Part 1

PRECAUTION

1. WORK PRECAUTIONS





a. VEHICLE PROTECTION
1. When welding, cover glass, seats, carpets, etc. with heat resistant fireproof covers to protect them.

b. SAFETY





1. Never stand in the path of the chain when using a puller on the body or frame, and be sure to attach a safety cable.





2. If it is necessary to use a flame in the area of the fuel tank, first remove the tank and plug the fuel line.








c. SAFETY WORK CLOTHES
1. In addition to the usual mechanic's wear, cap and safety shoes, the appropriate gloves, head protector, welder's glasses, ear plugs, face protector, dust mask, etc. should be worn as the situation demands.

2. PRECAUTIONS WHEN REPAIRING BODY FRAME PARTS (INCLUDING CRUSH BOX)





a. PROHIBITION OF HEAT REPAIR FOR BODY FRAME PARTS
1. Rustproof high strength steel sheets are used for the body frame. Therefore, if these parts are heat repaired using an acetylene torch or equivalent, the crystalline structure changes, causing the strength of the steel sheets to decrease. Also, the zinc coating which is used to protect the body from rust will be damaged. This causes the surface of the steel sheets to become oxidized, which reduces their ability to resist rust.





b. WHEN TO REPLACE FRAME PARTS

NOTICE: Replace frame parts that have kinks.

HINT: What is kink?

A deformation on a steel sheet that cannot be returned to its original shape by pulling or hammering due to the deformation angle being sharp.








c. REPAIR OF DOOR SIDE IMPACT BEAM IS PROHIBITED
1. The impact beam is designed so that it performs at 100% in its original shape. However, if the impact beam is repaired, its performance may not be the same as before the accident.

PARTS WHICH ARE PROHIBITED TO BE REPAIRED: Door side impact beam





d. REPAIR OF BUMPER REINFORCEMENT IS PROHIBITED
1. The bumper reinforcement is designed so that it performs at 100% in its original shape. However, if the bumper reinforcement is repaired, its performance may not be the same as before the accident.

PARTS WHICH ARE PROHIBITED TO BE REPAIRED: Bumper reinforcement

3. PRECAUTIONS FOR CORRECT REPAIR





a. REMOVAL OF ADJACENT COMPONENTS
1. When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage.

NOTICE: If the paint film is damaged, make sure to refinish the paint.





b. ANTI-RUST TREATMENT BEFORE WELDING
1. Apply welding primer to the contact surfaces of the welding areas to protect them from rust.

NOTICE: Do not apply welding primer outside of the contact surfaces.








c. MAKING HOLES FOR PLUG WELDING
1. For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding.





d. WELDING PRECAUTIONS
1. The number of welding spots should be as follows.

Spot weld: 1.3 X No. of manufacturer's spots
Plug weld: More than No. of manufacturer's plugs.

2. Spot weld locations Avoid welding over previously welded areas.

4. ANTI-RUST TREATMENT AFTER INSTALLATION





a. BODY SEALER APPLICATION

PURPOSE: For water-proofing and anti-rust measures, always apply the body sealer to the body panel seams and hems of the doors, hood, etc.

NOTICE: Apply body sealer neatly to parts that require a high quality appearance.





b. UNDERCOAT APPLICATION

PURPOSE: To prevent corrosion and protect the body from gravel, always apply a sufficient undercoating to the areas indicated.





c. VEHICLE BODY ANTI-RUST AGENT APPLICATION

PURPOSE: The purpose is to protect areas from rust which are difficult to paint such as the backside of the box-shaped cross section frame parts.

METHOD: Apply anti-rust agent through the service holes and/or installation holes of the parts.