Toyota Avalon GSX30 Series Manual
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Toyota Avalon GSX30 Series Manual

Toyota Avalon GSX30 Series Manual

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FOREWORD
This repair manual has been prepared to provide essential in-
formation on body panel repair methods (including cutting and
welding operations, but excluding painting) for the TOYOTA
AVALON.
Applicable models: GSX30 series
This manual consists of body repair methods, exploded dia-
grams and illustrations of the body components and other in-
formation relating to body panel replacement such as handling
precautions, etc. However, it should be noted that the front fend-
ers of the TOYOTA model is bolted on and require no welding.
When repairing, don't cut and join areas that are not shown in
this manual. Only work on the specified contents to maintain
body strength.
Body construction will sometimes differ depending on specifica-
tions and country of destination. Therefore, please keep in mind
that the information contained herein is based on vehicles for
general destinations.
For the repair procedures and specifications other than collision-
damaged body components of the TOYOTA AVALON refer to
the repair manuals.
If you require the above manuals, please contact your TOYOTA
Dealer.
All information contained in this manual is the most up-to-date at
the time of publication. However, specifications and procedures
are subject to change without prior notice.

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Summary of Contents for Toyota Avalon GSX30 Series

  • Page 1 However, it should be noted that the front fend- ers of the TOYOTA model is bolted on and require no welding. When repairing, don’t cut and join areas that are not shown in this manual.
  • Page 2 VIEWS OF THIS TEXT Scope of the repair work explanation This text explains the welding panel replacement instructions from the vehicle’s white body condi- tion. We have abbreviated the explanations of the removal and reinstallation of the equipment parts up to the white body condition and of the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel.

  • Page 3: General Repair Instructions

    INTRODUCTION IN-1 GENERAL REPAIR INSTRUCTIONS 1. WORK PRECAUTIONS (a) VEHICLE PROTECTION Glass Cover (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fire-proof covers. Seat Cover F10001A (b) SAFETY (1) Never stand in direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable.
  • Page 4 IN-2 INTRODUCTION 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, paint- ing etc.), consideration must be given to the property of the plastic.
  • Page 5 Avoid dipping or immersing Thermoplastic short time in small amounts (e.g., quick in alcohol, gasoline, Polyurethane (176) wiping to remove grease). solvents, etc. TOYOTA TSOP Super Alcohol and gasoline are harmless. Most solvents are harmless. (176) Olefine Polymer Unsaturated Alcohol and gasoline are harmless.
  • Page 6 IN-4 INTRODUCTION 3. LOCATION OF PLASTIC BODY PARTS Parts Name Code Radiator Grille Front Bumper Cover TSOP Front Bumper Hole Cover PC/ABS Headlight PP/PC Foglight PC/PE Cowl Top Ventilator Louver TSOP Door Window Frame Moulding Door Outside Handle Outer Rear View Mirror Door Outside Moulding Body Rocker Panel Moulding Rocker Panel Moulding Protector...

  • Page 7: How To Use This Manual

    INTRODUCTION IN-5 HOW TO USE THIS MANUAL 1. BODY PANEL REPLACEMENT THIS MANUAL F13890A...
  • Page 8 IN-6 INTRODUCTION F13891A...
  • Page 9 INTRODUCTION IN-7 2. SYMBOLS The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the types of weld required. F13893A...
  • Page 10 IN-8 INTRODUCTION SYMBOLS MEANING ILLUSTRATION — Assembly Mark — BODY SEALER — (Flat Finishing) BODY SEALER — (No flat Finishing) F13894A...
  • Page 11 INTRODUCTION IN-9 3. ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE: F13892A...
  • Page 12 IN-10 INTRODUCTION PROPER AND EFFICIENT WORK PROCEDURES 1. REMOVAL (a) PRE-REMOVAL MEASURING (1) Before removal or cutting operations, take measure- ments in accordance with the dimension diagram. Al- ways use a puller to straighten a damaged body or frame. F10007A (b) CUTTING AREA Cutting Okay (1) Always cut in a straight line and avoid reinforced area.

  • Page 13: Preparation For Installation

    INTRODUCTION IN-11 2. PREPARATION FOR INSTALLATION (a) SPOT WELD POINTS (1) When welding panels with a combined thickness of Less than over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) 3 mm welder for plug welding. HINT: Spot welding will not provide sufficient durability for panels over 3 mm (0.12 in.) thick.
  • Page 14 IN-12 INTRODUCTION 3. INSTALLATION Body Measurement Diagrams (a) PRE-WELDING MEASUREMENTS (1) Always take measurements before installing under- body or engine components to insure correct assem- bly. After installation, confirm proper fit. F10016A (b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld: 1.3 X No.
  • Page 15 INTRODUCTION IN-13 4. ANTI-RUST TREATMENT Sealer Gun (a) BODY SEALER APPLICATION (1) For water-proofing and anti-corrosion measures, al- ways apply the body sealer to the body panel seams and hems of the doors, hoods, etc. F10021A (b) UNDERCOAT APPLICATION (1) To prevent corrosion and protect the body from dam- age by flying stones, always apply sufficient under- coat to the bottom surface of the under body and in- side of the wheel housings.
  • Page 16 IN-14 INTRODUCTION 6. ANTI-RUST TREATMENT BY PAINTING REFERENCE: Painting prevents corrosion and protect the sheet metal from damage. In this section, anti-chipping paint only for anti-corrosion purpose is described. (a) ANTI-CHIPPING PAINT (1) To prevent corrosion and protect the body from dam- age by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, balance panel, etc.
  • Page 17 INTRODUCTION IN-15 HANDLING PRECAUTIONS ON RELATED COMPONENTS 1. BRAKE SYSTEM The brake system is one of the most important safety components. Always follow the directions and notes given in brake (32) section of the repair manual for the relevant model when handling brake system parts.
  • Page 18 STRUCTURE PANELS 1. HEAT REPAIR FOR BODY STRUCTURE PANELS Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a col- lision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are being sought after.
  • Page 19 INTRODUCTION IN-17 3. IMPACT BEAM REPAIR The impact beam and bracket are necessary and important parts that help reduce the probability of injury to passen- gers in side collisions. For impact beam, we use special high tensile strength steel. The high tensile strength steel maintains its special crystal- line organization by heat treatment or alloy additives.

  • Page 20: Abbreviations Used In This Manual

    IN-18 INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL For convenience, the following abbreviations are used in this manual. Antilock Brake System Air Conditioner assy assembly Electronic Controlled Transmission Electronic Control Unit e.g. Exempli Gratia (for Example) Except Front Wheel Drive Vehicles Two Wheel Drive Vehicles Four Wheel Drive Vehicles inch...
  • Page 21 BODY PANEL REPLACEMENT IN-81 FIT STANDARDS 3.7 mm 5.4 mm 5.75 mm 4.8 mm 4.8 mm 4.2 mm 4.2 mm 4.2 mm 5.2 mm 5.2 mm F22065 3.7 mm (0.146 in.) 4.2 mm (0.165 in.) 4.8 mm (0.189 in.) 5.2 mm (0.205 in.) 5.4 mm (0.213 in.) 5.75 mm (0.226 in.)
  • Page 22 IN-82 BODY PANEL REPLACEMENT 3.7 mm 4.5 mm 5.75 mm F22066 3.7 mm (0.146 in.) 4.5 mm (0.177 in.) 5.75 mm (0. 226 in.)
  • Page 23 BODY PANEL REPLACEMENT BP-1 RADIATOR UPPER SUPPORT (ASSY) REPLACEMENT F22067A REMOVAL F22067...

  • Page 24: Installation

    BP-2 BODY PANEL REPLACEMENT INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 25 BODY PANEL REPLACEMENT BP-3 1,425 mm 1,210 mm F22069 POINT Measure the dimensions before installing the headlight. These values are reference values. 296 mm (11.65 in.) 480 mm (18.90 in.) 866 mm (34.09 in.) 1,210 mm (47.64 in.) 1,425 mm (56.10 in.)
  • Page 26 BP-4 BODY PANEL REPLACEMENT RADIATOR SIDE SUPPORT (ASSY) REPLACEMENT With the radiator upper support removed. F22070A REMOVAL F22070...
  • Page 27 BODY PANEL REPLACEMENT BP-5 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.

  • Page 28: Front Crossmember (Assy)

    BODY PANEL REPLACEMENT BP-7 FRONT CROSSMEMBER (ASSY) REPLACEMENT F22072A REMOVAL F22072...
  • Page 29 BP-8 BODY PANEL REPLACEMENT INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.

  • Page 30: Radiator Support (Assy)

    BP-8 BODY PANEL REPLACEMENT RADIATOR SUPPORT (ASSY) REPLACEMENT F22074A REMOVAL F22074...
  • Page 31 BODY PANEL REPLACEMENT BP-9 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.

  • Page 32: Front Fender Front Apron (Assy)

    BP-10 BODY PANEL REPLACEMENT FRONT FENDER FRONT APRON (ASSY) REPLACEMENT With the radiator upper support removed. F22076A REMOVAL [RH only] F22076 POINT Remove the [A] at the same time. PART NAME Front Fender Apron Front Extension...
  • Page 33 BODY PANEL REPLACEMENT BP-11 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 34 BP-12 BODY PANEL REPLACEMENT FRONT APRON TO COWL SIDE UPPER MEMBER (ASSY) REPLACEMENT With the front fender front apron and front body pillar lower gusset removed. F22078A REMOVAL F22078 POINT After remove the [A], remove the front apron to cowl side upper member. PART NAME Front Apron To Cowl Side Lower Front Member...
  • Page 35 BODY PANEL REPLACEMENT BP-13 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.

  • Page 36: Front Fender Apron (Assy)

    BP-14 BODY PANEL REPLACEMENT FRONT FENDER APRON (ASSY) REPLACEMENT With the radiator upper support and front body pillar lower gusset removed. F22080A REMOVAL [RH only] F22080...
  • Page 37 BODY PANEL REPLACEMENT BP-15 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.

  • Page 38: Front Sidemember (Cut-P)

    BP-16 BODY PANEL REPLACEMENT FRONT SIDEMEMBER (CUT-P) REPLACEMENT With the radiator side support and front crossmember removed. F22082A REMOVAL F22082 POINT Remove the [A] at the same time. PART NAME Front Sidemember No.2 Plate 100 mm (3.94 in.)
  • Page 39 BODY PANEL REPLACEMENT BP-17 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 40 BP-18 BODY PANEL REPLACEMENT FRONT SIDEMEMBER (CUT-H) REPLACEMENT With the radiator side support, front crossmember and front fender apron removed. F22084A REMOVAL F22084 POINT Separate the front sidemember, [A] and [B] at the welded part, and remove the front sidemember. PART NAME Front Side Inner Rear Member Front Sidemember Outer Plate...
  • Page 41 BODY PANEL REPLACEMENT BP-19 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 42 BP-20 BODY PANEL REPLACEMENT F22086 POINT Make sure each mesurement is correct as this parts affects the front wheel alignment. PART NAME Front Sidemember No.2 Plate...
  • Page 43 BODY PANEL REPLACEMENT BP-21 FRONT BODY PILLAR LOWER GUSSET (ASSY) REPLACEMENT F22087A REMOVAL F22087...
  • Page 44 BP-22 BODY PANEL REPLACEMENT INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.

  • Page 45: Front Body Pillar (Cut)

    BODY PANEL REPLACEMENT BP-23 FRONT BODY PILLAR (CUT) REPLACEMENT With the front body pillar lower gusset removed. F22089A REMOVAL F22089 30 mm (1.18 in.) 60 mm (2.36 in.) 65 mm (2.56 in.) 120 mm (4.72 in.) 170 mm (6.69 in.) 200 mm (7.87 in.)
  • Page 46 BP-24 BODY PANEL REPLACEMENT F22090 POINT Remove the [A] at the same time. PART NAME Front Piller Upper Corner Gusset...
  • Page 47 BODY PANEL REPLACEMENT BP-25 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 48 BP-26 BODY PANEL REPLACEMENT F22092 POINT Inspect the fitting of the front door, front fender and windshield glass etc., before welding, since this affects the appearance of the finish. PART NAME Front Piller Upper Corner Gusset 8 mm (0.31 in.) 10 mm (0.39 in.) 20 mm (0.79 in.)

  • Page 49: Center Body Pillar (Cut)

    BODY PANEL REPLACEMENT BP-27 CENTER BODY PILLAR (CUT) REPLACEMENT F22093A REMOVAL F22093 30 mm (1.18 in.) 50 mm (1.97 in.) 160 mm (6.30 in.) 200 mm (7.87 in.)
  • Page 50 BP-28 BODY PANEL REPLACEMENT F22094 60 mm (2.36 in.) 100 mm (3.94 in.)
  • Page 51 BODY PANEL REPLACEMENT BP-29 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 52 BP-30 BODY PANEL REPLACEMENT F22096 POINT Inspect the fitting of the front door and rear door, etc., before welding, since this affects the appearance of the finish. After welding the reinforcement to the vehicle side, install the outer panel.
  • Page 53 BODY PANEL REPLACEMENT BP-31 F22097 20 mm (0.79 in.)

  • Page 54: Front Door Outer Panel (Assy)

    BP-32 BODY PANEL REPLACEMENT FRONT DOOR OUTER PANEL (ASSY) REPLACEMENT F22098A REMOVAL Positioning Tape Installation Position Hemming Location Disk Sander F22098 POINT Before removing the outer panel, mark the installation position with a tape. Before removing the outer panel, establish its exact position in relation to the window frame using a reference maker, etc.
  • Page 55 BODY PANEL REPLACEMENT BP-33 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.

  • Page 56: Rear Door Outer Panel (Assy)

    BP-34 BODY PANEL REPLACEMENT REAR DOOR OUTER PANEL (ASSY) REPLACEMENT F22100A REMOVAL Positioning Tape Installation Position Hemming Location Disk Sander F22100 POINT Before removing the outer panel, mark the installation position with a tape. Before removing the outer panel, establish its exact position in relation to the window frame using a reference marker, etc.
  • Page 57 BODY PANEL REPLACEMENT BP-35 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 58 BP-36 BODY PANEL REPLACEMENT ROCKER OUTER PANEL (CUT) REPLACEMENT F22102A REMOVAL F22102 30 mm (1.18 in.) 50 mm (1.97 in.) 200 mm (7.87 in.)
  • Page 59 BODY PANEL REPLACEMENT BP-37 F22103 60 mm (2.36 in.)
  • Page 60 BP-38 BODY PANEL REPLACEMENT INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 61 BODY PANEL REPLACEMENT BP-39 F22105 POINT After welding the reinforcement to the vehicle side, install the outer panel. PART NAME Center Body Pillar Upper Reinforce Center Body Pillar Lower Reinforce...
  • Page 62 BP-40 BODY PANEL REPLACEMENT F22106 PART NAME Center Body Inner Pillar 20 mm (0.79 in.)
  • Page 63 BODY PANEL REPLACEMENT BP-57 QUARTER PANEL END HOUSING (ASSY) REPLACEMENT F22123A REMOVAL F22123...
  • Page 64 BP-58 BODY PANEL REPLACEMENT INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 65 BODY PANEL REPLACEMENT BP-41 ROCKER OUTER EXTENSION (ASSY) REPLACEMENT F22107A REMOVAL F22107 POINT *1: Reuse Remove the [C] at the same time. PART NAME Center Body Outer Pillar Quarter Panel Center Body Pillar Lower Reinforce 50 mm (1.97 in.) 250 mm (9.84 in.) 300 mm (11.81 in.)
  • Page 66 BP-42 BODY PANEL REPLACEMENT INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 67 BODY PANEL REPLACEMENT BP-59 REAR FLOOR NO.3 CROSSMEMBER (ASSY) REPLACEMENT With the body lower back panel removed. F22125A REMOVAL F22125...
  • Page 68 BP-60 BODY PANEL REPLACEMENT INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 69 BODY PANEL REPLACEMENT BP-43 QUARTER PANEL (CUT) REPLACEMENT F22109A REMOVAL F22109 POINT Remove the [A] at the same time. PART NAME Quarter Lock Pillar Reinforcement 80 mm (3.15 in.)
  • Page 70 BP-44 BODY PANEL REPLACEMENT F22110...
  • Page 71 BODY PANEL REPLACEMENT BP-45 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 72 BP-46 BODY PANEL REPLACEMENT F22112...
  • Page 73 BODY PANEL REPLACEMENT BP-61 REAR FLOOR PAN (ASSY) REPLACEMENT With the rear floor No.3 crossmember removed. F22127A REMOVAL F22127 PART MANE Rear Floor Pan Reinforcement...
  • Page 74 BP-62 BODY PANEL REPLACEMENT INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 75 BODY PANEL REPLACEMENT BP-63 F22129 PART NAME Rear Floor Pan Reinforcement...
  • Page 76 BODY PANEL REPLACEMENT BP-47 QUARTER WHEEL HOUSING OUTER PANEL (ASSY) REPLACEMENT With the quarter panel removed F22113A REMOVAL F22113 POINT After removing the [A] and [B], remove the quarter wheel housing outer panel. : Reuse PART NAME Rocker Outer Extension Roof Side Outer Panel 340 mm (13.39 in.)
  • Page 77 BP-48 BODY PANEL REPLACEMENT F22114...
  • Page 78 BODY PANEL REPLACEMENT BP-49 F22115 POINT After removing the [A] and [B], remove the quarter wheel housing outer panel. : Reuse PART NAME Rocker Outer Extension Roof Side Outer Panel 340 mm (13.39 in.)
  • Page 79 BP-50 BODY PANEL REPLACEMENT F22116...
  • Page 80 BODY PANEL REPLACEMENT BP-51 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 81 BP-52 BODY PANEL REPLACEMENT F22118 POINT After welding the quarter wheel housing outer panel to the vehicle side, install the [A] and [B]. PART NAME Rocker Outer Extension Roof Side Outer Panel 20 mm (0.79 in.)
  • Page 82 BODY PANEL REPLACEMENT BP-53 F22119 PART NAME Weld Bolt...
  • Page 83 BP-54 BODY PANEL REPLACEMENT F22120 POINT After welding the quarter wheel housing outer panel to the vehicle side, install the [A] and [B]. PART NAME Rocker Outer Extension Roof Side Outer Panel 20 mm (0.79 in.)
  • Page 84 BP-64 BODY PANEL REPLACEMENT REAR FLOOR SIDE PANEL (ASSY) REPLACEMENT With the body lower back panel removed. F22130A REMOVAL F22130...
  • Page 85 BODY PANEL REPLACEMENT BP-65 F22131...
  • Page 86 BP-66 BODY PANEL REPLACEMENT INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 87 BODY PANEL REPLACEMENT BP-67 F22133...
  • Page 88 BODY PANEL REPLACEMENT BP-55 BODY LOWER BACK PANEL (ASSY) REPLACEMENT F22121A REMOVAL F22121...
  • Page 89 BP-56 BODY PANEL REPLACEMENT INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 90 BP-68 BODY PANEL REPLACEMENT REAR FLOOR SIDE REAR MEMBER (CUT−H) REPLACEMENT With the rear floor No.3 crossmember removed. F22134A REMOVAL F22134 160 mm (6.30 in.)
  • Page 91 BODY PANEL REPLACEMENT BP-69 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 92 BP-70 BODY PANEL REPLACEMENT REAR FLOOR SIDE REAR MEMBER (ASSY) REPLACEMENT With the rear floor No.3 crossmember removed. F22136A REMOVAL F22136...
  • Page 93 BODY PANEL REPLACEMENT BP-71 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 94 BP-72 BODY PANEL REPLACEMENT REAR FLOOR NO.2 CROSSMEMBER (ASSY) REPLACEMENT F22138A REMOVAL F22138...
  • Page 95 BODY PANEL REPLACEMENT BP-73 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 96 BP-74 BODY PANEL REPLACEMENT ROOF PANEL (ASSY): w/o Moon Roof REPLACEMENT F22140A REMOVAL F22140...
  • Page 97 BODY PANEL REPLACEMENT BP-75 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 98 BP-76 BODY PANEL REPLACEMENT ROOF PANEL (ASSY): w/ Moon Roof REPLACEMENT F22142A REMOVAL Disk Sander F22142 POINT If reusing the roof panel reinforcement, trim the hemming location using a disc sander, etc.
  • Page 99 BODY PANEL REPLACEMENT BP-77 INSTALLATION D Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) D Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
  • Page 100 BP-78 BODY PANEL REPLACEMENT OUTER PANEL INSTALLATION TORQUE T = 13.0 N T = 13.0 N T = 13.0 N T = 8.0 N T = 13.0 N T = 6.0 N T = 6.0 N T = 6.0 N T = 8.0 N T = 5.0 N T = 92.0 N...
  • Page 101 BODY PANEL REPLACEMENT BP-79 T = 26.0 N T = 26.0 N T = 26.0 N T = 26.0 N F22063 26.0 N m (265 kgf cm, 19 ft lbf) — —...
  • Page 102 BP-80 BODY PANEL REPLACEMENT T = 8.0 N T = 8.0 N T = 55.0 N T = 55.0 N T = 55.0 N F22064 8.0 N m (82 kgf cm, 71 in. lbf) 55.0 N m (561 kgf cm, 41 ft lbf) —...
  • Page 103 PAINT COATING PC-1 BODY PANEL SEALING AREAS HINT: Prior to applying body sealer, clean the area with a rag soaked in silicone remover. If weld-through primer was used, first wipe off any excess and coat with anti-corrosion primer before applying body sealer.
  • Page 104 PC-2 PAINT COATING INSIDE F22052...
  • Page 105 PAINT COATING PC-3 OUTSIDE F22053...

  • Page 106: Door Parts

    PC-4 PAINT COATING DOOR PARTS F22054...
  • Page 107 PAINT COATING PC-5 F22055...
  • Page 108 PC-6 PAINT COATING BODY PANEL UNDERCOATING AREAS HINT: First wipe off any dirt, grease or oil with a rag soaked in silicone remover. Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are acci- dently coated, wipe off the coating immediately.
  • Page 109 PAINT COATING PC-7 FOAMED MATERIAL APPLICATION AREAS The sections shown in the figure below are filled with foamed material to provide noise insulation. After repairing these sections or their peripheries, refill with foamed materials. HINT: Use the service holes located on the reverse side of the body panel to refill with foamed materials. When handling foamed material, follow the directions of the material’s manufacturer.
  • Page 110 PC-8 PAINT COATING F22058...
  • Page 111 PAINT COATING PC-9 BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS HINT: Whenever adjusting the doors and hoods, apply anti-rust agent (wax) around the hinges. Even if partially repairing a part, apply anti-rust agent (wax) over the entire application area of the part. Wipe off the anti-rust agent immediately with a rag soaked in silicone remover, if accidently applied to other areas.
  • Page 112 PC-10 PAINT COATING SILENCER SHEET INSTALLATION AREAS HINT: Use a silencer seat as a replacement of damping coat in the area where damping coat is applied. F22060 Thickness of Silencer Sheet 1.3 mm (0.051 in.) 1.8 mm (0.071 in.) 2.3 mm (0.091 in.) 3.3 mm (0.130 in.) 4.7 mm (0.185 in.) —...
  • Page 113 PAINT COATING PC-11 BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS HINT: Anti-chipping paint should be applied to some areas before the second coat and to other after the top coat. If other areas are accidentally coated, wipe off the paint immediately with a rag soaked in silicone remover. F22061 SOFT−CHIP PRIMER —...

  • Page 114: Body Dimensions

    BODY DIMENSIONS DI-1 GENERAL INFORMATION Three-dimensional Center-to-center distance straight-line BASIC DIMENSIONS distance (a) There are two types of dimensions in the diagram. (1) (Three-dimensional distance) Straight-line distance between the centers of two measuring points. (2) (Two-dimensional distance) Two-dimensional Center-to-center Horizontal distance distance Horizontal distance in forward/rearward between the in forward / rearward...
  • Page 115 DI-2 BODY DIMENSIONS MEASURING Plate Looseness (a) Basically, all measurements are to be done with a tracking Body Looseness gauge. For portions where it is not possible to use a track- ing gauge, a tape measure should be used. (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers.

  • Page 116: Engine Compartment

    BODY DIMENSIONS DI-3 BODY DIMENSION DRAWINGS ENGINE COMPARTMENT (Three-Dimensional Distance) 1,591 (62.64) 1,691 (66.57) (30.24) (12.44) (22.76) 1,115 1,618 (43.90) (63.70) (16.89) (30.47) (17.48) (13.43) 1,481 (58.31) (30.75) 1,006 (39.61) 1,488 (58.58) (12.56) 1,427 (56.18) (35.35) 1,508 (59.37) (32.95) (33.07) (11.77) (24.84) (38.58)
  • Page 117 DI-4 BODY DIMENSIONS BODY OPENING AREAS (Side View-Front) (Three-Dimensional Distance) 1,210 (47.64) 1,674 (36.93) (30.51) (65.91) (33.35) 1,080 1,591 (42.52) (62.64) 1,186 (46.69) 1,261 (33.39) (49.65) 1,121 (35.39) (44.13) Vehicle Dimensions Left  Right 1,403 1,501 1,491 1,491 1,242 1,354 1,526 (55.24) (59.09)
  • Page 118 BODY DIMENSIONS DI-5 BODY OPENING AREAS (Side View-Rear) (Three-Dimensional Distance) (32.87) 1,069 (42.09) (37.05) 1,102 (43.39) (39.06) (27.64) Vehicle Dimensions Left  Right 1,365 1,526 1,491 1,236 1,348 1,496 (53.74) (60.08) (58.70) (48.66) (53.07) (58.90) 1,808 1,272 1,593 1,711 1,666 1,682 1,573 (71.18)
  • Page 119 DI-6 BODY DIMENSIONS BODY OPENING AREAS (Rear View) (Three-Dimensional Distance) 1,172 (46.14) 1,713 (26.10) 1,387 (67.44) 1,177 (54.61) (46.34) 1,267 (49.88) 1,208 (47.56) 1,174 (46.22) 1,434 (56.46) (22.44) 1,051 (38.62) (17.87) (41.38) (25.35) Vehicle Dimensions 1,137 (44.76) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear).
  • Page 120 BODY DIMENSIONS DI-7 UNDER BODY (Three-Dimensional Distance) 1,180 (46.46) (28.90) (12.68) 1,135 (22.32) (27.52) (16.93) (12.17) 1,037 (44.69) 1,144 (40.83) (31.61) (45.04) 1,103 1,190 1,005 1,007 1,088 (43.43) (46.85) (39.57) 1,526 (39.65) (42.83) 1,228 (60.08) 1,131 (48.35) 1,464 1,025 (36.85) 1,072 (44.53) 1,140...
  • Page 121 DI-8 BODY DIMENSIONS UNDER BODY (Two-Dimensional Distance) 2,518 2,285 1,706 1,265 1,135 1,395 1,961 (99.13) (89.96) (67.17) (49.80) (26.57) (44.69) (54.92) (77.20) (20.43) 500 (26.06) (26.18) (19.69) (23.03) (21.65) (20.67) (20.20) (17.95) (12.95) (18.43) (17.95) (19.84) (19.80) (20.12) (21.42) (21.54) (7.87) 2,405 2,177...

  • Page 122: Suspension Crossmember

    BODY DIMENSIONS DI-9 SUSPENSION CROSSMEMBER (Three-Dimensional Distance) Front (27.56) (36.22) (34.61) (37.20) 1,029 (40.51) (20.47) (24.25) (25.91) (26.61) (19.13) (29.06) Imaginary Standard Line (3.11) (2.87) (3.46) (2.13) (2.80) (2.80) (2.13) (3.46) (2.87) (3.11) HINT: For sysmbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear).
  • Page 123 DI-10 BODY DIMENSIONS SUSPENSION CROSSMEMBER (Two-Dimensional Distance) Front 635 (25.00) 635 (25.00) (13.78) (13.78) 505 (19.88) 505 (19.88) (18.11) (18.11) (13.31) (13.31) 14 (0.55) 14 (0.55) (9.57) (9.57) 104 (4.09) 104 (4.09) (14.53) (14.53) Imaginary Standard Line (3.11) (2.87) (3.46) (2.13) (2.80) (2.80)

  • Page 124: Reference Value

    BODY DIMENSIONS DI-11 REFERENCE VALUE ENGINE COMPARTMENT (Three-Dimensional Distance) 1,528 (60.16) 1,542 1,632 1,618 (64.25) (60.71) (63.70) (13.43) 1,481 (58.31) (23.03) 1,488 (58.58) (35.31) (12.56) 1,427 (56.18) 1,425 (56.10) 1,258 (12.83) 1,444 (49.53) (56.85) (13.46) (32.95) 1,145 1,441 (45.08) (56.73) (27.40) (26.02) HINT:...
  • Page 125 DI-12 BODY DIMENSIONS UNDER BODY (Two-Dimensional Distance) Front bumper reinforcement 12.9D 12.9D 12.3D 12.4D 3M10 NUT 3M10 NUT 25.4 31.4 Front spring support Rear spring support 11.6 12.5 39.5 37.9 62.0 50.4 5.8D 3.1D...

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