General Repair Instructions

1. WORK PRECAUTIONS

(a) VEHICLE PROTECTION

(1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fireproof covers.

(b) SAFETY

(1) Never stand in a direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable.

(2) Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening completely.

(3) If it is necessary to use a flame in the area of the fuel tank, first remove the tank and plug the fuel line.

(c) SAFETY WORK CLOTHES

(1) 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.

Code

Name

A

Dust-Prevention Mask

B

Face Protector

C

Eye Protector

D

Safety Shoes

E

Welder's Glasses

F

Ear Plugs

G

Head Protector

H

Welder's Gloves

2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS

(1) The repair procedure for plastic body parts must conform with the type of plastic material.

(2) Plastic body parts are identified by the codes in the following table.

(3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must be given to the properties of the plastic.

Code

Material name

Heat* resistant temperature limit °C (°F)

Resistance to alcohol or gasoline

Notes

AAS

Acrylonitrile Acrylic Styrene

80 (176)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid gasoline and organic or aromatic solvents.

ABS

Acrylonitrile Butadiene Styrene

80 (176)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid gasoline and organic or aromatic solvents.

AES

Acrylonitrile Ethylene Styrene

80 (176)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid gasoline and organic or aromatic solvents.

Styrene

Acrylate

80 (176)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid gasoline and organic or aromatic solvents.

CAB

Cellulose Acetate

80 (176)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid gasoline and organic or aromatic solvents.

EPDM

Ethylene Propylene

Gasoline is harmless if applied only for short time in small amounts.

Most solvents are harmless but avoid dipping in gasoline, solvents, etc.

Reinforced Plastics

180 (356)

Alcohol and gasoline are harmless.

Avoid alkali.

EVA

Ethylene Acetate

70 (158)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid gasoline and organic or aromatic solvents.

Vinyl

Acetate

Copolymer

Resin

70 (158)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid gasoline and organic or aromatic solvents.

PA

Polyamide (Nylon)

80 (176)

Alcohol and gasoline are harmless.

Avoid battery acid.

PBT

Polybutylene Terephthalate

160 (320)

Alcohol and gasoline are harmless.

Most solvents are harmless.

PC

Polycarbonate

120 (248)

Alcohol is harmless.

Avoid gasoline, brake fluid, wax, wax removers and organic solvents. Avoid alkali.

Code

Material name

Heat* resistant temperature limit °C (°F)

Resistance to alcohol or gasoline

Notes

PE

Polyethylene

80 (176)

Alcohol and gasoline are harmless.

Most solvents are harmless.

PET

Polyethylene Terephthalate

75 (167)

Alcohol and gasoline are harmless.

Avoid dipping in water.

PMMA

Polymethyl Methacrylate

80 (176)

Alcohol is harmless if applied only for short time in small amounts.

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

POM

Polyoxymethylene (Polyacetal)

100 (212)

Alcohol and gasoline are harmless.

Most solvents are harmless.

PP

Polypropylene

80 (176)

Alcohol and gasoline are harmless.

Most solvents are harmless.

PPF

Composite Reinforced Polypropylene

80 (176)

Alcohol and gasoline are harmless.

Most solvents are harmless.

Polyphenylene

Oxide

100 (212)

Alcohol is harmless.

Gasoline is harmless if applied only for quick wiping to remove grease.

PS

Polystyrene

60 (140)

Alcohol and gasoline are harmless if applied only for short time in small amounts.

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

PUR

Polyurethane

80 (176)

Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wiping to remove grease).

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

PVC

Polyvinylchloride (Vinyl)

80 (176)

Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

SAN

Styrene Acrylonitrile

80 (176)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

TPO

Thermoplastic Olefine

Gasoline is harmless if applied only for short time in small amounts.

Most solvents are harmless but avoid dipping in gasoline, solvents, etc.

TPU

Thermoplastic Polyurethane

80 (176)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

Olefine Polymer

80 (176)

Alcohol and gasoline are harmless.

Most solvents are harmless.

UP

Unsaturated Polyester

110 (233)

Alcohol and gasoline are harmless.

Avoid alkali.

3. LOCATION OF PLASTIC BODY PARTS

Parts Name

Code

Front Bumper Cover

TSOP

Radiator Grille

TSOP

Headlight

PC/PP

Fog Light

TSOP

Front Pillar Upper Cover

AES

Side Turn Signal Light

PMMA/PC/ABS

Cowl Top Ventilator Louver

TSOP/PP/PE

Rear Body Mudguard

PP

Door Outside Handle

PA/PC/PBT

Outer Rear View Mirror

PP/PA/ABS * ASA

Front Door Window Frame Front Moulding

ASA

Front Spoiler Cover

TSOP

Front Fender Mudguard

PP

Back Door Outside Handle

PA

License Plate Light

PC

Rear Combination Light

PMMA/ASA

Rear Bumper Cover

* Resin material differs depending on model.

/ Made up of 2 or more kinds of materials.

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

Don't pay hundreds of dollars to find out what is wrong with your car. This book is dedicated to helping the do it yourself home and independent technician understand and use OBD-II technology to diagnose and repair their own vehicles.

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