Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Camry Toyota Toyota_5F40 07_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: ACV 40 series
GSV 40 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 this TOYOTA model are 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.
ABOUT THIS MANUAL
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 This manual 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.
Instructions for replacing the weld panels Front side member replacement.
from the white body condition, from which Quarter panel replacement.
BODY PANEL REPLACEMENT
bolted parts have been removed, with
individual supply parts.
BODY DIMENSIONS Body aligning measurements. Dimension diagrams.
Scope and type of anti-rust treatment, etc. Under coating.
PAINT D COATING
together with weld panel replacement. Body sealer.
Contents omitted in this manual.
D Make sure to perform the following essential procedures, although they are omitted in this manual.
(1) Clean and wash removed parts, if necessary.
(2) Visual inspection.
INTRODUCTION IN-1
PRECAUTION
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, fireproof covers.
Seat Cover
F33000
(b) SAFETY
(1) Never stand in a direct line with the chain when using a
puller on the body or frame, and be sure to attach a
safety cable.
WRONG
F33001
(2) Before performing repair work, check for fuel leaks.
If a leak is found, be sure to close the opening com-
pletely.
(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 F33002
(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
F33003 C Eye Protector
D Safety Shoes
E Welder's Glasses
F Ear Plugs
G Head Protector
H Welder's Gloves
IN-2 INTRODUCTION
PRECAUTIONS FOR REPAIRING BODY
STRUCTURE PANELS
1. HEAT REPAIR FOR BODY STRUCTURE
PANELS
Toyota prohibits the use of the heat repair method on body
structure panels when repairing a vehicle damaged in a col-
lision.
Panels that have high strength and rigidity, as well as a long
life span for the automobile body are in high demand.
At Toyota, in order to fulfill these requirements, we use high
tensile strength steel sheets and rust preventive steel
F33014
sheets on the body. High tensile steel sheets are made with
alloy additives and a special heat treatment in order to im-
prove their strength.
To prevent the occurrence of rust for a long period of time,
the surface of the steel is coated with a zinc alloy.
If body structure parts are heat repaired with an acetylene
torch or other heating source, the crystalline organization of
the steel sheet will change and their strength of the steel
sheet will be reduced. The ability of the body to resist rust is
significantly lowered as well since the rust resistant zinc
coating is destroyed by heat and the steel sheet surface is
oxidized.
2. STRUCTURE PANEL KINKS
A sharp deformation angle on a panel that cannot be re-
turned to its original shape by pulling or hammering is
called a kink.
Structural parts are designed to perform in their original
shape. If parts are deformed in an accident, or if the de-
formed parts are repaired and reused, the parts may be un-
able to perform as intended.
It is necessary to replace the part where the kink has oc-
curred.
F33015
INTRODUCTION IN-3
3. IMPACT BEAM REPAIR
The impact beam and bracket are necessary and important
parts that help reduce the probability of injury to passen-
gers in side collisions.
For impact beams, we use special high tensile strength
steel.
The high tensile strength steel maintains its special crystal-
line organization by heat treatment or alloy additives.
Structural parts are designed to perform in their original
F33016
shape. If parts are deformed in an accident, or if the de-
formed parts are repaired and reused, the parts may be un-
able to perform as intended.
If the impact beam or bracket is damaged, replace the door
assembly that has the damaged beam.
Also, the bumper reinforcement is a necessary and impor-
tant part that helps reduce the probability of injury to pas-
sengers in front collisions, and for the same reasons ex-
plained above, should be replaced if damaged.
F33017
IN-4 INTRODUCTION
PROPER AND EFFICIENT WORK
PROCEDURES
Body Measument Diagrams 1. REMOVAL
(a) PRE-REMOVAL MEASURING
(1) Before removal or cutting operations, take measure-
ments in accordance with the dimensions diagram. Al-
ways use a puller to straighten a damaged body or
frame.
F33020
Cutting Okay (b) CUTTING AREA
(1) Always cut in a straight line and avoid cutting rein-
forced areas.
Corners
Reinforcement
F33021
(c) PRECAUTIONS FOR DRILLING OR CUTTING
(1) Check behind any area to be drilled or cut to ensure
that there are no hoses, wires, etc., that may be dam-
aged.
HINT: See "Handling Precautions on Related Compo-
nents" on page IN-9.
WRONG F33022
(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 IN-9.
F33007
INTRODUCTION IN-5
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 does not provide sufficient dura-
bility for panels with a combined thickness of over 3
mm (0.12 in.)
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.
F33008
(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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