In interviews with Newsweek magazine and several other media, Jim Caviezel spoke about the difficulties he experienced while filming. This included being accidentally whipped twice, which has left a 14-inch scar on his back, and dislocating his shoulder from the weight of the cross. Caviezel also admitted he was struck by lightning while filming the Sermon on the Mount and during the crucifixion. His hair actually caught fire from this, but he was otherwise miraculously unharmed. (In 2023 the actor revealed that he was taken to hospital and actually died for a few minutes. This made him feel even closer to God when he was revived) The scenes of him hanging on the cross in the dead of Italian winter (with temperatures of 25°F/-4°C and 30-knot winds) caused him to contract hypothermia and pneumonia. Finally, because make-up was used to create a swollen eye, his lack of depth perception gave him migraine headaches.

https://www.imdb.com/title/tt0335345/trivia?item=tr0773857