vehicle.
• Check for noise, vibration and harshness (NVH).
• Check for wind noises.

After repair work on the body and vehicle, not only the visual restoration of the damaged vehicle, but also the functional restoration must be guaranteed.

Customers are making increasingly high demands of vehicles, particularly in terms of driving comfort.

Customers find noise, vibrations and harshness (NVH) as well as squeaking and rattling annoying, particularly after repair work. It is therefore important that the condition of the vehicle at the time of production be restored after an accident repair.

After body repairs, the entire repair area must be checked for any water leaks. It is crucial that a leak test be carried out as part of the final inspection so that water leaks can be detected and eliminated even before delivery of the vehicle to the customer.

The requirements of the vehicle manufacturer are to be taken into consideration during all inspections. Only in this way can it be guaranteed that the vehicle quality is not reduced through insufficient repair quality.

Description and Usage of Body Repair Literature

Symbols

Health and Safety Precautions

Environmental Regulations

Body Construction

Diagnosis and Damage Evaluation

Body Sheet Metal

Tools and Equipment for Body Repairs

Establish Repair Method

Alignment Check

Straightening

Complete Panel Replacement/Partial Replacement

Corrosion Prevention

Corrosion Damage/Corrosion Repair

Sealer, Underbody Protection Material and Adhesives

Cutting Technique

Panel Beating Technique and Smart Repairs

Paintless Dent Removal

Plastic Repairs

Joining Techniques

Special Repair Techniques

Impact of Insufficient Repair Quality

Water Leaks

Wind Noise

Wind Noise

Noise, Vibration and Harshness