Vehicle-Specific Repair Procedures and OEM Welding Requirements
OEM procedure is the authority
Vehicle-specific repair procedures define weld type, location, count, sequence, and finish. The exam tests whether you retrieve and apply the correct procedure for the vehicle, not whether you can weld in general. Identify the year, make, model, and trim; check body repair manuals and technical service bulletins; confirm sectioning locations and allowed joining methods.
What to verify
- Weld count and spacing on flanges, pillars, rails, and aprons.
- Whether the joint is STRSW, GMAW, rivet-bond, or adhesive-only.
- Filler, gas, and equipment approvals.
- Battery disconnect, SRS disable, and high-voltage precautions.
- Corrosion protection: e-coat, weld-through primer, seam sealer, cavity wax.
- Post-repair inspections and ADAS calibration.
Worked example
A quarter-panel replacement on an AHSS vehicle lists 12 spot welds, 4 MIG plug welds, and structural adhesive. The reasoning: use the specified squeeze welder for the 12 welds, follow the plug-weld locations and hole size, apply adhesive in the stated pattern, and restore sealers. Adding extra MIG welds “for strength” can overheat the AHSS and violate the procedure.
Traps
Using a generic weld-count chart; assuming last year’s model is the same; ignoring a TSB; skipping e-coat restoration; forgetting ADAS calibration after structural repair.