SERVICE MANUAL
Contents
1. SHOULDER BELT ANCHOR COVER 41 418 30 REAR DOOR OPENING TRIM RH 41 418 30 REAR OUTER NO 1 SEAT BELT ASSEMBLY RH DECK TRIM SIDE PANEL ASSEMBLY RH REAR DOOR SCUFF PLATE RH CAUTION The bolts and nuts must be tightened to the torgue specification as they are related to vehicle safety during a collision N m kgf cm ft lbf Specified torque F30455 IN 26 INTRODUCTION ROOF HEADLINING ASSEMBLY ASSIST GRIP SUB ASSEMBLY WASHER HOSE NO 1 ROOF WIRE MAP LIGHT ASSEMBLY VISOR ASSEMBLY RH INNER REAR VIEW MIRROR TAY HOLDER COVER i R VISOR HOLDER NO 1 ROOM LIGHT ASSEMBLY VISOR ASSEMBLY LH INNER REAR VIEW MIRROR ASSEMBLY 2952 BACK DOOR WEATHERSTRIP with Air conditioning System AIR INLET DUCT AIR OUTLET DUCT BACK DOOR SCUFF PLATE F30456 INTRODUCTION IN 27 5 FRONT SEAT CAP FRONT SEAT ASSEMBLY RH SEAT TRACK COVER RH FRONT INNER SEATBELT ASSEMBLY RH 25 255 18 41 418 30 FRONT INNER SEAT CUSHION SHIELD RH CAUTION The bolts and nuts must be tightened to the torgue specification as they are related to vehicle safety during a collision ft lbf Specified torque B164666 IN 28 INTRODUCTION 6 REARSEAT REAR NO 1 SEAT ASSEMBLY RH REAR SEAT LAP TYPE BELT ASSEMBLY2. e CENTER OF VEHICLE GRAVITY unloaded condition Center of Lift D101716 3 NOTICE FOR USING PLATE TYPE LIFT Attachment Dimensions 85 mm 3 35 in 70 mm 2 76 in 100 mm 3 94 in 200 mm 7 87 in Attachment HINT Right and left set position Place the vehicle over the center of the lift HINT Front and left set position Place the attachments at the ends of the rubber plate surface under the vehicle lift pad A and C in the illustration Raise the plate slightly and reposition the vehicle so the top of the attachment B in the illustration is aligned with the front side notch in the vehicle rocker flange D101771 INTRODUCTION IN 17 DAMAGE DIAGNOSIS Front Bumper Front Side Member Rear Floor Side Member eee BSE 2 MW mm KC Front Side Member Inner Front Body Pillar Inner Apron Upper Member Rear Floor Side Member Front Side Member 2 Confirmation Point ED Collision Direction Collision Force Absorption Direction D30389 IN 18 INTRODUCTION Rear Floor Side Member Rear Bumper Rear Floor Side Member Reinforcement O Confirmation Point E Collision Direction E d Collision Force Absorption Direction INTRODUCTION IN 19 Center Floor Crossmember LATE uU TEI
3. Theimpactbeam and bracket are necessary and important parts that help reduce the probability of injury to passen gers in side collisions For impact beams we use special high tensile strength steel The high tensile strength steel maintains its special crystal line organization by heat treatment or alloy additives Structural parts are designed to perform in their original shape If parts are deformed in an accident or if the de formed parts are repaired and reused the parts may be un able to perform as intended If the impact beam or bracket is damaged replace the door assembly that has the damaged beam Also the bumper reinforcement is a necessary and impor tant part that helps reduce the probability of injury to pas sengers in front collisions and for the same reasons ex plained above should be replaced if damaged F33016 F33017 F30442 IN 4 INTRODUCTION PROPER AND EFFICIENT WORK PROCEDURES F33020 Corners Reinforcement F33021 F33022 d REMOVAL PRE REMOVAL MEASURING 1 Before removal or cutting operations take measure ments in accordance with the dimensions diagram Al ways use a puller to straighten a damaged body or frame CUTTING AREA 1 Always cut in a straight line and avoid cutting rein forced areas PRECAUTIONS FOR DRILLING OR CUTTING 1 Check behind any area to be drilled or cut to ensure that there are no hoses wires
4. etc that may be dam aged HINT See Handling Precautions dn Related Components on pagellN 9 REMOVAL OF ADJACENT COMPONENTS 1 When removing adjacent components apply protec tive tape to the surrounding body and your tools to pre vent damage HINT See Handling Precautions on Related Components on pagellN 9 INTRODUCTION IN 5 2 PREPARATION FOR INSTALLATION a SPOT WELD POINTS 1 When welding panels with a combined thickness of over 3 mm 0 12 in use a MIG Metal Inert Gas welder for plug welding HINT Spot welding does not provide sufficient dura bility for panels with a combined thickness of over 3 mm 0 12 in F10011A b APPLICATION OF WELD THROUGH PRIMER SPOT SEALER 1 Remove the paint from the portion of the new parts and body to be welded and apply weld through prim er F33008 c MAKING HOLES FOR PLUG WELDING 1 Forareas where a spot welder cannot be used use a puncher or drill to make holes for plug welding REFERENCE mm in Thickness of welded portion Size of plug hole 1 0 0 04 under 5 0 20 over A 1 1 0 0 04 1 6 0 06 g 6 5 0 26 over Puncher 1 7 0 07 2 3 0 09 2 8 0 31 over 2 4 0 09 over 10 0 39 over d SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS 1 When welding there is a danger that electrical compo nents willbe damaged by the electrical current flowing th
5. 48 2 30 87 2 aa yhte A Inside B Outside SA00028 Camber Tire Size Camber 0 30 45 R1 215S 65R16 0 5 0 75 Alignment Gauge 0 30 45 Tester R1 235 60R16 0 5 0 75 Caster Tire Size Caster 4 53 1 R1 21862815 4 88 1 4 52 4 Er 2003382 235 60R16 4 87 1 Steering axis inclination Tire Size Steering axis inclination 12 25 1 215 65R16 12 42 1 12 25 1 12 42 1 235 60R16 IN 32 INTRODUCTION HOW TO USE THIS MANUAL 1 BODY PANEL REPLACEMENT THIS MANUAL BODY PANEL REPLACEMENT QUARTER PANEL CUT With the body Tower back panel emoved E Remove Weld Points x REMOVAL REMOVAL POINT 1 Remover the Fuel FillerrDpening Lid t he ame time A REPLACEMENT PART AND METHOD 6 INSTALLATION POSITION DF QUARTER PANEL CUT WELD POINTS T Replacementiineth Weld method and panel position ASSY mar symbols See page IN 41 CUT Major utting lesB ihan 2 f part used SYMBOLS See page lN 39 CUT H Half tuttingilabout 1 2 0f part used CUT P Partial tutting most 0f part used Replacement part PART LOCATION REMOVAL CONDITIONS B SYMBOL MEANING E REMOVAL DIAGRAM
6. Describes in detaillihe femoval ofithe dlamaged partlinvolving tepairlby tutting D REMOVAL GUIDE Provides amp dditional information to more fficiently help you perform the Temoval INTRODUCTION IN 33 e eoo 360 BODY PANEL REPLACEMENT Symbol meaning WMigPlugWeld S pot Weld Body ealer Futtyveld T INSTALLATION mm in POINT 1 Before lemporarily installingilhelhew parts applylbody ealer lo ihe Wheel arch HINT 1 Applylbody ealer amp venlylabout mm j0 20 n rom ihe flange avoiding any bozing 2 Applyi ealer evenly about 3 Imm 0 12 0 16 n h Wiameter 2 Memporarily ihstalliihelhew parts and measure amp ach part df ihe hew parts in amp ccordanceWwith thelbody dimension diagram See the body dimension diagram 3 Bfter Welding applylbody ealer and Undercoating lo lhe torresponding parts SYMBOLS INSTALLATION DIAGRAM Describeslin detail ihe installation to ihelhew parts involving tepairlby Welding and Bbr cutting but amp xcluding painting INSTALLATION GUIDE Provides additional information to Mmore efficiently help you perform ihefinstallation SYMBOLS See page IN 39 INSTALLATION DF WELD POINTS See page IN 41 Weld method and panel position symbols PART NAME F33026 IN 34 INTRODUCTION 2 SYMBOLS The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the typ
7. bat tery When the negative terminal cable is disconnected from the battery the memory of the clock and audio systems will be erased Before starting work make a record of the contents memorized by each memory system Then when work is finished reset the clock and audio systems as before When the vehicle has tilt and telescopic steering power seats and outside rear view mirrors which are all equipped with a memory function it is not possible to make a record of the memory contents When the operation is finished it will be necessary to explain this fact to the customer and request the customer to adjust the features and reset the memory Do not expose the ECUs to ambient temperatures above 80 C 176 NOTICE If it is possible that the ambient temperature may reach 80 C 176 F or more remove the ECUs from the vehicle before starting work careful not to drop the ECUs not to apply physical shocks to them IN 10 INTRODUCTION DAMAGED VEHICLE DISPOSAL PRECAUTION SRS AIRBAG SYSTEM For SRS airbag system adjustment service and repair procedures refer to the Repair Manual 1 When using an electric welder first remove all airbags and seat pretensioners 2 Ifimpacts are likely to occur to the front airbag sensors or center airbag sensor remove each sensor as necessary beforehand 3 Donotallow the front airbag sensors or center airbag sensor to become heated to high temperatures COMBINATIO
8. 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 HINT Depending on the model or the application area there are cases where the application of anti chipping paint is necessary before the second coat or after the top coat Apply the anti chipping paint before the second coat je Top Coat Anti Chipping Paint Second Coat Top Coat DEM Second Coat Anti Chipping Paint 7 Under Coat ED Primer Steel Metal Steel Metal Under Coat ED Primer F10024A INTRODUCTION IN 9 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 the brake section of the repair manual for the relevant model year when handling brake system parts NOTICE When repairing the brake master cylinder or ABS and TRAC system bleed the air out of the ABS and TRAC system DRIVE TRAIN AND CHASSIS The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle After installing components in the sections listed in the table below perform alignments to ensure correct mounting angles and dimensions Body repair must be particularly accurate to ensure correct alignment HINT Correct procedures and special
9. B ASSEMBLY FINISH PANEL GARNISH STEREO COMPONENT TUNER ASSEMBLY NO 2 INSTRUMENT PANEL UNDER COVER CONSOLE BOX 1 INSTRUMENT PANEL UNDER COVER SUB ASSEMBLY for Automatic for Manual Transmission Transmission TAN SHIFT LEVER KNOB SHIFT LEVER KNOB SUB ASSEMBLY SUB ASSEMBLY GLOVE COMPARTMENT __ SHIFTING DOOR ASSEMBLY Qs HOLE COVER N HIFTIN SS F SHIFTING FRONT DOOR HOLE BEZEL HOLE PLATE SCUFF PLATE COIN BOX ASSEMBLY e SIDE COWL TRIM BOARD CONSOLE BOX HOLE COVER REAR INNER ASH RECEP TACLE RETAINER REAR 1 NO 1 CONSOLE BOX RECEPTACLE MOUNTING BRACKET RETAINER ASH RECEPTACLE BOX SUB ASSEMBLY F30453 IN 24 INTRODUCTION 4 INTERIOR TRIM FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY 41 418 30 SHOULDER BELT ANCHOR COVER UPPER CENTER PILLAR GARNISH RH REAR DOOR OPENING TRIM RH FRONT DOOR OPENING TRIM RH 1 41 418 30 d gt __ FRONT OUTER SEAT BELT ASSEMBLY RH 41 418 30 i REAR DOOR 655 SCUFF PLATE RH LOWER CENTER PILLAR GARNISH RH FRONT DOOR SCUFF PLATE RH 41 418 30 CAUTION The bolts and nuts must be tightened to the torgue specification as they are related to vehicle safety during a collision kgf cm ft lbf Specified torque INTRODUCTION IN 25 ROOF SIDE INNER GARNISH RH SEAT BELT ANCHOR COVER 41 418 30
10. BREVIATIONS USED IN THIS MANUAL IN 37 NOTE This manual has references to the Daihatsu TERIOS Service Manual s heater amp air conditioning system body electrical and suspension amp axle sections F33000 F33001 INTRODUCTION IN 1 PRECAUTION GENERAL REPAIR INSTRUCTIONS 1 a b c WORK PRECAUTIONS VEHICLE PROTECTION 1 When welding protect the painted surfaces windows seats and carpet with heat resistant fireproof covers SAFETY 1 Neverstandinadirectline with the chain when using a puller on the body or frame and be sure to attach a safety cable 2 Before performing repair work check for fuel leaks If a leak is found be sure to close the opening com pletely 3 If itis necessary to use a flame in the area of the fuel tank first remove the tank and plug the fuel line SAFETY WORK CLOTHES 1 In addition to the usual mechanic s wear cap and safety shoes the appropriate gloves head protector glasses ear plugs face protector dust prevention mask etc should be worn as the situation demands Name Dust Prevention Mask Face Protector Eye Protector Safety Shoes Welder s Glasses Ear Plugs Head Protector Welder s Gloves IN 2 INTRODUCTION PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS 1 HEAT REPAIR FOR BODY STRUCTURE PANELS Toyota prohibits the use of the heat repair meth
11. INTRODUCTION PRECAUTION GENERAL REPAIR INSTRUCTIONS s IN 1 PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS eene IN 2 PROPER AND EFFICIENT WORK PROCEDURES IN 4 HANDLING PRECAUTIONS ON RELATED COMPONENTS IN 9 DAMAGED VEHICLE DISPOSAL PRECAUTION SRS AIRBAG SYSTEM eee IN 10 HANDLING PRECAUTIONS ON RELATED COMPONENTS IN 11 ABOUT THIS VEHICLE STRUCTUAL OUTLINE I s IN 14 NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE 1 NOTICE FOR USING JACK AND SAFETY STAND IN 15 2 NOTICE FOR USING SWING ARM TYPE LIFT IN 16 3 NOTICE FOR USING PLATE TYPE LIFT IN 16 DAMAGE DIAGNOSIS IN 17 COMPONENTS 1 FRONT BUMPER esee nnne nenas IN 20 2 REAR nca t c oia e a IN 21 3 INSTRUMENT PANEL seen IN 22 4 INTERIOR die n t nra a crab IN 24 5 FRONT SEAT co adve CR e ER EAT E EAR IN 27 6 REAR SEAT I IN 28 WHEEL ALIGNMENT STANDARD 1 FRONT WHEEL ALIGNMENT ene IN 30 HOW TO USE THIS MANUAL 1 BODY PANEL REPLACEMENT THIS MANUAL IN 32 2 SYMBOLS u u l I IN 34 3 ILLUSTRATION OF WELD POINT SYMBOLS IN 36 AB
12. L 0 22777777227 lt DZ IT Front Door Outer Panel Side Reinforcement O Confirmation Point E Collision Direction Collision Force Absorption Direction F30391 IN 20 INTRODUCTION COMPONENTS 1 FRONT BUMPER FRONT FENDER LINER RH FRONT BUMPER x2 SIDE SUPPORT RH lt um FRONT BUMPER et FRONT FENDER oe LINER LH ui x2 FOG LIGHT 6 6 0 61 53 in Ibf F FOG LIGHT COVER LH FRONT BUMPER SIDE FRONT BUMPER SUPPORT LH HOLE COVER with Fog Light FOG LIGHT ASSEMBLY RH k FOG LIGHT ASSEMBLY LH CAUTION The bolts and nuts must be tightened to the torgue specification as they are related to vehicle safety during a collision N m kgf cm ft lbf Specified torque F30449 INTRODUCTION IN 21 REAR BUMPER 13 5 137 9 9 REAR BUMPER SIDE SUPPORT LH REAR WHEEL HOUSE LINER LH x2 REAR WHEEL HOUSE LINER RH QUARTER PANEL REAR BUMPER MUDGUARD REAR RH 4 COVER OUARTER PANEL MUDGUARD REAR LH 6 0 61 53 in Ibf 1 1 1 1 1 1 1 1 1 1 1 1 x4 se gt REAR BUMPER UPPER L KA COVER RH i EX 6 0 61 53 in Ibf LICENSE PLATE LIGHT REFLEX REFLECTOR REFLEX REFLECTOR ASSEMBLY LH CA
13. N METER FRONT AIRBAG SENSOR RH STEERING PAD FRONT PASSENGER B AIRBAG ASSEMBLY O CENTER AIRBAG SENSOR ASSEMBLY C156068 INTRODUCTION 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 Whenrepairing metal body parts adjoining plastic body parts by brazing frame cutting welding paint IN 11 ing etc consideration must be given to the properties of the plastic Material name Heat resistant temperature limit C F Resistance to alcohol or gasoline Acrylonitrile Acrylic Styrene 80 176 Alcohol is harmless if applied only for short time in small amounts e g quick wiping to remove grease Avoid gasoline and organic or aromatic solvents Acrylonitrile Butadiene Styrene 80 176 Alcohol is harmless if applied only for short time in small amounts e g quick wiping to remove grease Avoid gasoline and organic or aromatic solvents Acrylonitrile Ethylene Styrene 80 176 Alcohol is harmless if applied only for short time in small amounts e g quick wiping to remove grease Avoid gasoline and organic or aromatic solvents Acrylonitrile Styrene Acrylate 80 176 Alcohol is harmless if applied only for short time in small amounts e g quick wiping to remove gre
14. RH REAR SEAT CUSHION HINGE COVER REAR SEAT CUSHION COVER RH REAR SEAT HINGE COVER CAUTION The bolts and nuts must be tightened to the torgue specification as they are related to vehicle safety during a collision kgf cm ft lbf Specified torque INTRODUCTION IN 29 w Rear No 2 Seat REAR NO 2 SEAT ASSEMBLY 25 255 18 with Cover REAR SEAT SEAT LEG COVER RH A VA NO 2 SEAT SEAT LEG COVERLH CAUTION The bolts and nuts must be tightened to the torgue specification as they are related to vehicle safety during a collision ft lbf Specified torque B165004 IN 30 INTRODUCTION WHEEL ALIGNMENT STANDARD 1 FRONT WHEEL ALIGNMENT Vehicle height Tire Size A B C D 34 5 15 mm 34 0 15 mm 1 36 0 59 in 1 35 0 59 in 34 6 15 mm 34 3 15 mm 1 36 0 59 in 1 35 0 59 in 215 65R16 235 60R16 C158417 Toe in A B C D 0 0912 0 2 0 mm 0 0 22 0 0 08 in SA03213 INTRODUCTION IN 31 Wheel turning angle Tire Size Inside Wheel SSI wheel B JA Reference 39211 2 31 59 2 Front N 89 18 2 31 98 2 37 29 2 30 52 2 t 295 60R16 37
15. UTION The bolts and nuts must be tightened to the torgue specification as they are related to vehicle safety during a collision ft lbf Specified torque F30451 IN 22 INTRODUCTION 3 INSTRUMENT PANEL NO 1 INSTRUMENT PANEL CUSHION ee NO 1 DEFROSTER NOZZLE GARNISH NO 2 DEFROSTER NOZZLE GARNISH NO 2 INSTRUMENT PANEL CUSHION CENTER HEATER TO REGISTER DUCT SUB ASSEMBLY FRONT PASSENGER AIR BAG ASSEMBLY INSTRUMENT PANEL FRONT PILLAR SUB ASSEMBLY GARNISH B Ei 8 2 84 73 in Ibf x GLOVE COMPARTMENET z DOOR LOCK STRIKER NO 1 INSTRUMENT PANEL REGISTER ASSEMBLY NO 1 SWITCH HOLE BASE NO 2 INSTRUMENT PANEL REGISTER ASSEMBLY COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER NO 1 INSTRUMENT PANEL FINISH PANEL BRACE SUB ASSEMBLY STEERING WHEEL NO 2 STEERING WHEEL WINDSHIELD WIPER SUB ASSEMBLY LOWER COVER SWITCH ASSEMBLY YU STEERING COLUMN HEADLIGHT DIMMER UPPER COVER SWITCH ASSEMBLY STE 34 STEERING COLUMN LOWER COVER NO 3 STEERING WHEEL LOWER COVER STEERING PAD 8 8 90 78 in Ibf CAUTION The bolts and nuts must be tightened to the torque specification as they are related to vehicle safety during a collision kgf cm ft lbf Specified torque INTRODUCTION IN 23 CENTER INSTRUMENT CLUSTER NO 1 INSTRUMENT CLUSTER FINISH PANEL SU
16. ase Avoid gasoline and organic or aromatic solvents Ethylene Propylene 100 212 Alcohol is harmless Gasoline is harmless if applied only for short time in small amounts Most solvents are harmless but avoid dipping in gasoline solvents etc Polyamide Nylon 80 176 Alcohol and gasoline are harmless Avoid battery acid Polybutylene Terephthalate 160 320 Alcohol and gasoline are harmless Most solvents are harmless Polycarbonate 120 248 Alcohol is harmless Avoid gasoline brake fluid wax wax removers and organic solvents Avoid alkali Polymethyl Methacrylate 80 176 Alcohol is harmless if applied only for short time in small amounts Avoid dipping or immersing in alcohol gasoline solvents etc Polyoxymethylene Polyacetal 100 212 Alcohol and gasoline are harmless Most solvents are harmless Polypropylene 80 176 Alcohol and gasoline are harmless Most solvents are harmless Polyvinylchloride Vinyl 80 176 Alcohol and gasoline are harmless if applied only for short time in small amounts e g guick wiping to remove grease Avoid dipping or immersing in alcohol gasoline solvents etc Thermoplastic Olefine 80 Alcohol is harmless Gasoline is harmless if applied only for short time in small amounts Temperatures higher than those listed here may result in material defor
17. es of weld reguired SYMBOLS MEANING SYMBOLS MEANING ILLUSTRATION CUT AND JOIN LOCATION Saw Cut CUT LOCATION CUT WITH DISC SANDER ETC CUT AND JOIN LOCATION Cut Location for Supply Parts BRAZE Removal f BRAZE BRAZE Installation A WELD 1 POINTS M SPOT WELD OR MIG PLUG WELD CONTINUOUS MIG WELD BUTT WELD WELDING i CONTINUOUS MIG WELD TACK WELD SEALER BODY SEALER F33004 IN 35 INTRODUCTION SYMBOLS MEANING ILLUSTRATION Assembly Mark BODY SEALER Flat Finishing BODY SEALER W Flat Finishing F33005 IN 36 INTRODUCTION 3 ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE REMOVAL INSTALLATION Weld points Weld points Removal weld point and panel position Installation weld point and panel position BE Spot MIG Weld
18. mation during repair Most solvents are harmless but avoid dipping in gasoline solvents etc IN 12 INTRODUCTION Outer Rear View Light Mirror ABS AAS PBT Roof Drip Side Finish Moulding PVC Rear Door Guide Bracket Garnish ASA Cowl Top Ventilator Louver PP Radiator Grille ABS Headlight PC PP Side Step End Cap PE 2 Front Door Outside Handle Emblem ABS Rear Door Outside Handle PA PC PBT Side Step End Cap PE Side Turn Signel Light PMMA PC PBT Front Bumper Cover PP Made up of 2 or more kinds of materials F30394 INTRODUCTION IN 13 Roof Rack Leg Cover ABS Roof Rack Leg Cover ABS Back Door Outside Handle PC PBT Rear Bumper Cover PP License Plate Light PC PBT Spare Wheel Cover AES Reflex Refrector PMMA ABS Rear Combination Light PMMA ASA Made up of 2 or more kinds of materials F30395 IN 14 INTRODUCTION ABOUT THIS VEHICLE STRUCTURAL OUTLINE NN 340 Mpa High strength steel 440 Mpa High strength steel INTRODUCTION IN 15 NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE 1 NOTICE FOR USING JACK AND SAFETY STAND O JACK POSITION Jack Point SUPPORT POSITION PANTOGRAPH JACK POSITION D10170 IN 16 INTRODUCTION 2 NOTICE FOR USING SWING ARM TYPE LIFT
19. od on body structure panels when repairing a vehicle damaged in a col lision Panels that have high strength and rigidity as well as along span for the automobile body are in high demand At Toyota in order to fulfill these reguirements we use high tensile strength steel sheets and rust preventive steel sheets on the body High tensile steel sheets are made with alloy additives and a special heat treatment in order to im prove their strength To prevent the occurrence of rust for a long period of time the surface of the steel is coated with a zinc alloy If body structure parts are heat repaired with an acetylene torch or other heating source the crystalline organization of the steel sheet will change and their strength of the steel sheet will be reduced The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized 2 STRUCTURE PANEL KINKS A sharp deformation angle on a panel that cannot be re turned to its original shape by pulling or hammering is called a kink Structural parts are designed to perform in their original shape If parts are deformed in an accident or if the de formed parts are repaired and reused the parts may be un able to perform as intended It is necessary to replace the part where the kink has oc curred INTRODUCTION IN 3 3 IMPACT BEAM AND BUMPER REINFORCEMENT REPAIR
20. remove the paintfrom the areas to be spot welded including the seams and the surfaces that come in contact with the welding tip 3 Use sander to remove any burrs that are created during spot welding Tip Cutter F33011 F33012 F33013 INTRODUCTION IN 7 ANTI RUST TREATMENT AFTER INSTALLATION BEFORE PAINTING PROCESS 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 hood etc UNDERCOAT APPLICATION 1 Toprevent corrosion and protect the body from dam age by flying stones always apply sufficient under coating to the bottom surface of the under body and inside of the wheel housings ANTI RUST TREATMENT AFTER INSTALLATION AFTER PAINTING PROCESS ANTI RUST AGENT WAX APPLICATION 1 To preserve impossible to paint areas from corrosion always apply sufficient anti rust agent wax to the in side of the hemming areas of the doors and hood and around the hinges or the welded surfaces inside the box shaped cross sections of the side members body pillars etc IN 8 Apply the anti chipping paint after the top coat INTRODUCTION 6 ANTI RUST TREATMENT BY PAINTING REFERENCE Painting prevents corrosion and protects the sheet metal from damage In this section anti chipping paint only for anti corrosion purposes is described a ANTI CHIPPING PAINT 1 To prevent
21. rough the body 2 Before starting work disconnectthe negative terminal of the battery and ground the welder near the welding location of the body F33023 e ROUGH CUTTING OF JOINTS zx OSIA 1 Forjoint areas rough cut the new parts leaving 20 30 mm 0 79 1 18 in of overlap F33024 IN 6 INTRODUCTION INSTALLATION PRE WELDING MEASUREMENTS 1 Always take measurements before installing under body or engine components to ensure correct assem bly After installation confirm proper fit WELDING PRECAUTIONS 1 The number of welding spots should be as follows Spot weld 1 3 X No of manufacturer s spots Plug weld More than No of manufacturer s plugs 2 Plug welding should be done with a MIG Metal Inert Gas welder Do not gas weld or braze panels at areas other than where specified POST WELDING REFINISHING rr 1 Alwayscheckthe welded spots to ensure that they are secure 2 When smoothing out the weld spots with a disc grind er becareful notto grind offtoo much asthis will weak x 2 en the weld CORRECT WRONG F10018A SPOT WELD LOCATIONS 1 Avoid welding over previously welded areas SPOT WELDING PRECAUTIONS 1 The shape of the tip point of the spot welder signifi cantly affects the strength of the weld Therefore maintain the tip point in the proper shape and allow it to cool after every five or six spots 2 Completely
22. tools are reguired for alignment Always follow the directions giv en in the repair manual for the relevant model year during alignment and in section DI of this section Section of repair manual Component to be aligned for relegant modeil Front Wheels Front Suspension section Rear Wheels Rear Suspension section Propeller Shaft Propeller Shaft section COMPONENTS ADJACENT TO THE BODY PANELS Various types of component parts are mounted directly on or adjacent to the body panels Strictly ob serve the following precautions to prevent damaging these components and the body panels during han dling Before repairing the body panels remove their components or apply protective covers over the com ponents Before prying components off using a screwdriver or a scraper etc attach protective tape to the tool tip or blade to prevent damaging the components and the body paint Before removing components from the outer surface of the body attach protective tape to the body to ensure no damage to painted areas HINT Apply touch up paint to any damaged paint surfaces Before drilling or cutting sections make sure that there are no wires etc on the reverse side ECU ELECTRONIC CONTROL UNIT Many ECUs are mounted in this vehicle Take the following precautions during body repair to prevent damage to the ECUs Before starting electric welding operations disconnect the negative terminal cable from the
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