Body and Frame: Service Precautions
Precautions for Body Structure
Operation
WARNING:
- Failure to take proper precautions when performing the body repair work can result in severe personal injury.
- Be sure to take the following precautions to reduce the risk of injury.
- Wear clothing and protective items suitable for operation.
- Before attempting any body repair, be sure to disconnect negative (-) cable at battery.
- When using the body frame repair device for pulling-out operation, avoid standing in front of the pulling chain.
- Whenever repairing the body panel work near the fuel tank using flames or sparks, be sure to remove the fuel tank from the vehicle and prevent the removed fuel tank from fuel leakage referring to Fuel Tank Removal and Installation.
High-Strength Steel
NOTE:
- When body panels made of high-strength steel having the tensile strength more than 590 MPa damaged or deformed, be sure to replace them with new spare panels in repair work. Because such high-strength steel panels will remarkably loose it strength by cutting, heating and welding.
- Refer to Sheet Metal Description for tensile strength of steel panels.
Body Panel Repair
NOTE:
- Side body outer panel is to be replaced as the entire unit, not partially.
Procedures of replacing side body outer panel in this section show procedures of partial replacement considering degree of damage and man-hours for repair specific to some market.
- The number of spot welded points should be increased by 20 to 30% in number from original welding points. The numbers and locations of the welding points in the drawings show the original spot welding.
- Although the spot welding is recommended in the repair procedure, you shall adopt the plug welding when the panel thickness for welding points exceeds the performance of your spot welding device.
- Select hole diameter for plug welding referring to following table according to panel thickness and type of steel panel.
- Refer to Sheet Metal Description for types and thickness of steel panels.
- Prior to welding, always remove paint layer and plating from body panels at every welding points in order to prevent incomplete welding. Also, always apply the welding primer/spot sealer to prevent rust on welding points.
- When installing new parts, refer to "Body Dimensions" and Panel Clearance.
- After repairing body panels, be sure to apply seam sealer, cavity protection, underbody coating and anti-corrosion compound to all areas originally protected by the manufacture referring to Sealant Application Areas, Undercoating Application Areas and Anti-Corrosion Compound Application Area.
Precautions for Working on Air Bag System
WARNING:
- Failure to take proper precautions when performing the body repair work can result in severe personal injury.
- Be sure to take the following precautions to reduce the risk of injury.
- When performing repair work around air bag system related parts, be careful not to apply strong impact with hammer or impact wrench.
- When performing sheet metal work near air bag system related parts, be sure to check system for function (that air bag warning light lights up properly).