Body and Frame: Service Precautions

Precautions For Body Structure

Operation

WARNING: 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. Secure the chain with the safety wires. Whenever a repair work near the fuel tank using frames or sparkes, be sure to remove the fuel tank from the vehicle and prevent the removed fuel tank from fuel leakage.

High-Strength Steel

CAUTION:
- 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 Specification for tensile strength of steel panels.

Body Panel Repair

CAUTION:
- 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 shows 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 exceed 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.

* dia. 10.0 (dia. 0.39 in.) or more for parts using high-tensile steel panel

- Refer to Sheet Metal Specification 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 "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.

Foamed Material Filling Area Repair

CAUTION:
Follow instructions below when repairing body part filled with foamed material because such foamed material may start fire when heated.
- Do not heat or cut panels with gas torch or the like.
- Use a fire-free tools such as air-saw when cutting panels.
- Remove foamed material close to welding part before welding.