IN-10
Cutting Okay
Reinforcement
INTRODUCTION
PROPER AND EFFICIENT WORK
PROCEDURES
1. REMOVAL
(a) PRE-REMOVAL MEASURING
(1) Before removal or cutting operations, take measure-
ments in accordance with the dimensions diagram. Always use a puller to straighten a damaged body or
frame.
F10007A
(b) CUTTING AREA
(1) Always cut in a straight line and avoid cutting rein-
forced areas.
WRONG
Corners
F10008A
(c) PRECAUTIONS FOR DRILLING OR CUTTING
(1) Check behind any area to be drilled or cut to ensure
that there are no hoses, wires, etc., that may be damaged.
HINT: See “Handling Precautions on Related Components” on page IN-15.
F10009A
(d) REMOVAL OF ADJACENT COMPONENTS
(1) When removing adjacent components, apply protec-
tive tape to the surrounding body and your tools to prevent damage.
HINT: See “Handling Precautions on RelatedComponents” on page IN-15.
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Less than
3mm
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INTRODUCTION
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 does not provide sufficient durability for panels with a combined thickness of over 3 mm
(0.12 in.)
(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.
IN-11
Puncher
Air Saw
20 − 30 mm
F10013A
F10014A
Overlap
(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.
REFERENCE: mm (in.)
Thickness of welded portion Size of plug hole
1.0 (0.04) under 5 (0.20) ø over
1.0 (0.04) − 1.6 (0.06) 6.5 (0.26) ø over
1.7 (0.07) − 2.3 (0.09) 8 (0.31) ø over
2.4 (0.09) over 10 (0.39) ø over
(d) SAFETY PRECAUTIONS FOR ELECTRICAL
COMPONENTS
(1) When welding, there is a danger that electrical compo-
nents 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.) of overlap.
F10015A
IN-12
INTRODUCTION
Body Measurement Diagrams
WRONG
3. INSTALLATION
(a) PRE-WELDING MEASUREMENTS
(1) Always take measurements before installing under-
body or engine components to ensure correct assembly. After installation, confirm proper fit.
F10016A
(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 where specified.
F10017A
(c) POST-WELDING REFINISHING
(1) Always check the welded spots to ensure that they are
secure.
(2) When smoothing out the weld spots with a disc grind-
er,be careful not to grind off too much as this will weaken the weld.
CORRECT WRONG
Old
Spot
Locations
Tip Cutter
New Spot
Locations
F10018A
F10020A
F10019A
(d) SPOT WELD LOCATIONS
(1) Avoid welding over previously welded areas.
(e) SPOT WELDING PRECAUTIONS
(1) The shape of the tip point of the spot welder signifi-
cantly affects the strength of the weld. Therefore,
maintain the tip point in the proper shape, and allow it
to cool after every five or six spots.
(2) Completely remove the paint from the areas to be spot
welded, including the seams and the surfaces that
come in contact with the welding tip.
(3) Use a sander to remove any burrs that are created
during spot welding.
INTRODUCTION
IN-13
Sealer Gun
4. ANTI-RUST TREATMENT AFTER
INSTALLATION (BEFORE PAINTING
PROCESS)
(a) BODY SEALER APPLICATION
(1) For water-proofing and anti-corrosion measures, al-
ways apply the body sealer to the body panel seams
and hems of the doors, hood, etc.
F10021A
(b) UNDERCOAT APPLICATION
(1) To prevent corrosion and protect the body from dam-
age by flying stones, always apply sufficient under
coating to the bottom surface of the under body and
inside of the wheel housings.
F10022A
5. ANTI-RUST TREATMENT AFTER
INSTALLATION (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 hood, and
around the hinges, or the welded surfaces inside the
box-shaped cross sections of the side members, body
pillars, etc.
F10023A
IN-14
INTRODUCTION
6. ANTI-RUST TREATMENT BY PAINTING
REFERENCE:
Painting prevents corrosion and protects the sheet
metal from damage. In this section, anti-chipping paint
only for anti-corrosion purposes is described.
(a) ANTI-CHIPPING PAINT
(1) To prevent corrosion and protect the body from dam-
age 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.
S Apply the anti-chipping paint after
the top coat.
Anti-Chipping Paint
Top Coat
Second Coat
Under Coat (ED Primer)
Steel Metal
S Apply the anti-chipping paint before
the second coat.
Top Coat
Second Coat
Anti-Chipping Paint
Under Coat (ED Primer)
Steel Metal
F10024A
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