To learn more about ALLDATA Collision S3500 and the essential procedural information that it provides to make your
business more profitable, visit www.alldata.com/11/collision.
PROCEDURE 1: Sectioning
EXAMPLE VEHICLE: 2010 Mercedes Benz CL 550 4MATIC (216.386) V8-5.5L (273.961)
Front Lower Frame Rail
Service and Repair, Sectioning: AR62.20-P-1260-01SX Separate Longitudinal Member Front Section
The following operation steps are shown on model 221 on the left side of the vehicle and must be performed
analogously on the right side in the event of damage.
IMAGE: Covers Steps 1 – 3:
1.
Mark separation line on longitudinal member front section (1) (area A).
2.
Cut longitudinal member front section (1) at separation point with body saw (area A).
Completely separate longitudinal member front section (1).
3.
Remove damaged longitudinal member front section (1).
IMAGE: Covers Steps 4 – 6:
4.
Install left straightening tool (2).
5.
Position new part of longitudinal member front section (1) on left straightening tool (2).
Use new part of longitudinal member front section (1) as cutting template.
6.
Mark cutting line with marking needle (4) (area E).
IMAGE: Covers Steps 7 – 12:
7.
Remove left straightening tool (2).
8.
Install right straightening tool (3).
9.
Position new part of longitudinal member front section (1) on right straightening tool (3).
Use new part of longitudinal member front section (1) as cutting template.
10. Mark cutting line with marking needle (4) (area F).
11. Connect cutting lines and mark with marking needle (4) (areas E and F).
12. Separate at separation point with body saw (areas E and F).
IMAGE: Covers Steps 13 – 14:
13. Grind mating surfaces in cross-hatched areas down to bare metal using round wire brush.
14. Remove sanding dust using wet/dry vacuum cleaner.
PROCEDURE 2: Body Construction — Treatment of steels
EXAMPLE VEHICLE: 2011 Dodge Caliber L4-2.0L
BODY CONSTRUCTION CHARACTERISTICS
Definitions of Steels used in the Jeep Compass:

MS 66 — Represents an uncoated Hot Rolled Steel Sheet used mainly for interior braces and reinforcements.

MS 67 — Represents an uncoated Cold Rolled Sheet structural steel used in areas where structural integrity is
critical. EG., the type of steel used for the “A” pillar.

MS 264 — Represents an uncoated high strength low alloy (HSLA) steel used in applications where structural
integrity is critical.

MS 6000-44A — Low carbon , hot dipped galvanneal (or EGA) with 45 g/m2 minimum coating weight on both
sides. — Most common Sheet Steel product used by Chrysler.

MS 6000-44VA — 50 ksi min. yield strength , HSLA, killed steel, with 44 g/m2 minimum coating weight on both
sides. — Most common high strength coated steel product used by Chrysler.

MS 10176 — Boron-alloyed steels ate analogy with 22MnB5 which are matched to the hardening process die.
Sheet blanks are heat treated in the furnace on an inert gas or air atmosphere and then formed in the press die
and hardened at the same time. The boron is produced in two configurations one for use in upper body and one
that has hot dip aluminizated coating for corrosion protection.

MS82-1228 — Represent a coated high strength low alloy (HSLA) hot or cold rolled sheet steel used in
applications where structural integrity is critical.
PARTIAL LIST OF STEEL APPLICATIONS
Galvannealed Steel

Body Side Aperture

Cowl Plenum Panel

Cowl Side Panel

Dash Panel

Front Door — Inner Panel

Front Door — Outer Panel

Front Fender

Front Floor Pan

Front Hinge Pillar

Front Rail

Front Strut Mounting

Tower Front Wheelhouse (Front and Rear)

Lower Radiator Crossmember

Rear Door — Inner Panel

Rear Door — Outer Panel

Rear Floor Pan

Rear Floor Pan

Front Crossmember

Rear Floor Pan Side Rail

Rear Suspension Crossmember

Rear Quarter Panel — Inner

Rear Quarter Panel — Outer

Rear Wheelhouse — Inner

Roof Panel

UpperLoad Path Beam

Upper Radiator Crossmember
The following measures have been implemented in order to provide maximum corrosion prevention and protection.
1.
The use of galvannealed coatings throughout the body structure.
2.
Ecoat is used on the complete body in all instances.
3.
Body sealing.
4.
Stone-chipping resistant primer application.
5.
Underbody corrosion prevention.
PROCEDURE 3: Body Sealant
EXAMPLE VEHICLE: 2007 Volvo S80 AWD V8-4.4L VIN 85 B8444S
Body Sealant
Service and Repair, Procedures: Body Seal, Sealing Diagram
BODY SEAL, SEALING DIAGRAM
NOTE: Some variation in the illustrations may occur, but the essential information is always correct.
1.
Weatherstrip
When replacing sheet metal parts, the joints between the different sheet metal parts shall be sealed according to
illustration with 116 1767.
2.
Spray sealant
Part number 116 1651 is a spray body sealant which restores the vehicle in production-like condition after body
work. The sealant can be applied in bead or sprayed in a thin layer with a spray gun, it is also easy to apply with
a brush. When applying in a bead, this type of sealant is very difficult to rework since the sealant has a loose
consistency. It is possible to paint over the sealant and it hardens approx. 3 mm per 24 h.
3.
Seal that can be sanded
Visible seals, such as the joint between roof sill and roof panel, require sealants that:
o
flows out without running
o
has the correct hardness
o
can be sanded when hardened
o
has the correct flexibility.
The above criteria are satisfied by 3M 08115, which has been tested and approved for sealing.
NOTE: 3M 08458 is not approved as a substitute for Volvo bodywork adhesive.
4.
Foam rubber replacement soft (soundproofing foam)
Soundproofing foam is installed in hollow spaces to counteract propagation of sound in the body. There are 2
types of approved soundproofing foam:
o
Volvo’s soundproofing foam part number 681 7640 consists of a wax-treated cylinder 50x50 mm. It can be
compressed for installation between metal parts. Several cylinders can be used if one is not enough.
o
3M 08463 is a 2-component foam that starts to foam when the components are mixed. The foam is suitable
for filling of larger hollow spaces and can be applied between the roof bow and the roof panel where foam is
to be used. Follow the supplier's instructions for application.
PROCEDURE 4: Rustproofing
EXAMPLE VEHICLE: Volvo S80 AWD V8-4.4L
RUSTPROOFING
NOTE: Some variation in the illustrations may occur, but the essential information is always correct.
RUSTPROOFING SCHEDULE, CAVITY PROTECTION
981 4075 Spray gun and a hose nozzle with 360 degree spray pattern (see illustration). Insert the hose in the cavity
and spray while slowly pulling the hose out.
If repairs are made to the body, the areas marked in the illustrations are to rustproofed extra thoroughly. Use: Cavity
protection, 116 1682
This applies, for example, to weld seams and areas that have been worked with in other ways.
RUSTPROOFING SCHEDULE, STONE-CHIP PROTECTION
Use: Stone-chip protection, 116 1299
Apply stone-chip protection to the areas of the vehicle marked in grey on the illustration. 981 4076 Spray gun 981
4076 Spray Gun.
RUSTPROOFING SCHEDULE, UNDERBODY PROTECTION
Use: Underbody protection, 116 1298
Apply underbody protection to the areas of the vehicle marked in grey on the illustration.981 4076 Spray gun 981
4076 Spray Gun.