Proper and Efficient Work Procedures
PROPER AND EFFICIENT WORK PROCEDURES1. REMOVAL
a. PRE-REMOVAL MEASURING
1. Before removal or cutting operations, take measurements in accordance with the dimension diagram. Always use a puller to straighten a damaged body or frame.
b. CUTTING AREA
1. Always cut in a straight line and avoid reinforced area.
c. PRECAUTIONS FOR DRILLING OR CUTTING
1. Check behind any area to be drilled or cut to insure that there are no hoses, wires, etc., that may be damaged.
HINT: See "Handling Precautions on Related Components".
d. REMOVAL OF ADJACENT COMPONENTS
1. When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage.
HINT: See "Handling Precautions on Related Components".
2. PREPARATION FOR INSTALLATION
a. SPOT WELD POINTS
1. When welding panels with a combined thickness of over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) welder for plug welding.
HINT: Spot welding will not provide sufficient durability for panels over 3 mm (0.12 in.) thick.
b. APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER)
1. Remove the paint from the portion of the new parts and body to be welded, and apply weld-through primer.
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. SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS
1. When welding, there is a danger that electrical components will be damaged by the electrical current flowing through the body.
2. Before starting work, disconnect the negative terminal of the battery and ground the welder near the welding location of the body.
e. ROUGH CUTTING OF JOINTS
1. For joint areas, rough cut the new parts, leaving 20 - 30 mm (0.79 - 1.18 in.) overlap.
3. INSTALLATION
a. PRE-WELDING MEASUREMENTS
1. Always take measurements before installing underbody or engine components to insure correct assembly. After installation, confirm proper fit.
b. 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. Plug welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than specified.
c. POST-WELDING REFINISHING
1. Always check the welded spots to insure they are secure.
2. When smoothing out the weld spots with a disc grinder, be careful not to grind off too much as this would weaken the weld.
d. SPOT WELD LOCATIONS
1. Try to avoid welding over previous spots.
e. SPOT WELDING PRECAUTIONS
1. The shape of the welding tip point has an effect on the strength of the weld.
2. Always insure that the seams and welding tip are free of paint.
4. ANTI-RUST TREATMENT
a. BODY SEALER APPLICATION
1. For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams and hems of the doors, hoods, etc.
b. UNDERCOAT APPLICATION
1. To prevent corrosion and protect the body from damage by flying stones, always apply sufficient undercoat to the bottom surface of the under body and inside of the wheel housings.
5. ANTI-RUST TREATMENT AFTER PAINTING PROCESS
a. ANTI-RUST AGENT (WAX) APPLICATION
1. To preserve impossible to paint areas from corrosion, always apply sufficient anti-rust agent (wax) to the inside of the hemming areas of the doors and hoods, and around the hinges, or the welded surfaces inside the boxed cross-section structure of the side member, body pillar, etc.
6. ANTI-RUST TREATMENT BY PAINTING
REFERENCE:
Painting prevents corrosion and protect the sheet metal from damage. In this anti-chipping paint only for anti-corrosion purpose is described.
a. ANTI-CHIPPING PAINT
1. To prevent corrosion and protect the body from damage by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, balance panel, etc.
HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat.