Fundamental Procedures
FUNDAMENTAL PROCEDURES
VEHICLE PROTECTION
1. Cover the seats before performing any procedure to keep them from getting dirty.
2. Cover all glasses, seats and mats with a heat resistant cover when welding.
3. Protect moldings, garnishes and ornaments.
SAFETY FACTORS
1. Disconnect the negative(-) battery cable before performing any work on the vehicle.
2. Protect yourself by wearing goggles, earplugs, respirators, gloves, safety shoes, caps, etc. when working on a vehicle.
3. Safely support the vehicle before any work is done. Block the front or rear wheels if the vehicle is not lifted off of the ground.
4. When welding or performing other procedures that require the use of an open flame near the fuel tank, disconnect and remove the tank and fuel pipe, and cap the pipe to prevent fuel leakage.
5. Insure proper ventilation of your working area. Some paint and sealant can generate toxic gases when heated. Use an air chisel or saw to remove damaged panels instead of a gas torch.
6. Observe all local and national safety regulations when performing any work.
7. Cover interior with heat-resistant cover to insure safety when welding.
8. Take care when using gas or cutting torches so as not to burn body sealer or interior. Extinguish immediately if they should catch fire.
SRS AIR-BAG
The SOUL is equipped with a Supplemental Restraint System AIR-BAG to provide the vehicle's driver and/or the front passenger with additional protection than that offered by the seat-belt system alone, in case of a frontal impact of sufficient severity.
When handling airbag components (removal, installation or inspection, etc.), always follow the directions given in the repair manual for the relevant model to prevent the occurrence of accidents and airbag malfunction.
Also take the following precautions when repairing the body:
1. Work must be started after approximately 30 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery. (The airbag system is equipped with a back-up power source so that if work is started within 30 seconds of disconnecting the negative (-) terminal cable of the battery, the airbag may be deployed.)
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 the audio memory system. Then when work is finished, reset the audio system as before and adjust the clock.
2. When using electric welding, first disconnect the air-bag connectors under the steering column near the MULTI-FUNCTION SWITCH and the passenger's side crash pad before starting work.
3. Store the air-bag modules where the ambient temperature remains below 93 °C (200 °F), without high humidity and away from electrical noise.
4. WARNING/CAUTION labels are attached to the periphery of the air-bag components.
Refer to the SOUL SHOP MANUAL.
WELDING
All repairs require the use of a Metal-Inert Gas (MIG) welder, Gas (oxyacetylene) welding must not be used. Both high strength steel and mild steel can be welded using the MIG welder. The I-CAR recommendations for welding should be followed. The shielding gas should be 75% Argon and 25% CO2.
The recommended welding wire size is 0.23" and the wire should satisfy the American Welding Society standard code AWSER70S-6.
During the repair process, plug welds are used to duplicate original factory spot welds. All plug welds should be done with the MIG welder. An 8 mm (5/16") hole is placed in the top (welding side) sheetmetal.
You then begin welding along the edges and the spiral towards the center (see illustration). This is important so that weld penetration between the two metal pieces takes place along the circumference of the circle.
Observe the following tips when welding.
1. Wear appropriate eye protection.
2. Carefully follow the manufacturers operating instructions for the welding machine you are using.
3. Do not weld, smoke or allow open flames around volatile chemicals, cleaners or solvents or in any area where they have just been used.
BODY FRAME STRAIGHTENER
When using a frame straightener, do not enter the area where the body is being straightened by the chain.
ELECTRONIC PARTS
Vehicles today include a great many electronic parts and components, and these are in general very susceptible to adverse effects caused by overcurrent, reverse current, electromagnetic waves, high temperature, high humidity impacts, etc.
In particular such electronic components can be damaged if there is a large current flow during welding from the body side.
Therefore, take the following precautions during body repair to prevent damage to the CONTROL MODULES (ECM, TCM, ABS CM, SRS CM, etc.)
1. Before removing and inspecting the electrical parts or before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
2. Do not expose the CONTROL MODULES to ambient temperatures above 80 °C (176 °F).
NOTE: If it is possible the ambient temperatures may reach 80 °C (176 °F) or more, remove the CONTROL MODULES from the vehicle before starting work.
3. Be careful not to drop the CONTROL MODULES and not to apply physical shocks to them.