Toyota 1991 CAMRY Body Section Betriebsanleitung

Manual Name Pub. No.

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

Electrical Wiring Diagram

(Ex. USA and Canada)

(USA and Canada)

CAMRY Chassis and Body Repair Manual

CAMRY Repair Manual (USA and Canada)

36438E

BRM002E

RM025E

EWD027E

Model Year

Version

RM051E

36216E

Model Year

Version

Applicable models:

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.

SV20, 21 series

CV20 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 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.

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.

TOYOTA MOTOR CORPORATION

200

300

mm in.

7.87

11.81

QUARTER PANEL (CUT)

QUARTER PANEL

Replacement part

RE-34

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.

BODY PANEL REPLACEMENT-Rear Body Components

REMOVAL

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

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. .

Wagon Wagon models.

REMOVAL DIAGRAM

Describes in detail removal of the damaged part involving repair by cutting.

REMOVAL GUIDE

Provides additional information to more efficiently help you perform the removal.

INTRODUCTION

IN-2

mm in.

50.20

2. Temporarily install the new part and check fit for

the rear door, luggage compartment door and

rear combination light.

RE-35

BODY PANEL REPLACEMENT-Rear Body Components

INSTALLATION

Butt Weld Body Sealer

Braze

Body Sealer

About 5 mm

1. Before temporarily installing the new part, apply

body sealer 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.

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 installation.

SYMBOLS

See page IN-4 .

ILLUSTRATION of WELD POINT

Weld method and panel position symbols.

See page IN-5 .

INTRODUCTION IN-3

SYMBOLS MEANING ILLUSTRATION

SAW CUT OR

ROUGH CUT

REMOVE BRAZE

(See page 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

Remove weld point and panel position

Weld points

REMOVAL

Weld method and panel position

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

IN0102

SUPPORT 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

Assy, assy Assembly, assembly

Sub-assy Sub-assembly

Ex. Except

in. Inch

IRS Independent Rear Suspension

4-link 4-link 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

GENERAL REPAIR INSTRUCTIONS

Work Precautions

SAFETY

Never stand in direct

line with the chain when

using a puller on the

body or frame, and be

sure to attach a safety

cable.

SAFETY

1. Before performing repair work, check

for fuel leaks. If a leak is found, be sure

to close the opening totally.

2. If it is necessary to use a frame in the

area of the fuel tank, first remove the

tank and plug the fuel line.

VEHICLE PROTECTION

When welding, protect the

painted 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.

Dust-

Prevention

Mask Welder’s

Glasses Body

Mechanic

Stand

Face

Protector Ear

Plugs

Head

Protector Welder’s

Gloves

Cotton

Gloves

HAND TOOLS

Keeping your hand tools

to neat order will have

an effect on your work

efficiency.

Safety

Shoes

INTRODUCTION

IN-6

Proper and Efficient Work Procedures

REMOVAL REMOVAL OF ADJACENT COMPONENTS

When removing adjacent components,

apply protective tape to the surrounding

body and your tools to prevent damage.

CAUTION:

1. Be especially careful not to damage

screw or clip holes.

2. If the paint is accidently scratched, ap-

ply touch-up paint immediately. Even

the slightest scratch may result in cor-

rosion or appearance of 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 or

cut to insure that there are no hoses,

wires, etc., that may be damaged.

CUTTING AREA

Always cut in a straight

line and avoid reinforced

areas.

Cutting Okay

Corners

Reinforcement

WRONG

INTRODUCTION IN-7

Thickness of

welded portion Size of plug hole

1.0 (0.04) under 5 (0.20) φover

1.0 (0.04) over 6.5 (0.26) φover

REFERENCE: mm (in.)

PREPARATION FOR INSTALLATION

SPOT WELD POINTS APPLICATION OF WELD-THROUGH PRIMER

For treatment

against corrosion,

remove the paint

from the portion of

the new part and

body to be welded,

and apply weld-

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 WELDING

For areas where a spot welder cannot

be used, use a puncher or drill to make

holes for plug welding.

INTRODUCTION

IN-8

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