Toyota Supra 1997 Betriebsanleitung

Manual Name Pub. No.

7M−GE Engine Repair Manual

TOYOTA SUPRA Chassis and Body

Repair Manual

TOYOTA SUPRA Chassis and Body

Repair Manual Supplement

TOYOTA SUPRA Electrical Wiring

Diagram Manual

TOYOTA SUPRA Repair Manual

(USA and Canada)

TOYOTA SUPRA Electrical Wiring

Diagram Manual (USA and Canada)

Fundamental Body Repair Procedures

Fundamental Painting Procedures

BRM002E

36438E

M/Y Version

EWD013E

RM036E

RM029E

RM027E

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 SUPRA.

Applicable models: MA70 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

SUPRA, 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

mm in.

87 3.15

200 7.87

QUARTER PANEL

Cut and Join Location

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−26 BODY PANEL REPLACEMENT−Rear Body Components

QUARTER PANEL (CUT)

REMOVAL

Cut and Join Location

200 mm

80 mm

[Cut and Join Location]

Front

Braze

Rear

1. Cut and join the quarter panel as shown above.

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). . . .

Replacement part

BODY VARIATIONS AND PART LOCATION

Body variations: Non All 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

1. Before temporarily installing the new part, apply

body sealer to the wheel arch portion.

NOTE:

1) Apply sealer approx. 5 mm (0.20 in.) from the

flange, avoiding any oozing.

2) Apply evenly, approx. 3 −4 mm (0.12 −0.16 in.)

in diameter.

3) For other sealing points, refer to section SU.

BODY PANEL REPLACEMENT−Rear Body Components RE−27

INSTALLATION

Butt Weld

Body Sealer

Braze

Body Sealer

About 5 mm

2. Temporarily installing the new part and check the fit of

the front door, luggage compartment door and rear

combination lamp.

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

GENERAL REPAIR INSTRUCTIONS

Work Precautions

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.

SAFETY

Never stand in direct

line with the chain when

using a puller an the

body or frame, and be

sure to attach a safety

cable.

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.

Welder’s

Glasses Body

Mechanic

Stand

Dust−

Prevention

Mask

Face

Protector Ear

Plugs

Head

Protector Welder’s

Gloves

HAND TOOLS

Keeping your hand tools

in neat order will have

an effect on your work

efficiency.

Safety

Shoes

Cotton

Gloves

INTRODUCTION

IN-6

REMOVAL OF ADJACENT

PARTS

When removing adjacent parts

by avoid accidental marring,

etc., wrapping the tools used

and surrounding body parts in

protective tape.

NOTE:

1) Take particular care not

to damage any screw or

clip holes.

2) If you do scratch a

painted surface, retouch

immediatly after. Even a

small scratch will result

in rust and corrosion.

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

number of spot welds

for later 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.

CUTTING AREA

Always cut in a straight

line and avoid reinforced

areas.

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 Okay

Corners

Reinforcement

WRONG

INTRODUCTION IN-7

INSTALLATION

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.

POST−WELDING REFINISH-

ING

1. Always check the welded

spots to insure they are

secure.

2. When smoothing out the

weld spots with a disc

grinder, be careful not to

grind off too much as this

would weaken the weld.

PRE−WELDING MEASUREMENTS

Always take measurements before

installing underbody or engine com-

ponents to insure correct assembly.

After installation, confirm proper fit.

WRONGOKAY

Seal

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

1. The shape of the welding

tip point has an effect on

the strength of the weld.

2. Always insure that the

seams and welding tip are

free of paint.

SPOT WELD LOCATIONS

Try to avoid welding over

previous spots.

Old

Spot

Locations

New Spot

Locations

Tip Cutter

INTRODUCTION

IN-8

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

Less than

3 mm

When welding panels with a

combined thickness of over 3

mm (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.

For treatment

against corrosion,

remove the paint

from the portion of

the new part and

body to be welded,

and apply weld−

through primer.

Air Saw

WRONG

20 −30 mm Puncher

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

he used, use a puncher or drill to make

holes for plug welding.

INTRODUCTION IN-9

ANTI−CORROSIVE TREATMENT

When replacing body panels, always apply body sealer, anti−rust treatment or undercoating according to

the requirements of your country.

CHASSIS RUST−PROOFING

Anti−rust treatment for weld-

ing spots or inside brazed

areas (torque box).

BODY SEALER

Apply body sealer to the

required areas.

Nozzle

Tube

Type Air Gun

Cartridge

Type

UNDERCOATING

Anti−rust treatment for underbody welding

spots and wheel housings.

Spray Gun

Undercoating

(Water base)

Undercoating

(Oil base)

INTRODUCTION

IN-10

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