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INTRODUCTION IN-5
HOW TO USE THIS MANUAL
1. BODY PANEL REPLACEMENT THIS MANUAL
BP-34 BODY PANEL REPLACEMENT
QUARTER PANEL (CUT)
REPLACEMENT
REMOVAL
POINT
1 Remove the [A] at the same time.
PART NAME
[A] Fuel Filler Opening Lid
A : REPLACEMENT PART AND METHOD
QUARTER PANEL (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
B : REMOVAL CONDTIONS
C : PART LOCATION
D : REMOVAL DIAGRAM
Describes in detail removal of the damaged part involving repair by cutting.
E : REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
F13890A
IN-6 INTRODUCTION
BODY PANEL REPLACEMENT BP-35
INSTALLATION
S Temporaily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
S Inspect the fiting of the related parts around the new parts before welding. This affects the appearance of the F
finish.
S After welding, apply the polyurethane foam to the corresponding parts.
S After welding, apply body sealer and under-coating to the corresponding parts.
S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
I
J
G
I
5mm
POINT
1 Before temporarily installing the new parts, apply body sealer to the wheel arch.
HINT:
1) Apply body sealer about 5mm (0.20in.) front the flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4mm (0.12 - 0.16in.) in diameter. H
3) For other sealing points, refer to section PC.
PART NAME
[A] Fuel Filler Opening Lid [B] Waterproof Rivet
F : INSTALLATION CONDITIONS
G : INSTALLATION DIAGRAM
Describes in detail installation to the new part involving repair by welding and / or
cutting, but excluding painting.
H : INSTALLATIOLN GUIDE
Provides additional information to more efficiently help you perform the installation.
I : SYMBOLS
(See page IN-7)
J : ILLUSTRATION OF WELD POINTS
Weld method and panel position symbols (See page IN-9)
K : PART NAME
F13891A
INTRODUCTION IN-7
2. SYMBOLS
The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas
and the types of weld required.
SYMBOLS MEANING ILLUSTRATION
CUT AND JOIN LOCATION
(SAW CUT)
CUT AND JOIN LOCATION
(Cut Location for
Supply Parts)
CUT LOCATION
CUT WITH DISC
SANDER, ETC.
BRAZE
(Removal)
BRAZE
(Installation)
-- WELD POINTS
SPOT WELD OR
-- MIG PLUG WELD
(See Page IN-9)
CONTINUOUS
MIG WELD
(BUTT WELD)
CONTINUOUS
MIG WELD
(TACK WELD)
BODY SEALER
F13893A
IN-8 INTRODUCTION
SYMBOLS MEANING ILLUSTRATION
-- Assembly Mark
BODY SEALER
-- (Flat Finishing)
BODY SEALER
-- (No flat Finishing)
F13894A
INTRODUCTION IN-9
3. ILLUSTRATION OF WELD POINT SYMBOLS
EXAMPLE:
REMOVAL INSTALLATION
Weld points Weld points
Remove weld point and panel position Weld method and panel position
SYMBOLS MEANING ILLUSTRATION SYMBOLS MEANING ILLUSTRATION
Remove
Weld
Spot Weld
Points
(Outside)
MIG Plug
Weld
(Middle)
(Inside)
Spot MIG
Weld
HINT: Panel position symbols are as seen from
the working posture.
F13892A
BRM
SIENNA
117U
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