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PERFORMING A POST-REPAIR INSPECTION

April 21, 2003 -After a vehicle has been involved in a collision and repairs have been made, a post-repair inspection may have to be performed. A simple checklist can be used during the post-repair inspection (see Figure 1). A sample checklist that can be downloaded is available at the end of this article. Using a checklist will provide documentation that all of the tasks have been performed. Depending on the location and extent of the damage, some areas on the inspection checklist can be overlooked. Obviously, it may not be necessary to perform a complete post-repair inspection on a vehicle that had a minor dent in a door repaired and refinished, but it may be necessary to check the panel gaps for the proper clearance. More extensive structural repairs may require a more thorough inspection.

The first part of the checklist is the pre-test-drive inspection. This includes checking all of the fluid levels, including engine oil, engine coolant, transmission fluid, brake fluid, power steering fluid and windshield washer fluid to ensure that they are filled to the proper levels. The belts can be checked to ensure that the routing is correct and that the proper tension is applied. The convenience accessories, including the radio presets and clock, should be reprogrammed if the battery was disconnected (see Figure 2). Operate the blower motor on all speeds to verify that it is operational and that it is free from dust and debris. Check and record the tire air pressure. Check the wheel nuts with a torque wrench and operate all of the exterior lamps to verify that they are working properly. If body panels were removed or any structural repairs were performed, the gaps can be measured with a gap gauge as well as visually inspected for any contact with other panels (see Figure 3).

Next, the engine run test can be performed. Start the engine to see if there are any Diagnostic Trouble Codes (DTC) (see Figure 4). While the engine is running, inspect any fluid connection points that were disconnected during repairs. These points may include coolant hoses, transmission cooler lines, engine oil cooler lines, power steering hoses and lines, and brake lines. If no leaks are present, warm the engine to operating temperature to verify that the engine thermostat opens and that the heater control mix valves are operational. Check the air conditioning system to make sure that it cools to the recommended temperature. Check the automatic transmission fluid level while the engine is running at operating temperature (see Figure 5). Depress the brake pedal to verify that the braking system is operational and that there is no air in the brake hydraulic system. The exhaust system can be checked while the engine is running by holding a towel over the tailpipe and listening for any leaks.

After the engine run test has been performed and all of the items are verified, the vehicle can be test-driven. When performing a test-drive, verify that the vehicle drives straight and does not pull or wander. Ensure that the transmission and transfer case shift smoothly. Listen for any noise that occurs, including clunks, rattles, squeaks or wind noise. Also check for any DTCs that may occur.

After the test-drive, recheck all of the fluid levels and test the coolant for the correct freeze protection (see Figure 6). Also, visually check the panel alignment again due to any settling of body mounts that may have occurred. A torque wrench can be used to recheck the wheel nut torque if the wheels were removed during repairs (see Figure 7). The vehicle can now be sent to the detailing department to be prepared for delivery to the customer.

Again, a complete post-repair inspection is not always necessary, and not all parts of the checklist will have to be performed for every repair. A downloadable example of an inspection checklist is provided below. A collision repair business can create a checklist that may better suit its needs. The end result is that the consumer and the collision repair business are assured that a complete repair has been performed.