3.6 Bolted and welded connections

3.6 Bolted and welded connections

a Risk of accident

Do not modify any bolted connections that are relevant to safety, e.g. that are required for wheel alignment, steering or braking functions. When unfastening bolted connections make sure that, when work is complete, the connection again corresponds with the original condition. Welding work on the chassis/body may only be carried out by trained and qualified personnel. The body, the attached or installed equipment and any modifications must comply with the applicable laws and ordinances as well as work safety or accident prevention regulations, safety rules and accident insurer requirements.

3.6.1 Nuts and Bolts for Use on Frame

Pay attention to the following when removing nuts and bolts used on a standard vehicle.

• Target Locations

Nuts and bolts used for tightening frame crossmembers and side members (including nuts and bolts used for tightening the fuel tank and battery together)

How to distinguish nuts and bolts

Bolt (8T) .... Identifying letter "8"

Nut (6T) .... Identification at diagonal corner

• Handling of nuts and bolts (a)Bolts that have been removed cannot be used again. Tighten again using new bolts having the same strength. (b)Nuts and bolts must be tightened to the following torques: M10: 60 to 80 Nm {44 to 59 ft.lbs, 6.1 to 8.2 kgf.m} M12: 98 to 120 Nm {72 to 89 ft.lbs, 10.0 to 12.0 kgf.m}

• In particular, cross-members must be tightened when bolts used for tightening cross-members together are removed for moving the fuel tank and battery.

i Further information on bolted and welded connections can be found in Section 5 "Damage prevention" e page 65 and Section 6 "Modifications to the basic vehicle" e page 81.

3.6.2 Welded connections

Welding work on the chassis/body may only be carried out by trained and qualified personnel.

Parts which must not be welded:

• Assemblies such as the engine, gearbox, axles, etc. • The chassis frame (except frame modifications).

i Further information on bolted and welded connections can be found in Section 5 "Damage prevention" e page 65 and Section 6 "Modifications to the basic vehicle" e page 81.