Body repairs

Fuel vapour is highly flammable and in confined The transfer of fuel from the vehicle fuel tank must be spaces is also very explosive and toxic. carried out in a well ventilated area. An approved transfer tank must be used according to the transfer When fuel evaporates it produces 150 times its own tank manufacturer’s instructions and local regulations, volume in vapour, which when diluted with air including attention to grounding of tanks. becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. Fuel tank removal It can readily be distributed throughout a workshop by air current, consequently, even a small spillage of fuel A FUEL VAPOUR is very dangerous. the fuel tank upon removal from the vehicle.

Always have a fire extinguisher containing₂ FOAM, Fuel tank repair CO GAS or POWDER close at hand when handling fuel, or when dismantling fuel systems and in areas Under no circumstances should a repair to any tank where fuel containers are stored. be attempted.

• WARNING: lt is imperative that the battery
• is not disconnected during fuel system
• repairs as arcing at the battery terminal

BODY REPAIRS

could ignite fuel vapour in the atmosphere. Always disconnect the vehicle battery BEFORE

Body shells are of welded construction and bolted to

carrying out work on the fuel system.

the chassis frame. Front and rear sections of the shell are designed as ’energy absorbing’ zones. This

Whenever fuel is being handled, transferred or

means they are designed to deform progressively

stored, or when fuel systems are being dismantled

when subjected to impact in order to minimise the

all forms of ignition must be extinguished or

likelihood of injury to vehicle occupants.

removed, any leadlamps used must be flame proof and kept clear of spillage.

It is essential that design dimensions and strength are restored in accident rectification. It is important that

No one should be permitted to repair components

neither structural weakness nor excessive local

associated with fuel without first having had fuel

stiffness are introduced into the vehicle during body or

system training.

chassis repair.

Hot fuel handling precautions

Repairs usually involve a combination of operations ranging from straightening procedures to renewal of

WARNING: Before commencing any

either individual panels or panel assemblies. The

operation requiring fuel to be drained from

repairer will determine the repair method and this

the fuel tank, the following procedure must

decision will take into account a balance of economics

be adhered to:

between labour and material costs and the availability of repair facilities in both equipment and skills. It may

1. Allow sufficient time for the fuel to cool, thus

also involve considerations of vehicles down-time,

avoiding contact with hot fuels.

replacement vehicle availability and repair turn-around

2. Vent the system by removing the fuel filler cap in

time.

a well ventilated area. Refit the filler cap until the commencement of fuel drainage.

Fuel transfer

• WARNING: Fuel must not be extracted or
• drained from any vehicle while it is
• standing over a pit.

warning label must be attached to