Toyota 1991 CAMRY Body Section Repair Manual Download Page 17

Page: 17 / 111

BODY PANEL REPLACEMENT

Page

FRONT BODY COMPONENTS

RADIATOR SUPPORT (ASSY)

RE-2

. . . . . . . . . . . . . . . . . . . . . . . .

FRONT CROSSMEMBER (ASSY)

RE-4

. . . . . . . . . . . . . . . . . . . . .

FRONT FENDER APRON (ASSY)

RE-6

. . . . . . . . . . . . . . . . . . . . .

FRONT FENDER FRONT APRON (ASSY)

RE-8

. . . . . . . . . . . . .

FRONT SIDE MEMBER (ASSY)

RE-10

. . . . . . . . . . . . . . . . . . . . . . .

FRONT SIDE MEMBER (CUT-P)

RE-12

. . . . . . . . . . . . . . . . . . . . . .

CENTER BODY COMPONENTS

COWL TOP SIDE PANEL (ASSY)

RE-14

. . . . . . . . . . . . . . . . . . . . .

FRONT BODY PILLAR (CUT)

RE-16

. . . . . . . . . . . . . . . . . . . . . . . . .

CENTER BODY PILLAR (CUT)

RE-18

. . . . . . . . . . . . . . . . . . . . . . .

OUTER ROCKER PANEL (CUT)

RE-20

. . . . . . . . . . . . . . . . . . . . . .

ROOF PANEL (ASSY) SEDAN W/O MOONROOF

RE-22

. . . . . . .

ROOF PANEL (ASSY) SEDAN W/ MOONROOF

RE-24

. . . . . . . .

ROOF PANEL (ASSY) WAGON W/O MOONROOF

RE-26

. . . . . .

ROOF PANEL (ASSY) WAGON W/ MOONROOF

RE-28

. . . . . . .

FRONT DOOR OUTER PANEL (ASSY)

RE-30

. . . . . . . . . . . . . . . .

REAR DOOR OUTER PANEL (ASSY)

RE-32

. . . . . . . . . . . . . . . . .

REAR BODY COMPONENTS

QUARTER PANEL (CUT): SEDAN

RE-34

. . . . . . . . . . . . . . . . . . . .

QUARTER PANEL (CUT): WAGON

RE-36

. . . . . . . . . . . . . . . . . . . .

QUARTER PANEL (CUT-P): SEDAN

RE-38

. . . . . . . . . . . . . . . . . .

QUARTER PANEL (CUT-P): WAGON

RE-40

. . . . . . . . . . . . . . . . .

BODY LOWER BACK PANEL (ASSY): SEDAN

RE-42

. . . . . . . . .

BODY LOWER OUTER BACK PANEL (ASSY):

WAGON

RE-44

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BACK DOOR FRONT OPENING TROUGH (ASSY):

WAGON

RE-46

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ROOF SIDE OUTER PANEL (ASSY):

WAGON

RE-48

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

QUARTER WHEEL HOUSING OUTER PANEL (ASSY):

SEDAN

RE-50

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

QUARTER WHEEL HOUSING OUTER PANEL (ASSY):

WAGON

RE-52

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR UNDER BODY COMPONENTS

REAR FLOOR REAR INNER CROSSMEMBER (CUT):

WAGON

RE-54

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR FLOOR PAN (CUT): SEDAN

RE-56

. . . . . . . . . . . . . . . . . . . .

REAR FLOOR PAN (CUT): WAGON

RE-58

. . . . . . . . . . . . . . . . . . .

REAR FLOOR REAR SIDE MEMBER (ASSY)

RE-60

. . . . . . . . . .

REAR FLOOR SIDE MEMBER (ASSY)

RE-62

. . . . . . . . . . . . . . . .

CENTER FLOOR NO. 2 CROSSMEMBER (ASSY)

RE-64

. . . . . .

RE-1

Summary of Contents for 1991 CAMRY Body Section

Page 1: ... series 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 an...

Page 2: ... Rear 1 Cut and join the part at area as shown above NOTE Before cutting remove the drain hole of the moon roof REPLACEMENT PART AND METHOD CUT Replacement method ASSY Assembly replacement CUT Major cutting less than 1 2 of part used CUT H Half cutting about 1 2 of part used CUT P Partial cutting most of part used BODY VARIATIONS AND PART LOCATION Body variations Non All models Sedan Sedan models ...

Page 3: ...NOTE 1 Apply sealer about 5 mm 0 20 in from the flange avoiding any oozing 2 Apply evenly about 3 4 mm 0 12 0 16 in in diameter 3 For other sealing points refer to AR INSTALLATION DIAGRAM Describes in detail installation of the new part involving repair by welding and or cutting but exclud ing painting INSTALLATION GUIDE Provides additional information to more efficiently help you perform the inst...

Page 4: ... IN 5 SPOT WELD OR MIG PLUG WELD WELD POINTS BRAZE CONTINUOUS MIG WELD BUTT WELD OR TACK WELD BODY SEALER 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 INTRODUCTION IN 4 ...

Page 5: ...n Weld points INSTALLATION SYMBOL MEANING ILLUSTRATION SYMBOL Spot Weld MEANING ILLUSTRATION Remove Weld Points Outside Mig Plug Weld Middle Inside Spot MIG Weld HINT Panel position syrnbols are as seen from the working posture Illustration of Weld Point Symbols EXAMPLE INTRODUCTION IN 5 ...

Page 6: ...T POSITION PANTOGRAPH JACK POSITION Front Center of engine mounting center member Rear Jack up support of rear suspension member JACK POSITION Front Safety stand VEHICLE LIFT AND SUPPORT LOCATIONS INTRODUCTION IN 11 ...

Page 7: ...ink Rear Suspension MIG Metal Inert Gas OPN Operation SP Spot Weld Resistance Spot Weld w With w o Without FR Front RR Rear RH Right hand RHD Right hand Drive LH Left hand LHD Left hand Drive ABBREVIATIONS USED IN THIS MANUAL For convenience the following abbreviations are used in this manual INTRODUCTION IN 12 ...

Page 8: ...surfaces windows seats and carpet with heat resistant fire proof covers WRONG Glass Cover Safety Cable Seat Cover WRONG SAFETY Before performing repair work disconnect the battery cables SAFETY WORK CLOTHES In addition to the usual mechanic wear cap and safety shoes the necessary gloves head protector glasses ear plugs face protector dust prevention mask etc should be worn as the situation demands...

Page 9: ...rust NO OF SPOT WELDS Make a note of the num ber of spot welds for lat er reference NOTE The number of spot welds may vary depending on the vehicle PRE REMOVAL MEASURING Before removal or cutting opera tions take measurements in ac cordance with the dimension dia gram Always use a puller to straighten a damaged body or frame PRECAUTIONS FOR DRILLING OR CUTTING Check behind any area to be drilled o...

Page 10: ...d through primer Less than 3 mm When welding panels with a combined thickness of over 3 mrn 0 12 in use a MIG Metal Inert Gas welder for plug welding NOTE Spot welding will not provide sufficient dura bility for panels over 3 mm 0 12 in thick Air Saw WRONG 20 30 mm Overlap ROUGH CUTTING OF JOINTS For joint areas rough cut the new part leaving 20 30 mm 0 79 1 18 in overlap MAKING HOLES FOR PLUG WEL...

Page 11: ...s take measurements before installing underbody or engine components to insure correct assembly After installation confirm proper fit WRONG OKAY OKAY WRONG 2 Plug welding should be done with a MIG Metal Inert Gas welder Do not gas weld or braze panels at areas other than specified Safety Glass Body Measurement Diagrams SPOT WELDING PRECAUTIONS SPOT WELD LOCATIONS Try to avoid welding over previous...

Page 12: ...e required areas ANTI RUST AGENT WAX Apply anti rust agent to following sections Inside of the hems of the doors and hood Around the hinges of the doors and hood Inside of the welded parts with boxed cross section Nozzle Tube Type Cartridge Type Air Gun UNDERCOAT Apply undercoat to the underbody and wheel housings Spray Gun Undercoat Water base Undercoat Oil base INTRODUCTION IN 10 ...

Page 13: ...pot welds Air powered Cutter For cutting panels Air powered Chuck Grinder For separating spot and plug welds and grinding off traces of plug welds Tracking Gauge For measuring body dimensions Frame Centering Gauge When 3 or 4 are used together measure ments of twists bends or warps in the body and frame are possible MEASURING INSTRUMENTS SEPARATING TOOLS TOOLS AND EQUIPMENT TE 2 ...

Page 14: ...flattening in hard to reach areas For separating spot welds For rough cutting of panels Air powered Saw For rough cutting of pillars rocker panels etc Air powered Saw For rough cutting of pillars rocker panels etc Hacksaw For rough cutting of pillars rocker panels etc SEPARATING TOOLS Cont d TOOLS AND EQUIPMENT TE 3 ...

Page 15: ... etc Vise Grip Wrench For temporary installation of panels and holding of portions to be welded Flanging Tool For making flanges in overlapping panels Hemming Tool For hemming door outer panels etc Hole Punch For making holes for MIG plug weld ing INSTALLATION ASSISTANCE TOOLS BODY PROTECTORS TOOLS AND EQUIPMENT TE 4 ...

Page 16: ...s Welder Torch Gas Cutter Torch For rough cutting of panels members etc Acetylene Gas Torch For soldering and peeling of paint Straightening Machine For straightening distorted panels Panel Extractor For extraction of closed in panels WELDING INSTRUMENTS TOOLS AND EQUIPMENT TE 5 ...

Page 17: ...DOOR OUTER PANEL ASSY RE 30 REAR DOOR OUTER PANEL ASSY RE 32 REAR BODY COMPONENTS QUARTER PANEL CUT SEDAN RE 34 QUARTER PANEL CUT WAGON RE 36 QUARTER PANEL CUT P SEDAN RE 38 QUARTER PANEL CUT P WAGON RE 40 BODY LOWER BACK PANEL ASSY SEDAN RE 42 BODY LOWER OUTER BACK PANEL ASSY WAGON RE 44 BACK DOOR FRONT OPENING TROUGH ASSY WAGON RE 46 ROOF SIDE OUTER PANEL ASSY WAGON RE 48 QUARTER WHEEL HOUSING O...

Page 18: ... For grinding plug welds butt welds and door hems Belt Sander For removing paint around weld areas Double action Sander For rough grinding and polishing and feather edging Body Pullers For straightening lightly dam aged panels LIGHT BODY REPAIR TOOLS GRINDING AND POLISHING TOOLS TOOLS AND EQUIPMENT TE 6 ...

Page 19: ... over a wide area resurfacing and refinishing Air powered Disc Sander For peeling paint File Holder For paint removal Flexible File Holder For correction of soldering spots and resurfacing of panels Surform Tool For rough finishing of panels GRINDING AND POLISHING TOOLS Cont d TOOLS AND EQUIPMENT TE 7 ...

Page 20: ...RADIATOR SUPPORT ASSY REMOVAL BODY PANEL REPLACEMENT RE 2 ...

Page 21: ...mbly Mark 1 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 BODY PANEL REPLACEMENT RE 3 ...

Page 22: ...FRONT CROSSMEMBER ASSY REMOVAL With the radiator support removed BODY PANEL REPLACEMENT RE 4 ...

Page 23: ...INSTALLATION 1 Temporarily install the new part and measure each part in accordance with the body dimen sion diagram BODY PANEL REPLACEMENT RE 5 ...

Page 24: ...FENDER APRON ASSY REMOVAL With the radiator support removed LH only Front Body Pillar Lower Gusset 1 After removing the front body pillar lower gusset remove the front fender apron BODY PANEL REPLACEMENT RE 6 ...

Page 25: ...e new part by the assembly mark 2 Measurements must be accurate with the body dimension diagram as this effects the front wheel alignment NOTE The position of the front spring support hole is very important 3 Check the fit of the front fender and hood BODY PANEL REPLACEMENT RE 7 ...

Page 26: ...FRONT FENDER FRONT APRON ASSY REMOVAL With the radiator support removed LH only BODY PANEL REPLACEMENT RE 8 ...

Page 27: ...INSTALLATION LH only 1 Temporarily install the new part and measure each part in accordance with the body dimen sion diagram BODY PANEL REPLACEMENT RE 9 ...

Page 28: ...FRONT SIDE MEMBER ASSY REMOVAL With the front fender apron removed BODY PANEL REPLACEMENT RE 10 ...

Page 29: ...ssmember Brace 1 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 BODY PANEL REPLACEMENT RE 11 ...

Page 30: ...mber plate CROSS SECTIONAL VIEW RH 15φ LH 9 φ 20 mm Front Side Member Front Side Member No 5 Plate Front Side Member Front Side Member No 6 Reinforcement Front Side Member Plate NOTE Be careful not to damage the front side member No 6 reinforcement when cut ting the member 2 Be careful not to damage the front side member No 6 reinforcement when cutting the members 1 Before cutting the side member ...

Page 31: ... side mem ber plate and front side member No 5 plate at the same place Battery Carrier Support LH only 1 Cut the supply part in the same way as removal 2 Temporarily install the new part measure each part in accordance with the body dimension diagram 3 After installing the new side member install the battery carrier support LH only BODY PANEL REPLACEMENT RE 13 ...

Page 32: ...COWL TOP SIDE PANEL ASSY REMOVAL Cut with a disc sander etc BODY PANEL REPLACEMENT RE 14 ...

Page 33: ...mm in 30 1 18 INSTALLATION Tack Weld 30 mm Assembly Mark Assembly Mark 1 Determine the installation position of the new part by the assembly mark BODY PANEL REPLACEMENT RE 15 ...

Page 34: ...e cutting remove the antenna cord and drain hole of the moonroof 2 Remove the weld points of the roof drip channel make an incision of it and bend it 1 Cut and join the new part at the location as shown above NOTE 1 Avoid the antenna installation hole for the cut and join location 2 As shown above cut and join the front body pillar outer and inner panels at a position shifted above 50 mm 1 97 in B...

Page 35: ...1 392 1 18 24 57 29 29 31 26 34 21 43 74 48 86 54 65 54 80 INSTALLATION Butt Weld Butt Weld Reference mm Tack Weld 30 mm 1 Temporarily install the new part and check fit for the front fender hood and windshield glass BODY PANEL REPLACEMENT RE 17 ...

Page 36: ...ner Pillar Upper Inner Pillar 1 Cut and join the outer pillar at the location as shown above NOTE Be careful not to damage the roof side outer rail when cutting the outer pillar with a cut grinder or such 2 Heat the brazed areas of the roof side outer rail and scrape it with a wire brush NOTE Before performing these operations place a wet rag on the roof panel to protect it from dam age BODY PANEL...

Page 37: ... Pillar REFERENCE Door Lock Striker Plate Retainer NOTE Before performing these operations place a wet rag on the roof panel to protect it from damage 3 Braze the roof side outer rail and center pillar connection NOTE Smooth down the surface Rail leakage will occur if the weather strip con tact is defective Preparation for supply parts 1 After installing the upper reinforcement to the outer pillar...

Page 38: ...mm in 70 2 76 OUTER ROCKER PANEL CUT REMOVAL 70 mm or more Cut and Join Location Cut and Join Location 1 Cut and join the part at the area as shown above BODY PANEL REPLACEMENT RE 20 ...

Page 39: ...mm in 30 40 1 18 1 57 INSTALLATION Butt Weld 30 40 mm Cut piece of new part 1 Temporarily install the new part and check fit for the front door rear door and front fender BODY PANEL REPLACEMENT RE 21 ...

Page 40: ...s 2 Cut off the roof panel tip at the quarter panel arc brazing connection with a cut grinder 1 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 parcel BODY PANEL REPLACEMENT RE 22 ...

Page 41: ... connection NOTE Before performing these operations place a wet rag on the roof panel to protect it from damage 1 Before temporarily installing the new part apply body sealer to the windshield header panel roof panel reinforcement and back window opening frame NOTE 1 Apply just enough sealer for the new part to make contact 2 For other sealing points refer to section AR BODY PANEL REPLACEMENT RE 2...

Page 42: ... REMOVAL Hemming Location Disc Sander Braze both sides Arc Brazing both sides Braze both sides 1 If reusing the roof panel reinforcement slightly heating the roof panel will soften sealer and make removal easier BODY PANEL REPLACEMENT RE 24 ...

Page 43: ...header panel roof panel reinforcement and back window opening frame NOTE 1 Apply just enough sealer for the new part to make contact 2 For other sealing points refer to section AR 2 Hem the area tip of the roof panel opening NOTE 1 Bend the flange hem about 30 with a ham mer and dolly Then fasten tightly with a hemming tool 2 Perform hemming three steps being careful not to warp the panel BODY PAN...

Page 44: ...AL Braze both sides Braze both sides 1 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 BODY PANEL REPLACEMENT RE 26 ...

Page 45: ...l connections NOTE Before performing these operations place a wet rag on the roof panel to protect it from damage 1 Before temporarily installing the new part apply body sealer to the windshield header panel roof panel reinforcement and back door opening frame NOTE 1 Apply just enough sealer for the new parr to make contact 2 For other sealing points refer to section AR BODY PANEL REPLACEMENT RE 2...

Page 46: ...NROOF Wagon REMOVAL Hemming Location Disc Sander Braze both sides Braze both sides 1 If reusing the roof panel reinforcement slightly heating the roof panel will soften sealer and make removal easier BODY PANEL REPLACEMENT RE 28 ...

Page 47: ...m about 30 with a ham mer and dolly Then fasten tightly with a hemming tool 2 Perform hemming three steps being care ful not to warp the panel 1 Before temporarily installing the new part apply body sealer to the windshield header panel roof panel reinforcement and back door opening frame NOTE 1 Apply just enough sealer for the new part to make contact 2 For other sealing points refer to section A...

Page 48: ...ightly W Front Door Side Impact Protection Beam Disc Sander 1 Grind out the hemming location and remove the outer panel NOTE Slightly heatinq the outer panel will soften the sealer and make removal easier w front door side impact protection beam BODY PANEL REPLACEMENT RE 30 ...

Page 49: ...he new part coat the back side with body sealer NOTE 1 Coat evenly about 10 mm 0 39 in from the flange and 3 mm 0 12 in in diameter 2 For other sealing points refer to section AR 2 Bend the flange hem about 30 with a hammer and dolly Then fasten tightly with a hemming tool NOTE 1 Perform hemming in three steps being careful not to warp the panel 2 If hemming tool cannot be used hem with a hammer a...

Page 50: ...light W Rear Door Side Impact Protection Beam Disc Sander 1 Grind out the hemming location and remove the outer panel NOTE Slightly heating the outer panel will soften the sealer and make removal easier w front door side impact protection beam BODY PANEL REPLACEMENT RE 32 ...

Page 51: ...th a hammer and dolly Then fasten tightly with a hemming tool NOTE 1 Performing hemming in three steps being careful not to warp the panel 2 If hemming tool cannot be used hem with a hammer and dolly 1 Before temporarily installing the new part coat the back side with body sealer NOTE 1 Coat evenly about 10 mm 0 39 in from the flange and 3 mm 0 12 in in diameter 2 For other sealing points refer to...

Page 52: ...CUT SEDAN Sedan REMOVAL 200 300 mm 200 300 mm Cut and Join Location Cut and Join Location Front Braze Rear 1 Cut and join the part at area as shown above NOTE Before cutting remove the drain hole of the moonroof BODY PANEL REPLACEMENT RE 34 ...

Page 53: ...aler to the wheel arch NOTE 1 Apply sealer about 5 mm 0 20 in from the flange avoiding any oozing 2 Apply evenly about 3 4 mm 0 12 0 16 in in diameter 3 For other sealing points refer to AR 2 Temporarily install the new part and check fit for the rear door luggage compartment door and rear combination light BODY PANEL REPLACEMENT RE 35 ...

Page 54: ... REMOVAL Cut and Join Location Cut and Join Location 100 mm or more 200 mm or more Cut and Join Location Front Braze Rear 1 Cut and join the part at area as shown above NOTE Before cutting remove the drain hole of the moonroof BODY PANEL REPLACEMENT RE 36 ...

Page 55: ...ler to the wheel arch NOTE 1 Apply sealer about 5 mm 0 20 in from the flange avoiding any oozing 2 Apply evenly about 3 4 mm 0 12 0 16 in in diameter 3 For other sealing points refer to section AR 2 Temporarily install the new part and check the fit for the rear door back door and rear combina tion light BODY PANEL REPLACEMENT RE 37 ...

Page 56: ...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 1 Cut on the line shown above BODY PANEL REPLACEMENT RE 38 ...

Page 57: ...ggage compartment door and rear combination light 2 Before welding apply body sealer from inside of the vehicle NOTE 1 Do not apply body sealer to the weld seams before welding as the sealer will melt re sulting in a bad seal and a bad weld 2 For other sealing points refer to section AR 3 Surface finish the weld seam from the inside also NOTE Be careful not to grind off to much weld as it will res...

Page 58: ...PANEL CUT P 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 1 Cut on the line shown above Wagon BODY PANEL REPLACEMENT RE 40 ...

Page 59: ...nish the weld seam from the inside also NOTE Be careful not to grind off to much weld as it will result in loss of durability 1 Before cutting the overlap areas check the fit for the luggage compartment door and rear combination light 2 Before welding apply body sealer from inside of the vehicle NOTE 1 Do not apply body sealer to the weld seams before welding as the sealer will melt re sulting in ...

Page 60: ...Sedan BODY LOWER BACK PANEL ASSY SEDAN REMOVAL Braze Braze BODY PANEL REPLACEMENT RE 42 ...

Page 61: ...INSTALLATION Braze Braze 1 Temporarily install the new part and check fit for the rear combination light and luggage compart ment door BODY PANEL REPLACEMENT RE 43 ...

Page 62: ...BODY LOWER OUTER BACK PANEL ASSY WAGON Wagon REMOVAL BODY PANEL REPLACEMENT RE 44 ...

Page 63: ...INSTALLATION 1 Temporarily install the new part and check fit for the back door BODY PANEL REPLACEMENT RE 45 ...

Page 64: ...BACK DOOR FRONT OPENING TROUGH ASSY WAGON Wagon REMOVAL Braze BODY PANEL REPLACEMENT RE 46 ...

Page 65: ...INSTALLATION Braze 1 Temporarily install the new part and check fit for the back door and rear combination light BODY PANEL REPLACEMENT RE 47 ...

Page 66: ...ROOF SIDE OUTER PANEL ASSY WAGON Wagon REMOVAL With the quarter panel and back door front opening trough removed BODY PANEL REPLACEMENT RE 48 ...

Page 67: ...INSTALLATION 1 Before welding temporarily install the quarter panel and back door front opening trough and check the fit BODY PANEL REPLACEMENT RE 49 ...

Page 68: ... HOUSING OUTER PANEL ASSY SEDAN Sedan REMOVAL With the quarter panel removed Roof Side Outer Panel 1 After removing the roof side outer panel remove the quarter wheel housing outer panel BODY PANEL REPLACEMENT RE 50 ...

Page 69: ...ark Assembly Mark 1 Determine the position of the new part by the assembly marks of the inner and outer panels 2 Before welding the new part temporarily install the quarter panel and check the fit BODY PANEL REPLACEMENT RE 51 ...

Page 70: ...NEL ASSY WAGON Wagon REMOVAL With the quarter panel removed Roof Side Inner to Wheel Housing Brace 1 After removing the roof side inner to wheel housing brace remove the quarter wheel housing outer panel BODY PANEL REPLACEMENT RE 52 ...

Page 71: ...embly Mark 1 Determine the position of the new part by the assembly marks of the inner and outer panels 2 Before welding the new part temporarily install the quarter panel and check the fit BODY PANEL REPLACEMENT RE 53 ...

Page 72: ...INNER CROSSMEMBER CUT WAGON Wagon REMOVAL With the body lower outer back panel and roof side outer panel removed Cut and Join Location 1 Cut and join the part at the location as shown above BODY PANEL REPLACEMENT RE 54 ...

Page 73: ...INSTALLATION Butt Weld BODY PANEL REPLACEMENT RE 55 ...

Page 74: ...EMOVAL With the body lower back panel removed Cut Location Cut Location RH LH 1 Cut the part at the location as shown above 2 Avoid the rear floor side member and rear floor crossmember when rough cutting BODY PANEL REPLACEMENT RE 56 ...

Page 75: ...the location as shown above 2 Temporarily install the new part and measure each part in accordance with the body dimen sion diagram 3 Plug weld the overlapping portion of the new part NOTE Be sure the portion to be welded are align and not loose BODY PANEL REPLACEMENT RE 57 ...

Page 76: ... WAGON Wagon REMOVAL With the rear floor rear inner crossmember removed Cut and Join Location 90 mm RH LH 1 Cut the part at the location as shown above 2 Avoid the rear floor side member when rough cutting BODY PANEL REPLACEMENT RE 58 ...

Page 77: ...t the new part at the location as shown above 2 Temporarily install the new part and measure each part in accordance with the body dimen sion diagram 3 Plug weld the overlapping portion of the new part NOTE Be sure the portion to be welded align and not loose BODY PANEL REPLACEMENT RE 59 ...

Page 78: ...REAR FLOOR REAR SIDE MEMBER ASSY REMOVAL Sedan With the body lower back panel removed Wagon With the rear floor rear inner crossmember removed Sedan only BODY PANEL REPLACEMENT RE 60 ...

Page 79: ...y Assembly Mark 1 Determine the installation position of the new part by the assembly mark 2 Temporarily install the new part and measure each part in accordance with the body dimen sion diagram BODY PANEL REPLACEMENT RE 61 ...

Page 80: ...R ASSY REMOVAL With the rear floor pan removed Make an incision Rear Floor Crossmember Side Extension 1 After removing the rear floor crossmember side extension remove the rear floor side member BODY PANEL REPLACEMENT RE 62 ...

Page 81: ...INSTALLATION Butt Weld 1 Temporarily install the new part and measure each part in accordance with the body dimen sion diagram BODY PANEL REPLACEMENT RE 63 ...

Page 82: ...SMEMBER ASSY REMOVAL Make and incision 1 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 2 crossmember BODY PANEL REPLACEMENT RE 64 ...

Page 83: ...INSTALLATION Butt Weld BODY PANEL REPLACEMENT RE 65 ...

Page 84: ...08 7 0 28 9 0 35 10 0 39 11 0 43 13 0 51 9φ 9φ 11φ 7φ 10φ 13φ 2R 2 R STANDARD BODY MARKS Center Mark Assembly Mark Assembly Mark Center Mark Assembly Mark Assembly Mark Assembly Mark BODY PANEL CONSTRUCTION CN 2 ...

Page 85: ...er Roof Side Inner and Outer Rail HIGH STRENGTH STEEL HSS PARTS Generally High Strength Steel HSS is that which has an intensity value of at least 35 kgf mm2 and distinguished from mild steel The handling of HSS is the same as for mild steel but the following should be observed 1 Panel Hammering Because HSS is thinner than mild steel care should be taken to avoid warping during hammering operation...

Page 86: ...s harmless if applied only for short time in small amounts Most solvents are harm less but avoid dipping in gasoline solvents etc PA Polyamide Nylon 80 176 Alcohol and gasoline are harmless Avoid battery acid PC Polycarbonate 120 248 Alcohol is harmless Avoid gasoline brake fluid wax wax removers and or ganic solvents PE Polyethylene 80 176 Alcohol and gasoline are harmless Most solvents are harml...

Page 87: ...l gasoline sol vents etc PMMA Polymethyl Methacrylate 80 176 Alcohol is harmless if applied only for short time in small amounts Avoid dipping or immersing in alcohol gasoline sol vents etc SAN Styrene Acrylonitrile Resin 80 176 Alcohol is harmless if applied only for short time in small amounts ex quick wiping to re move grease Avoid dipping or immersing in alcohol gasoline sol vents etc SMC Shee...

Page 88: ...8A Hood Lock Support Sub Assy 53211 53212 Radiator Support 53911 Front Valance Panel 53932 Front End Panel Sub Assy 53217B Radiator Support to Crossmember Brace 55101 Dash Panel Sub Assy 53301 Hood Sub Assy 55701 Cowl Panel Sub Assy 53701 53702 Front Fender Apron Sub Assy 55713A 55714A Cowl Top Side Panel 53711B 53712B Front Fender Front Apron 57161 Front Crossmember 57301A Steering Gear Box Suppo...

Page 89: ...ge Compartment Door Panel Sub Assy 63104 Roof Panel Center Reinforcement Sub Assy 67001 67002 Front Door Panel Sub Assy 63105A Back Door Opening Frame Sub Assy 63111 Roof Panel 67003 67004 Rear Door Panel Sub Assy 63133 Back Window Opening Upper Frame 63142 Roof Panel No 2 Reinforcement 67005 Back Door Panel Sub Assy 63143B Roof Panel No 3 Reinforcement 67111 67112 Front Door Outlet Panel 63144A R...

Page 90: ...58208 58314 58301A 58313 58371B 57068 Wagon 58208 58301A 58313E RH 58314E LH 58131A 57206A 58131A 58369B 58027A 58171 58307 58367 Sedan 58207 58396A 58102A 58111 58313 RH 58314 LH PART LISTS PL 4 ...

Page 91: ... Sub Assy 57401 57402 Main Floor Side Member Sub Assy 58208 Center Floor Pan 58301A Rear Floor Panel Sub Assy 57417 57418 Front Floor Under Reinforcement 58307 Body Lower Back Panel Sub Assy 58313 58314 Rear Floor Side Panel 57451 Front Floor Crossmember Member 57601 57602 Rear Floor Side Member Sub Assy 58313E 58314E Rear Floor Side Panel Extension 57607 57608 Rear Floor No 1 Crossmember Sub Assy...

Page 92: ...232 Roof Side Inner Rail 61623D 61624D Quarter Panel Front Extension 61261 61262 Roof Drip Channel 61631A 61632A Quarter Wheel Housing Outer Panel 61301B 61302B Center Body Outer Pillar 61633A 61634A Quarter Wheel Housing inner Panel 61331C 61332C Center Pillar Upper Outer Reinforcement 61711 61712 Roof Side Outer Panel 61343 61344 Center Body Inner Upper Pillar 61731B 61732B Roof Side Inner Panel...

Page 93: ...61632A Quarter Wheel Housing Outer Panel 61261 61262 Roof Drip Channel 61633A 61634A Quarter Wheel Housing Inner Panel 61301B 61302B Center Body Outer Pillar 61635A 61636A Quarter Wheel Housing Brace 61331C 61332C Center Pillar Upper Outer Reinforcement 61711 61712 Roof Side Outer Panel 61343 61344 Center Body Inner Upper Pillar 61717A 61718A Quarter Panel Extension Reinforcement 61343A 61344A Cen...

Page 94: ...ter Vent Duct PP Quarter Vent Duct PE Radiator Grille ABS Front Bumper Cover PP PUR Front Bumper Extension PP Quarter Vent Duct PP Outside Moulding PVC Radiator Lower Grille PP Front Turn Signal Light SAN PP Speaker Box PP Mud Guard EPDM Fender Liner PE Front Spoiler PP NOTE Resin material differs with model Made up of 2 or more kinds of materials PLASTIC BODY PARTS PP 4 ...

Page 95: ...P 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 Engine Under Cover PE Radiator Reserve Tank PP NOTE Resin material differs with model Made up of 2 or more kinds of materials PLASTIC BODY PARTS PP 5 ...

Page 96: ...S License Plate Light PC ABS Rear Combination Light PMMA PC PP PMMA SAN PC PP License Plate Light PMMA PC PP ABS Rear Fog Light Back Up Light Wagon only Back Door Upper Trim Cover ABS Roof Side Trim Garnish ABS Tonneau Side Cover ABS Deck Side Trim Panel ABS Back Door Finish Panel ABS PMMA Rear Combination Light PMMA PP Back Up Light PMMA PP License Plate Light SAN PP PMMA Back Door Trim Board ABS...

Page 97: ... seal er so that it does not ooze out from the joining surfaces WELD THROUGH PRIMER SPOT SEALER APPLICATION ANTI RUST TREATMENT BEFORE PAINTING PROCESS 1 BODY SEALER APPLICATION For waterproofing and anti corrosion measures al ways apply the body sealer to the body panel seams and hems of the doors hoods etc Sealer Gun BODY SEALER APPLICATION 2 UNDERCOAT APPLICATION To prevent corrosion and protec...

Page 98: ...RUST TREATMENT BY PAINTING Painting prevents corrosion and protects the sheet metal from damage In this section the anti chipping paint only for the anti corrosion purpose is described 1 ANTI CHIPPING PAINT To prevent corrosion and protect the body from damage by flying stones etc apply the anti chipping paint to the rocker panel wheel arch areas valance panel etc NOTE According to the models or a...

Page 99: ...ly a second coat over entire area 4 Do not coat parts which become hot such as the tailpipe or moving parts such as the propeller shaft 5 Besides the locations described below apply undercoating to all weld points under the body to insure corrosion prevention 6 Be sure to seal the edge of the flange of the member and bracket with undercoating 7 If undercoat is damaged by peeling cracks etc be sure...

Page 100: ...er was used first wipe off any excess and coat with anti corrosion primer before applying body sealer 3 Wipe off any excess body sealer with a rag soaked in grease wax and silicone remover 4 If body sealer is damaged by peeling cracks etc be sure to repair as necessary Do not close the drain beads Flat Surfacing Flat Surfacing ANTI RUST TREATMENT AR 4 ...

Page 101: ...Moonroof Housing Flat Surfacing Flat Surfacing ANTI RUST TREATMENT AR 5 ...

Page 102: ...Flat Surfacing Flat Surfacing Flat Surfacing ANTI RUST TREATMENT AR 6 ...

Page 103: ...Do not close the drain hole Fuel Inlet Box Cover Fuel Inlet Box ANTI RUST TREATMENT AR 7 ...

Page 104: ... over entire application area of the part 3 Wipe off the anti rust agent immediately with a rag soaked in grease wax and silicone remover if other areas are accidently applied Luggage Compartment Door Engine Hood Inside of Hemming Areas Inside of Hemming Areas Around Hinges Front Door and Rear Door Around Hinges Inside of Hemming Areas Back Door Inside of Hemming Areas Around Hinges ANTI RUST TREA...

Page 105: ...hould be after a finishing coating 2 Wipe off the coating immediately with a rag soaked in grease wax and silicone remover if other areas are accidently coated Front Wheel Arch Area Rear Wheel Arch Area Outer Rocker Panel Front Valance Panel C C Cross Section B B Cross Section A A Cross Section Apply the anti chipping paint before a second coating ANTI RUST TREATMENT AR 10 ...

Page 106: ...sion is given left and right are symmetrical c The dimensions in the following drawing indicate actual distance Therefore please use the dimen sions as a reference 2 MEASURING a Basically all measurements are to be done with a tracking 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 meas...

Page 107: ... panel center mark E e Front side member bumper installation hole 15 0 59 F f Front side member standard hole 15 0 59 G g Headlight installation hole 20 6 5 0 79 0 26 H h Tube clamp installation nut 6 0 24 I i Front fender iinstallation nut 6 0 24 J j Cowl top panel standard hole 10 0 39 K k Front crossmember bumper installation nut 12 0 47 BODY DIMENSION DRAWINGS ENGINE COMPARTMENT BODY DIMENSION...

Page 108: ...t bar inner installation hole Rear floor side member standard hole Rear floor side member transport hook installation hole Symbol S s T t U u V v W w X x Note dia 10 0 39 10 0 39 10 0 39 13 0 51 14 0 55 10 0 39 15 0 59 Nomenclature Engine mounting member installation nut Strut bar bracket front inner installation nut Strut bar bracket rear front installation nut Engine mounting bracket front hole ...

Page 109: ...Imaginary Standard Line mm in Two dimensional Distance UNDER BODY Cont d BO2224 BO2225 BODY DIMENSIONS DI 5 ...

Page 110: ...lature Hole dia BO1975 Y y Back window upper frame standard hole rear 10 0 39 Z z Rear spring support front hole 9 5 0 37 AA Upper back reinforcement center mark 3 0 12 BB bb Rear floor pan bumper front installation hole front 45 1 77 LUGGAGE COMPARTMENT SEDAN BODY DIMENSIONS DI 6 ...

Page 111: ...nal Distance Symbol Nomenclature Hole dia BO1976 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 LUGGAGE COMPARTMENT WAGON BODY DIMENSIONS DI 7 ...

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Toyota 1991 CAMRY Body Section, Repair Manual

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