Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Camry Toyota Toyota_30 02-06_Collision
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FOREWORD
This repair manual has been prepared to provide essential in-
formation on body panel repair methods (including cutting and
welding operations, but excluding painting) for the TOYOTA
CAMRY.
Applicable models:ACV30, 31 series
MCV30, 31 series
This manual consists of body repair methods, exploded dia-
grams and illustrations of the body components and other in-
formation relating to body panel replacement such as handling
precautions, etc. However, it should be noted that the front fend-
ers of the TOYOTA model is bolted on and require no welding.
When repairing, don't cut and join areas that are not shown in
this manual. Only work on the specified contents to maintain
body strength.
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 repair procedures and specifications other than collision-
damaged body components of the TOYOTA CAMRY refer to the
repair manuals.
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.
VIEWS OF THIS TEXT
Scope of the repair work explanation
D This text explains the welding panel replacement instructions from the vehicle's white body condi-
tion. We have abbreviated the explanations of the removal and reinstallation of the equipment parts
up to the white body condition and of the installation, inspection, adjustment and final inspection of
equipment parts after replacing the weld panel.
Section categories
D Each section has been divided as shown below.
Section Title Contents Examples
Explanation of general body repair. Cautionary items.
INTRODUCTION
Views of weld panel replacement instructions. Views of weld panel replacement instructions.
Body aligning measurements and instructions Front side member replacement.
for replacing the weld panels from the white Quarter panel replacement.
BODY PANEL REPLACEMENT
body condition, from which bolted parts have Dimension diagrams.
been removed, with individual supply parts.
Scope and type of anti-rust treatment, etc. Under coat.
PAINT D COATING
together with weld panel replacement. Body sealer.
Abbreviation of contents in this text.
D The following essential procedures have been abbreviated. When actually working, conduct this
work properly.
(1) Jack and lift operations.
(2) Clean and wash removed parts, if necessary.
(3) Visual inspection.
INTRODUCTION SS-1
GENERAL REPAIR INSTRUCTIONS
1. WORK PRECAUTIONS
(a) VEHICLE PROTECTION
Glass Cover
(1) When welding, protect the painted surfaces, windows,
seats and carpet with heat resistant, fire-proof covers.
Seat Cover
F10001A
(b) SAFETY
(1) 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.
WRONG
F10002A
(2) Before performing repair work, check for fuel leaks.
If a leak is found, be sure to close the opening totally.
(3) If it is necessary to use a flame in the area of the fuel
tank, first remove the tank and plug the fuel line.
WRONG F10003A
(c) SAFETY WORK CLOTHES
(1) In addition to the usual mechanic's wear, cap and
safety shoes, the appropriate gloves, head protector,
glasses, ear plugs, face protector, dust-prevention
mask, etc. should be worn as the situation demands.
Code Name
A Dust-Prevention Mask
B Face Protector
F10004 C Eye Protector
D Safety Shoes
E Welder's Glasses
F Ear Plugs
G Head Protector
H Welder's Gloves
SS-2 INTRODUCTION
2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS
(1) The repair procedure for plastic body parts must conform with the type of plastic material.
(2) Plastic body parts are identified by the codes in the following table.
(3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint-
ing etc.), consideration must be given to the property of the plastic.
Heat*
Material resistant Resistance to
Code Notes
name temperature alcohol or gasoline
limit _C (_F)
Alcohol is harmless if applied only for
Acrylonitrile 80 Avoid gasoline and organic
AAS short time in small amounts (e.g., quick
Acrylic Styrene (176) or aromatic solvents.
wiping to remove grease).
Alcohol is harmless if applied only for
Acrylonitrile 80 Avoid gasoline and organic
ABS short time in small amounts (e.g., quick
Butadiene Styrene (176) or aromatic solvents.
wiping to remove grease).
Alcohol is harmless if applied only for
Acylonitrile 80 Avoid gasoline and organic
AES short time in small amounts (e.g., quick
Ethylene Styrene (176) or aromatic solvents.
wiping to remove grease).
Acrylonitrile Alcohol is harmless if applied only for
80 Avoid gasoline and organic
ASA Styrene short time in small amounts (e.g., quick
(176) or aromatic solvents.
Acrylate wiping to remove grease).
Alcohol is harmless if applied only for
Cellulose 80 Avoid gasoline and organic
CAB short time in small amounts (e.g., quick
Acetate (176) or aromatic solvents.
wiping to remove grease).
Alcohol is harmless. Most solvents are harmless
Ethylene 100
EPDM Gasoline is harmless if applied only for but avoid dipping in gasoline,
Propylene (212)
short time in small amounts. solvents, etc.
Fiber
180
FRP Reinforced Alcohol and gasoline are harmless. Avoid alkali.
(356)
Plastics
Alcohol is harmless if applied only for
Ethylene 70 Avoid gasoline and organic
EVA short time in small amounts (e.g., quick
Acetate (158) or aromatic solvents.
wiping to remove grease).
Polyamide 80
PA Alcohol and gasoline are harmless. Avoid battery acid.
(Nylon) (176)
Polybutylene 160
PBT Alcohol and gasoline are harmless. Most solvents are harmless.
Terephthalate (320)
Avoid gasoline brake fluid,
120
PC Polycarbonate Alcohol is harmless. wax, wax removers and
(248)
organic solvents. Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.
INTRODUCTION SS-3
Heat*
Material resistant Resistance to
Code Notes
name temperature alcohol or gasoline
limit _C (_F)
80
PE Polyethylene Alcohol and gasoline are harmless. Most solvents are harmless.
(176)
Polyethylene 75
PET Alcohol and gasoline are harmless. Avoid dipping in water.
Terephthalate (167)
Avoid dipping or immersing
Polymethyl 80 Alcohol is harmless if applied only for
PMMA in alcohol, gasoline,
Methacrylate (176) short time in small amounts.
solvents, etc.
Polyoxymethylene 100
POM Alcohol and gasoline are harmless. Most solvents are harmless.
(Polyacetal) (212)
80
PP Polypropylene Alcohol and gasoline are harmless. Most solvents are harmless.
(176)
Modified Gasoline is harmless if
100
PPO Polyphenylene Alcohol is harmless. applied only for quick wiping
(212)
Oxide to remove grease.
Alcohol and gasoline are harmless if Avoid dipping or immersing
60
PS Polystyrene applied only for short time in small in alcohol, gasoline,
(140)
amounts. solvents, etc.
Alcohol is harmless if applied only for very Avoid dipping or immersing
80
PUR Polyurethane short time in small amounts (e.g., quick in alcohol, gasoline,
(176)
wiping to remove grease). solvents, etc.
Alcohol and gasoline are harmless if
Avoid dipping or immersing
Polyvinylchloride 80 applied only for short time in small
PVC in alcohol, gasoline,
(Vinyl) (176) amounts (e.g., quick wiping to remove
solvents, etc.
grease).
Alcohol is harmless if applied only for Avoid dipping or immersing
Styrene 80
SAN short time in small amounts (e.g., quick in alcohol, gasoline, solvents
Acrylonitrile (176)
wiping to remove grease). etc.
Alcohol is harmless. Most solvents are harmless
Thermoplastic 80
TPO Gasoline is harmless if applied only for but avoid dipping in gasoline,
Olefine (176)
short time in small amounts. solvents, etc.
Alcohol is harmless if applied only for Avoid dipping or immersing
Thermoplastic 80
TPU short time in small amounts (e.g., quick in alcohol, gasoline,
Polyurethane (176)
wiping to remove grease). solvents, etc.
TOYOTA
80
TSOP Super Alcohol and gasoline are harmless. Most solvents are harmless.
(176)
Olefine Polymer
Unsaturated 110
UP Alcohol and gasoline are harmless. Avoid alkali.
Polyester (233)
*Temperatures higher than those listed here may result in material deformation during repair.
SS-4 INTRODUCTION
3. LOCATION OF PLASTIC BODY PARTS
Parts Name Code
Radiator Grille ABS
Front Bumper Cover TSOP
Headlight PC/PP
Fog Light PC/PP
Sido Turn Signal Light (EUROPE) PMMA/ABS
Outer Rear View Mirror ABS
Door Outside Handle PC/PBT
Door Outside Moulding PP D PP/TPO
Rocker Panel Moulding TPO
Rear Combination Light ASA/PMMA
Rear Bumper Cover TSOP
Luggage Compartment Outside Garnish ABS
License Plate Light PC
Rear Spoiler ABS
HINT:
D Resin material differs with model.
/ Made up of 2 or more kinds of materials.
INTRODUCTION SS-5
HOW TO USE THIS MANUAL
1. BODY PANEL REPLACEMENT THIS MANUAL
BP-34
BODY PANEL REPLACEMENT
QUARTER PANEL (CUT)
REPLACEMENT
1. REMOVE QUARTER PANEL
(a) Cut and join the part at the location as shown below.
Cut and Join Location
[Cut and Join Location]
Cut and Join Location
[Cut Location for supply parts]
Braze
[Cut and Join Location]
REPLACEMENT PARTS
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
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.
F10113
SS-6 INTRODUCTION
BP-35
BODY PANEL REPLACEMENT
2. INSTALL QUARTER PANEL
HINT:
Inspect the fitting of the rear door, luggage compartment door and rear combination light, etc.,
before welding, since this affects the appearance of the finish, (a) Before temporarily installing
the new parts, apply body sealer to the wheel arch.
HINT:
D Apply body sealer about 5 mm (0.20 in.) from the flange, avoiding any oozing.
D Apply sealer evenly, about 3 - 4 mm (0.12 - 0.16 in.) in diameter.
D For other sealing points, refer to section PC.
Butt Weld
Body Sealer
Braze
Butt Weld
Body Sealer
about 5 mm
3. MEASURING THE OPENING PORTION DIMENSIONS (See page BP-XX)
4. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-XX)
5. APPLYING SEALER TO THE REAR, LUGGAGE COMPARTMENT (See page PC-XX)
6. CHARGING THE POLYURETHANE FOAM (See page PC-XX)
7. APPLYING ANTI-RUST AGENT
(a). After applying the top coat layer, apply the anti-rust agent to the inside of the necked section
structural weld spots.
INSTALLATION GUIDE
Provides additional information to more efficiently help you perform the installation.
INSTALLATION DIAGRAM
Describes in detail installation of the new parts involving repair by welding and / or cutting, but
excluding painting.
SYMBOLS
See page SS-7.
ILLUSTRATION OF WELD POINTS
Weld method and panel position symbols.
See page SS-8. F10114A
INTRODUCTION SS-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
SAW CUT OR
ROUGH CUT
REMOVE BRAZE
WELD POINTS
SPOT WELD OR
MIG PLUG WELD
(See Page SS-8)
CONTINUOUS MIG
WELD (BUTT WELD
OR TACK WELD)
BRAZE
BODY SEALER
F10005B
SS-8 INTRODUCTION
3. ILLUSTRATION OF WELD POINT SYMBOLS
EXAMPLE:
REMOVAL INSTALLATION
Braze Braze
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 symbols are as seen from
the working posture.
F10005C
INTRODUCTION SS-9
PROPER AND EFFICIENT WORK
PROCEDURES
1. REMOVAL
(a) PRE-REMOVAL MEASURING
(1) Before removal or cutting operations, take measure-
ments in accordance with the dimension diagram. Al-
ways use a puller to straighten a damaged body or
frame.
F10007A
(b) CUTTING AREA
Cutting Okay
(1) Always cut in a straight line and avoid reinforced area.
Reinforcement
Corners
F10008A
(c) PRECAUTIONS FOR DRILLING OR CUTTING
(1) Check behind any area to be drilled or cut to insure
that there are no hoses, wires, etc., that may be dam-
aged.
HINT: See "Handling Precautions on Related Compo-
nents" on page SS-14.
WRONG F10009A
(d) REMOVAL OF ADJACENT COMPONENTS
(1) When removing adjacent components, apply protec-
tive tape to the surrounding body and your tools to pre-
vent damage.
HINT: See "Handling Precautions on Related Compo-
nents" on page SS-14.
F10010A
SS-10 INTRODUCTION
2. PREPARATION FOR INSTALLATION
(a) SPOT WELD POINTS
(1) When welding panels with a combined thickness of
Less than over 3 mm (0.12 in.), use a MIG (Metal Inert Gas)
3 mm
welder for plug welding.
HINT: Spot welding will not provide sufficient durability
for panels over 3 mm (0.12 in.) thick.
F10011A
(b) APPLICATION OF WELD-THROUGH PRIMER
(SPOT SEALER)
(1) Remove the paint from the portion of the new parts
and body to be welded, and apply weld-through prim-
er.
F10012A
(c) MAKING HOLES FOR PLUG WELDING
(1) For areas where a spot welder cannot be used, use a
puncher or drill to make holes for plug welding.
REFERENCE: mm (in.)
Thickness of welded portion Size of plug hole
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