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Mitsubishi Galant (2004+). Manual - part 38

BODY REPAIR

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BASE OF BODY REPAIR

9-31

NOTES REGARDING REPAIR WORK

M4090015000028

SAFETY MEASURES

PROTECTIVE GEAR
During body repair work, a work suit, a work cap, and safety
shoes should be worn at all times. Depending on the work
being done, safety glasses, gloves, ear protectors, a dustproof
mask, etc., should also be worn as needed.

1. Safety glasses
2. Work cap
3. Ear protectors
4. Head protector
5. Work suit
6. Dustproof mask
7. Work apron
8. Welding gloves
9. Foot and ankle protectors

10. Safety shoes
11. Work gloves

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
1. Items to review when servicing SRS

(1) Be sure to read Service Manual GROUP 52B,

Supplemental Restraint System (SRS). For
safe operation, please follow the directions
and heed all warnings.

(2) Wait at least 60 seconds after disconnecting

the battery cable before doing any further
work. The SRS system is designed to retain
enough voltage to deploy the air bag even
after the battery has been disconnected.
Serious injury may result from unintended air
bag deployment if work is done on the SRS
system immediately after the battery cable is
disconnected.

(3) Warning labels must be heeded when

servicing or handling SRS components.

(4) Always use the designated special tools and

test equipment.

(5) Store components removed from the SRS in a

clean and dry place. The air bag module
should be stored on a flat surface and placed
so that the pad surface is facing upward.

(6) Never attempt to disassemble or repair the

SRS components (SRS-ECU, air bag module
and clock spring). If there is a defect, replace
the defective part.

(7) Whenever you finish servicing the SRS, check

the SRS warning light operation to make sure
that the system functions properly.

(8) Be sure to deploy the air bag before disposing

of the air bag module or disposing of a vehicle
equipped with an air bag.

2. Observe the following when carrying out

operations on places where SRS components are
installed, including operations not directly related
to the SRS air bag.
(1) When removing or installing parts, do not allow

any impact or shock to occur to the SRS
components.

(2) If heat damage may occur during paint work,

remove the SRS-ECU, the air bag module,
clock spring, the front impact sensor, the side
impact sensor, and the seat belt pre-tensioner.

•

SRS-ECU, air bag module, clock spring, front
impact sensor, the side impact sensor: 93

(200

F) or more

•

Seat belt pre-tensioner: 90

C (194

F) or more

AB200104

BODY REPAIR

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BASE OF BODY REPAIR

9-32

SECURING THE VEHICLE
If the vehicle is raised on a jack, be sure to always support it
with jack stands positioned at the specified points.

CLEARING THE AREA OF FLAMMABLE MATERIALS
Because of the presence of many various kinds of flammable
materials, organic solvents, etc., in the work area, there is
always the possibility of a fire or explosion. It is, therefore,
important to keep the work area as clear as possible of such
dangerous materials.

HANDLING ELECTRONIC PARTS AND SEMICONDUCTORS

WARNING

Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.

When the body is used as the ground during welding for body
repairs, be absolutely sure to first disconnect the battery's posi-
tive (+) cable.

CAUTION

•

Be sure that both the ignition and lighting switches are
"LOCK" (OFF) position before either disconnecting or
reconnecting a battery cable. (If this is not done, equip-
ment containing semiconductors could be damaged).

•

Note that the memory of electronic equipment having a
memory function will be cleared when the battery cable
is disconnected.

NOTE: 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, elec-
tromagnetic 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, etc.
This is because, for electronic components that incorporate a
back-up circuit (for memory retention) that functions (by a
trickle current) even when the ignition switch is at OFF, an elec-
tronic circuit is formed even when the switch is at OFF.

HANDLING COMBUSTIBLE MATERIALS
If welding work is to be done in the area of the fuel tank, the fuel
tank must be removed to prevent the generation of flammable
gases. Also be sure to cap the inlet port and the pipes of the
fuel tank after removal to prevent the escape of any fuel or
flammable gases.
Wipe up any fuel, oil, etc., spilled in the work area as soon as
possible.
Only the amounts of paint to be used for the day's work should
be in the work area; do not keep excessive amounts of paint, or
paint which is not going to be used, in the work area.

AB200105

BODY REPAIR

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BASE OF BODY REPAIR

9-33

HEALTH AND SANITATION PROCEDURES

The following points should be noted for employee health and
sanitation.

•

The work area should be well ventilated in order to prevent
the inhalation of dust, organic solvent vapors, etc.

•

All unused paint cans must be securely covered.

•

Care should be taken to avoid exposure to the skin of adhe-
sives, organic solvents, etc.
If an unavoidable exposure occurs, the exposed area
should be immediately washed with clean water.

VEHICLE PROTECTION

•

Vehicle covers (fender covers, seat covers, etc.) and tape (if
there is the possibility of damage by tools, equipment, etc.)
should be used to protect painted surfaces, interior/exterior
parts and components, etc., from staining and damage.

•

For welding operations, a heat-resistant protective cover
should be used to protect glass, seats, instrument panel,
carpeting, etc.

AB200106

AB200107

BODY REPAIR

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9-34

HEAT-WITHSTAND TEMPERATURES OF RESIN-PLASTIC PARTS

M4090016000021

Because resin-plastic parts are deformed by heat,
they should be removed if the heat to be applied is
high enough to cause deformation, as shown by the
table below.

MATERIAL NAME ABBREVIATION

HEAT-DEFORMATION
TEMPERATURE

C (

WHERE MAINLY USED

Acrylonitrile
styrene acrylate

ASA

80 (176)

Door mirror, Pillar garnish, License
garnish, Radiator grille

Acrylonitrile
butadiene styrene

ABS

80 (176)

Air spoiler, Console box, Radiator grille,
Rear garnish, Headlight bezel

Cellulose acetate

−

90 (122

−

194)

Cellulose acetate
butyrate

CAB

−

100 (140

−

212)

Door trim molding

Polyamide

140

−

160 (284

−

320)

Harness connector, Wheel cover,
Cooling fan, Fuel strainer

Talc filled
polyamide

PA-TD

190

−

200 (374

−

392)

Hood garnish, Door outside handle

Polybutylene
terephthalate

PBT

120 (248)

Dome lamp lens, Headlight lens

Polyethylene

100 (212)

Heater duct, Fender liner, Washer tank

High density
polyethylene

PE-HD (HDPE)

−

90 (158

−

194)

Fuel tank, Splash shield

Phenole
formaldehyde

170

−

190 (338

−

374)

Ashtray

Polymethyl
methacrylate

PMMA

−

100 (176

−

212)

Light lens

Polyacetal

POM

120 (248)

Door regulator handle, Ball joint seat

Polypropylene

80 (176)

Glove compartment, Bumper face,
Pillar trim, Steering wheel, Heater unit,
Cooling fan

Polyphenylene
ether

PPE (PPO)

130

−

140 (266

−

284)

Accelerator pedal pad, Wheel cover,
Speaker garnish

Talc filled
polypropylene

PP-TD (PPF)

100 (212)

Front deck garnish, Stone guard, Floor
console, Instrument panel

Talc filled
polypropylene
(10%)

PP-TD10 (PPF)

110

−

120 (230

−

248)

Center pillar trim

Talc filled
polypropylene
(15%)

PP-TD15 (PPF)

110

−

120 (230

−

248)

Front pillar trim, Center pillar trim, Rear
pillar trim

Talc filled
polypropylene
(20%)

PP-TD20 (PPF)

120

−

130 (248

−

266)

Beltline trim, Front deck garnish, Front
pillar trim

Talc filled
polypropylene
(30%)

PP-TD30 (PPF)

130

−

140 (266

−

284)

Quarter trim, Rear side trim

Content .. 36 37 38 39 ..