Page 377 of 1807

Light Failure Sensor Fuel Pump ECURear Wiper Relay
5. COMPONENTS ADJACENT TO THE BODY PANELS Locations of ECUs (Cont'd)
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.
Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all
equipped with memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.
Do not expose the ECUs to ambient temperatures above 80°C (176°F).
NOTICE: if it is possible the ambient temperature may reach 80°C (176°F) or more, remove the ECUs
from the vehicle before starting work.
Be careful not to drop the ECUs and not to apply physical shocks to them.
Various types of component parts are mounted directly on or adjacently to the body panels.
Strictly observe the following precautions to prevent damaging these components and the body panels
during handling.
Before repairing the body panels, remove their components or apply protective covers over the
components.
Before prying components off using screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components an the body paint.
Before removing components from the outer surface of the body, attach protective tape to the body
to ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.
Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
INTRODUCTIONIN-9
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GENERAL REPAIR INSTRUCTIONS
Work Precautions
VEHICLE PROTECTION
When welding, protect the
painted surfaces, windows,
seats an carpet with heat-
resistant, fire-proof covers.SAFETY
1. Before performing repair work, check
for fuel leaks. If a leak is found, be
sure to close the opening totally.
2. If it is necessary to use a frame in the
area of the-fuel tank, first remove the
tank and plug the fuel line. SAFETY
Never stand in direct line
with the chain when using
a puller on the body or
frame, and be sure to
attach a safety cable.
WRONG
Glass Cover
Safety Cable
Seat Cover
WRONG
HAND TOOLS
keeping your hand tools
in neat order improve
your work efficiency. SAFETY WORK CLOTHES
In addition to the usual mechanic's wear, cap and safety shoes,
the appropriate gloves, head protector, glasses, ear plugs, face
protector, dust-prevention mask, etc. should be worn as the
situation demands.
Dust-
Prevention
Mask.Welder's
Glasses
Ear
Plugs
Body
Mechanic
Stand Face
Protector
Head
Protector
Eye
Protector
Welder's
Gloves Safety
Shoes
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Proper and Efficient Work Procedures
REMOVAL
NUMBER OF SPOT WELDS AND PANEL POSITIONS
The number of spot welds and the panel positions to be
removed are shown for your reference.
HINT: See ºSymbolsº on page IN-4, 5.
PRE-REMOV AL MEASURING
Before removal or cutting
operations, take measurements
in accordance with the dimension
diagram. Always use a puller to
straighten a damaged body or
frame.
REMOVAL OF ADJACENT COMPONENTS
When removing adjacent components, apply
protective tape to the surrounding body and
your tools to prevent damage.
HINT: See ºHandling Precautions on Related
Componentsº on age IN-6.
PRECAUTIONS FOR DRILLING OR
CUTTING
Check behind any area to be drilled or
cut to insure that there are no hoses,
wires, etc., that may be damaged.
HINT: See ºHandling Precautions on
Related Componentsº on page IN-6.
CUTTING AREA
Always cut in a straight
line and avoid reinforced
area.
Cutting Okay
Corners
Reinforcement
WRONG
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Page 380 of 1807
Thickness of
welded portionSize of plug hole
1.0 (0.04) under5 (0.20)
f over
1.0 (0.04) - 1.5 (0.06)6.5 (0.26)
f over
1.5 (0.06) over8 (0.31)
f over
REFERENCE:mm (in.)
PREPARATION FOR INSTALLATION
APPLICATION OF WELD-THROUGH PRIMER
(SPOT SEALER) SPOT WELD POINTS
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.
Remove the paint
from the portion of the
new parts and body to
be welded, and apply
weld-through primer.
HINT: See ºANTI-
RUST TREATMENTº
on page AR-2.
Less than
3 mm
Air Saw
WRONG
Puncher
20 - 30 mm
Overlap
ROUGH CUTTING OF JOINTS
For joint areas, rough cut the
new parts, leaving 20 - 30 mm
(0.79 - 1.18 in.) overlap.MAKING HOLES FOR PLUG WELDING
For areas where a spot welder cannot be
used, use a puncher or drill to make holes
for plug welding.
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SPOT WELD LOCATIONS
Try to avoid welding over pre-
vious spots.
New Spot
Locations
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.
INSTALLATION
POST-WELDLNG REFINISH-
ING
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. PRE-WELDING MEASUREMENTS
Always take measurements
before installing underbody or
engine components to insure
correct assembly. After installation,
confirm proper fit.
WRONG
WRONG
OKAY
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.
Safety Glass
Body
Measurement
Diagrams
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.
Oil
spot
Locations
Tip Cutter
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Cartridge Type
ANTI-RUST TREATMENT
When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the
requirements of your country.
HINT: For further details, see the description given in section AR of this manual.
BODY SEALER
Apply body sealer to the
required areas.ANTI-RUST AGENT (WAX)
Apply anti-rust agent to
following sections.
Inside of the hems of the
doors and hood.
Around the hinges of the
doors and hood.
Inside of the welded parts
with boxed cross-section.
Tube Type
UNDERCOAT
Apply undercoat to the underbody and
wheel housings.
spray Gun
Undercoating
(Oil base)Undercoating
(Water base)
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SUPPORT POSITIONPANTOGRAPH JACK POSITION
CAUTION: Before jacking-up the rear and front, make sure the car is
not carrying any extra weight.
Front Front crossmember. . . . . . . .
Rear Rear axle beam. . . . . . . . .
JACK POSITION
Front
Safety stand and swing arm type lift . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE LIFT AND SUPPORT LOCATIONS
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ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
FWD Front Wheel Drive Vehicles
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
w/ with
w/o without
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
INTRODUCTIONIN-16