Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Supra 1986-1987.1990.1995.1997 Approved Toyota Supra 1997 Collision Repar

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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) for collision-damaged body components of the
TOYOTA SUPRA.

Applicable models: JZA80 series

This manual consists of body repair methods, exploded diagrams
and illustrations of the body components and other information re-
lating to body panel replacement such as handling precautions,
etc. However, it should be noted that the front fenders of the
TOYOTA models are bolted on and require 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 gen-
eral destinations.

For the repair procedures and specifications other than collisionda-
maged body components of the TOYOTA SUPRA refer to the fol-
lowing repair manuals.

Manual Name Pub. No.
(USA and CANADA)
S SUPRA Repair Manual M/Y Version
S Supra Electrical Wiring Diagram M/Y Version
Manual
S 1/2 SUPRA New Car Features NCF096U
(Models except USA and CANADA)
S SUPRA Chassis and Body Repair Manual RM344E
S Supra Electrical Wiring Diagram EWD175Y
Manual
S SUPRA New Car Features NCF097E
(All Countries)
S Fundamental Painting Procedures BRM024E
S Fundamental Body Repair Procedures BRM002E

If you require the above manuals, please contact your TOYOTA
Dealer.

All information contained in this manual is the most up-to-date at
the time of publication. However, specifications and procedures are
subject to change without prior notice.

TOYOTA MOTOR CORPORATION
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

QUARTER PANEL (CUT)

REMOVAL
(Cut and Join Location)

200 mm (Cut and Join Location)

Cut and Join Location
Cut and Join 100 mm
Location

Cut and Join Location
(Cut Location for Supply Parts)

(Cut and Join Location) (Cut and Join Location)
Normal Roof Sport Roof

1. Cut and join the parts at the location shown above. mm in.
100 3.94
200 7.87

REPLACEMENT PARTS AND METHOD

QUARTER PANEL (CUT)
Replacement method
(ASSY) . . . . . Assembly replacement
(CUT) . . . . . . Major cutting (less than 1/2 of parts used)
(CUT-H) . . . . Half cutting (about 1/2 of parts used)
(CUT-P) . . . . Partial cutting (most of parts used)
Replacement parts
PARTS LOCATION

REMOVAL DIAGRAM
Describes in detail removal of the damaged parts involving repair by cutting.

REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
INTRODUCTION IN-3

RE-36 BODY PANEL REPLACEMENT

INSTALLATION

Butt Weld

Body Sealer

Butt Weld

Body Sealer

about 5 mm

Normal Roof:
Sport Roof:
mm in.
5 0.20

1. Before temporarily installing the new parts, apply 2. Temporarily install the new parts and check the fit of
body sealer to the wheel arch. the front door, back door and rear combination lamp.
HINT: 3. Apply foamed material to the pillar section.
1) Apply body sealer about 5 mm (0.20 in.) from the HINT: For the foamed material application areas, refer to
flange, avoiding any oozing. page AP-4.
2) Apply sealer evenly, about 3 - 4 mm (0.12 - 0.16
in.) in diameter.
3) For other sealing points, refer to section AR.

INSTALLATION DIAGRAM
Describes in detail installation of the new parts involving repair by welding and/or cutting, but
excluding painting.

INSTALLATION GUIDE
Provides additional information to more efficiently help you perform the installation.

SYMBOLS
See page IN-4 .

ILLUSTRATION OF WELD POINTS
Weld method and panel position symbols.
See page IN-5 .
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.

SYMBOLS MEANING ILLUSTRATION

SAW CUT OR
ROUGH CUT

REMOVE BRAZE

WELD POINTS

SPOT WELD OR
MIG PLUG WELD

(See page IN-5 )

CONTINUOUS MIG
WELD (BUTT WELD
OR TACK WELD)

BRAZE

BODY SEALER
INTRODUCTION IN-5

Illustration of Weld Point Symbols
EXAMPLE:
REMOVAL INSTALLATION

Weld points Weld points

Remove weld point and panel position Weld method and panel position

SYMBOL MEANING ILLUSTRATION SYMBOL MEANING ILLUSTRATION

Remove
Weld
Points Spot Weld

(Outside)

Mig Plug
Weld
(Middle)

(Inside)

Spot MIG
Weld

HINT: Panel position syrnbols are as seen from the
working posture.
IN-6 INTRODUCTION

HANDLING PRECAUTIONS ON RELATED COMPONENTS
1. SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Locations of SRS Components

SRS Warning Light
Front Airbag Sensor RH Front Passenger Airbag Assembly
Front Airbag Sensor LH
Center Airbag Sensor Assembly

Junction Block No. 1
Spiral Cable

Steering Wheel Pad
(with Airbag)

Servicing vehicle with a Supplemental Restraint System (referrerd to as the SRS in the remainder of this
manual) installed.
When handling SRS components (removal, installation or inspection, etc.), always follow the directions
given in the repair manual for the relevant model year to prevent the occurrence of accidents and airbag
malfunction.
Also take the following precautions when repairing the body:
S Work must be started after 90 seconds or longer from the time the ignition switch is set to the LOCK
position and the negative (-) terminal cable is disconnected from the battery.
(The airbag system is equipped with a backup power source so that if work is started within 20 seconds
of disconnecting the negative (-) terminal cable of the battery, the airbag may be deployed.)
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So 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 seat, outside rear view mirror and power shoul-
der belt anchorage, which are all equipped with memory function, it is not possible to make a record of
the memory contents. So 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.
S When using electric welding, first disconnect the SRS connector (yellow color and 2 pins) under the
steering column near the combination switch connector on the glove compartment finish plate and lower
the front scuff plate before starting work.
INTRODUCTION IN-7

S Before repairing the body, remove the SRS parts if, during repair, shocks are likely to be applied to
the sensors due to vibrations of the body or direct tapping with tools or other parts.
S Do not expose the SRS parts directly to hot air or flames.
NOTICE:
1) The maximum ambient temperature tolerance is 120

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