Precautions for Body Structure
Precautions: Precautions for Body, Cab and Accessories · General safety (00)
Operation
WARNING:
Failure to take proper precautions when performing body repair work can result in severe personal injury.
Take the following precautions to reduce the risk of injury.
•Wear clothing and protective items suitable for operation.
•Before attempting any body repair, disconnect negative (–) cable at battery.
•When using body frame repair device for pulling-out operation, avoid standing in front of the pulling chain.
•Whenever performing body panel work near fuel tank using flames or sparks, remove the fuel tank from the vehicle and prevent the removed fuel tank from fuel leakage referring to Fuel Tank Removal and Installation:M16A or Fuel Tank Removal and Installation:D16AA.
•Before attempting any body repair, disconnect negative (–) cable at battery.
•When using body frame repair device for pulling-out operation, avoid standing in front of the pulling chain.
•Whenever performing body panel work near fuel tank using flames or sparks, remove the fuel tank from the vehicle and prevent the removed fuel tank from fuel leakage referring to Fuel Tank Removal and Installation:M16A or Fuel Tank Removal and Installation:D16AA.
High-Strength Steel
NOTICE:
Body panels of high-strength steel with the tensile strength more than 590 MPa will remarkably reduce its strength as the ultra-high-strength steel does by cutting, heating and welding.
Replace them with new spare panels and apply specified spot welding condition in the repair work, referring to Sheet Metal Description for tensile strength of steel panels.
Body Panel Repair
NOTICE:
Failure to take proper precautions when performing body repair work can reduce original strength of the body.
•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 plug welding when the panel thickness for welding points exceeds the performance of your spot welding device. Take the following precautions to reduce the risk of the strength reduction.
For the plug welding, select hole diameter referring to the following table according to the panel thickness and type of the steel panel.
•Select hole diameter for plug welding referring to the following table according to panel thickness and type of steel panel.
* ø10.0 (ø0.39 in.) or more for parts using ultra-high-tensile steel panel and high-tensile steel panel
•Refer to Sheet Metal Description for types and thickness of steel panels.
•Before welding, always remove paint layer and plating from body panels at every welding point to prevent incomplete welding. Also, always apply 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, apply seam sealer, cavity protection, underbody coating and anti-corrosion compound to all areas originally protected by the manufacturer referring to Sealant Application Areas, Undercoating Application Areas and Anti-Corrosion Compound Application Area.
•Although the spot welding is recommended in the repair procedure, you shall adopt plug welding when the panel thickness for welding points exceeds the performance of your spot welding device. Take the following precautions to reduce the risk of the strength reduction.
For the plug welding, select hole diameter referring to the following table according to the panel thickness and type of the steel panel.
•Select hole diameter for plug welding referring to the following table according to panel thickness and type of steel panel.
| Panel thickness | Hole diameter for plug welding |
|---|---|
| 1.0 mm (0.04 in.) or less * | ø 6.0 (ø 0.24 in.) or more |
| 1.0 mm – 1.5 mm (0.04 in. – 0.06 in.)* | ø 8.0 (ø 0.31 in.) or more |
| 1.5 mm (0.06 in.) or more * | ø 10.0 (ø 0.39 in.) or more |
•Refer to Sheet Metal Description for types and thickness of steel panels.
•Before welding, always remove paint layer and plating from body panels at every welding point to prevent incomplete welding. Also, always apply 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, apply seam sealer, cavity protection, underbody coating and anti-corrosion compound to all areas originally protected by the manufacturer 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.
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, check system for function (that “AIR BAG” warning light lights up properly).
•When performing sheet metal work near air bag system related parts, check system for function (that “AIR BAG” warning light lights up properly).