CollisionStudyguide2021

I ncludes d amage a nalysIs & e stImatIng ! T he O fficial aSe S Tudy G uide ASE Collision Repair and Re fi nish Tests

ASE C olliSion R EpAiR And R EfiniSh T ESTS Overview ................................................................................................ 3–8 Collision Repair/Re fi nish Tests ........................................................... 9–38 • Painting and Re fi nishing (B2) ........................................................... 9 • Non-Structural Analysis and Damage Repair (B3) ......................... 14 • Structural Analysis and Damage Repair (B4) ................................. 20 • Mechanical and Electrical Components (B5) ................................. 25 • Damage Analysis and Estimating (B6) ........................................... 33 Test Prep & Training ............................................................................... 39 Table of Contents COPYRIGHT © 2021 by National Institute for A UTOMOTIVE S ERVICE E XCELLENCE All rights reserved

p AGE 4 ASE C olliSion R EpAiR And R EfiniSh S tudy G uidE o vERviEw ( ConTinuEd ) Your test results will be emailed to you immediately following your testing appointment. Results will not be given over the phone nor will they be released to anyone without your writtten permission. If you fail a test, you must wait 30 days from the test date before you can purchase it again. Certi fi cation credentials are valid for fi ve years. Recerti fi cation ensures certi fi ed technicians are seen as up-to-date in their profession. If you have been certi fi ed in an area for almost 5 years, it is time to register for the corresponding recerti fi cation test. Most recerti fi cation tests are about half the length of the initial certi fi cation tests. Collision Repair & Re fi nish Tests This Study Guide contains Test Speci fi cations, Task Lists, and sample questions for the following ASE tests: • Painting and Re fi nishing (Test B2) • Non-Structural Analysis and Damage Repair (Test B3) • Structural Analysis and Damage Repair (Test B4) • Mechanical and Electrical Components (Test B5) • Damage Analysis and Estimating (Test B6) ASE offers certi fi cation in areas including Automobile, Medium/Heavy Truck, Truck Equipment, Transit Bus, School Bus, Maintenance & Light Repair, Parts Specialist, and Advanced Level specialties. Separate guides are available for those test series. For full information on ASE testing as well as downloadable Study Guides and other test preparation resources, visit www.ase.com . Who Writes the Questions? Working professionals from the service industry with expertise in the test topic write the questions, which are entirely job-related. The questions are designed to test knowledge of the skills that you need to know in collision repair, re fi nishing or estimating; theoretical knowledge is not covered. Each question has its roots in an ASE “item-writing” workshop where working collision technicians, service representatives from automobile manufacturers (domestic and import), aftermarket parts and equipment manufacturers, estimators, and technical educators meet to share ideas and translate them into test questions. Each test question written must survive review by all members of the group. The

ASE C olliSion R EpAiR And R EfiniSh S tudy G uidE p AGE 5 o vERviEw ( ConTinuEd ) questions are written to mirror practical problems relevant to the collision repair, re fi nishing or estimating performed by technicians and estimators in their day-to- day work. After being written, all questions are pre-tested and quality-checked on a national sample of technicians or estimators. Those questions meeting ASE standards of quality and accuracy are then included in the scored sections of the tests; those that do not are redrafted or discarded altogether. How Do I Prepare for the ASE Tests? The most important thing you can do is become familiar with test content and question format. The Test Speci fi cations in this booklet describe the content covered by each test. The Task Lists detail the actual work performed in each specialty area. Together, these are the blueprint for writing and assembling the ASE tests. How Long are the Tests? Collision Repair & Re fi nish Tests 2021 Certi fi cation Tests Recerti fi cation Tests Name Number of questions Testing time Number of questions Testing time B2 Painting and Re fi nishing 65* 1.5 hrs 28 45 mins B3 Non-structural Analysis & Damage Repair 65* 1.5 hrs 28 45 mins B4 Structural Analysis & Damage Repair 60* 1.25 hrs 25 30 mins B5 Mechanical / Electrical Components 60* 1.25 hrs 25 30 mins B6 Damage Analysis and Estimating 60* 1.25 hrs 25 30 mins * Certi fi cation tests contain 10 research questions that are not counted for score. Since you don't know which questions those are, you need to answer every question. You must have passed the corresponding certi fi cation once to be eligible for the shorter recerti fi cation test.

ASE C olliSion R EpAiR And R EfiniSh S tudy G uidE p AGE 7 Bring your Admission Ticket and unexpired, government-issued photo ID with you. Books, notes, calculators, and electronic devices (including cell phones) will not be permitted in the test room. You will be assigned a locker to store personal items. Most test centers have airport-level security procedures for all candidates, so be prepared for “wanding” or other security checks. You will receive scratch paper and pencils, and for certain advanced level tests , a printed reference booklet. Each test appointment begins with a short tutorial on the operation of the testing platform. You may also preview the platform online at www.ase.com/asedemo before you arrive at the Test Center. Each test has a time limit, as listed in the chart on page 5. After you start your test, the computer screen will continuously display the amount of time left. If you fi nish early, you can either review your answers or end the test and continue to the next test (if you are taking more than one). Once you submit a test for scoring, you cannot go back and review it. If you are taking several tests and need a short break, take it between tests. Take your break when you reach the screen that asks if you are taking additional tests. Do not take a break during your test as the test clock will continue to run. If a question is dif fi cult, mark the answer that you think is correct and fl ag the question using the on-screen button. Then go on to the next question. When you have fi nished the test, you may have time to go back to the fl agged questions. Your score is based on the number of correct answers, so you should try to answer every question. When you fi nish your last test, you will be given a short customer satisfaction survey. After you complete the survey, inform the staff and leave. When you check your email, your test results will be waiting for you! If you need a paper copy right away, ask the staff to print your results before you leave the test center. Test Content and Sample Questions To help you prepare, each section begins with the Test Speci fi cations, which will list the main categories covered and the number of test questions, as well as percentage of the test devoted to each topic. The Task List describes the work activities a technician should be able to perform . This list was developed by working technicians and technical experts from across the country and will provide a valuable checklist telling you what you should know for the test. o vERviEw ( ConTinuEd )

p AGE 8 ASE C olliSion R EpAiR And R EfiniSh S tudy G uidE o vERviEw ( ConTinuEd ) The number of tasks listed does not equal the number of questions. Although every question relates to at least one listed task, some tasks may not appear on the test. Some complex tasks may be covered by several questions. Some questions may cover multiple simple tasks. The main goal of the list is to describe what is done on the job; any task on the list may be covered on the test. Sample questions follow the Task List. Although these speci fi c questions will not appear on tests, they are in the same format as actual test questions. The ASE tests employ several types of multiple-choice questions. Note that some questions have special instructions; the same instructions will appear with similar questions on the ASE tests. ■

p AGE 10 ASE C olliSion R EpAiR And R EfiniSh S tudy G uidE B2 T ASk l iST ( ConTinuEd ) 22. Prepare surfaces for seam sealer application; evaluate the application of seam sealers prior to re fi nishing. 23. Identify pin holing; determine the cause(s) and correct the condition. B. Spray Gun Operation and Related Equipment (6 questions) 1. Inspect, clean, adjust, maintain, and determine condition of spray guns and adequacy of related equipment (air hoses, regulator, air lines, air source, fi ltration unit and spray environment). 2. Adjust spray gun, air pressure, fl uid, and pattern control valves. 3. Select correct spray gun, needle, fl uid tip, and air cap for material being sprayed. 4. Force-dry sprayed materials (bake, infrared, UV lamps, air fl ow, etc.). C. Paint Mixing, Matching, and Applying (15 questions) 1. Determine the color, code, and type of fi nish on the vehicle. 2. Identify paint color formula and the use of mixing equipment and materials. 3. Mix and strain re fi nish material. 4. Use appropriate spray gun technique (arc, angle, distance, speed, and spray pattern overlap) for the fi nish being applied. 5. Apply selected product on test panel or let-down panel. 6. Check color match; adjust as necessary. 7. Apply single-stage topcoat for panel re fi nishing. 8. Apply basecoat or multi-stage (mica, pearl, etc.) coats for spot, panel, blending, and overall re fi nishing. 9. Apply clearcoat. 10. Re fi nish interior and exterior trim components. D. Solving Paint Problems During the Application Process (8 questions) 1. Identify dirt or other foreign objects in the re fi nished surface; determine the source(s), and correct the condition. 2. Identify a dry spray appearance in the re fi nished surface; determine the cause(s), and correct the condition. 3. Identify the presence of fi sh-eyes (crater like appearance); determine the cause(s), and correct the condition. 4. Identify lifting (surface distortion or wrinkling) of the re fi nished surface; determine the cause(s), and correct the condition. 5. Identify mottling or streaking in metallic, mica, and effect paint fi nishes; determine the cause(s), and correct the condition. 6. Identify excessive or lack of texture (orange peel); determine the cause(s), and correct the condition. 7. Identify an overspray condition; determine the cause(s), and correct the condition. 8. Identify sags and runs; determine the cause(s), and correct the condition. 9. Identify color mismatch, due to application variables; determine the cause(s), and correct the condition. 10. Identify tape tracking/marking; determine the cause(s), and correct the condition. 11. Identify poor hiding/lack of coverage; determine the cause(s) and correct the condition.

ASE C olliSion R EpAiR And R EfiniSh S tudy G uidE p AGE 11 B2 T ASk l iST ( ConTinuEd ) E. Finish Defects, Causes, and Cures (6 questions) 1. Identify delamination (poor adhesion, peeling); determine the cause(s) and correct the condition. 2. Identify fi nish cracking (crows feet or line-checking, micro-checking, etc.); determine the cause(s) and correct the condition. 3. Identify sags and runs in the re fi nished surface; determine the cause(s) and correct the condition. 4. Identify blistering in the fi nished surface; determine the cause(s) and correct the condition. 5. Identify water spotting on the fi nished surface; determine the cause and correct the condition. 6. Identify fi nish damage caused by bird droppings, tree sap, and other causes; correct the condition. 7. Identify fi nish damage caused by airborne contaminants (acids, soot, rail dust, chemi - cals, and other industrial-related causes); correct the condition. 8. Identify chalking (oxidation); correct the condition. 9. Identify bleed-through or staining; determine the cause and correct the condition. 10. Identify damage caused during buf fi ng/polishing painted surfaces; correct the condition. 11. Identify fi lm defects from too much or too little fi lm build; determine the cause and correct the condition. 12. Identify minor surface imperfections; determine the cause, and correct the condition. 13. Identify topcoat blend issues; determine the cause(s) and correct the condition. 14. Identify solvent popping; determine the cause(s) and correct the condition. 15. Identify shrinking, swelling, or splitting while the fi nish is curing; determine the cause(s), and correct the condition. 16. Identify die-back (dulling of the paint fi lm); determine the cause(s) and correct the condition. F. Safety Precautions (5 questions) Note: Federal EPA law, OSHA/NIOSA, establishes minimum compliance requirements for re fi nishing materials. States and local municipalities may institute requirements that exceed the Federal EPA, OSHA/NIOSA requirements. Knowledge of the Federal EPA, OSHA/NIOSA requirements will be addressed in the following tasks. 1. Identify and take necessary precautions with hazardous operations and materials. 2. Identify and correct vehicle, equipment and material hazards to employee health and safety. 3. Select personal protection equipment (PPE); inspect to insure fi t, operation, and maintenance. ■

ASE C olliSion R EpAiR And R EfiniSh S tudy G uidE p AGE 13 6. Which of these should be used when re fi nishing a plastic part? (A) A self-etching primer (C) A urethane primer (B) A primer surfacer * (D) An adhesion promoter 7. Dirt nibs are being sanded from a metallic base coat before applying the clearcoat. Painter A says that the clearcoat may be applied directly over the sanded basecoat. Painter B says that applying another basecoat will help prevent sandscratches from appearing. Who is right? (A) A only * (B) B only (C) Both A and B (D) Neither A nor B 8. A quarter panel and sail panel are being prepared for a clearcoat blend. The recommended plan of repair is to: (A) sand the sail panel with P220 grit sandpaper to insure proper clearcoat adhesion. * (B) extend the masking and clearcoat to nearest panel edge or breakpoint. (C) lightly buff with a fi nishing compound prior to color application. (D) lower the air pressure during the fi nal application of clearcoat. 9. The masking tape on a freshly painted vehicle has gotten damp overnight. The tape should be removed: (A) after the tape has completely dried. (B) when detailing begins. (C) when trim-out is complete. * (D) as soon as possible. B2 S AmplE Q uESTionS ( ConTinuEd )

p AGE 14 ASE C olliSion R EpAiR And R EfiniSh S tudy G uidE Content Questions Percentage Area in Test of Test A. Preparation 7 13% B. Outer Body Panel Repairs, Replacements, and Adjustments 17 31% C. Metal Finishing and Body Filling 8 15% D. Glass and Hardware 5 9% E. Welding, Cutting, and Removal 12 22% F. Plastic Repair 6 11% Total 55 100% T EST S pECifiCATionS And T ASk l iST n on -S TRuCTuRAl A nAlySiS And d AmAgE R EpAiR (T EST B3) A. Preparation (7 questions) 1. Review damage report and replacement parts for accuracy. Inspect for prior damage and repairs. Inspect for proper systems operation. 2. Identify potential health, safety, and environmental concerns associated with vehicle components and systems, i.e. ABS, air bags (SRS), refrigerants, hybrid electric vehicles, coolants, etc. 3. Research and determine repair plan, procedures, and methods of overall repairs in accordance with the vehicle manufacturer’s speci fi cations and accepted industry procedures (including calibration/initialization of advanced vehicle systems). 4. Position vehicle to perform repairs; lift, raise, or support if necessary. 5. Remove damaged or undamaged interior and exterior trim and moldings/claddings as necessary; document missing or broken one-time use parts/fasteners/components, store removed parts/fasteners/components. 6. Remove and store undamaged, non-structural body panels and components and mechanical/electrical components that may interfere with or be damaged during the repair process. 7. Check for malfunction indicator lamp (MIL) illumination; scan all computer systems and retrieve codes and settings; identify battery disconnect procedures. 8. Protect panels and parts adjacent to repair area to prevent damage during repair. 9. Remove dirt, grease, wax, and other contaminants from areas to be repaired. 10. Remove pinstripes, emblems and decals (transfers/overlays and other paint protection accessories); remove adhesives if necessary. 11. Remove corrosion protection, undercoatings, sealers, and other protective coatings as necessary to perform repairs. 12. Remove repairable plastics and other parts for off-vehicle repair. 13. Identify safety considerations: Personal Protection Equipment (PPE), shock hazards, fumes, safety data sheet (SDS), etc. before beginning any repair operation.

p AGE 16 ASE C olliSion R EpAiR And R EfiniSh S tudy G uidE B3 T ASk l iST ( ConTinuEd ) D. Glass and Hardware (5 questions) 1. Inspect, adjust, remove and/or replace moveable, electrically-heated, stationary, mechanically-fastened, bonded, and hinged glass. 2. Inspect, adjust, repair, or replace window regulators, run channels, power mechanisms, and related controls. Reset automatic features and clear stored codes if necessary. 3. Inspect, adjust, repair, remove or replace power glass roof panels and related controls. Reset automatic features and clear stored codes if necessary. 4. Inspect, adjust, repair, remove, or replace removable, manually-operated glass roof panels and hardware. 5. Diagnose and repair water leaks, dust leaks, wind noises; rattles, and vibrations; inspect, repair, or replace weatherstripping. 6. Inspect, adjust, and install convertible or retractable roof and related mechanisms. Reset automatic features and clear stored codes if necessary. 7. Scan computer systems and verify proper system operation following stationary glass removal or replacement. E. Welding, Cutting, and Removal (12 questions) 1. Identify weldable and non-weldable materials used in vehicle construction. 2. Identify the considerations for cutting, removing, and welding various types of steels, aluminum and other metals. 3. Determine the correct welding process to be used in speci fi c welding situations: [compression/inverter/squeeze type resistance spot (STRSW), GTAW (TIG), GMAW (MIG), MIG-brazing]; determine settings, electrode, wire type, diameter, gas and bonding material to be used in speci fi c welding processes. 4. Adjust the welding equipment for proper operation. 5. Perform test welds. Visually inspect, perform destructive test, and make adjustments as necessary. 6. Determine proper work clamp (ground) location. 7. Use the proper gun-to-joint angle, distance, speed, and direction of gun travel for welds being made in all positions. 8. Select proper STRSW arm set, electrode type and diameter, and settings based on the location and material to be welded. 9. Protect vehicle components (adjacent components, hybrid components, computers and other electronic modules) from possible damage caused by welding and cutting. 10. Clean or prepare the metal to be welded; ensure proper weld joint fi t-up; apply weld through primer if required. 11. Select and prepare the correct joint type (butt, lap, etc.) for the repair. 12. Identify and perform the correct type of weld (continuous, stitch, tack, plug, spot, slot, etc.) for each speci fi c welding operation. 13. Identify the causes of weld defects; perform required equipment maintenance and/or make necessary adjustments.

ASE C olliSion R EpAiR And R EfiniSh S tudy G uidE p AGE 17 F. Plastic Repair (6 questions) 1. Identify the types of plastic(s) or composite(s); determine repairability. 2. Identify the proper plastic or composite repair/cleaning procedures; clean and prepare the surfaces of plastic or composite parts for repair. 3. Repair plastic parts by welding or using adhesive repair materials; repair composite parts using adhesive repair materials; use reinforcing materials as required. 4. Reshape plastic parts. 5. Perform single or two-sided repairs in plastic or composite panels. 6. Replace bonded plastic or composite body panels; straighten or align mounting locations. 7. Replace mechanically fastened plastic or composite body panels; straighten or align mounting locations if necessary; torque fasteners to speci fi cations. ■

ASE C olliSion R EpAiR And R EfiniSh S tudy G uidE p AGE 19 5. After high-strength steel is heated, it should be cooled by: (A) spraying it with cold water. (B) air hosing it. * (C) letting it cool naturally. (D) wiping it with oil. 6. Technician A says that the gas fl ow rate must be regulated before using a GMAW (MIG) welder. Technician B says that the wire speed must be adjusted before using a GMAW (MIG) welder. Who is right? (A) A only * (C) Both A and B (B) B only (D) Neither A nor B 7. A fully charged A/C condenser is undamaged. However, it is blocking repair access to the damaged radiator core support. The technician should: (A) try to work around the condenser. * (B) recover the refrigerant and remove the condenser. (C) cut the radiator core support to gain access. (D) bend the condenser lines to hain access. 8. Cracks in a thermoplastic bumper fascia are to be repaired. Technician A says that the repairs can be made with a plastic welder. Technician B says that the repairs can be made with a structural adhesive. Who is right? * (A) A only (C) Both A and B (B) B only (D) Neither A nor B B3 S AmplE Q uESTionS ( ConTinuEd )

p AGE 20 ASE C olliSion R EpAiR And R EfiniSh S tudy G uidE T EST S pECifiCATionS And T ASk l iST S TRuCTuRAl A nAlySiS And d AmAgE R EpAiR (T EST B4) Content Questions Percentage Area in Test of Test A. Frame Inspection and Repair 16 32% B. Unibody and Unitized Structure Inspection, Measurement, and Repair 18 36% C. Stationary Glass 4 8% D. Welding, Cutting, and Joining 12 24% Total 50 100% A. Frame Inspection and Repair (16 questions) 1. Diagnose, repair, verify, and document repairs on underbody and upperbody structural damage using three-dimensional measuring systems (mechanical, elec - tronic/computerized, laser), and dedicated or universal fi xtures, in accordance with vehicle manufacturer/industry recommended procedures. 2. Check the vehicle with a tram gauge to determine further diagnostic procedures. 3. Lift, anchor, and support vehicle for repair and realignment. 4. Repair and align mash/collapse damage (change in length from body zero). 5. Repair and align sag/kickup damage (change in height from datum). 6. Repair and align sidesway/sway damage (change in width from centerline). 7. Repair and align twist damage (vertical misalignment in the center section). 8. Repair and align diamond damage. 9. Diagnose, repair, or replace damaged frame, frame horns, side rails, cross members, frame brackets, supplemental restraint system (SRS) mounting locations, and front, rear, or center sections in accordance with vehicle manufacturer/ industry recommended procedures. 10. Replace protective coatings, restore corrosion protection to repaired or replaced frame areas and anchoring locations. 11. Repair or replace stress-cracked frame members in accordance with vehicle manufacturer/industry recommended procedures. 12. Diagnose damaged mounting locations for steering, suspension, and powertrain components, which can cause vibration, steering, and wheel alignment problems, in accordance with vehicle manufacturer/ industry recommended procedures. 13. Perform stress-relieving procedures in accordance with vehicle manufacturer/industry recommended procedures. 14. Determine the direction of impact and the extent of direct and indirect damage. 15. Identify the frame type and composition; plan the methods and sequence of repair in accordance with vehicle manufacturer/industry recommended procedures.