HƯỚNG DẪN SỬA CHỮA THÂN XE TOYOTA CAMRY ĐỜI 2006-2011
FOREWORD This repair manual has been prepared to provide essential information 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 diagrams and illustrations of the body components and other information relating to body panel replacement such as handling precautions, etc However, it should be noted that the front fenders 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 specifications 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 collisiondamaged 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 condition 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 INTRODUCTION Explanation of general body repair Views of weld panel replacement instructions Cautionary items Views of weld panel replacement instructions BODY PANEL REPLACEMENT Instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts Front side member replacement Quarter panel replacement BODY DIMENSIONS Body aligning measurements Dimension diagrams PAINT D COATING Scope and type of anti-rust treatment, etc together with weld panel replacement Under coating 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 WORK PRECAUTIONS (a) VEHICLE PROTECTION (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fireproof covers Glass Cover 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 completely (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 A Dust-Prevention Mask B F33003 Name Face Protector C Eye Protector D Safety Shoes E Welder’s Glasses F Ear Plugs G Head Protector H Welder’s Gloves INTRODUCTION IN-2 PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a collision 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 sheets on the body High tensile steel sheets are made with alloy additives and a special heat treatment in order to improve 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 F33014 F33015 HEAT REPAIR FOR BODY STRUCTURE PANELS STRUCTURE PANEL KINKS A sharp deformation angle on a panel that cannot be returned 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 deformed parts are repaired and reused, the parts may be unable to perform as intended It is necessary to replace the part where the kink has occurred INTRODUCTION F33016 F33017 IN-3 IMPACT BEAM REPAIR The impact beam and bracket are necessary and important parts that help reduce the probability of injury to passengers in side collisions For impact beams, we use special high tensile strength steel The high tensile strength steel maintains its special crystalline organization by heat treatment or alloy additives Structural parts are designed to perform in their original shape If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable 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 important part that helps reduce the probability of injury to passengers in front collisions, and for the same reasons explained above, should be replaced if damaged INTRODUCTION IN-4 PROPER AND EFFICIENT WORK PROCEDURES Body Measument Diagrams REMOVAL (a) PRE-REMOVAL MEASURING (1) Before removal or cutting operations, take measurements in accordance with the dimensions diagram Always use a puller to straighten a damaged body or frame F33020 (b) CUTTING AREA (1) Always cut in a straight line and avoid cutting reinforced areas Cutting Okay Corners Reinforcement F33021 (c) WRONG 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 damaged HINT: See “Handling Precautions on Related Components” on page IN-9 F33022 (d) REMOVAL OF ADJACENT COMPONENTS (1) When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage HINT: See “Handling Precautions on Related Components” on page IN-9 F33007 INTRODUCTION IN-5 PREPARATION FOR INSTALLATION (a) SPOT WELD POINTS (1) When welding panels with a combined thickness of over mm (0.12 in.), use a MIG (Metal Inert Gas) welder for plug welding HINT: Spot welding does not provide sufficient durability for panels with a combined thickness of over mm (0.12 in.) Less than mm 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 primer 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 1.0 (0.04) under ø 6.5 (0.26) over 1.7 (0.07) − 2.3 (0.09) ø (0.31) over 2.4 (0.09) over Puncher ø (0.20) over 1.0 (0.04) − 1.6 (0.06) ø 10 (0.39) over F33009 (d) SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS (1) When welding, there is a danger that electrical components will be damaged by the electrical current flowing through the body (2) Before starting work, disconnect the negative terminal of the battery and ground the welder near the welding location of the body F33023 Air Saw 20 − 30 mm Overlap F33024 (e) ROUGH CUTTING OF JOINTS (1) For joint areas, rough cut the new parts, leaving 20 − 30 mm (0.79 − 1.18 in.) of overlap INTRODUCTION IN-6 INSTALLATION (a) PRE-WELDING MEASUREMENTS (1) Always take measurements before installing underbody or engine components to ensure correct assembly After installation, confirm proper fit F33025 (b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows Spot weld: 1.3 X No of manufacturer’s spots Plug weld: More than No of manufacturer’s plugs (2) Plug welding should be done with a MIG (Metal Inert Gas) welder Do not gas weld or braze panels at areas other than where specified WRONG F10017A (c) CORRECT POST-WELDING REFINISHING (1) Always check the welded spots to ensure that they are secure (2) When smoothing out the weld spots with a disc grinder, be careful not to grind off too much as this will weaken the weld WRONG F10018A (d) SPOT WELD LOCATIONS (1) Avoid welding over previously welded areas Old Spot Locations New Spot Locations F33010 Tip Cutter F10019A (e) SPOT WELDING PRECAUTIONS (1) The shape of the tip point of the spot welder significantly affects the strength of the weld Therefore, maintain the tip point in the proper shape, and allow it to cool after every five or six spots (2) Completely remove the paint from the areas to be spot welded, including the seams and the surfaces that come in contact with the welding tip (3) Use a sander to remove any burrs that are created during spot welding INTRODUCTION Sealer Gun IN-7 ANTI-RUST TREATMENT AFTER INSTALLATION (BEFORE PAINTING PROCESS) (a) BODY SEALER APPLICATION (1) For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams and hems of the doors, hood, etc F33011 (b) UNDERCOAT APPLICATION (1) To prevent corrosion and protect the body from damage by flying stones, always apply sufficient under coating to the bottom surface of the under body and inside of the wheel housings F33012 ANTI-RUST TREATMENT AFTER INSTALLATION (AFTER PAINTING PROCESS) (a) ANTI-RUST AGENT (WAX) APPLICATION (1) To preserve impossible to paint areas from corrosion, always apply sufficient anti-rust agent (wax) to the inside of the hemming areas of the doors and hood, and around the hinges, or the welded surfaces inside the box-shaped cross sections of the side members, body pillars, etc F33013 INTRODUCTION IN-8 ANTI-RUST TREATMENT BY PAINTING REFERENCE: Painting prevents corrosion and protects the sheet metal from damage In this section, anti-chipping paint only for anti-corrosion purposes is described (a) ANTI-CHIPPING PAINT (1) To prevent corrosion and protect the body from damage by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, balance panel, etc HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat D Apply the anti-chipping paint after the top coat D Apply the anti-chipping paint before the second coat Anti-Chipping Paint Top Coat Second Coat Top Coat Second Coat Anti-Chipping Paint Under Coat (ED Primer) Under Coat (ED Primer) Steel Metal Steel Metal F10024A PC-12 PAINT D COATING BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS To protect the body from damage due to flying rocks, apply the anti-chipping paint to the rocker panels, wheel arches, and lower parts of the doors HINT: 1) Work must be performed while wearing the appropriate protective gear and in a well-ventilated area 2) Apply anti-chipping paint to the indicated areas first, before applying the top coat 3) If anti-chipping paint is unnecessarily applied to an area, apply degreasing agent to a clean cloth and clean the paint off immediately SOFT − CHIP PRIMER ANTI − CHIPPING PAINT (INTERMEDIATE COAT) PROTECTOR SEAL F25792 BODY DIMENSIONS Three-dimensional distance Center-to-center straight-line distance DI-1 GENERAL INFORMATION BASIC DIMENSIONS (a) There are two types of dimensions in the diagram (1) (Three-dimensional distance) D Straight-line distance between the centers of two measuring points Center-to-center horizontal distance in forward / rearward direction Two-dimensional distance Vertical distance to center Vertical distance to lower surface Imaginary Standard Line (2) (Two-dimensional distance) D Horizontal distance in forward/rearward between the centers of two measuring points D The height from an imaginary standard line (b) In cases in which only one dimension is given, left and right are symmetrical (c) The dimensions in the following drawing indicate actual distance Therefore, please use the dimensions as a reference (d) The line that connects the places listed below is the imaginary standard line when measuring the height (The dimensions are printed in the text.) A mm B mm C mm Imaginary Standard Line SYMBOL Name Under Surface of The Rocker Panel The place that was lowered A mm from the under surface of the rocker panel centered on the front jack up point The place that was lowered B mm from the under surface of the rocker panel centered between and 3 The place that was lowered C mm from the under surface of the rocker panel centered on the rear jack up point BODY DIMENSIONS DI-2 Plate Looseness Body Looseness Pointer Looseness MEASURING (a) Basically, all measurements are to be done with a tracking gauge For portions where it is not possible to use a tracking gauge, a tape measure should be used (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers Pointer Master Gauge Wrong Correct Pointer HINT: 1) The height of the left and right pointers must be equal 2) Always calibrate the tracking gauge before measuring or after adjusting the pointer height 3) Take care not to drop the tracking gauge or otherwise shock it 4) Confirm that the pointers are securely in the holes (c) When using a tape measure, avoid twists and bends in the tape BODY DIMENSIONS DI-3 BODY DIMENSION DRAWINGS ENGINE COMPARTMENT (for LHD) (Three-Dimensional Distance) 1,532 (60.31) 706 (27.80) 1,657 (65.24) 588 (23.15) 1,115 (43.90) 439 (17.28) 753 (29.65) 581 (23.15) 1,075 (42.32) 1,467 (57.76) 1,582 (62.28) 1,068 (42.05) 1,502 (59.13) 1,513 (59.57) 832 (32.76) 341 349 (13.43) (13.74) 319 (12.56) 753 (29.65) 1,520 996 (59.84) (39.21) 1,379 (54.29) 454 (17.87) 237 (9.33) 788 (31.02) 239 (9.41) 865 (34.06) 826 (32.52) 911 (35.87) 913 (35.94) 850 (33.46) 453 (17.83) 656 (25.83) 355 (13.98) 1,037 (40.83) 451 (17.76) Height from Imaginary Standard Line A, a C, c K, k 706 (27.80) 794 (31.26) 639 (25.16) Vehicle Dimensions A-M or a-m B-c or b-C B-f D-E D-e G-n or g-N L-l L-m or l-M M-m 475 (18.70) 1,345 (52.95) 1,078 (42.44) 869 (34.21) 1,060 (41.73) 989 (38.94) 1,536 (60.47) 1,562 (61.50) 1,552 (61.10) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear) Symbol Name A, a Front fender installation nut B, b Front spring support hole-inner C, c Hood hinge installation nut D, d Cowl panel installation nut E, e Front side member standard hole F, f Front side member standard hole G, g Radiator upper support installation nut mm (in.) Hole dia H, h M6 (0.24) I Radiator support standard hole ø10 (0.39) Hood lock support installation nut M6 (0.24) ø12.5 (0.492) J, j Front fender bracket installation nut M6 (0.24) M8 (0.31) K, k Radiator upper support installation nut M6 (0.24) M6 (0.24) L, l Front fender installation nut M6 (0.24) ø18 (0.71) M, m Front fender installation nut M6 (0.24) ø18 (0.71) N, n Front bumper reinforcement installation nut M10 (0.39) M6 (0.24) — — — BODY DIMENSIONS DI-4 BODY DIMENSION DRAWINGS ENGINE COMPARTMENT (for RHD) (Three-Dimensional Distance) 1,532 (60.31) 706 (27.80) 1,657 (65.24) 579 (22.80) 1,115 (43.90) 443 (17.44) 762 (30.00) 588 (23.15) 1,075 (42.32) 1,467 (57.76) 1,582 (62.28) 1,063 (41.85) 1,502 (59.13) 1,513 (59.57) 832 (32.76) 341 349 (13.43) (13.74) 319 (12.56) 747 (29.41) 1,520 996 (59.84) (39.21) 1,379 (54.29) 458 (18.03) 237 (9.33) 788 (31.02) 239 (9.41) 867 (34.13) 826 (32.52) 911 (35.87) 913 (35.94) 850 (33.46) 453 (17.83) 656 (25.83) 355 (13.98) 1,037 (40.83) 451 (17.76) Height from Imaginary Standard Line A, a C, c K, k 706 (27.80) 794 (31.26) 639 (25.16) Vehicle Dimensions A-M or a-m B-c or b-C B-f D-E D-e G-n or g-N L-l L-m or l-M M-m 475 (18.70) 1,345 (52.95) 1,078 (42.44) 875 (34.45) 1,071 (42.17) 989 (38.94) 1,536 (60.47) 1,562 (61.50) 1,552 (61.10) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear) Symbol Name A, a Front fender installation nut B, b Front spring support hole-inner C, c Hood hinge installation nut D, d Cowl panel installation nut E, e Front side member standard hole F, f Front side member standard hole G, g Radiator upper support installation nut mm (in.) Hole dia H, h M6 (0.24) I Radiator support standard hole ø10 (0.39) Hood lock support installation nut M6 (0.24) ø12.5 (0.492) J, j Front fender bracket installation nut M6 (0.24) M8 (0.31) K, k Radiator upper support installation nut M6 (0.24) M6 (0.24) L, l Front fender installation nut M6 (0.24) ø18 (0.71) M, m Front fender installation nut M6 (0.24) ø18 (0.71) N, n Front bumper reinforcement installation nut M10 (0.39) M6 (0.24) — — — BODY DIMENSIONS DI-5 BODY OPENING AREAS (Side View: Front) (Three-Dimensional Distance) 1,139 (44.84) 1,604 (63.15) 761 (29.96) 909 (35.79) 1,532 (60.31) 1,005 (39.57) 856 (33.70) 826 (32.52) 1,191 (46.89) 1,141 (44.92) 1,272 (50.08) 855 (33.66) 1,116 (43.94) Vehicle Dimensions E-e F-f G-g H-h I-i J-j K-k 1,345 (52.95) 1,493 (58.78) 1,491 (58.70) 1,491 (58.70) 1,176 (46.30) 1,288 (50.71) 1,491 (58.70) E-f or e-F E-h or e-H E-j or e-J F-j or f-J F-k or f-K G-q or g-Q H-I or h-i J-k or j-K 1,579 (62.17) 1,640 (64.57) 1,520 (59.84) 1,881 (74.06) 1,720 (67.72) 1,795 (70.67) 1,663 (65.47) 1,579 (62.17) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear) Symbol Name A, a Roof panel corner mm (in.) Hole dia H, h Rocker panel assemby mark — — I, i Roof side rail assembly mark — B, b Hood hinge installation nut M8 (0.31) J, i Center body pillar assembly mark — C, c Front door hinge installation nut M8 (0.31) K, k Center body pillar assembly mark — D, d Front door hinge installation nut M8 (0.31) L, l Front door lock striker installation nut M8 (0.31) E, e Front body pillar assembly mark — M, m Rear door hinge installation nut M8 (0.31) F, f Front body pillar assembly mark — N, n Rear door hinge installation nut M8 (0.31) G, g Rocker panel assembly mark — Q, q Rocker panel assembly mark — BODY DIMENSIONS DI-6 BODY OPENING AREAS (Side View: Rear) (Three-Dimensional Distance) 747 (29.41) 883 (34.76) 1,004 (39.53) 1,068 (42.05) 1,080 (42.52) 1,058 (41.65) 742 (29.21) Vehicle Dimensions O-o P-p Q-q R-r S-s T-t U-u 1,311 (51.61) 1,491 (58.70) 1,491 (58.70) 1,172 (46.14) 1,298 (51.10) 1,492 (58.74) 1,576 (62.05) I-r or i-R O-s or o-S O-t or o-T P-t or P-T Q-r or q-R S-t or s-T 1,362 (53.62) 1,503 (59.17) 1,654 (65.12) 1,666 (65.59) 1,584 (62.36) 1,516 (59.69) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear) Symbol I, i Name Roof side rail assembly mark mm (in.) Hole dia Q, q Rocker panel assembly mark — — R, r Roof side rail assembly mark — M, m Rear door hinge installation nut M8 (0.31) S, s Quarter panel assembly mark — N, n Rear door hinge installation nut M8 (0.31) T, t Quarter panel assembly mark — O, o Center body pillar assembly mark — U, u Rear door lock striker installation nut P, p Center body pillar assembly mark — — — M8 (0.31) — BODY DIMENSIONS DI-7 BODY OPENING AREAS (Rear View) (Three-Dimensional Distance) 1,020 (40.16) 1,659 (65.31) 724 (28.50) 1,320 (51.97) 1,124 (44.25) 1,196 (47.09) 1,291 (50.83) 587 (23.11) 1,232 (48.50) 1,033 (40.67) 439 (17.28) 1,485 (58.46) 1,123 (44.21) 710 (27.95) Vehicle Dimensions G-g 1,137 (44.76) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear) Symbol Name mm (in.) Hole dia D, d Luggage opening trough / Quarter panel adjoining point A, a Roof panel corner — E, e Quarter panel standard hole ø13 (0.51) B, b Upper back reinforcement / Quarter panel adjoining point — C, c Upper back reinforcement / Quarter panel adjoining point — — F, f Luggage trim installation hole ø8.5 (0.335) G, g Rear spring support hole inner-front ø9.5 (0.374) H, h Center body pillar assembly mark — BODY DIMENSIONS DI-8 UNDER BODY (Three-Dimensional Distance) 1,180 (46.46) 734 (28.90) RH 679 (26.73) 1,228 (48.35) (60.08) LH 1,000 1,037 (39.37) 1,007 (40.83) (39.65) 936 (36.85) 1,464 (57.64) 1,224 (48.19) 1,001 (39.41) 1,005 (39.57) 912 (35.91) 658 (25.91) 843 (33.19) 1,131 (44.53) 1,170 (46.06) 922 (36.30) 567 (22.32) 430 (16.93) 1,093 (43.03) 1,088 (42.83) 1,144 (45.04) 1,526 1,203 (47.36) 322 (12.68) 656 (25.83) 1,135 (44.69) 309 (12.17) 803 (31.61) 1,203 (47.36) 1,024 (40.31) 1,190 (46.85) 1,103 (43.43) 410 (16.14) 1,072 (42.20) 588 (23.15) 715 (28.15) F-f A, a B, b C, c 94 290 316 (12.44) (3.70) (11.42) F-g or f-G 1,100 (43.31) Front F-G or f-g 158 (6.22) 1,027 (40.43) 100 (3.94) 100 (3.94) 98 (3.86) D, d 180 (7.09) E, e F, f 120 63 (4.72) (2.48) G, g 29 (1.14) H, h 31 (1.22) I, i J, j K, k 125 159 272 (4.92) (6.26) (10.71) l L 285 284 (11.18) (11.22) M, m 259 (10.20) Imaginary Standard Line mm (in.) Symbol Name Hole dia G, g Front side member standard hole ø18 (0.71) A, a Front bumper reinforcement installation nut M10 (0.39) H, h Front floor under reinforcement standard hole ø15 (0.59) B, b Front crossmember standard hole ø18 (0.71) I, i Strut bar installation hole-inner ø12 (0.47) C, c Front side member standard hole ø18 (0.71) J, j Rear floor side member standard hole ø18 (0.71) D, d Front suspension member installation nut-front M16 (0.63) K, k Rear suspension member installation nut M12 (0.47) E, e Front suspension member installation nut-rear M16 (0.63) L, l Rear floor side member standard hole ø18 (0.71) F, f Torque box front standard hole ø25 (0.98) M, m Rear floor side member standard hole ø18 (0.71) BODY DIMENSIONS DI-9 UNDER BODY (Two-Dimensional Distance) 2,518 2,285 (99.13) (89.96) 1,706 (67.17) 519 500 (20.43) (19.69) 665 (26.18) RH 550 (21.65) 456 (17.95) 329 (12.95) 504 (19.84) LH 1,265 (49.80) 630 (24.80) 585 (23.03) 456 (17.95) 468 (18.43) 544 (21.42) 1,090 1,350 (42.91) (53.15) 1,916 (75.43) 662 (26.06) 525 (20.67) 513 (20.20) 503 (19.80) 511 (20.12) 547 (21.54) 1,330 (52.36) 1,916 (75.43) 340 (13.39) 2,395 2,177 (94.29) (85.71) 1,395 1,135 (54.92) (44.69) 541 (21.30) Front A, a B, b C, c D, d 316 94 290 180 (12.44) (3.70) (11.42) (7.09) 100 (3.94) Wheel base 100 (3.94) 920 (36.22) 98 (3.86) 2,775 (109.25) E, e F, f 752 120 (29.61) (4.72) G, g 63 (2.48) H, h 29 (1.14) I, i 31 (1.22) N n J, j K, k L, l M, m O, o 284 285 125 159 272 779 259 (4.92) (6.26) (10.71) (30.67) (11.18) (11.22) (10.20) Imaginary Standard Line mm (in.) Hole dia H, h Front side member standard hole ø18 (0.71) A, a Front bumper reinforcement installation nut M10 (0.39) I, i Front floor under reinforcement standard hole ø15 (0.59) Symbol Name B, b Front crossmember standard hole ø18 (0.71) J, j Strut bar installation hole-inner ø12 (0.47) C, c Front side member standard hole ø18 (0.71) K, k Rear floor side member standard hole ø18 (0.71) D, d Front suspension member installation nut-front M16 (0.63) L, l Rear suspension member installation nut M12 (0.47) E, e Front spring support hole-outer ø12.5 (0.492) M, m Rear spring support hole-outer ø9.5 (0.374) F, f Front suspension member installation nut-rear M16 (0.63) N, n Rear floor side member standard hole ø18 (0.71) Torque box front standard hole ø25 (0.98) O, o Rear floor side member standard hole ø18 (0.71) G, g BODY DIMENSIONS DI-10 SUSPENSION CROSSMEMBER (Three-Dimensional Distance) Front RH LH 700 (27.56) 920 (36.22) 879 (34.61) 945 (37.20) 1,029 (40.51) 616 (24.25) 520 (20.47) 658 (25.91) 676 (26.61) 486 (19.13) 738 (29.06) 80 74 89 55 72 (3.15) (2.91) (3.50) (2.17) (2.83) 72 55 89 74 80 (2.83) (2.17) (3.50) (2.91) (3.15) Imaginary Standard Line HINT: For sysmbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear) Symbol mm (in.) Name Hole dia C, c Front frame standard hole ø13 (0.51) A, a Front frame standard hole ø13 (0.51) D, d Front frame standard hole ø13 (0.51) B, b Front frame standard hole ø13 (0.51) E, e Lower arm installation hole-lower ø15 (0.59) BODY DIMENSIONS DI-11 SUSPENSION CROSSMEMBER (Two-Dimensional Distance) Front LH 635 (25.00) 350 (13.78) 505 (19.88) RH 460 (18.11) 14 (0.55) 104 (4.09) 338 (13.31) 243 (9.57) 369 (14.53) 80 74 89 55 72 (3.15) (2.91) (3.50) (2.17) (2.83) 350 (13.78) 635 (25.00) 460 (18.11) 338 (13.31) 243 (9.57) 369 (14.53) 72 55 89 74 80 (2.83) (2.17) (3.50)(2.91) (3.15) 505 (19.88) 14 (0.55) 104 (4.09) Imaginary Standard Line HINT: For sysmbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear) Symbol mm (in.) Name Hole dia C, c Front frame standard hole ø13 (0.51) A, a Front frame standard hole ø13 (0.51) D, d Front frame standard hole ø13 (0.51) B, b Front frame standard hole ø13 (0.51) E, e Lower arm installation hole-lower ø15 (0.59) BODY DIMENSIONS DI-12 REFERENCE VALUE ENGINE COMPARTMENT (Three-Dimensional Distance) 1,552 (61.10) 1,582 (62.28) 1,562 (61.50) 633 (24.92) 387 (15.24) 1,595 (62.80) 1,463 (57.60) 1,536 (60.47) 1,520 (59.84) 1,467 (57.76) 1,328 (52.28) 237 (9.33) 848 (33.39) 240 (9.45) 1,216 (47.87) 887 (34.92) 1,203 (47.36) 1,448 (57.01) 422 (16.61) Vehicle Dimensions B-E or b-e C-E or c-e 524 (20.63) 476 (18.74) HINT: 1) For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear) 2) These values are actual measurements made on model Use these reference values 3) Measure point with the Front fender to cowl side seal and Cool air intake dust seal removed mm (in.) Symbol Name Hole dia C, c Front fender installation bolt — A, a Front bumper cover installation bolt — D, d Front fender installation bolt — B, b Headlight installation bolt — E, e Front fender installation bolt — BODY DIMENSIONS DI-13 UNDER BODY (Three-Dimensional Distance) 679 (26.73) 871 (34.29) 274 (10.79) 1,007 (39.65) 1,205 (47.44) 1,498 (58.98) 1,425 (56.10) 802 (31.57) 1,002 (39.45) 1,268 (49.92) 1,044 (41.10) 658 (25.91) 936 (36.85) HINT: 1) For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear) 2) These values are actual measurements made on model Use these reference values 3) Measure point with the Engine under cover removed mm (in.) Symbol Name A, a Front crossmember reinforcement No.2 standard hole B, b Front suspension member installation bolt Hole dia C, c Front suspension member installation bolt — ø10 (0.39) D, d Front side member standard hole — — — — — BODY DIMENSIONS DI-14 UNDER BODY (Two-Dimensional Distance) Front bumper reinforcement [RH] 12.9D [LH] 12.9D 12.3D 12.4D 72.9 3M10 NUT 72.9 3M10 NUT 25.4 31.4 Rear spring support Front spring support 11.6 9.5 0.6 36.1 36.6 56.5 2.7 22.6 42.3 64.9 2.9 0.6 12.5 2.3 2.4 2.5 4.9 20.2 5.8D 3.1D 2.2 39.5 37.9 50.4 12.3 62.0 mm ... Gloves INTRODUCTION IN-2 PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a collision... PLASTIC BODY PARTS The repair procedure for plastic body parts must conform with the type of plastic material Plastic body parts are identified by the codes in the following table When repairing... less IN-39 INTRODUCTION IN-40 HOW TO USE THIS MANUAL BODY PANEL REPLACEMENT THIS MANUAL BODY PANEL REPLACEMENT BP-34 QUARTER PANEL (CUT) X With the body lower back panel removed Symbol meaning