Seat Leon 2013- Body Repairs

Seat

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

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

Seat Leon 2013- Body Repairs

CONTENTS