Toyota 1991 CAMRY Body Section Repair Manual
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Toyota 1991 CAMRY Body Section Repair Manual

1991 camry body section;
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FOREWORD
This repair manual has been prepared to provide information on
the repair methods (including cutting and welding operations,
but excluding painting) recommended by TOYOTA for collision-
damaged body components of the TOYOTA CAMRY.
Applicable models:
This manual consists of body repair methods, exploded dia-
grams and illustrations of the body components and other infor-
mation relating to body panel replacement such as handling pre-
cautions, tools, equipment, etc. However, it should be noted that
the front fenders of all TOYOTA models are bolted on and re-
quire no welding.
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 service of specifications and repair procedures other
than collision-damaged body components of the TOYOTA
CAMRY, refer to the following repair manuals.
Manual Name
CAMRY Chassis and Body Repair Manual
CAMRY Repair Manual (USA and Canada)
Electrical Wiring Diagram
(Ex. USA and Canada)
(USA and Canada)
1S, 1S-E, 2S, 2S-C, 2S-E, 3S-FE & 3S-GE
Engine Repair Manual (Ex. USA and
Canada)
1C, 2C & 2C-T Engine Repair Manual
(Ex. USA and Canada)
Fundamental Painting Procedures
Fundamental Body Repair Procedures
All information contained in this manual is the most up-to-date
at the time of publication. However, specifications and proce-
dures are subject to change without prior notice.
SV20, 21 series
CV20 series
TOYOTA MOTOR CORPORATION
Pub. No.
36216E
Model Year
Version
EWD027E
Model Year
Version
RM051E
RM025E
36438E
BRM002E

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Summary of Contents for Toyota 1991 CAMRY Body Section

  • Page 1 However, it should be noted that the front fenders of all TOYOTA models are bolted on and re- quire no welding. Body construction will sometimes differ depending on specifica- tions and country of destination.

  • Page 2: How To Use This Manual

    IN-2 INTRODUCTION HOW TO USE THIS MANUAL Each repair method description provided in Section RE of this manual comprises two pages, divided into 2 blocks (REMOVAL AND INSTALLATION) and includes illustrations to facilitate body repair. RE-34 BODY PANEL REPLACEMENT-Rear Body Components QUARTER PANEL (CUT) REMOVAL 200 - 300 mm...

  • Page 3: Installation Guide

    INTRODUCTION IN-3 BODY PANEL REPLACEMENT-Rear Body Components RE-35 INSTALLATION Butt Weld Body Sealer Braze Body Sealer About 5 mm 0.20 Temporarily install the new part and check fit for Before temporarily installing the new part, apply the rear door, luggage compartment door and body sealer to the wheel arch.
  • Page 4 IN-4 INTRODUCTION SYMBOLS The following symbols are used in the welding Diagrams in Section RE of this manual to indicate cutting areas and the types of weld required. MEANING ILLUSTRATION SYMBOLS SAW CUT OR ROUGH CUT REMOVE BRAZE WELD POINTS SPOT WELD OR MIG PLUG WELD (See page...
  • Page 5 INTRODUCTION IN-5 Illustration of Weld Point Symbols EXAMPLE: INSTALLATION REMOVAL Weld points Weld points Weld method and panel position Remove weld point and panel position SYMBOL MEANING ILLUSTRATION SYMBOL MEANING ILLUSTRATION Remove Weld Points Spot Weld (Outside) Mig Plug Weld (Middle) (Inside) Spot MIG...
  • Page 6 INTRODUCTION IN-11 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION Front ..Center of engine mounting center member Rear ..Jack up support of rear suspension member PANTOGRAPH JACK POSITION SUPPORT POSITION Safety stand .
  • Page 7 IN-12 INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL For convenience, the following abbreviations are used in this manual Assy, assy Assembly, assembly Sub-assy Sub-assembly Except Inch Independent Rear Suspension 4-link 4-link Rear Suspension Metal Inert Gas Operation Spot Weld (Resistance Spot Weld) With Without Front...

  • Page 8: General Repair Instructions

    IN-6 INTRODUCTION GENERAL REPAIR INSTRUCTIONS Work Precautions SAFETY VEHICLE PROTECTION SAFETY Never stand in direct When welding, protect the Before performing repair work, check line with the chain when painted surfaces, windows, for fuel leaks. If a leak is found, be sure using a puller on the seats and carpet with heat- to close the opening totally.
  • Page 9 INTRODUCTION IN-7 Proper and Efficient Work Procedures REMOVAL NO. OF SPOT WELDS REMOVAL OF ADJACENT COMPONENTS PRE-REMOV AL MEASURING Make a note of the num- When removing adjacent components, Before removal or cutting opera- ber of spot welds for lat- apply protective tape to the surrounding tions, take measurements in ac- er reference.
  • Page 10 IN-8 INTRODUCTION PREPARATION FOR INSTALLATION SPOT WELD POINTS APPLICATION OF WELD-THROUGH PRIMER When welding panels with a For treatment combined thickness of over 3 against corrosion, mrn (0.12 in.), use a MIG remove the paint (Metal Inert Gas) welder for from the portion of plug welding.
  • Page 11 INTRODUCTION IN-9 INSTALLATION POST-WELDING REFINISH- WELDING PRECAUTIONS PRE-WELDING MEASUREMENTS Always take measurements before The number of welding spots Always check the welded installing underbody or engine should be as follows. spots to insure they are components to insure correct Spot weld: 1.3 x No. of secure.
  • Page 12 IN-10 INTRODUCTION ANTI-RUST TREATMENT When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the requirements of your country. BODY SEALER ANTI-RUST AGENT (WAX) Apply body sealer to the Apply anti-rust agent to required areas. following sections. S Inside of the hems of the doors and hood.
  • Page 13 TE-2 TOOLS AND EQUIPMENT MEASURING INSTRUMENTS For measuring body dimensions Tracking Gauge When 3 or 4 are used together, measure- ments of twists, bends or warps in the body and frame are possible. Frame Centering Gauge SEPARATING TOOLS For separating spot welds and making holes in the body.
  • Page 14 TOOLS AND EQUIPMENT TE-3 SEPARATING TOOLS (Cont’d) For rough cutting and rough flattening of panels. Air-powered Chisel For rough cutting of panels. Panel Cutter For separating spot welds. Flat Chisel For rough flattening in hard-to-reach areas. Hammer Tool For rough cutting of pillars, rocker panels, etc.
  • Page 15 TE-4 TOOLS AND EQUIPMENT INSTALLATION ASSISTANCE TOOLS For temporary installation of panels and holding of portions to be welded. Vise Grip Wrench For making flanges in overlapping panels. Flanging Tool For hemming door outer panels, etc. Hemming Tool For making holes for MIG plug weld- ing.
  • Page 16 TOOLS AND EQUIPMENT TE-5 WELDING INSTRUMENTS For panel welding. MIG Welder (Metal Inert Gas) For panel welding. Spot Welder For rough cutting of panels, members, etc. Gas Welder Torch Gas Cutter Torch For soldering and peeling of paint. Acetylene Gas Torch For straightening distorted panels.

  • Page 17: Table Of Contents

    RE-1 BODY PANEL REPLACEMENT Page FRONT BODY COMPONENTS RADIATOR SUPPORT (ASSY) ......RE-2 FRONT CROSSMEMBER (ASSY) ..... RE-4 FRONT FENDER APRON (ASSY) .
  • Page 18 TE-6 TOOLS AND EQUIPMENT LIGHT BODY REPAIR TOOLS For straightening lightly dam- aged panels. Body Pullers GRINDING AND POLISHING TOOLS For grinding plug welds, butt welds and door hems. Air-powered Disc Grinder For grinding plug welds, butt welds and door hems. Electric- powered Disc Sander...
  • Page 19 TOOLS AND EQUIPMENT TE-7 GRINDING AND POLISHING TOOLS (Cont’d) For rough polishing of panel putty. Straight-line Sander For removing putty over a wide area, resurfacing and refinishing. Air-powered Orbital Sander For peeling paint. Air-powered Disc Sander For paint removal. File Holder For correction of soldering spots and resurfacing of panels.

  • Page 20: Radiator Support (Assy

    RE-2 BODY PANEL REPLACEMENT RADIATOR SUPPORT (ASSY) REMOVAL...
  • Page 21 BODY PANEL REPLACEMENT RE-3 INSTALLATION Assembly Mark Temporarily install the new part with the assem- bly mark and measure each part in accordance with the body dimension diagram. NOTE: Work after installing the radiator upper support.

  • Page 22: Front Crossmember (Assy

    RE-4 BODY PANEL REPLACEMENT FRONT CROSSMEMBER (ASSY) REMOVAL (With the radiator support removed.)
  • Page 23 BODY PANEL REPLACEMENT RE-5 INSTALLATION Temporarily install the new part and measure each part in accordance with the body dimen- sion diagram.

  • Page 24: Front Fender Apron (Assy

    RE-6 BODY PANEL REPLACEMENT FRONT FENDER APRON (ASSY) REMOVAL (With the radiator support removed.) (LH only) Front Body Pillar Lower Gusset After removing the front body pillar lower gusset, remove the front fender apron.
  • Page 25 BODY PANEL REPLACEMENT RE-7 INSTALLATION (LH only) Assembly Mark Check the fit of the front fender and hood. Determine the installation position of the new part by the assembly mark. Measurements must be accurate with the body dimension diagram, as this effects the front wheel alignment.

  • Page 26: Front Fender Front Apron (Assy

    RE-8 BODY PANEL REPLACEMENT FRONT FENDER FRONT APRON (ASSY) REMOVAL (With the radiator support removed.) (LH only)
  • Page 27 BODY PANEL REPLACEMENT RE-9 INSTALLATION (LH only) Temporarily install the new part and measure each part in accordance with the body dimen- sion diagram.

  • Page 28: Front Side Member (Assy

    RE-10 BODY PANEL REPLACEMENT FRONT SIDE MEMBER (ASSY) REMOVAL (With the front fender apron removed.)
  • Page 29 BODY PANEL REPLACEMENT RE-11 INSTALLATION Radiator Support to Crossmember Brace Temporarily install the new part and measure each part in accordance with the body dimen- sion diagram. NOTE: Make sure each measurement is correct, as this part effects the front wheel alignment.

  • Page 30: Front Side Member (Cut-P

    RE-12 BODY PANEL REPLACEMENT FRONT SIDE MEMBER (CUT-P) REMOVAL (With the front fender front apron removed.) Battery Carrier Support Front Side Member No. 5 Plate Front Side Member No. 6 Reinforcement Cut and Join Location [LH only] 35 mm Front Side Member Plate Cut and Join Location NOTE:...
  • Page 31 BODY PANEL REPLACEMENT RE-13 INSTALLATION Front Side Member Butt Weld Front Side Member No. 5 Plate Front Side Member No. 6 Reinforcement Butt Weld Front Side Member Plate NOTE: Weld the front side mem- Battery Carrier Support ber plate and front side member No.

  • Page 32: Cowl Top Side Panel (Assy

    RE-14 BODY PANEL REPLACEMENT COWL TOP SIDE PANEL (ASSY) REMOVAL Cut with a disc sander etc..
  • Page 33 BODY PANEL REPLACEMENT RE-15 INSTALLATION Tack Weld (30 mm) Assembly Mark Assembly Mark 1.18 Determine the installation position of the new part by the assembly mark.

  • Page 34: Front Body Pillar (Cut

    RE-16 BODY PANEL REPLACEMENT FRONT BODY PILLAR (CUT) REMOVAL 200 mm or move [Cut and Join Location] Cut and Join Location 50 mm or more Make an incision Front Body Pillar Lower Gusset Roof Drip Channel Cut with a disc sander etc.
  • Page 35 BODY PANEL REPLACEMENT RE-17 INSTALLATION Butt Weld Butt Weld [Reference] (mm) Tack Weld (30 mm) Temporarily install the new part and check fit for the front fender, hood and windshield glass. 1.18 24.57 29.29 31.26 34.21 1,111 43.74 1,241 48.86 1,388 54.65 1,392...

  • Page 36: Center Body Pillar (Cut

    RE-18 BODY PANEL REPLACEMENT CENTER BODY PILLAR (CUT) REMOVAL Cut and Join Wet Rag Location [CROSS-SECTIONAL VIEW] about 15 mm about 15 mm Cutting Location Braze (front side) W/O Automatic Shoulder W/ Automatic Shoulder Belt Belt Upper Inner Upper Inner Pillar Pillar 0.59...
  • Page 37 BODY PANEL REPLACEMENT RE-19 INSTALLATION Butt Weld Wet Rag Preparation for Supply Parts Outer Pillar Cutting Location about Butt Weld 15 mm Wet Rag Automatic Automatic Shoulder Braze Shoulder (front side and rear side) Belt Belt w/ Automatic w/ Automatic Shoulder Belt Shoulder Belt w/ Automatic Shoulder Belt...

  • Page 38: Outer Rocker Panel (Cut

    RE-20 BODY PANEL REPLACEMENT OUTER ROCKER PANEL (CUT) REMOVAL 70 mm or more Cut and Join Location [Cut and Join Location] 2.76 Cut and join the part at the area as shown above.
  • Page 39 BODY PANEL REPLACEMENT RE-21 INSTALLATION Butt Weld 30 - 40 mm Cut piece of new part 1.18 1.57 Temporarily install the new part and check fit for the front door, rear door and front fender.

  • Page 40: Roof Panel (Assy) Sedan W/O Moonroof

    RE-22 BODY PANEL REPLACEMENT ROOF PANEL (ASSY) SEDAN W/O MOONROOF Sedan REMOVAL Braze (both sides) Arc Brazing (both sides) Braze (both sides) Cut off the roof panel tip at the quarter panel Heat the brazed area of the front body pillar arc brazing connection with a cut grinder.
  • Page 41 BODY PANEL REPLACEMENT RE-23 INSTALLATION Body Sealer (9 points) Body Sealer (9 points) Body Sealer (4 points) Braze (both sides) Body Sealer (9 points) Body Sealer (11 points) Braze (both sides) Before temporarily installing the new part, Braze the front body pillar and quarter panel apply body sealer to the windshield header connection.

  • Page 42: Roof Panel (Assy) Sedan W/ Moonroof

    RE-24 BODY PANEL REPLACEMENT ROOF PANEL (ASSY) SEDAN W/ MOONROOF Sedan REMOVAL Hemming Location Disc Sander Braze (both sides) Arc Brazing (both sides) Braze (both sides) If reusing the roof panel reinforcement, slightly heating the roof panel will soften sealer and make removal easier.
  • Page 43 BODY PANEL REPLACEMENT RE-25 INSTALLATION Cloth Tape ° Hemming Tool Body Sealer (9 points) Body Sealer (12 points) Braze (both sides) Body Sealer (9 points) Braze (both sides) Before temporarily installing the new part, Hem the area tip of the roof panel opening. apply body sealer to the windshield header NOTE: panel, roof panel reinforcement and back...

  • Page 44: Roof Panel (Assy) Wagon W/O Moonroof

    RE-26 BODY PANEL REPLACEMENT ROOF PANEL (ASSY) WAGON W/O MOONROOF Wagon REMOVAL Braze (both sides) Braze (both sides) Heat the brazed area of the front body pillar and quarter panel and scrape off the brazing with a wire brush. NOTE: Be careful not to overheat the front body pillar and quarter panel.
  • Page 45 BODY PANEL REPLACEMENT RE-27 INSTALLATION Body Sealer (3 points) Body Sealer (9 points) Body Sealer (9 points) Braze (both sides) Body Sealer (4 points) Body Sealer (11 points) Braze (both sides) Before temporarily installing the new part, Braze the front body pillar and quarter panel apply body sealer to the windshield header connections.

  • Page 46: Roof Panel (Assy) Wagon W/ Moonroof

    RE-28 BODY PANEL REPLACEMENT ROOF PANEL (ASSY) WAGON W/ MOONROOF Wagon REMOVAL Hemming Location Disc Sander Braze (both sides) Braze (both sides) If reusing the roof panel reinforcement, slightly heating the roof panel will soften sealer and make removal easier.
  • Page 47 BODY PANEL REPLACEMENT RE-29 INSTALLATION Cloth Tape ° Hemming Tool Body Sealer (9 points) Body Sealer (3 points) Braze (both sides) Body Sealer (12 points) Body Sealer (9 points) Braze (both sides) Before temporarily installing the new part, Hem the area tip of the roof panel opening. apply body sealer to the windshield header NOTE: panel, roof panel reinforcement and back...

  • Page 48: Front Door Outer Panel (Assy

    RE-30 BODY PANEL REPLACEMENT FRONT DOOR OUTER PANEL (ASSY) REMOVAL Braze Braze Hemming Location Heat Slightly (W/ Front Door Side Impact Protection Beam) Disc Sander Grind out the hemming location, and remove the outer panel. NOTE: Slightly heatinq the outer panel will soften the sealer and make removal easier.
  • Page 49 BODY PANEL REPLACEMENT RE-31 INSTALLATION Braze Body Sealer Braze Assembly Mark About 10 mm Do not close the drain hole. Body Sealer (3 points: W/ Front Door Side Impact Protection Beam) Body Sealer Cloth Tape ° Hemming Tool 0.39 Before temporarily install the new part, coat Bend the flange hem about 30°...

  • Page 50: Rear Door Outer Panel (Assy

    RE-32 BODY PANEL REPLACEMENT REAR DOOR OUTER PANEL (ASSY) REMOVAL Braze Braze Hemming Location Heat slight (W/ Rear Door Side Impact Protection Beam) Disc Sander Grind out the hemming location, and remove the outer panel. NOTE: Slightly heating the outer panel will soften the sealer and make removal easier.
  • Page 51 BODY PANEL REPLACEMENT RE-33 INSTALLATION Braze Braze Body Sealer Assembly Mark About 10 mm Do not close the drain hole Body Sealer (3 points: W/ Rear Door Side Impact Protection Beam) Body Sealer Cloth Tape ° Hemming Tool 0.39 Before temporarily installing the new part, Bend the flange hem about 30°...

  • Page 52: Quarter Panel (Cut): Sedan

    RE-34 BODY PANEL REPLACEMENT QUARTER PANEL (CUT): SEDAN Sedan REMOVAL 200 - 300 mm 200 - 300 mm Cut and Join Location [Cut and Join Location] Front Braze Rear 7.87 11.81 Cut and join the part at area as shown above. NOTE: Before cutting, remove the drain hole of the moonroof.
  • Page 53 BODY PANEL REPLACEMENT RE-35 INSTALLATION Butt Weld Body Sealer Braze Body Sealer About 5 mm 0.20 Before temporarily installing the new part, Temporarily install the new part and check fit apply body sealer to the wheel arch. for the rear door, luggage compartment door and rear combination light.

  • Page 54: Quarter Panel (Cut): Wagon

    RE-36 BODY PANEL REPLACEMENT QUARTER PANEL (CUT): Wagon Wagon REMOVAL Cut and Join Location Cut and Join Location 100 mm 200 mm or more or more [Cut and Join Location] Front Braze Rear 3.94 7.87 Cut and join the part at area as shown above. NOTE: Before cutting, remove the drain hole of the moonroof.
  • Page 55 BODY PANEL REPLACEMENT RE-37 INSTALLATION Butt Weld Butt Weld Body Sealer Braze Body Sealer about 5 mm Before temporarily installing the new part, apply Temporarily install the new part and check the fit body sealer to the wheel arch. for the rear door, back door and rear combina- tion light.

  • Page 56: Quarter Panel (Cut-P): Sedan

    RE-38 BODY PANEL REPLACEMENT QUARTER PANEL (CUT-P): Sedan Sedan REMOVAL Cut and Join Location Cut and Join Location * This section is a cut and join location only. Refer to RE-34 for weld points. Cut on the line shown above.
  • Page 57 BODY PANEL REPLACEMENT RE-39 INSTALLATION Butt Weld After butt welding, apply body sealer. Body Sealer Butt Weld Body Sealer about 5 mm * This section is a cut and join location only. Refer to RE-35 for weld points. 0.20 Before cutting the overlap areas, check the fit For other sealing points, refer to section AR.

  • Page 58: Quarter Panel (Cut-P): Wagon

    RE-40 BODY PANEL REPLACEMENT QUARTER PANEL (CUT-P): Wagon Wagon REMOVAL Cut and Join Location Cut and Join Location * This section is a cut and join location only. Refer to RE-36 for weld points. Cut on the line shown above.
  • Page 59 BODY PANEL REPLACEMENT RE-41 INSTALLATION Butt Weld After butt welding, apply body sealer. Body Sealer Butt Weld Body Sealer about 5 mm * This section is a cut and join location only. 0.20 Refer to RE-37 for weld points. For other sealing points, refer to section AR. Before cutting the overlap areas, check the fit for the luggage compartment door and rear Surface finish the weld seam from the inside...

  • Page 60: Body Lower Back Panel (Assy): Sedan

    RE-42 BODY PANEL REPLACEMENT BODY LOWER BACK PANEL (ASSY): SEDAN Sedan REMOVAL Braze Braze...
  • Page 61 BODY PANEL REPLACEMENT RE-43 INSTALLATION Braze Braze Temporarily install the new part and check fit for the rear combination light and luggage compart- ment door.

  • Page 62: Body Lower Outer Back Panel (Assy): Wagon

    RE-44 BODY PANEL REPLACEMENT BODY LOWER OUTER BACK PANEL (ASSY): WAGON Wagon REMOVAL...
  • Page 63 BODY PANEL REPLACEMENT RE-45 INSTALLATION Temporarily install the new part and check fit for the back door.

  • Page 64: Back Door Front Opening Trough (Assy): Wagon

    RE-46 BODY PANEL REPLACEMENT Wagon BACK DOOR FRONT OPENING TROUGH (ASSY): WAGON REMOVAL Braze...
  • Page 65 BODY PANEL REPLACEMENT RE-47 INSTALLATION Braze Temporarily install the new part and check fit for the back door and rear combination light.

  • Page 66: Roof Side Outer Panel (Assy): Wagon

    RE-48 BODY PANEL REPLACEMENT ROOF SIDE OUTER PANEL (ASSY): WAGON Wagon REMOVAL With the quarter panel and back door front opening trough removed.
  • Page 67 BODY PANEL REPLACEMENT RE-49 INSTALLATION Before welding, temporarily install the quarter panel and back door front opening trough and check the fit.

  • Page 68: Quarter Wheel Housing Outer Panel (Assy): Sedan

    RE-50 BODY PANEL REPLACEMENT Sedan QUARTER WHEEL HOUSING OUTER PANEL (ASSY): SEDAN REMOVAL (With the quarter panel removed) Roof Side Outer Panel After removing the roof side outer panel, remove the quarter wheel housing outer panel.
  • Page 69 BODY PANEL REPLACEMENT RE-51 INSTALLATION Assembly Mark Assembly Mark Determine the position of the new part by the assembly marks of the inner and outer panels. Before welding the new part, temporarily install the quarter panel and check the fit.

  • Page 70: Quarter Wheel Housing Outer Panel (Assy): Wagon

    RE-52 BODY PANEL REPLACEMENT Wagon QUARTER WHEEL HOUSING OUTER PANEL (ASSY): WAGON REMOVAL (With the quarter panel removed.) Roof Side Inner to Wheel Housing Brace After removing the roof side inner to wheel housing brace, remove the quarter wheel housing outer panel.
  • Page 71 BODY PANEL REPLACEMENT RE-53 INSTALLATION Assembly Mark Determine the position of the new part by the assembly marks of the inner and outer panels. Before welding the new part, temporarily install the quarter panel and check the fit.

  • Page 72: Rear Floor Rear Inner Crossmember (Cut): Wagon

    RE-54 BODY PANEL REPLACEMENT Wagon REAR FLOOR REAR INNER CROSSMEMBER (CUT): WAGON With the body lower outer back panel and REMOVAL roof side outer panel removed. Cut and Join Location Cut and join the part at the location as shown above.
  • Page 73 BODY PANEL REPLACEMENT RE-55 INSTALLATION Butt Weld...

  • Page 74: Rear Floor Pan (Cut): Sedan

    RE-56 BODY PANEL REPLACEMENT REAR FLOOR PAN (CUT): SEDAN Sedan REMOVAL (With the body lower back panel removed.) Cut Location Cut Location [LH] [RH] Cut the part at the location as shown above. Avoid the rear floor side member and rear floor crossmember when rough cutting.
  • Page 75 BODY PANEL REPLACEMENT RE-57 INSTALLATION [New Part] Remove the side panel. [LH] [RH] Cut the new part at the location as shown Plug weld the overlapping portion of the new above. part. NOTE: Be sure the portion to be welded are align Temporarily install the new part and measure and not loose.

  • Page 76: Rear Floor Pan (Cut): Wagon

    RE-58 BODY PANEL REPLACEMENT REAR FLOOR PAN (CUT): WAGON Wagon REMOVAL With the rear floor rear inner crossmember removed. Cut and Join Location 90 mm [RH] [LH] 3.54 Cut the part at the location as shown above. Avoid the rear floor side member when rough cutting.
  • Page 77 BODY PANEL REPLACEMENT RE-59 INSTALLATION Cut Location [New Part] 70 mm Remove the side panel [RH] [LH] 2.76 Plug weld the overlapping portion of the new Cut the new part at the location as shown above. part. NOTE: Be sure the portion to be welded align and Temporarily install the new part and measure not loose.

  • Page 78: Rear Floor Rear Side Member (Assy

    RE-60 BODY PANEL REPLACEMENT REAR FLOOR REAR SIDE MEMBER (ASSY) Sedan: With the body lower back panel REMOVAL removed. Wagon: With the rear floor rear inner crossmember removed. (Sedan only)
  • Page 79 BODY PANEL REPLACEMENT RE-61 INSTALLATION (Sedan only) Assembly Mark Determine the installation position of the new part by the assembly mark. Temporarily install the new part and measure each part in accordance with the body dimen- sion diagram.

  • Page 80: Rear Floor Side Member (Assy

    RE-62 BODY PANEL REPLACEMENT REAR FLOOR SIDE MEMBER (ASSY) REMOVAL (With the rear floor pan removed.) Make an incision. Rear Floor Crossmember Side Extension After removing the rear floor crossmember side extension, remove the rear floor side member.
  • Page 81 BODY PANEL REPLACEMENT RE-63 INSTALLATION Butt Weld Temporarily install the new part and measure each part in accordance with the body dimen- sion diagram.

  • Page 82: Center Floor No. 2 Crossmember (Assy

    RE-64 BODY PANEL REPLACEMENT CENTER FLOOR NO. 2 CROSSMEMBER (ASSY) REMOVAL Make and incision. Bend the wheel housing inner panel after mak- ing an incision it where the rear floor side mem- ber is welded. Then remove the center floor No.
  • Page 83 BODY PANEL REPLACEMENT RE-65 INSTALLATION Butt Weld...
  • Page 84 CN-2 BODY PANEL CONSTRUCTION STANDARD BODY MARKS Center Mark Assembly Mark Assembly Mark Center Mark φ φ φ φ Assembly Mark φ Assembly Mark Assembly Mark φ 0.08 0.28 0.35 0.39 0.43 0.51...
  • Page 85 BODY PANEL CONSTRUCTION CN-3 HIGH-STRENGTH STEEL (HSS) PARTS Generally, High-Strength Steel (HSS) is that which has an intensity value of at least 35 kgf/mm , and distinguished from mild steel. The handling of HSS is the same as for mild steel, but the following should be observed. Panel Hammering: Because HSS is thinner than mild steel, care should be taken to avoid warping during hammering operations.
  • Page 86 PP-2 PLASTIC BODY PARTS HANDLING PRECAUTIONS The repair procedure for plastic body parts must conform with the type of plastic material. Plastic body parts are identified by the codes in the following chart. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint- ing, etc.), consideration must given to the property of the plastic.
  • Page 87 PLASTIC BODY PARTS PP-3 Heat * resisting Material Resistance to Code Notes temperature name alcohol or gasoline ° ° C (F Alcohol and gasoline are Most solvents are Polypropylene (176) harmless. harmless. Gasoline is harmless if ap- Modified plied only for quick wiping to Polyphenylene Alcohol is harmless.
  • Page 88 PL-2 PART LISTS 53301 55101 55713A (RH) 55714A (LH) 57301A 53205 53211 55701 53932 53217B 53731D (RH) 53208A 53732D (LH) 53711B (RH) 53212 53712B (LH) 53701 (RH) 53702 (LH) 53217B 57161 53911 53801 (RH) 53802 (LH) Code Part Name Code Part Name 53205 Radiator Upper Support Sub-Assy...
  • Page 89 PART LISTS PL-3 Wagon Sedan 63111 63111 53105A 63133 63144A 64101 63148A 63102A 63144A 63104 63102A 63104 63143B Wagon Sedan 63111 63111 63133 63105A 63144A 64101 63148A 63102A 63142 63142 63102A 67005 64401 67113 (RH) 67111 (RH) 67114 (LH) 67112 (LH) 67003 (RH) 67001 (RH) 67004 (LH)
  • Page 90 PL-4 PART LISTS 58102A 58396A 58111 58207 Sedan 58367 58307 58171 58027A 58369B 58131A 57206A 58131A 58313E (RH) 58313 (RH) 58314 (LH) 58314E (LH) 58301A 58208 Wagon 57068 58371B 58313 58301A 58314 58208...
  • Page 91 PART LISTS PL-5 57608 57607 57451 57616 57601 57401 57617 57602 57101 57417 57402 57418 57102 Code Part Name Code Part Name 58102A Front Floor Reinforcement Sub-Assy Rear Floor Rear Inner Crossmember 57068 Sub-Assy 58111 Front Floor Pan 58131A Front Floor Heat Insulator No. 1 Bracket 57101 Front Side Member Sub-Assy 57102...
  • Page 92 PL-6 PART LISTS Sedan 67261 (RH) 61731B 61211 67262 (LH) 61741A 61621C 61231 61711 61331C 61103 61301B 61343 61633A (RH) 61634A (LH) 61505 61631A (RH) 61611 61632A (LH) 64312 61343A 61623D 61735A 61411 61742A 61732B 61622C 64313 61232 61212 61104 61612 61332C 61344...
  • Page 93 PART LISTS PL-7 Wagon 61717A 61611 61631A (RH) 61211 61261 (RH) 61632A (LH) 61262 (LH) 61741A 61731B 61633A (RH) 61723A 61231 61634A (LH) 61735A 61331C 61103 61301B 61343 61505 61613B (RH) 61614B (LH) 61635A (RH) 61623D 61343A 61711 61636A (LH) 61621B 61411 61742A...
  • Page 94 PP-4 PLASTIC BODY PARTS LOCATION OF PLASTIC BODY PARTS Instrument Panel Safety Pad (PVC/PUR) Outer Rear View Mirror (ABS) Clearance Light Rear Spoiler (PUR) (PMMA/SAN/ABS PMMA/ABS) Headlight Door (ABS) Quarter Vent Duct (PP) Quarter Vent Duct (PE) Radiator Grille (ABS) Front Bumper Cover (PP PUR) Front Bumper Extension...
  • Page 95 PLASTIC BODY PARTS PP-5 Rear Seat Side Garnish (PP) Center Pillar Upper Garnish (ABS) Roof Side Trim Garnish (ABS) Center Pillar Lower Garnish (PP) Roof Headlining Rear Trim (PVC Coated Steel) Front Body Pillar Garnish (ABS) Cowl Side Trim Board (PP) Fuel Tank Inlet Pipe Protector (PE) Washer Jar (PP) Door Scuff Plate (PP)
  • Page 96 PP-6 PLASTIC BODY PARTS Luggage Compartment Trim Cover (PP/PE) High Mount Stop Light Cover (ABS) Rear Floor Finish Plate (PP) High Mount Stop Light Rear Side Marker Light (PMMA/ABS) (PC/ABS) Luggage Compartment Rear Cover (PP) Luggage Door Finish Panel (ABS) Heater Blower (PP) Cooler Unit (PP) Rear Bumper Cover (PP PUR)

  • Page 97: General Information

    AR-2 ANTI-RUST TREATMENT GENERAL INFORMATION Anti-rust treatment is necessary before welding and before and after the painting process. ANTI-RUST TREATMENT BEFORE WELDING WELD-THROUGH PRIMER (SPOT SEALER) Weld-Through Primer (Spot Sealer) APPLICATION For anti-corrosion measures, always apply the weld- through primer (spot sealer) to welding surfaces where the paint film was removed.
  • Page 98 ANTI-RUST TREATMENT AR-3 ANTI-RUST TREATMENT AFTER PAINTING PROCESS ANTI-RUST AGENT (WAX) APPLICATION To prevent painting impossible areas from cor- rosion, always apply the anti-rust agent (wax) enough to the inside of the hemming areas of the doors and hoods, and around the hinges, or the welded surfaces inside the boxed cross-section structure of the side member, body pillar, etc.
  • Page 99 AR-8 ANTI-RUST TREATMENT BODY PANEL UNDERCOATING AREAS NOTE: First wipe off any dirt, grease or oil with a rag soaked in 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 100 AR-4 ANTI-RUST TREATMENT BODY PANEL SEALING AREAS NOTE: Prior to applying body sealer, clean the area with a rag soaked in 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 101 ANTI-RUST TREATMENT AR-5 Moonroof Housing Flat Surfacing Flat Surfacing...
  • Page 102 AR-6 ANTI-RUST TREATMENT Flat Surfacing Flat Surfacing Flat Surfacing...
  • Page 103 ANTI-RUST TREATMENT AR-7 Do not close the drain hole. Fuel Inlet Box Cover Fuel Inlet Box...
  • Page 104 ANTI-RUST TREATMENT AR-9 BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS NOTE: Whenever adjusting the doors and hoods, apply the anti-rust agent (wax) around the hinges. Even if repairing a part partially, apply the anti-rust agent (wax) over entire application area of the part.
  • Page 105 AR-10 ANTI-RUST TREATMENT BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS NOTE: Some areas should be applied before a second coating and the other should be after a finishing coating. Wipe off the coating immediately with a rag soaked in grease, wax, and silicone remover, if other areas are accidently coated.
  • Page 106 DI-2 BODY DIMENSIONS GENERAL INFORMATION Three-dimensional Center-to-center distance straight-line distance BASIC DIMENSIONS (a) There are two types of dimensions in the diagram. (Three-dimensional distance) S Straight-line distance between the centers of two measuring points. (Two-dimensional distance) Two-dimensional Center-to-center distance Horizontal distance in S Horizontal distance in forward/rearward between forward/rearward the centers of two measuring points.

  • Page 107: Engine Compartment

    BODY DIMENSIONS DI-3 BODY DIMENSION DRAWINGS ENGINE COMPARTMENT (Three-dimensional Distance) mm (in.) Symbol Nomenclature Hole dia. A, a Front fender installation nut 6 (0.24) B, b 11 (0.43) Front spring support inner hole C, c Front fender installation nut 6 (0.24) Cowl top panel center mark E, e Front side member bumper installation hole...
  • Page 108 *1: L-Q 927 (36.50) *2: l-q 927 (35,50) *3: P-S 433 (17.05) *4: q-s 404 (15.91) Wheel Base 2,600 (102.36) Imaginary Standard Line mm (in.) Note dia. Nomenclature Hole dia. Symbol Nomenclature Symbol 10 (0.39) S, s Front floor under reinforcement working hole 10 (0.39) Engine mounting member installation nut L, l...
  • Page 109 BODY DIMENSIONS DI-5 UNDER BODY (Cont’d) (Two-dimensional Distance) BO2224 BO2225...
  • Page 110 DI-6 BODY DIMENSIONS LUGGAGE COMPARTMENT (SEDAN) (Three-dimensional Distance) BB, bb Points AA Point Y, y Points mm (in.) Hole dia. Symbol Nomenclature Y, y Back window upper frame standard hole-rear 10 (0.39) Rear spring support front hole 9.5 (0.37) Z, z Upper back reinforcement center mark 3 (0.12) 45 (1.77)
  • Page 111 BODY DIMENSIONS DI-7 LUGGAGE COMPARTMENT (WAGON) (Three-dimensional Distance) Y, y Points BB, bb Points Outer mm (in.) Symbol Nomenclature Hole dia. Y, y Back door installation outer hole-rear 13 (0.51) Z, z Rear spring support front hole 9.5 (0.37) BB, bb Rear floor bumper installation front hole-front 45 (1.77) BO1976...

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