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BODY
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22.3. BODY REPAIR:
In case of minor collision, body shell can be
repaired by use of the recommended body
collision repair fixtures. The dimensions given in
this group should be measured and corrected only
on the fixture. Use proper measuring tools for
measuring point to point dimension given in the
sketches.
NOTE:
Repairs done without use of proper fixture and
procedure could adversely affect the performance
of vehicle
.
PRECAUTIONS:
Following precaution to be taken while performing
any repair work on body shell:
1. Safely support the vehicle before any work.
Block the front or rear wheel if the vehicle is
not lifted off the ground.
2. Disconnect the battery negative (-) terminal
before performing any work on the vehicle.
3. Put protection cap or remove the fuel tank
while working on the rear section of the
vehicle.
4. Ensure proper ventilation of the working area.
Some paint and sealant can generate toxic
gases when heated.
5. Cover interior with heat resistant material to
ensure safety while performing welding
operations.
WELDING PRECAUTIONS:
Large voltage spikes will occur when striking an
arc during arc welding or cutting operation. These
voltage spikes can easily damage the electronic
modules in the vehicle electrical systems. The
various system used in the vehicle share chassis
ground and therefore simply disconnecting the
battery cables will not afford the protection
required. All electronic equipment must be
isolated from the vehicle chassis ground
whenever performing arc welding or cutting
operation on the vehicle.
Following precautions will minimize the
electronic module damage:
6. Turn off the engine and disconnect the battery
negative (-) terminal before performing any
work on the vehicle.
7. Before starting to perform welding operation
on the body shell one should always assure
that all the ECU’s are removed.
8. One should not forget to disconnect all the
ground connections before performing any
welding operation.
(For ground connection
details refer A3 book of electrical section.)
9. Ensure welding ground clamp is of adequate
size for the welder and the clamp is as close
as to the area being welded.
10. Make sure that ground clamp make good
connection to the ground surface. Remove
any paints or coatings so that bare metal is
exposed at the ground point.
11. Ensure that the cable ground side of the
clamp makes good connection with the
vehicle if using one side ground clamp. Do not
rely on the opposite side of ground clamp to
make the ground connection.
12. Do not route welder electrical cables directly
across from or near any of the vehicle’s
electrical wiring harnesses.