Toyota ZZW30 Series Repair Manual
  1. Manuals
  2. Brands
  3. Toyota Manuals
  4. Automobile
  5. ZZW30 Series
  6. Repair manual
Toyota ZZW30 Series Repair Manual

Toyota ZZW30 Series Repair Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

FOREWORD
This repair manual has been prepared to provide essential information on
body panel repair methods (including cutting and welding operations, but
excluding painting) for the TOYOTA MR2.
Applicable models: ZZW30 series
This manual consists of body repair methods, exploded diagrams and il-
lustrations of the body components and other information relating to body
panel replacement such as handling precautions, etc. However, it should
be noted that the front fenders 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 specifications 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 MR2 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.

Advertisement

Table of Contents
loading

Related Manuals for Toyota ZZW30 Series

Summary of Contents for Toyota ZZW30 Series

  • Page 1 However, it should be noted that the front fenders 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 for the removal and reinstallation of the equipment parts up to the white body condition and for the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel.

  • Page 3: General Repair Instructions

    INTRODUCTION SS-1 GENERAL REPAIR INSTRUCTIONS 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 SS-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 chart. (3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must given to the property of the plastic.
  • Page 5 Avoid dipping or immersing Thermoplastic time in small amounts (e.g., quick wiping to in alcohol, gasoline, Polyurethane (176) 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 SS-4 INTRODUCTION 3. LOCATION OF PLASTIC BODY PARTS Parts Name Code Front Bumper Cover TSOP Headlight PC/PP Side Turn Signal Light SAN /ABS Outer Rear View Mirror Front Door Outside Handle PC/PBT Front Fender Mudguard PP/EPDM Rear Bumper Cover TSOP Quarter Panel Mudguard PP/EPDM Rear Combination Light...

  • Page 7: How To Use This Manual

    INTRODUCTION SS-5 HOW TO USE THIS MANUAL 1. BODY PANEL REPLACEMENT THIS MANUAL BODY PANEL REPLACEMENT QUARTER PANEL (CUT) REPLACEMENT 1. REMOVE QUARTER PANEL (a) Cut and join the part at the location as shown below. Cut and Join Location [Cut and Join Loca- tion] Cut and Join Location...

  • Page 8: Body Panel Replacement

    SS-6 INTRODUCTION BODY PANEL REPLACEMENT 2. INSTALL QUARTER PANEL HINT: Inspect the fitting of the rear door, luggage compartment door and rear combination light, etc., before welding, since this affects the appearance of the finish, (a) Before temporarily installing the new parts, apply body sealer to the wheel arch. HINT: S Apply body sealer about 5 mm (0.20 in.) from the flange, avoiding any oozing.
  • Page 9 INTRODUCTION SS-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. SYMBOLS MEANING ILLUSTRATION SAW CUT OR ROUGH CUT REMOVE BRAZE WELD POINTS SPOT WELD OR MIG PLUG WELD (See Page SS-8)
  • Page 10 SS-8 INTRODUCTION 3. ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE: REMOVAL INSTALLATION Braze Braze Weld points Weld points Remove weld point and panel position Weld method and panel position SYMBOL MEANING ILLUSTRATION SYMBOL MEANING ILLUSTRATION Remove Weld Spot Weld Points (Outside) Mig Plug Weld (Middle)
  • Page 11 INTRODUCTION SS-9 PROPER AND EFFICIENT WORK PROCEDURES 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. (b) CUTTING AREA (1) Always cut in a straight line and avoid reinforced area.
  • Page 12 SS-10 INTRODUCTION PREPARATION FOR INSTALLATION (a) SPOT WELD POINTS (1) When welding panels with a combined thickness of Lessthan over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) weld- 3 mm er for plug welding. HINT: Spot welding will not provide sufficient durability for panels over 3 mm (0.12 in.) thick.
  • Page 13 INTRODUCTION SS-11 INSTALLATION (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. Body Measurement Diagrams F10016A (b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld: 1.3 X No.
  • Page 14 SS-12 INTRODUCTION 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 undercoat to the bottom surface of the under body and inside of the wheel housings.
  • Page 15 INTRODUCTION SS-13 ANTI-RUST TREATMENT BY PAINTING REFERANCE: Painting prevents corrosion and protect the sheet met- al 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, valance panel, etc.
  • Page 16 SS-14 INTRODUCTION 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 section BR of the repair manual for the relevant model year when handling brake system parts. NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC sys- tem.
  • Page 17 STRUCTURE PANELS 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 18 SS-16 INTRODUCTION IMPACT BEAM REPAIR The impact beam and bracket are necessary and important parts in maintaining a survival space for passengers in a side collision. 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 19: Abbreviations Used In This Manual

    INTRODUCTION SS-17 ABBREVIATIONS USED IN THIS MANU- 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 Four Wheel Drive Vehicles inch Left-hand...
  • Page 20 BODY PANEL REPLACEMENT BP-1 RADIATOR UPPER SIDE SUPPORT (ASSY) REPLACEMENT REMOVE RADIATOR UPPER SIDE SUPPORT F10801A...
  • Page 21 BP-2 BODY PANEL REPLACEMENT INSTALL RADIATOR UPPER SIDE SUPPORT F10802A MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) APPLYING SEALER TO THE FRONT LUGGAGE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 22 BODY PANEL REPLACEMENT BP-3 RADIATOR UPPER SUPPORT (ASSY) REPLACEMENT REMOVE RADIATOR UPPER SIDE SUPPORT (See page BP-1) REMOVE RADIATOR UPPER SUPPORT F10803A...
  • Page 23 BP-4 BODY PANEL REPLACEMENT INSTALL RADIATOR UPPER SUPPORT (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: First install the hood lock support. F10804A...
  • Page 24 BODY PANEL REPLACEMENT BP-5 INSTALL RADIATOR UPPER SIDE SUPPORT (See page BP-2) MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) APPLYING SEALER TO THE FRONT LUGGAGE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 25 BP-6 BODY PANEL REPLACEMENT FRONT SIDE MEMBER NO.1 REINFORCEMENT (ASSY) REPLACEMENT REMOVE RADIATOR UPPER SIDE SUPPORT (See page BP-1) REMOVE RADIATOR UPPER SUPPORT (See page BP-3) REMOVE FRONT SIDE MEMBER NO.1 REINFORCEMENT (a) Replace the horn mounting bracket (LH only) at the same time. [LH only] Horn Mounting Bracket F10805A...
  • Page 26 BODY PANEL REPLACEMENT BP-7 INSTALL FRONT SIDE MEMBER NO.1 REINFORCEMENT (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: First install the radiator upper support. [LH only] Horn Mounting Bracket F10806A...
  • Page 27 BP-8 BODY PANEL REPLACEMENT INSTALL RADIATOR UPPER SUPPORT (See page BP-4) INSTALL RADIATOR UPPER SIDE SUPPORT (See page BP-2) MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.

  • Page 28: Front Crossmember (Assy)

    BODY PANEL REPLACEMENT BP-9 FRONT CROSSMEMBER (ASSY) REPLACEMENT REMOVE FRONT CROSSMEMBER F10807A...
  • Page 29 BP-10 BODY PANEL REPLACEMENT INSTALL FRONT CROSSMEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: First install the hood lock support. F10808A...
  • Page 30 BODY PANEL REPLACEMENT BP-11 MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) MEASURING THE UNDER BODY DIMENSIONS (See page BP-95) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.

  • Page 31: Radiator Support (Assy)

    BP-12 BODY PANEL REPLACEMENT RADIATOR SUPPORT (ASSY) REPLACEMENT REMOVE RADIATOR SUPPORT F10809A...
  • Page 32 BODY PANEL REPLACEMENT BP-13 INSTALL RADIATOR SUPPORT (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10810A...
  • Page 33 BP-14 BODY PANEL REPLACEMENT MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) MEASURING THE UNDER BODY DIMENSIONS (See page BP-95) APPLYING SEALER TO THE FRONT LUGGAGE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.

  • Page 34: Front Fender Front Apron (Assy)

    BODY PANEL REPLACEMENT BP-15 FRONT FENDER FRONT APRON (ASSY) REPLACEMENT REMOVE FRONT FENDER FRONT APRON (a) Replace the front fender mounting bracket at the same time. Front Fender Mounting Bracket [LH only] [LH only] F10811A...
  • Page 35 BP-16 BODY PANEL REPLACEMENT INSTALL FRONT FENDER FRONT APRON (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. [LH only] [LH only] F10812A MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) APPLYING SEALER TO THE FRONT LUGGAGE COMPARTMENT (See page PC-1) APPLYING UNDER COATING (See page PC-6) APPLYING ANTI-RUST AGENT...
  • Page 36 BODY PANEL REPLACEMENT BP-17 FRONT APRON TO COWL SIDE UPPER MEMBER (ASSY) REPLACEMENT REMOVE FRONT FENDER APRON LOWER GUSSET (See page BP-36) REMOVE FRONT APRON TO COWL SIDE UPPER MEMBER F10813A...
  • Page 37 BP-18 BODY PANEL REPLACEMENT INSTALL FRONT APRON TO COWL SIDE UPPER MEMBER HINT: Inspect the fitting of the front fender and hood, etc. before welding, since this affects the appearance of the finish. F10814A...
  • Page 38 BODY PANEL REPLACEMENT BP-19 MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) INSTALL FRONT FENDER APRON LOWER GUSSET (See page BP-37) APPLYING SEALER TO THE FRONT LUGGAGE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.

  • Page 39: Front Fender Apron (Assy)

    BP-20 BODY PANEL REPLACEMENT FRONT FENDER APRON (ASSY) REPLACEMENT REMOVE RADIATOR UPPER SIDE SUPPORT (See page BP-1) REMOVE FRONT FENDER APRON LOWER GUSSET (See page BP-36) REMOVE FRONT FENDER APRON [LH only] F10815A...
  • Page 40 BODY PANEL REPLACEMENT BP-21 INSTALL FRONT FENDER APRON HINT: Inspect the fitting of the front fender and hood, etc. before welding, since this affects the appearance of the finish. (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Make sure each measurement is correct, as this parts affects the front wheel alignment.
  • Page 41 BP-22 BODY PANEL REPLACEMENT 5. MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) 6. MEASURING THE UNDER BODY DIMENSIONS (See page BP-95) 7. INSTALL FRONT FENDER APRON LOWER GUSSET (See page BP-37) 8. INSTALL RADIATOR UPPER SIDE SUPPORT (See page BP-2) 9.

  • Page 42: Front Side Member (Cut-P)

    BODY PANEL REPLACEMENT BP-23 FRONT SIDE MEMBER (CUT-P) REPLACEMENT REMOVE RADIATOR UPPER SIDE SUPPORT (See page BP-1) REMOVE RADIATOR UPPER SUPPORT (See page BP-3) REMOVE FRONT SIDE MEMBER NO.1 REINFORCEMENT (See page BP-6) REMOVE FRONT CROSSMEMBER (See page BP-9) REMOVE FRONT SIDE MEMBER (a) Cut and join the parts at the location as shown below.
  • Page 43 BP-24 BODY PANEL REPLACEMENT INSTALL FRONT SIDE MEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. Butt Weld Butt Weld F10818A...
  • Page 44 BODY PANEL REPLACEMENT BP-25 7. MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) 8. MEASURING THE UNDER BODY DIMENSIONS (See page BP-95) 9. INSTALL FRONT CROSSMEMBER (See page BP-10) 10. INSTALL FRONT SIDE MEMBER NO.1 REINFORCEMENT (See page BP-7) INSTALL RADIATOR UPPER SUPPORT (See page BP-4) 12.

  • Page 45: Front Side Member (Assy)

    BP-26 BODY PANEL REPLACEMENT FRONT SIDE MEMBER (ASSY) REPLACEMENT REMOVE RADIATOR UPPER SIDE SUPPORT (See page BP-1) REMOVE RADIATOR UPPER SUPPORT (See page BP-3) REMOVE FRONT SIDE MEMBER NO.1 REINFORCEMENT (See page BP-6) REMOVE FRONT CROSSMEMBER (See page BP-9) REMOVE FRONT FENDER APRON LOWER GUSSET (See page BP-36) REMOVE FRONT FENDER APRON (See page BP-20) REMOVE FRONT LUGGAGE END PANEL (See page BP-30) REMOVE STEERING GEAR BOX SUPPORT MEMBER (See page BP-33)
  • Page 46 BODY PANEL REPLACEMENT BP-27 F10820A...
  • Page 47 BP-28 BODY PANEL REPLACEMENT 10. INSTALL FRONT SIDE MEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Make sure each measurement is correct, as this parts affects the front wheel alignment. F10821A...
  • Page 48 BODY PANEL REPLACEMENT BP-29 MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) 12. MEASURING THE UNDER BODY DIMENSIONS (See page BP-95) 13. INSTALL STEERING GEAR BOX SUPPORT MEMBER (See page BP-34) 14. INSTALL FRONT LUGGAGE END PANEL (See page BP-31) 15.
  • Page 49 BP-30 BODY PANEL REPLACEMENT FRONT LUGGAGE END PANEL (ASSY) REPLACEMENT REMOVE FRONT LUGGAGE END PANEL F10822A...
  • Page 50 BODY PANEL REPLACEMENT BP-31 INSTALL FRONT LUGGAGE END PANEL F10823A...
  • Page 51 BP-32 BODY PANEL REPLACEMENT MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) MEASURING THE UNDER BODY DIMENSIONS (See page BP-95) APPLYING SEALER TO THE FRONT LUGGAGE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 52 BODY PANEL REPLACEMENT BP-33 STEERING GEAR BOX SUPPORT MEMBER (ASSY) REPLACEMENT REMOVE STEERING GEAR BOX SUPPORT MEMBER F10824A...
  • Page 53 BP-34 BODY PANEL REPLACEMENT INSTALL STEERING GEAR BOX SUPPORT MEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Measurements must be accurate with the body dimension diagram, as this affects the front wheel align- ment.
  • Page 54 BODY PANEL REPLACEMENT BP-35 MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) MEASURING THE UNDER BODY DIMENSIONS (See page BP-95) APPLYING SEALER TO THE FRONT LUGGAGE COMPARTMENT (See page PC-1) APPLYING UNDER COATING (See page PC-6) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 55 BP-36 BODY PANEL REPLACEMENT FRONT FENDER APRON LOWER GUSSET (ASSY) REPLACEMENT REMOVE FRONT FENDER APRON LOWER GUSSET Cut with disc sander, etc. F10826A...
  • Page 56 BODY PANEL REPLACEMENT BP-37 INSTALL FRONT FENDER APRON LOWER GUSSET Tack Weld (15 mm each) 0.59 F10827A APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.

  • Page 57: Front Body Pillar (Cut)

    BP-38 BODY PANEL REPLACEMENT FRONT BODY PILLAR (CUT) REPLACEMENT REMOVE FRONT FENDER APRON LOWER GUSSET (See page BP-36) REMOVE FRONT BODY PILLAR (a) Cut and join the parts at the location as shown below. (b) Heat the brazed area of the roof panel, and scrape off the brazing with a wire brush. HINT: Be careful not to overheat the roof panel.
  • Page 58 BODY PANEL REPLACEMENT BP-39 Cut with disc sander, etc. Cut with disc sander, etc. F10829A...
  • Page 59 BP-40 BODY PANEL REPLACEMENT INSTALL FRONT BODY PILLAR HINT: Inspect the fitting of the front door, front fender and windshield glass, etc., before welding, since this af- fects the appearance of the finish. (a) Cut the new parts for the rocker outer panel at the location as shown below. (b) Before temporarily installing the new parts, weld the front body upper outer pillar, rocker outer panel, rock- er panel No.2 reinforcement and front body upper inner pillar with standard points.
  • Page 60 BODY PANEL REPLACEMENT BP-41 Braze Tack Weld (30 mm) 0.59 0.79 0.98 Butt Weld 1.18 Tack Weld (15 mm) Tack Weld (25 mm) Tack Weld (25 mm each) Tack Weld Tack Weld (20 mm) (15 mm each) F10831A...
  • Page 61 BP-42 BODY PANEL REPLACEMENT MEASURING THE FRONT LUGGAGE COMPARTMENT DIMENSIONS (See page BP-95) MEASURING THE OPENING PORTION DIMENSIONS (See page BP-95) INSTALL FRONT FENDER APRON LOWER GUSSET (See page BP-37) APPLYING SEALER TO THE FRONT LUGGAGE COMPARTMENT (See page PC-1) APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural...

  • Page 62: Front Door Outer Panel (Assy)

    BODY PANEL REPLACEMENT BP-43 FRONT DOOR OUTER PANEL (ASSY) REPLACEMENT REMOVE FRONT DOOR OUTER PANEL (a) After grinding off the hemming location, remove the outer panel. Hemming Location Disc Sander F10879A...
  • Page 63 BP-44 BODY PANEL REPLACEMENT INSTALL FRONT DOOR OUTER PANEL (a) Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and back side of the new parts. HINT: S Apply just enough sealer for the reinforcement and side impact beam to touch the new panel. Apply sealer evenly around the flange area, about 10 mm (0.39 in.) from the edge, as shown.
  • Page 64 BODY PANEL REPLACEMENT BP-45 APPLYING SEALER TO THE DOOR PARTS (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 65 BP-46 BODY PANEL REPLACEMENT ROCKER OUTER PANEL (CUT-P) REPLACEMENT REMOVE ROCKER OUTER PANEL (a) Cut and join the parts at the locations as shown below. 40 mm 80 mm Cut and Join Cut and Join Location Location [Cut and Join Location] 1.57 3.15 F10835A...
  • Page 66 BODY PANEL REPLACEMENT BP-47 INSTALL ROCKER OUTER PANEL (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Inspect the fitting of the front door, etc., before welding, since this affects the appearance of the finish. (b) Cut the new parts for the rocker outer panel at the locations as shown below.
  • Page 67 BP-48 BODY PANEL REPLACEMENT CENTER BODY OUTER PILLAR (CUT) REPLACEMENT REMOVE CENTER BODY OUTER PILLAR (a) Cut the rocker outer panel at the location as shown below. (b) Simultaneously exchange the rocker outer panel and center body outer pillar. (c) After removing the center body outer pillar, remove the rocker outer panel. Cut with disc sander, etc.
  • Page 68 BODY PANEL REPLACEMENT BP-49 INSTALL CENTER BODY OUTER PILLAR (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Inspect the fitting of the front door and quarter panel, etc., before welding since this affects the appear- ance of the finish.
  • Page 69 BP-50 BODY PANEL REPLACEMENT Tack Weld (15 mm) 0.59 F10834A MEASURING THE OPENING PORTION DIMENSIONS (See page BP-95) APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 70 BODY PANEL REPLACEMENT BP-51 SIDE PANEL NO.4 REINFORCEMENT (ASSY) REPLACEMENT REMOVE FRAME REAR UPPER CROSSMEMBER (See page BP-62) REMOVE SIDE PANEL NO.4 REINFORCEMENT Cut with disc sander, etc. F10837A...
  • Page 71 BP-52 BODY PANEL REPLACEMENT INSTALL SIDE PANEL NO.4 REINFORCEMENT Tack Weld (15 mm each) 0.59 F10838A...
  • Page 72 BODY PANEL REPLACEMENT BP-53 INSTALL FRAME REAR UPPER CROSSMEMBER (See page BP-63) APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 73 BP-54 BODY PANEL REPLACEMENT MOUNTING BRACKET (ASSY) REPLACEMENT REMOVE MOUNTING BRACKET F10839A...

  • Page 74: Install Mounting Bracket

    BODY PANEL REPLACEMENT BP-55 INSTALL MOUNTING BRACKET (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Inspect the fitting of the quarter panel and rear combination light etc., before welding, since this affects the appearance of the finish.
  • Page 75 BP-56 BODY PANEL REPLACEMENT LOWER BACK SIDE PANEL (ASSY) REPLACEMENT REMOVE LOWER BACK SIDE PANEL F10841A...
  • Page 76 BODY PANEL REPLACEMENT BP-57 INSTALL LOWER BACK SIDE PANEL (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Inspect the fitting of the quarter panel and rear combination light, etc., before welding, since this affects the appearance of the finish.
  • Page 77 BP-58 BODY PANEL REPLACEMENT BODY LOWER BACK UPPER PANEL (ASSY) REPLACEMENT REMOVE BODY LOWER BACK UPPER PANEL F10843A...
  • Page 78 BODY PANEL REPLACEMENT BP-59 INSTALL BODY LOWER BACK UPPER PANEL HINT: Inspect the fitting of the engine hood and rear combination light, etc., before welding, since this affects the appearance of the finish. F10844A APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 79 BP-60 BODY PANEL REPLACEMENT BODY LOWER BACK PANEL (ASSY) REPLACEMENT REMOVE BODY LOWER BACK UPPER PANEL (See page BP-58) REMOVE BODY LOWER BACK PANEL F10845A...
  • Page 80 BODY PANEL REPLACEMENT BP-61 INSTALL BODY LOWER BACK PANEL F10846A INSTALL BODY LOWER BACK UPPER PANEL (See page BP-59) APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 81 BP-62 BODY PANEL REPLACEMENT FRAME REAR UPPER CROSSMEMBER (ASSY) REPLACEMENT REMOVE FRAME REAR UPPER CROSSMEMBER Cut with disc sander, etc. F10847A...
  • Page 82 BODY PANEL REPLACEMENT BP-63 INSTALL FRAME REAR UPPER CROSSMEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Inspect the fitting of the engine hood and rear combination light, etc., before welding, since this affects the appearance of the finish.
  • Page 83 BP-64 BODY PANEL REPLACEMENT MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-95) APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 84 BODY PANEL REPLACEMENT BP-65 REAR FLOOR SIDE REAR MEMBER (ASSY) REPLACEMENT REMOVE LOWER BACK SIDE PANEL (See page BP-56) REMOVE REAR FLOOR SIDE REAR MEMBER Exhaust Pipe No.2 Hanger F10849A...
  • Page 85 BP-66 BODY PANEL REPLACEMENT INSTALL REAR FLOOR SIDE REAR MEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. 0.59 Tack Weld (15 mm) F10850A...
  • Page 86 BODY PANEL REPLACEMENT BP-67 MEASURING THE UNDER BODY DIMENSIONS (See page BP-95) MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-95) INSTALL LOWER BACK SIDE PANEL (See page BP-57) APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING UNDER COATING (See page PC-6) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 87 BP-68 BODY PANEL REPLACEMENT REAR DIAGONAL MEMBER (ASSY) REPLACEMENT REMOVE REAR DIAGONAL MEMBER F10851A...
  • Page 88 BODY PANEL REPLACEMENT BP-69 INSTALL REAR DIAGONAL MEMBER F10852A...
  • Page 89 BP-70 BODY PANEL REPLACEMENT APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 90 BODY PANEL REPLACEMENT BP-71 QUARTER INNER REAR PANEL (ASSY) REPLACEMENT REMOVE LOWER BACK SIDE PANEL (See page BP-56) REMOVE FRAME REAR UPPER CROSSMEMBER (See page BP-62) REMOVE QUARTER INNER REAR PANEL F10853A...
  • Page 91 BP-72 BODY PANEL REPLACEMENT INSTALL QUARTER INNER REAR PANEL F10854A...
  • Page 92 BODY PANEL REPLACEMENT BP-73 INSTALL FRAME REAR UPPER CROSSMEMBER (See page BP-63) INSTALL LOWER BACK SIDE PANEL (See page BP-57) APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING UNDER COATING (See page PC-6) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 93 BP-74 BODY PANEL REPLACEMENT SIDE PANEL NO.2 REINFORCEMENT (ASSY) REPLACEMENT REMOVE SIDE PANEL NO.2 REINFORCEMENT Cut with disc sander, etc. F10855A...
  • Page 94 BODY PANEL REPLACEMENT BP-75 INSTALL SIDE PANEL NO.2 REINFORCEMENT Tack Weld (15 mm each) 0.59 F10856A...
  • Page 95 BP-76 BODY PANEL REPLACEMENT APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 96 BODY PANEL REPLACEMENT BP-77 REAR FENDER APRON REINFORCEMENT (ASSY) REPLACEMENT REMOVE FRAME REAR UPPER CROSSMEMBER (See page BP-62) REMOVE SIDE PANEL NO.4 REINFORCEMENT (See page BP-51) REMOVE REAR FENDER APRON REINFORCEMENT F10857A...
  • Page 97 BP-78 BODY PANEL REPLACEMENT INSTALL REAR FENDER APRON REINFORCEMENT F10858A...
  • Page 98 BODY PANEL REPLACEMENT BP-79 INSTALL SIDE PANEL NO.4 REINFORCEMENT (See page BP-52) MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-95) INSTALL FRAME REAR UPPER CROSSMEMBER (See page BP-63) APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.
  • Page 99 BP-80 BODY PANEL REPLACEMENT WHEEL HOUSING REINFORCEMENT (ASSY) REPLACEMENT REMOVE SIDE PANEL NO.2 REINFORCEMENT (See page BP-74) REMOVE FRAME REAR UPPER CROSSMEMBER (See page BP-62) REMOVE SIDE PANEL NO.4 REINFORCEMENT (See page BP-51) REMOVE WHEEL HOUSING REINFORCEMENT F10859A...
  • Page 100 BODY PANEL REPLACEMENT BP-81 INSTALL WHEEL HOUSING REINFORCEMENT (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10860A...
  • Page 101 BP-82 BODY PANEL REPLACEMENT 6. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-95) 7. INSTALL SIDE PANEL NO.4 REINFORCEMENT (See page BP-52) 8. INSTALL FRAME REAR UPPER CROSSMEMBER (See page BP-63) 9. INSTALL SIDE PANEL NO.2 REINFORCEMENT (See page BP-75) 10.
  • Page 102 BODY PANEL REPLACEMENT BP-83 REAR SEAT BACK HINGE BRACKET (ASSY) REPLACEMENT REMOVE FRAME REAR UPPER CROSSMEMBER (See page BP-62) REMOVE SIDE PANEL NO.4 REINFORCEMENT (See page BP-51) REMOVE REAR SEAT BACK HINGE BRACKET (a) After removing the rear floor side member plate, remove the rear seat back hinge bracket. Cut with disc [LH only] sander, etc.
  • Page 103 BP-84 BODY PANEL REPLACEMENT F10862A...
  • Page 104 BODY PANEL REPLACEMENT BP-85 INSTALL REAR SEAT BACK HINGE BRACKET (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Measurements must be accurate with the body dimension diagram, as this affects the rear wheel align- ment.
  • Page 105 BP-86 BODY PANEL REPLACEMENT 0.39 1.18 [LH only] Tack Weld Tack Weld (30 mm each) (10 mm each) [RH side] F10864A 5. MEASURING THE UNDER BODY DIMENSIONS (See page BP-95) 6. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-95) 7. INSTALL SIDE PANEL NO.4 REINFORCEMENT (See page BP-52) 8.
  • Page 106 BODY PANEL REPLACEMENT BP-87 QUARTER WHEEL HOUSING INNER PANEL (ASSY) REPLACEMENT REMOVE FRAME REAR UPPER CROSSMEMBER (See page BP-62) REMOVE SIDE PANEL NO.4 REINFORCEMENT (See page BP-51) REMOVE REAR SEAT BACK HINGE BRACKET (See page BP-83) REMOVE SIDE PANEL NO.2 REINFORCEMENT (See page BP-74) REMOVE QUARTER WHEEL HOUSING INNER PANEL RH Side F10865A...
  • Page 107 BP-88 BODY PANEL REPLACEMENT INSTALL QUARTER WHEEL HOUSING INNER PANEL RH Side F10866A...
  • Page 108 BODY PANEL REPLACEMENT BP-89 7. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-95) 8. INSTALL SIDE PANEL NO.2 REINFORCEMENT (See page BP-75) 9. INSTALL REAR SEAT BACK HINGE BRACKET (See page BP-85) 10. INSTALL SIDE PANEL NO.4 REINFORCEMENT (See page BP-52) INSTALL FRAME REAR UPPER CROSSMEMBER (See page BP-63) 12.
  • Page 109 BP-90 BODY PANEL REPLACEMENT REAR FLOOR SIDE MEMBER (CUT) REPLACEMENT REMOVE FRAME REAR UPPER CROSSMEMBER (See page BP-62) REMOVE LOWER BACK SIDE PANEL (See page BP-56) REMOVE REAR DIAGONAL MEMBER (See page BP-68) REMOVE SIDE PANEL NO.4 REINFORCEMENT (See page BP-51) REMOVE REAR SEAT BACK HINGE BRACKET (See page BP-83) REMOVE REAR FLOOR SIDE REAR MEMBER (See page BP-65) REMOVE REAR FLOOR SIDE MEMBER...
  • Page 110 BODY PANEL REPLACEMENT BP-91 INSTALL REAR FLOOR SIDE MEMBER (a) Cut the new parts for the rear floor side member at the location as shown below. HINT: Remove rear floor side member center reinforcement without cutting it. (b) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. Rear Floor Side Member Rear Floor Side Member Center Reinforcement...
  • Page 111 BP-92 BODY PANEL REPLACEMENT 9. MEASURING THE UNDER BODY DIMENSIONS (See page BP-95) 10. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-95) INSTALL REAR FLOOR SIDE REAR MEMBER (See page BP-66) 12. INSTALL REAR SEAT BACK HINGE BRACKET (See page BP-85) 13.
  • Page 112 BODY PANEL REPLACEMENT BP-93 ROOF PANEL (ASSY) REPLACEMENT REMOVE ROOF PANEL (a) Heat the brazed area of the front body pillar, and scrape off the brazing with a wire brush. HINT: Be careful not to overheat the front body pillar. Braze (both sides) F10869A...
  • Page 113 BP-94 BODY PANEL REPLACEMENT INSTALL ROOF PANEL (a) Braze the front body pillar connection. HINT: Before performing these operations, place a wet rag on the roof panel to protect it from damage. Braze (both sides) F10870A APPLYING SEALER TO THE FRONT LUGGAGE COMPARTMENT (See page PC-1) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots.

  • Page 114: General Information

    BODY PANEL REPLACEMENT BP-95 GENERAL INFORMATION Three-dimensional Center-to-center distance straight-line BASIC DIMENSIONS distance (a) There are two typed of dimensions in the diagram. (1) (Three-dimensional distance) Straight-line distance between the centers of two mea- suring points. F10115A (2) (Two-dimensional distance) Center-to-center Two-dimensional distance...
  • Page 115 BP-96 BODY PANEL REPLACEMENT 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 tracking 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 1,368 (16.69) (53.86) 1,419 (55.87) 1,321 (52.01) (18.15) 1,199 (47.20) 1,340 1,120 (38.98) (52.76) (11.38) (44.09) (38.07) (20.28) (38.11) 1,113 (43.82) (28.58) (32.09) (16.89) (15.71) (32.09) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear). mm (in.) Symbol Name...
  • Page 117 1,004 (39.53) (22.80) 1,293 (50.91) 1,331 (29.02) (52.40) (31.30) 1,076 (23.35) (42.36) (36.54) HINT: For symbols, capital letters indicate right side of vehicle, 1,203 1,036 (47.36) (40.79) small letters indicate left side of vehicle (Seen from rear). Vehicle Dimensions Left $ Right 1,259 1,368 1,391...
  • Page 118 1,277 (50.28) (19.72) 1,398 (55.04) 1,375 (54.13) 1,140 (5.71) (44.88) (33.62) (18.03) 1,021 1,333 (40.20) (52.48) (37.68) (15.87) (33.90) (11.22) (36.61) (35.79) 627 (24.69) 685 (26.97) 629 (24.76) 664 (26.14) 572 (22.52) 611 (24.06) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear).
  • Page 120 1,980 1,727 1,530 1,217 1,377 (77.95) (67.99) (60.24) (47.91) (20.67) (18.11) (38.62) (54.21) (19.92) (19.29) (17.01) (16.85) (16.85) (15.94) (14.33) (8.03) (5.91) Front (6.30) (16.85) (16.85) (18.90) (19.13) (18.31) (23.98) (26.34) 1,955 1,727 1,453 1,051 (76.97) (67.99) (57.20) (38.86) (9.33) (23.43) (41.38) Wheel base...

  • Page 121: Front Luggage Compartment

    PAINT COATING PC-1 BODY PANEL SEALING AREAS HINT: Prior to applying body sealer, clean the area with a rag soaked in a grease, wax and silicone remover. If weld-through primer was used, first wipe off any excess and coat with anti-corrosion primer before applying body sealer.
  • Page 122 PC-2 PAINT COATING 2. INSIDE Flat Surfacing Flat Surfacing Flat Surfacing F10872A...

  • Page 123: Engine Compartment

    PAINT COATING PC-3 3. ENGINE COMPARTMENT Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing F10873A...

  • Page 124: Door Parts

    PC-4 PAINT COATING 4. DOOR PARTS (a) Please be sure to apply body sealer to the places indicated below, if the quarter panel has been removed. Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing F10874A...
  • Page 125 PAINT COATING PC-5 Flat Surfacing Flat Surfacing Flat Surfacing F10875A...
  • Page 126 PC-6 PAINT COATING BODY PANEL UNDERCOATING AREAS HINT: First wipe off any dirt, grease or oil with a rag soaked in a grease, wax and silicone remover. Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are accidently coated, wipe off the coating immediately.
  • Page 127 PAINT COATING PC-7 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 a grease, wax and silicone remover, if acci- dently applied to other areas.
  • Page 128 PC-8 PAINT COATING SILENCER SHEET INSTALLATION AREAS Thickness of Asphalt Sheet 1.5 mm (0.059 in.) 3.0 mm (0.118 in.) F10878A...
  • Page 129 PAINT COATING PC-9 BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS HINT: Anti-chipping paint should be applied to some areas before the second coat and to others after the top coat. If other areas are accidentally coated, wipe of the paint immediately with a rag soaked in grease, wax and silicone remover.

This manual is also suitable for:

Mr2

Table of Contents