Body and Trim //-->> ^izz^^ ' ^ ^
Body Repair ' —^^ '-^ >^-/
Body Repair
Introduction
This section contains information for the body repair and rectification of the vehicle. Wherever possible the vehicle
must be returned to its original manufactured condition. Following repair the vehicle must be fully checked and, if
necessary, the braking system and steering must be fully reset.
Health and Safety
Ensure that the correct working practices are established before beginning work.
Observe that the correct working practices are followed whether they be legislative or common sense.
Be aware of the potential risks of using materials used in the manufacture and repair of vehicles and take the
appropriate precautions.
Warning: Make sure that the working practices for the air conditioning
system
are followed: do not vent the refrigerant
directly into the atmosphere and always use the approved recovery/recycle /recharge equipment, always wear
suitable protective garments to prevent injury to the eyes and the skin.
Potential Risks
Paint
If the organic solvents, contained in paints, are inhaled for any length of time damage can be caused to the liver,
kidneys, respiratory tract and the digestive system.
Prolonged exposure to isocyanates can cause lung sensitisation and asthma-like symtoms can develop with
subsequent re-exposure to even low concentrations.
Solvent inhilation can cause dizziness or loss of consciousness.
Inhilation of spray dust and sanding debris can cause lung damage.
Paint activatorsand additives will damage the eyesor can cause dermatitis if allowed to splash and come into contact
with these areas. Peroxide and acid catalysts can cause burns.
Applied heat
There is considerable risk of damage to the eyes and skin when welding or flame cutting.
Fire is a serious danger as many materials and fluids in the vehicle are inflammable.
Toxic and dangerous fumes can be liberated when the following are subjected to heat; expanded foam, corrosion
protection,
adhesive and sealing compounds,
trim,
seat material and paints that contain isocyanates.
When heated to
a
temperature of 300°C, polyu rethane based compounds can
1
iberate small quantities of isocyanate.
Many types of nitrogen containing chemicals may be liberated as breakdown products, these chemicals can
contain isocyanates, oxides of nitrogen and hydrogen cyanide.
Potentially toxic or asphyxiant fumes and gases are produced by welding, for example; zinc oxide with zinc coated
panels and ozone gas from the MIC process.
Metal repair
There is considerable risk of damage to the eyes, ears and skin when metal cutting, forming and dressing is being
carried out.
Soldering may be hazardous because of heat generated fumes and skin contact with the materials.
7-2 May 1996
Em^^^?
Air Conditioning
General Description
General Description
Specifications
Refrigerant
Designation
Refrigerant R134A
(HFCUAA)
Compressor
Type
&
model
SD-7H15
Charge weight
1050g±50g
Configuration
7 cylinder
Compressor Lubricants
Designation
Polyalkylene glycol
(PAG)
Standard
for
Recovery, Recharge
and
Recycle Equipment,
System Capacity
120-150
ml
Manufacturer and Type
ICI Klea
or
equivalent
Manufacturer
Sanden
155 cm^
per
revolution
Manufacturer and Type
Sanden SP
20
Feature
Recovery rate
Cleaning capability
Oil separator
Vacuum pump
Filter
Charge
Hoses
Charge pressure
Compressor Belt Tension
Type
Vee belt
Burroughs method
Clavis method
Requirement
0.014-0.062
mVmin.
(1.36 kg in 20
minutes)
15
ppm
moisture; 4000
ppm oil; 330 ppm
non-condensable gases
in air
With hermetic compressor and automatic
oil
return
2 stage
0.07
-0.127 mVmin.
Replaceable with moisture indicator
Selectable charge weight and automatic delivery
Dedicated Refrigerant R134A port connections.
Heating element
to
increase pressure
Condition and range
All figures apply
to a
cold belt.
New belt
578 to 623 N
If tension
is
below
356 N,
reset
at 512 to 534 N
New belt
147 to 153 Hz
If tension
is
below
110 Hz,
reset
at 132 to 138 Hz
Note:
The
tension
is
measured
midway between the
compressor
and crankshaft pulleys. For a new
belt,
rotate engine three
revolutions minimum and then re-check the tension.
May 1996
8-5