Seat Leon 2013- Body Repairs

Edition 01.2014. Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

Repair Group overview for Body Repairs

Repair Group
00 – Technical data
50 – Body – front
51 – Body – centre
53 – Body – rear

CONTENTS

  • 00 – Technical data
    • 1 General instructions for body repair works
      • 1.1 Diagnosis of accident vehicles
      • 1.2 Diagnosis and assessment of body damages
      • 1.3 General notes on body repairs
      • 1.4 Consequences of poor quality of repair work
      • 1.5 Warranties
      • 1.6 Separating cuts
      • 1.7 Cuts and body sections
      • 1.8 Conditions in which body and / or parts are adjusted for painting
      • 1.9 Original joint
      • 1.10 Galvanised body parts
      • 1.11 Removing remaining material
      • 1.12 New parts
      • 1.13 Spare parts
    • 2 Security standards
      • 2.1 Collective protection elements of the body
      • 2.2 Collective protection in the bodywork areas
      • 2.3 Disassembly of components
      • 2.4 Battery, welding operations
      • 2.5 Electronic control units
      • 2.6 Procedure for electronic control units following accident repairs
      • 2.7 Paintwork, glass, upholstery, trim panels
      • 2.8 Fuel tank and fuel pipes
      • 2.9 Air conditioning
      • 2.10 Cutting, straightening and/or dent removal work on vehicles with airbag . .
      • 2.11 Checking the safety belts
      • 2.12 Working on vehicles with belt tensioners
      • 2.13 Removing seats with side airbag
    • 3 Body construction
      • 3.1 Tailored Blanks
    • 4 Anti-corrosion measures
      • 4.1 Anti-corrosion treatment
      • 4.2 Electrolytic galvanisation
      • 4.3 Hot-dip galvanisation
      • 4.4 Sealing compound
      • 4.5 Underbody protection
      • 4.6 Cavity wax
      • 4.7 Weldable prime coats
      • 4.8 Damper blades
      • 4.9 Noise insulation
      • 4.10 Long-term body protection
      • 4.11 Warranty information
    • 5 Body – Bonded joints
      • 5.1 Bonded joints
      • 5.2 Joints using adhesive and resistance spot welding
      • 5.3 Inspecting and repairing bonded joints
      • 5.4 Repair methods for replacing body parts
      • 5.5 Cutting
      • 5.6 Bonding procedure
    • 6 Meaning of the symbols used for the description of operations
    • 7 Equipment
      • 7.1 Generic equipment
      • 7.2 Welding points extraction equipment
      • 7.3 Welding and straightening equipment
      • 7.4 Application pistol
      • 7.5 Measurement equipment
      • 7.6 Workbenches
      • 7.7 Equipment equivalence table
    • 8 Equipment to cut out – separate parts
    • 9 Complete replacement I partial replacement
      • 9.1 Complete replacement
      • 9.2 Partial replacement
    • 10 Joining techniques used in manufacture
      • 10.1 Laser welding
      • 10.2 MIG-brazing welding (CuSi3)
    • 11 Sheet steel repairs
      • 11.1 Repair techniques for body sheets
      • 11.2 Steel parts of the body with higher elastic limit
      • 11.3 Galvanised body parts
      • 11.4 Joining techniques
    • 12 Welding work
      • 12.1 Technical instructions for welding work
      • 12.2 Initial electric precautions before beginning welding work
      • 12.3 Instructions on the resistance spot welding (RP)
      • 12.4 The principal faults in resistance spot welding
      • 12.5 Verification of the resistance points
      • 12.6 Electrode types
      • 12.7 Notes on inert gas welding (under a protective gas atmosphere) .
      • 12.8 The principal faults in inert gas welding
      • 12.9 Types and applications of welding joints
    • 13 Straightening
      • 13.1 Straightening Process
    • 14 Plastic repair techniques
      • 14.1 Plastic repair set
      • 14.2 Removing dents
      • 14.3 Repairing scratches
      • 14.4 Repairing cracks (with a length of up to 100 mm)
      • 14.5 Repairing holes (with a diameter of up to 30 mm)
    • 15 Glass repairs
      • 15.1 Repairing windscreens
      • 15.2 Conditions:
      • 15.3 Description of repair work
      • 16 Specific model data
    • 17 Labels
      • 17.1 Location of data labels
    • 18 Bodywork
      • 18.1 panel gaps
      • 18.2 Tolerances, rear
    • 19 Dimensions
      • 19.1 Bodywork dimensions, front section
      • 19.2 Bodywork dimensions, central section – lateral
      • 19.3 Bodywork dimensions, central section
      • 19.4 Floor dimensions, without mechanics
    • 20 Body elements made from ultra high strength steel
      • 20.1 Locations of the components made from ultra high strength steel
    • 21 Laser welding, MIG welding and MIG brazing welding (CuSi3)
      • 21.1 Position for laser welding
      • 21.2 Positions for MIG welding and MIG brazing
    • 22 Kleber
      • 22.1 Position for structural glue
      • 22.2 Position for partial structural glue
    • 23 Products for corrosion protection and soundproofing
      • 23.1 Noise insulation
      • 23.2 Damper blades
      • 23.3 Cavity wax
      • 23.4 Underbody protection
      • 23.5 Sealing compound
    • 24 Reshaping work, access zones
      • 24.1 Access zones for manual straightening
    • 25 Inspection areas of bodywork depending on the type of collision
      • 25.1 Frontal collision
      • 25.2 Front side impact
      • 25.3 Central side impact
      • 25.4 Rear side impact
      • 25.5 Rear central impact
    • 26 Platform repairs
      • 26.1 Work on the straightening jig with the MZ-SAT 5310 system – mechanics installed
      • 26.2 Work on the straightening jig with the MZ-SAT 5310 system – mechanics removed
      • 26.3 Portal gauge
      • 26.4 Work on the straightening jig with the SAT 5305 electrical system
    • 27 Check points for the platform
      • 27.1 Platform check points, with mechanics fitted
      • 27.2 Platform reference points, with mechanics removed
  • 50 – Body – front
    • 1 Parts breakdown
    • 2 Engine console – engine bracket: replacing, partially
      • 2.1 Initial removal of exterior and interior components
      • 2.2 Spare part
      • 2.3 Separation areas
      • 2.4 Preparing the new part
      • 2.5 Straightening the joint zones
      • 2.6 Part assembly
      • 3.2 Spare part
      • 3.3 Special characteristics of the repairs
      • 3.4 Separation areas
      • 3.5 Preparing the new part
      • 3.6 Straightening the joint zones
      • 3.7 Part assembly
      • 3.8 Final fitting operations
    • 4 Upper outer sill: replacing, partially
      • 4.1 Initial removal of exterior and interior components
      • 4.2 Spare part
      • 4.3 Separation areas
      • 4.4 Preparing the new part
      • 4.5 Straightening the joint zones
      • 4.6 Part assembly
    • 5 Upper inner sill: Renew
      • 5.1 Initial removal of exterior and interior components
      • 5.2 Initial removal of bodywork elements
      • 5.3 Spare part
      • 5.4 Special characteristics of the repairs
      • 5.5 Separation areas
      • 5.6 Preparing the new part
      • 5.7 Straightening the joint zones
      • 5.8 Part assembly
      • 5.9 Final fitting operations
    • 6 Front wheel housing: replace, complete part
      • 6.1 Initial removal of exterior and interior components
      • 6.2 Initial removal of bodywork elements
        6.3 Spare part
      • 6.4 Special characteristics of the repairs
      • 6.5 Separation areas
      • 6.6 Preparing the new part
      • 6.7 Straightening the joint zones
      • 6.8 Part assembly
      • 6.9 Final fitting operations
      • 7.1 Initial removal of exterior and interior components
      • 7.2 Spare part
      • 7.3 Separation areas
      • 7.4 Preparing the new part
      • 7.5 Straightening the joint zones
      • 7.6 Part assembly
      • 7.7 Final fitting operations
    • 8 Front sill cover: replace, complete part
      • 8.1 Initial removal of exterior and interior components
      • 8.2 Initial removal of bodywork elements
      • 8.3 Spare part
      • 8.4 Special characteristics of the repairs
      • 8.5 Separation areas
      • 8.6 Preparing the new part
      • 8.7 Straightening the joint zones
      • 8.8 Part assembly
      • 8.9 Final fitting operations
    • 9 Front sill: replace, complete part
      • 9.1 Initial removal of exterior and interior components
      • 9.2 Initial removal of bodywork elements
      • 9.3 Spare part
      • 9.4 Special characteristics of the repairs
      • 9.5 Separation areas
      • 9.6 Preparing the new part
      • 9.7 Straightening the joint zones
      • 9.8 Set
      • 9.9 Part assembly
      • 9.10 Final fitting operations
    • 10 Front sill: replacing, partially
      • 10.1 Initial removal of exterior and interior components
      • 10.2 Initial removal of bodywork elements
      • 10.3 Spare part
      • 10.4 Separation areas
      • 10.5 Preparing the new part
      • 10.6 Straightening the joint zones
      • 10.7 Set
      • 10.8 Part assembly
      • 10.9 Final fitting operations
    • 11 Front right-hand longitudinal member: replacing, partially
      • 11.1 Initial removal of exterior and interior components
      • 11.2 Initial removal of bodywork elements
      • 11.3 Spare part
      • 11.4 Separation areas
      • 11.5 Preparing the new part
      • 11.6 Straightening the joint zones
      • 11.7 Set
      • 11.8 Part assembly
      • 11.9 Final fitting operations
    • 12 Sill end: replace, complete part
      • 12.1 Initial removal of exterior and interior components
      • 12.2 Spare part
      • 12.3 Separation areas
      • 12.4 Preparing the new part
      • 12.5 Straightening the joint zones
      • 12.6 Part assembly
  • 51 – Body – centre
    • 1 Parts breakdown
    • 2 Breakdown of spare parts (Panoramic roof)
    • 3 Roof: replace, complete part
      • 3.1 Initial removal of exterior and interior components
      • 3.2 Spare part
      • 3.3 Special tools
      • 3.4 Special characteristics of the repairs
      • 3.5 Separation areas
      • 3.6 Preparing the new part
      • 3.7 Straightening the joint zones
      • 3.8 Set
      • 3.9 Fitting the roof
      • 3.10 Part assembly
      • 3.11 Final fitting operations
    • 4 Panoramic roof: replace, complete part
      • 4.1 Initial removal of exterior and interior components
      • 4.2 Spare part
      • 4.3 Tools and equipment
      • 4.4 Special characteristics of the repairs
      • 4.5 Separation areas
      • 4.6 Preparing the new part
      • 4.7 Straightening the joint zones
      • 4.8 Set
      • 4.9 Fitting the roof
      • 4 10 Part
      • 4.11 Final fitting operations
    • 5 Front roof crossbeam: replace, complete part
      • 5.1 Initial removal of exterior and interior components
      • 5.2 Initial removal of bodywork elements
      • 5.3 Spare part
      • 5.4 Separation areas
      • 5.5 Preparing the new part
      • 5.6 Straightening the joint zones
      • 5.7 Part assembly
    • 6 Cover of front panoramic roof cross member: replace, complete part . .
      • 6.1 Initial removal of exterior and interior components
      • 6.2 Spare part
      • 6.3 Special characteristics of the repairs
      • 6.4 Separation areas
      • 6.5 Preparing the new part
      • 6.6 Straightening the joint zones
      • 6.7 Part assembly
    • 7 Central roof beam: replace, complete part
      • 7.1 Initial removal of exterior and interior components
      • 7.2 Initial removal of bodywork elements
      • 7.3 Spare part
      • 7.4 Separation areas
      • 7.5 Preparing the new part
      • 7.6 Straightening the joint zones
      • 7.7 Part assembly
    • 8 Rear roof crossbeam: replace, complete part
      • 8.1 Initial removal of exterior and interior components
      • 8.2 Initial removal of bodywork elements
      • 8.3 Spare part
      • 8.4 Separation areas
      • 8.5 Preparing the new part
      • 8.6 Straightening the joint zones
      • 8.7 Part assembly
    • 9 Roof member: Renew
      • 9.1 Initial removal of exterior and interior components
      • 9.2 Initial removal of bodywork elements
      • 9.3 Spare part
      • 9.4 Special characteristics of the repairs
      • 9.5 Separation areas
      • 9.6 Preparing the new part
      • 9.7 Straightening the joint zones
      • 9.8 Part assembly
    • 10 Hinge pillar: replace, complete part
      • 10.1 Initial removal of exterior and interior components
      • 10.2 Spare part
      • 10.3 Special characteristics of the repairs
      • 10.4 Separa tion, pareas
      • 10.6 Straightening the joint zones
      • 10.7 Set
      • 10.8 Part assembly
      • 10.9 Final fitting operations
    • 11 Hinge pillar reinforcement: replace, complete part
      • 11.1 Initial removal of exterior and interior components
      • 11.2 Initial removal of bodywork elements
      • 11.3 Spare part
      • 11.4 Special tools
      • 11.5 Special characteristics of the repairs
      • 11.6 Separation areas
      • 11.7 Preparing the new part
      • 11.8 Straightening the joint zones
      • 11.9 Set
      • 11.10 Part assembly
      • 11.11 Final fitting operations
    • 12 Central strut B reinforcement. replace, complete part
      • 12.1 Initial removal of exterior and interior components
      • 12.2 Initial removal of bodywork elements
      • 12.3 Spare part
      • 12.4 Special tools
      • 12.5 Special characteristics of the repairs
      • 12.6 Separation areas
      • 12.7 Preparing the new part
      • 12.8 Straightening the joint zones
      • 12.9 Set
      • 12.10 Part assembly
    • 13 Outer lower sill: replace, complete part
      • 13.1 Initial removal of exterior and interior components
      • 13.2 Spare part
      • 13.3 Special characteristics of the repairs
      • 13.4 Separation areas
      • 13.5 Preparing the new part
      • 13.6 Straightening the joint zones
      • 13.7 Set
      • 13.8 Part assembly
      • 13.9 Final fitting operations
    • 14 Lower inner sill replace, complete part
      • 14.1 Initial removal of exterior and interior components
      • 14.2 Initial removal of bodywork elements
      • 14.3 Spare part
      • 14.4 Special characteristics of the repairs
      • 14.5 Separation areas
      • 14.6 Preparing the new part
      • 14.7 Straightening the joint zones
      • 14.8 Set
      • 14.9 Part assembly
    • 15 Lower inner sill replacing, partially
      • 15.1 Initial removal of exterior and interior components
      • 15.2 Initial removal of bodywork elements
      • 15.3 Spare part
      • 15.4 Special characteristics of the repairs
      • 15.5 Separation areas
      • 15.6 Preparing the new part
      • 15.7 Straightening the joint zones
      • 15.8 Set
      • 15.9 Part assembly
    • 16 Replacing the longitudinal member external seat guide
      • 16.1 Initial removal of exterior and interior components
      • 16.3 Spare part
      • 16.4 Special characteristics of the repairs
      • 16.5 Separation areas
      • 16.6 Preparing the new part
      • 16.7 Straightening the joint zones
      • 16.8 Set
      • 16.9 Part assembly
    • 17 Seat guide crossbeam: replace, complete part
      • 17.1 Initial removal of exterior and interior components . . . .
      • 17.2 Spare part
      • 17.3 Special characteristics of the repairs
      • 17.4 Separation areas
      • 17.5 Preparing the new part
      • 17.6 Straightening the joint zones
      • 17.7 Part assembly
  • 53 – Body – rear
    • 1 Parts breakdown
    • 2 End Plate: replace, complete part
      • 2.1 Initial removal of exterior and interior components . . . .
      • 2.2 Initial removal of bodywork elements
      • 2.3 Spare part
      • 2.4 Special characteristics
      • 2.5 Separation areas
      • 2.6 Preparing the new part
      • 2.7 Straightening the joint zones
      • 2.8 Part assembly
      • 2.9 Final fitting operations
    • 3 Reception plate: replace, complete part
      • 3.1 Initial removal of exterior and interior components . . . .
      • 3.2 Initial removal of bodywork elements
      • 3.3 Spare part
      • 3.5 Preparing the new part
      • 3.6 Straightening the joint zones
      • 3.7 Part assembly
      • 3.8 Final fitting operations
    • 4 Reception plate: replacing, partially
      • 4.1 Initial removal of exterior and interior components . . . .
      • 4.2 Initial removal of bodywork elements
      • 4.3 Spare part
      • 4.4 Separation areas
      • 4.5 Preparing the new part
      • 4.6 Straightening the joint zones
      • 4.7 Part assembly
      • 4.8 Final fitting operations
    • 5 Rain guard duct: replacing, partially
      • 5.1 Initial removal of exterior and interior components . . . .
      • 5.2 Initial removal of bodywork elements
      • 5.3 Spare part
      • 5.4 Special characteristics of the repairs
      • 5.5 Separation areas
      • 5.6 Preparing the new part
      • 5.7 Straightening the joint zones
      • 5.8 Part assembly
      • 5.9 Final fitting operations
    • 6 End plate crossbeam: replace, complete part
      • 6.1 Initial removal of exterior and interior components . . . .
      • 6.2 Spare part
      • 6.3 Special characteristics of the repairs
      • 6.4 Separation areas
      • 6.5 Preparing the new part
      • 6.6 Straightening the joint zones
      • 6.7 Part assembly
      • 6.8 Final fitting operations
    • 7 Boot floor: replace, complete part
      • 7.1 Initial removal of exterior and interior components
      • 7.2 Initial removal of bodywork elements
      • 7.3 Spare part
      • 7.4 Special characteristics of the repairs
      • 7.5 Separation areas
      • 7.6 Preparing the new part
      • 7.7 Straightening the joint zones
      • 7.8 Part assembly
      • 7.9 Final fitting operations
    • 8 Rear sill: replacing, partially
      • 8.1 Initial removal of exterior and interior components
      • 8.2 Initial removal of bodywork elements
      • 8.3 Spare part
      • 8.4 Special characteristics of the repairs
      • 8.5 Separation areas
      • 8.6 Preparing the new part
      • 8.7 Straightening the joint zones
      • 8.8 Set
      • 8.9 Part assembly
    • 9 Rear side piece: replace, complete part
      • 9.1 Initial removal of exterior and interior components
      • 9.2 Spare part
      • 9.3 Special characteristics of the repairs
      • 9.4 Separation areas
      • 9.5 Preparing the new part
      • 9 7 Set
      • 9.8 Part assembly
      • 9.9 Final fitting operations
    • 10 Rear outer wheel housing: replace, complete part
      • 10.1 Initial removal of exterior and interior components
      • 10.2 Initial removal of bodywork elements
      • 10.3 Spare part
      • 10.4 Special characteristics of the repairs
      • 10.5 Separation areas
      • 10.6 Preparing the new part
      • 10.7 Straightening the joint zones
      • 10.8 Set
      • 10.9 Part assembly
      • 10.10 Final fitting operations

Language: English
Format: PDF
Pages: 458

Seat Leon 2013- Body Repairs

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