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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) recommended by TOYOTA for collision-
damaged body components of the TOYOTA CAMRY.
Applicable models: SV20, 21 series
CV20 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
CAMRY, refer to the following repair manuals.

Manual Name Pub. No.
CAMRY Chassis and Body Repair Manual 36216E
CAMRY Repair Manual (USA and Canada) Model Year
Version
Electrical Wiring Diagram
(Ex. USA and Canada) EWD027E
(USA and Canada) Model Year
Version
1S, 1S-E, 2S, 2S-C, 2S-E, 3S-FE & 3S-GE RM051E
Engine Repair Manual (Ex. USA and
Canada)
1C, 2C & 2C-T Engine Repair Manual RM025E
(Ex. USA and Canada)
Fundamental Painting Procedures 36438E
Fundamental Body Repair Procedures BRM002E

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
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-Rear Body Components

QUARTER PANEL (CUT)

REMOVAL

200 - 300 mm

Cut and Join
Location

[Cut and Join Location]

Front

Braze

Rear

mm in.
200 7.87
300 11.81

1. Cut and join the part at area as shown above.
NOTE: Before cutting, remove the drain hole of the
moon roof.

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

BODY VARIATIONS AND PART LOCATION
Body variations: Non . . . . All models
Sedan . . Sedan models
Wagon . Wagon 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-3

BODY PANEL REPLACEMENT-Rear Body Components RE-35

INSTALLATION

Butt Weld Body Sealer

Braze

Body Sealer

About 5 mm

mm in.
5 0.20

1. Before temporarily installing the new part, apply 2. Temporarily install the new part and check fit for
body sealer to the wheel arch. the rear door, luggage compartment door and
NOTE: rear combination light.
1) Apply sealer about 5 mm (0.20 in.) from the
flange, avoiding any oozing.
2) Apply evenly, about 3 - 4 mm (0.12 - 0.16 in.) in
diameter.
3) For other sealing points, refer to AR.

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 .
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.
INTRODUCTION IN-11

VEHICLE LIFT AND SUPPORT LOCATIONS

Front

JACK POSITION

Front . . . . . . . . . Center of engine mounting center member
Rear . . . . . . . . . . Jack up support of rear suspension member

PANTOGRAPH JACK POSITION
SUPPORT POSITION
Safety stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IN0102
IN-12 INTRODUCTION

ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual
Assy, assy Assembly, assembly
Sub-assy Sub-assembly
Ex. Except
in. Inch
IRS Independent Rear Suspension
4-link 4-link Rear Suspension
MIG Metal Inert Gas
OPN Operation
SP Spot Weld (Resistance Spot Weld)
w/ With
w/o Without
FR Front
RR Rear
RH Right-hand
RHD Right-hand Drive
LH Left-hand
LHD Left-hand Drive
IN-6 INTRODUCTION

GENERAL REPAIR INSTRUCTIONS
Work Precautions
SAFETY VEHICLE PROTECTION SAFETY
Never stand in direct When welding, protect the 1. Before performing repair work, check
line with the chain when painted surfaces, windows, for fuel leaks. If a leak is found, be sure
using a puller on the seats and carpet with heat- to close the opening totally.
body or frame, and be resistant, fire-proof covers.
sure to attach a safety 2. If it is necessary to use a frame in the
cable. area of the fuel tank, first remove the
tank and plug the fuel line.

WRONG

Glass Cover

Safety Cable

Seat Cover

WRONG

SAFETY WORK CLOTHES SAFETY
In addition to the usual mechanic wear, cap and safety shoes, Before performing repair work,
the necessary gloves, head protector, glasses, ear plugs, face disconnect the battery cables.
protector, dust-prevention mask, etc. should be worn as the
situation demands.
Dust- Welder's
Prevention Glasses Body
Mask Mechanic
Stand
Face Ear
Protector Plugs

Head HAND TOOLS
Protector Welder's Keeping your hand tools
Gloves
to neat order will have
Safety Cotton an effect on your work
Shoes Gloves efficiency.
INTRODUCTION IN-7

Proper and Efficient Work Procedures

REMOVAL
PRE-REMOV AL MEASURING REMOVAL OF ADJACENT COMPONENTS NO. OF SPOT WELDS
Before removal or cutting opera- When removing adjacent components, Make a note of the num-
tions, take measurements in ac- apply protective tape to the surrounding ber of spot welds for lat-
cordance with the dimension dia- body and your tools to prevent damage. er reference.
gram. Always use a puller to CAUTION: NOTE: The number of
straighten a damaged body or 1. Be especially careful not to damage spot welds may vary
frame. screw or clip holes. depending on the
vehicle.
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.

PRECAUTIONS FOR DRILLING OR CUTTING AREA
CUTTING Always cut in a straight
Check behind any area to be drilled or line and avoid reinforced
cut to insure that there are no hoses, areas.
wires, etc., that may be damaged.

Cutting Okay

Corners
Reinforcement

WRONG
IN-8 INTRODUCTION

PREPARATION FOR INSTALLATION
SPOT WELD POINTS APPLICATION OF WELD-THROUGH PRIMER
When welding panels with a For treatment
combined thickness of over 3 against corrosion,
mrn (0.12 in.), use a MIG remove the paint
(Metal Inert Gas) welder for from the portion of
plug welding. the new part and
Less than NOTE: Spot welding will body to be welded,
3 mm not provide sufficient dura- and apply weld-
bility for panels over 3 mm through primer.
(0.12 in.) thick.

Air Saw

WRONG

20 - 30 mm

Overlap

ROUGH CUTTING OF JOINTS MAKING HOLES FOR PLUG WELDING
For joint areas, rough cut the For areas where a spot welder cannot
new part, leaving be used, use a puncher or drill to make
20 - 30 mm (0.79 - 1.18 in.) holes for plug welding.
overlap.
REFERENCE: mm (in.)
Thickness of Size of plug hole
welded portion
1.0 (0.04) under 5 (0.20) over
1.0 (0.04) over 6.5 (0.26) over
INTRODUCTION IN-9

INSTALLATION
PRE-WELDING MEASUREMENTS WELDING PRECAUTIONS POST-WELDING REFINISH-
Always take measurements before 1. The number of welding spots ING
installing underbody or engine should be as follows. 1. Always check the welded
components to insure correct Spot weld: 1.3 x No. of spots to insure they are
assembly. After installation, confirm manufacturer's spots. secure.
proper fit. Plug weld: More than No. of 2. When smoothing out the
manufacturer's plugs. weld spots with a disc
grinder, be careful not to
grind off too much as this
would weaken the weld.

OKAY WRONG
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 WELD LOCATIONS SPOT WELDING PRECAUTIONS
Try to avoid welding over 1. The shape of the welding
previous spots. tip point has an effect on
Old New Spot the strength of the weld.
Spot Locations
Locations 2. Always insure that the
seams and welding tip are
free of paint.

Tip Cutter
IN-10 INTRODUCTION

ANTI-RUST TREATMENT
When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the
requirements of your country.
BODY SEALER ANTI-RUST AGENT (WAX)
Apply body sealer to the Apply anti-rust agent to
required areas. following sections.
S Inside of the hems of the
doors and hood.
S Around the hinges of the
doors and hood.
Cartridge Tube Nozzle
Type Type S Inside of the welded parts
Air Gun with boxed cross-section.

UNDERCOAT
Apply undercoat to the underbody and
wheel housings.

Undercoat Undercoat Spray Gun
(Oil base) (Water base)
TE-2 TOOLS AND EQUIPMENT

MEASURING INSTRUMENTS
For measuring body dimensions

Tracking Gauge

When 3 or 4 are used together, measure-
ments of twists, bends or warps in the
body and frame are possible.
Frame Centering
Gauge

SEPARATING TOOLS
For separating spot welds and making
holes in the body.

Air-powered
Drill

For separating spot welds and making
holes in the body.
Electric-
powered
Drill

For separating spot welds.

Spot Cutter

For cutting panels.

Air-powered
Cutter

For separating spot and plug welds
and grinding off traces of plug welds.

Air-powered
Chuck Grinder
TOOLS AND EQUIPMENT TE-3

SEPARATING TOOLS (Cont'd)
For rough cutting and rough flattening
of panels.

Air-powered
Chisel

For rough cutting of panels.
Panel Cutter

For separating spot welds.
Flat Chisel

For rough flattening in hard-to-reach
Hammer Tool areas.

For rough cutting of pillars, rocker
panels, etc.

Air-powered
Saw

For rough cutting of pillars, rocker
panels, etc.

Air-powered
Saw

For rough cutting of pillars, rocker
panels, etc.

Hacksaw
TE-4 TOOLS AND EQUIPMENT

INSTALLATION ASSISTANCE TOOLS
For temporary installation of panels and
holding of portions to be welded.

Vise Grip
Wrench

For making flanges in overlapping
panels.

Flanging Tool

For hemming door outer panels, etc.

Hemming Tool

For making holes for MIG plug weld-
ing.

Hole Punch

BODY PROTECTORS
For protecting the seats from welding
sparks, etc.

Seat Cover

For protecting the glass from welding
sparks, etc.

Glass Cover
TOOLS AND EQUIPMENT TE-5

WELDING INSTRUMENTS
For panel welding.

MIG Welder
(Metal Inert Gas)

For panel welding.

Spot Welder

For rough cutting of panels,
members, etc.

Gas Welder Torch
Gas Cutter Torch

For soldering and peeling of
paint.

Acetylene Gas
Torch

For straightening distorted
panels.

Straightening
Machine

For extraction of closed-in
panels.

Panel
Extractor
RE-1

BODY PANEL REPLACEMENT
Page

FRONT BODY COMPONENTS
RADIATOR SUPPORT (ASSY) . . . . . . . . . . . . . . . . . . . . . . . . RE-2
FRONT CROSSMEMBER (ASSY) . . . . . . . . . . . . . . . . . . . . . RE-4
FRONT FENDER APRON (ASSY) . . . . . . . . . . . . . . . . . . . . . RE-6
FRONT FENDER FRONT APRON (ASSY) . . . . . . . . . . . . . RE-8
FRONT SIDE MEMBER (ASSY) . . . . . . . . . . . . . . . . . . . . . . . RE-10
FRONT SIDE MEMBER (CUT-P) . . . . . . . . . . . . . . . . . . . . . . RE-12

CENTER BODY COMPONENTS
COWL TOP SIDE PANEL (ASSY) . . . . . . . . . . . . . . . . . . . . . RE-14
FRONT BODY PILLAR (CUT) . . . . . . . . . . . . . . . . . . . . . . . . . RE-16
CENTER BODY PILLAR (CUT) . . . . . . . . . . . . . . . . . . . . . . . RE-18
OUTER ROCKER PANEL (CUT) . . . . . . . . . . . . . . . . . . . . . . RE-20
ROOF PANEL (ASSY) SEDAN W/O MOONROOF . . . . . . . RE-22
ROOF PANEL (ASSY) SEDAN W/ MOONROOF . . . . . . . . RE-24
ROOF PANEL (ASSY) WAGON W/O MOONROOF . . . . . . RE-26
ROOF PANEL (ASSY) WAGON W/ MOONROOF . . . . . . . RE-28
FRONT DOOR OUTER PANEL (ASSY) . . . . . . . . . . . . . . . . RE-30
REAR DOOR OUTER PANEL (ASSY) . . . . . . . . . . . . . . . . . RE-32

REAR BODY COMPONENTS
QUARTER PANEL (CUT): SEDAN . . . . . . . . . . . . . . . . . . . . RE-34
QUARTER PANEL (CUT): WAGON . . . . . . . . . . . . . . . . . . . . RE-36
QUARTER PANEL (CUT-P): SEDAN . . . . . . . . . . . . . . . . . . RE-38
QUARTER PANEL (CUT-P): WAGON . . . . . . . . . . . . . . . . . RE-40
BODY LOWER BACK PANEL (ASSY): SEDAN . . . . . . . . . RE-42
BODY LOWER OUTER BACK PANEL (ASSY):
WAGON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RE-44
BACK DOOR FRONT OPENING TROUGH (ASSY):
WAGON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RE-46
ROOF SIDE OUTER PANEL (ASSY):
WAGON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RE-48
QUARTER WHEEL HOUSING OUTER PANEL (ASSY):
SEDAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RE-50
QUARTER WHEEL HOUSING OUTER PANEL (ASSY):
WAGON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RE-52

REAR UNDER BODY COMPONENTS
REAR FLOOR REAR INNER CROSSMEMBER (CUT):
WAGON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RE-54
REAR FLOOR PAN (CUT): SEDAN . . . . . . . . . . . . . . . . . . . . RE-56
REAR FLOOR PAN (CUT): WAGON . . . . . . . . . . . . . . . . . . . RE-58
REAR FLOOR REAR SIDE MEMBER (ASSY) . . . . . . . . . . RE-60
REAR FLOOR SIDE MEMBER (ASSY) . . . . . . . . . . . . . . . . RE-62
CENTER FLOOR NO. 2 CROSSMEMBER (ASSY) . . . . . . RE-64
TE-6 TOOLS AND EQUIPMENT

LIGHT BODY REPAIR TOOLS
For straightening lightly dam-
aged panels.

Body Pullers

GRINDING AND POLISHING TOOLS
For grinding plug welds, butt welds
and door hems.

Air-powered
Disc Grinder

For grinding plug welds, butt welds
and door hems.
Electric-
powered
Disc Sander

For removing paint around weld
areas.

Belt Sander

For rough grinding and polishing, and
feather edging.

Double-action
Sander
TOOLS AND EQUIPMENT TE-7

GRINDING AND POLISHING TOOLS (Cont'd)
For rough polishing of panel putty.

Straight-line
Sander

For removing putty over a wide area,
resurfacing and refinishing.

Air-powered
Orbital Sander

For peeling paint.

Air-powered
Disc Sander

For paint removal.

File Holder

For correction of soldering spots
and resurfacing of panels.

Flexible File
Holder

For rough finishing of panels.

Surform Tool
RE-2 BODY PANEL REPLACEMENT

RADIATOR SUPPORT (ASSY)
REMOVAL
BODY PANEL REPLACEMENT RE-3

INSTALLATION

Assembly Mark

1. Temporarily install the new part with the assem-
bly mark and measure each part in accordance
with the body dimension diagram.
NOTE: Work after installing the radiator upper
support.
RE-4 BODY PANEL REPLACEMENT

FRONT CROSSMEMBER (ASSY)
REMOVAL (With the radiator support removed.)
BODY PANEL REPLACEMENT RE-5

INSTALLATION

1. Temporarily install the new part and measure
each part in accordance with the body dimen-
sion diagram.
RE-6 BODY PANEL REPLACEMENT

FRONT FENDER APRON (ASSY)
REMOVAL (With the radiator support removed.)

(LH only)

Front Body Pillar Lower Gusset

1. After removing the front body pillar lower gusset,
remove the front fender apron.
BODY PANEL REPLACEMENT RE-7

INSTALLATION

(LH only)

Assembly
Mark

1. Determine the installation position of the new 3. Check the fit of the front fender and hood.
part by the assembly mark.
2. Measurements must be accurate with the body
dimension diagram, as this effects the front
wheel alignment.
NOTE: The position of the front spring support
hole is very important.
RE-8 BODY PANEL REPLACEMENT

FRONT FENDER FRONT APRON (ASSY)
REMOVAL (With the radiator support removed.)

(LH only)
BODY PANEL REPLACEMENT RE-9

INSTALLATION

(LH only)

1. Temporarily install the new part and measure
each part in accordance with the body dimen-
sion diagram.
RE-10 BODY PANEL REPLACEMENT

FRONT SIDE MEMBER (ASSY)
REMOVAL (With the front fender apron removed.)
BODY PANEL REPLACEMENT RE-11

INSTALLATION

Radiator Support to
Crossmember Brace

1. Temporarily install the new part and measure
each part in accordance with the body dimen-
sion diagram.
NOTE: Make sure each measurement is correct,
as this part effects the front wheel alignment.
RE-12 BODY PANEL REPLACEMENT

FRONT SIDE MEMBER (CUT-P)
REMOVAL (With the front fender front apron removed.)

Battery Carrier Support

Front Side Member
No. 5 Plate

Front Side Member
No. 6 Reinforcement
Cut and Join
Location

[LH only]
35 mm
Front Side Member
Plate

Cut and Join Location
NOTE:
1) Cut and join the front side member
plate and front side member No. 5
plate at the same place.
2) Be careful not to damage the front
side member No. 6 reinforcement
when cutting the member plate.
RH 15 [CROSS-SECTIONAL VIEW]
LH 9

Front Side
20 mm Member Front Side Member
No. 5 Plate

Front Side Member

Front Side Member
NOTE: Be careful not to damage the front No. 6 Reinforcement
side member No. 6 reinforcement when cut- Front Side Member
Plate
ting the member.

1. Before cutting the side member, remove the 2) Be careful not to damage the front side
battery carrier support. (LH only) member No. 6 reinforcement when cutting
the members.
2. Cut and join the side member at the areas as
shown above.
NOTE:
1) Cut and join the front side member plate
and the front side member No. 5 plate at
the same place.
BODY PANEL REPLACEMENT RE-13

INSTALLATION

Front Side Member

Butt Weld

Front Side Member
No. 5 Plate

Front Side Member
No. 6 Reinforcement

Butt Weld

Front Side Member
Plate

NOTE: Weld the front side mem-
Battery Carrier Support ber plate and front side member
No. 5 plate at the same place.

[LH only]

1. Cut the supply part in the same way as removal.
2. Temporarily install the new part, measure each
part in accordance with the body dimension
diagram.
3. After installing the new side member, install the
battery carrier support. (LH only)
RE-14 BODY PANEL REPLACEMENT

COWL TOP SIDE PANEL (ASSY)
REMOVAL

Cut with a disc sander etc..
BODY PANEL REPLACEMENT RE-15

INSTALLATION

Tack Weld (30 mm)

Assembly Mark

mm in.
30 1.18

1. Determine the installation position of the new
part by the assembly mark.
RE-16 BODY PANEL REPLACEMENT

FRONT BODY PILLAR (CUT)
REMOVAL
200 mm or move

[Cut and Join Location]

Cut and Join Location 50 mm or
more

Make an incision

Front Body Pillar Lower Gusset

Roof Drip Channel

Cut with a disc
sander etc.

mm in.
50 1.97
200 7.87

1. Cut and join the new part at the location as 3) Before cutting, remove the antenna cord and
shown above. drain hole of the moonroof.
NOTE: 2. Remove the weld points of the roof drip channel,
1) Avoid the antenna installation hole for the make an incision of it and bend it.
cut and join location.
2) As shown above, cut and join the front body
pillar outer and inner panels at a position
shifted above 50 mm (1.97 in.).
BODY PANEL REPLACEMENT RE-17

INSTALLATION
Butt Weld

Butt Weld

[Reference]

(mm)

Tack Weld (30 mm)

1. Temporarily install the new part and check fit for mm in.
the front fender, hood and windshield glass. 30 1.18
624 24.57
744 29.29
794 31.26
869 34.21
1,111 43.74
1,241 48.86
1,388 54.65
1,392 54.80
RE-18 BODY PANEL REPLACEMENT

CENTER BODY PILLAR (CUT)
REMOVAL

Cut and Join
Location Wet Rag

[CROSS-SECTIONAL VIEW]

about 15 mm

about 15 mm
Cutting
Braze (front side) Location

W/O Automatic Shoulder W/ Automatic Shoulder
Belt Belt

Upper Inner Upper Inner
Pillar Pillar

mm in.
15 0.59

1. Cut and join the outer pillar at the location as 2. Heat the brazed areas of the roof side outer rail
shown above. and scrape it with a wire brush.
NOTE: Be careful not to damage the roof side NOTE: Before performing these operations, place
outer rail when cutting the outer pillar with a a wet rag on the roof panel to protect it from dam-
cut grinder or such. age.
BODY PANEL REPLACEMENT RE-19

INSTALLATION Butt Weld Wet Rag

Preparation for Supply Parts

Outer Pillar Cutting Location
about Butt Weld
15 mm

Wet Rag
w/o w/o
Automatic Automatic
Shoulder Braze
Shoulder (front side and rear side)
Belt Belt

w/ Automatic
Shoulder Belt w/ Automatic
Shoulder Belt
w/o Automatic Shoulder Belt w/ Automatic Shoulder Belt
Upper Reinforcement

Upper Inner Upper Inner
Pillar Pillar

[REFERENCE]

Door Lock Striker
Plate Retainer mm in. mm in.
15 0.59 1,111 43.74
624 24.57 1,320 51.97
744 29.29 1,392 54.80
869 34.21

[Preparation for supply parts] NOTE: Before performing these operations,
1. After installing the upper reinforcement to the place a wet rag on the roof panel to protect it
outer pillar, cut them at the location as shown from damage.
above. 3. Braze the roof side outer rail and center pillar
[Installation] connection.
1. After temporarily installing the new part, check NOTE: Smooth down the surface.
fit for the front and rear door. Rail leakage will occur if the weather strip con-
2. After butt welding the new joint with a MIG tact is defective.
welder, sand the weld joint with a sander.
RE-20 BODY PANEL REPLACEMENT

OUTER ROCKER PANEL (CUT)
REMOVAL

70 mm or more

Cut and Join Location

[Cut and Join Location]

mm in.
70 2.76

1. Cut and join the part at the area as shown
above.
BODY PANEL REPLACEMENT RE-21

INSTALLATION

Butt Weld

30 - 40 mm

Cut piece of new part
mm in.
30 1.18
40 1.57

1. Temporarily install the new part and check fit for
the front door, rear door and front fender.
RE-22 BODY PANEL REPLACEMENT

ROOF PANEL (ASSY) SEDAN W/O MOONROOF Sedan

REMOVAL

Braze
(both sides)

Arc Brazing (both sides)

Braze (both sides)

1. Heat the brazed area of the front body pillar 2. Cut off the roof panel tip at the quarter panel
and quarter panel and scrape off the brazing arc brazing connection with a cut grinder.
with a wire brush.
NOTE: Be careful not to overheat the front body
pillar and quarter parcel.
BODY PANEL REPLACEMENT RE-23

INSTALLATION

Body Sealer (9 points)
Body Sealer (9 points)
Body Sealer (4 points)

Braze (both sides)

Body Sealer (11 points) Body Sealer (9 points)

Braze (both sides)

1. Before temporarily installing the new part, 2. Braze the front body pillar and quarter panel
apply body sealer to the windshield header connection.
panel, roof panel reinforcement and back NOTE: Before performing these operations,
window opening frame. place a wet rag on the roof panel to protect it
NOTE: from damage.
1) Apply just enough sealer for the new part
to make contact.
2) For other sealing points, refer to section
AR.
RE-24 BODY PANEL REPLACEMENT

ROOF PANEL (ASSY) SEDAN W/ MOONROOF Sedan

REMOVAL
Hemming Location

Disc Sander

Braze
(both sides)

Arc Brazing (both sides)

Braze (both sides)

1. If reusing the roof panel reinforcement, slightly
heating the roof panel will soften sealer and
make removal easier.
BODY PANEL REPLACEMENT RE-25

INSTALLATION

Cloth Tape

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