HƯỚNG DẪN SỬA CHỮA THÂN XE LAND CRUISER ĐỜI 1998-2007
INTRODUCTION IN-9 ECU (ELECTRONIC CONTROL UNIT) Many ECUs are mounted in this vehicle Take the following precautions during body repair to prevent damage to the ECUs S Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled So before starting work, make a record of the contents memorized by each memory system Then when work is finished, reset the clock and audio systems as before When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all equipped with memory function, it is not possible to make a record of the memory contents So when the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory S Do not expose the ECUs to ambient temperatures above 80°C (176°F) NOTICE: If it is possible the ambient temperature may reach 80° (176°F) or more, remove the ECUs from the vehicle before starting work S Be careful not to drop the ECUs and not to apply physical shocks to them ABBREVIATIONS USED IN THIS MANUAL For convenience, the following abbreviations are used in this manual ABS Antilock Brake System A/C Air Conditioner assy assembly ECT Electronic Controlled Transmission ECU Electronic Control Unit e.g Exempli Gratia (for Example) Ex Except 4WD Four Wheel Drive Vehicles in inch LH Left-hand LHD Left-hand Drive MIG Metal Inert Gas M/Y Model Year PPS Progressive Power Steering RH Right-hand RHD Right-hand Drive SRS Supplemental Restraint System SSM Special Service Materials w/ with w/o without 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 LAND CRUISER Applicable models: UZJ100, FZJ10_ series HDJ10_, HZJ105 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 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 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 LAND CRUISER 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 TOYOTA MOTOR CORPORATION INTRODUCTION IN-10 GENERAL REPAIR INSTRUCTIONS Work Precautions SAFETY 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 VEHICLE PROTECTION When welding, protect the painted surfaces, windows, seats and carpet with heatresistant, fire-proof covers SAFETY Before performing repair work, check for fuel leaks If a leak is found, be sure to close the opening totally If it is necessary to use a frame in the area of the fuel tank, first remove the tank and plug the fuel line Glass Cover Safety Cable Seat Cover WRONG SAFETY WORK CLOTHES 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 DustPrevention Mask Face Protector Eye Protector Safety Shoes HAND TOOLS Keeping your hand tools in neat order improve your work efficiency Welder’s Glasses Ear Plugs Head Protector Welder’s Gloves Body Tools Stand INTRODUCTION IN-11 Proper and Efficient Work Procedures REMOVAL PRE-REMOV AL MEASURING Before removal or cutting operations, take measurements in accordance with the dimension diagram Always use a puller to straighten a damaged body or frame NUMBER OF SPOT WELDS AND PANEL POSITIONS The number of spot welds and the panel positions to be removed are shown for your reference HINT: See “Symbols” on page IN-4 , REMOVAL OF ADJACENT COMPONENTS 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-6 PRECAUTIONS FOR DRILLING OR CUTTING Check behind any area to be drilled or cut to insure that there are no hoses, wires, etc., that may be damaged HINT: See “Handling Precautions on Related Components” on page IN-6 CUTTING AREA Always cut in a straight line and avoid reinforced area Cutting Okay Corners Reinforcement WRONG INTRODUCTION IN-12 PREPARATION FOR INSTALLATION SPOT WELD POINTS Less Than mm 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 will not provide sufficient durability for panels over mm (0.12 in.) thick APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER) Remove the paint from the portion of the new parts and body to be welded, and apply weld-through primer HINT: See ”ANTIRUST TREATMENT”’ on page AR-2 Parts Name Parts Number Spot Sealer 08839 - 00070 *The above SSM or equivalent Air Saw 20 - 30 mm Puncher Overlap SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS When welding there is a danger that electrical components will be damaged by the electrical current flowing through the body Before starting work disconnect the negative terminal of the battery and ground the welder near the welding location of the body ROUGH CUTTING OF JOINTS For joint areas, rough cut the new parts, leaving 20 - 30 mm (0.79 - 1.18 in.) overlap MAKING HOLES FOR PLUG WELDING 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 (0.20) φ over 1.0 (0.04) - 1.5 (0.06) 6.5 (0.26) φ over 1.5 (0.06) over (0.31) φ over INTRODUCTION IN-13 INSTALLATION PRE-WELDING MEASUREMENTS WELDING PRECAUTIONS Always take measurements before The number of welding installing underbody or engine comspots should be as follows ponents to insure correct assembly Spot weld: 1.3 x No of After installation, confirm proper manufacturer’s spots fit Plug weld: More than No of manufacturer’s plugs POST WELDING REFINISHING Always check the welded spots to insure they are secure When smoothing out the weld spots with a disc grinder, be careful not to grind off too much as this would weaken the weld WRONG OKAY WRONG Plug welding should be done with a MIG (Metal Inert Gas) welder Do not gas weld or braze panes at areas other than specified Safety Glass Body Measurement Diagrams SPOT WELD LOCATIONS Try to avoid welding over New Spot previous spots Locations SPOT WELDING PRECAUTIONS The shape of the welding tip point has an effect on the strength of the weld Old Spot Locations Tip Cutter Always insure that the seams and welding tip are free of paint INTRODUCTION IN-14 ANTI-RUST TREATMENT When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the requirements of your country HINT: For further details, see the description given in Section AR of this manual BODY SEALER Apply body sealer to the required areas Tube Type Cartridge Type Parts Name Parts Number ANTI-RUST AGENT (WAX) Apply anti-rust agent to following sections S Inside of the hems of the doors and hood S Around the hinges of the doors and hood S Inside of the welded parts with boxed cross-section 08839-00030 Body Sealer, Black (Cartridge Type) 08839-00040 *The above SSM or equivalent Rustop W (Aerosol) 08860-00200 Rustop W (1ȏ Milky White) 08860-00210 08860-00230 08860-00220 Rustop B (18ȏ Black) Body Sealer, White (Tube Type) Parts Number Rustop B (1ȏ Black) 08839-00020 Parts Name Rustop W (18ȏ Milky White) Body Sealer, White (Cartridge Type) 08860-00240 *The above SSM or equivalent UNDERCOAT Apply undercoat to the underbody and wheel housings Parts Name Parts Number Pastar UC (Oil Base) 08836-00155 Pastar UW (Water Base) 08836-001 15 Pastar Gun (For thick application) 08836-00091 *The above SSM or equivalent Undercoating (Oil base) Undercoating (Water base) Spray Gun PLASTIC BODY PARTS PP-2 HANDLING PRECAUTIONS 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 chart When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must given to the property of the plastic Code Material name Heat* resistant temperature limit °C (°F) Resistance to alcohol or gasoline Notes AAS Acrylonitrile Acrylic Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease.) ABS Acrylonitrile Butadiene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease.) Avoid gasoline and organic or aromatic solvents AES Acrylonitrile Ethylene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease.) Avoid gasoline and organic or aromatic solvents ASA Acrylonitrile Styrene Acrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease.) Avoid gasoline and organic or aromatic solvents CAB Cellulose Acetate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease.) Avoid gasoline and organic or aromatic solvents EPDM Ethylene Propylene 100 (212) Alcohol is harmless Gasoline is harmless if applied only for short time in small amounts Most solvents are harmless but avoid dipping in gasoline, solvents, etc FRP Fiber Reinforced Plastics 180 (356) Alcohol and gasoline are harmless Avoid alkali EVA Ethylene Acetate 70 (158) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease) Avoid gasoline and organic oraromatic solvents Polyamide (Nylon) 80 (176) Alcohol and gasoline are harmless Avoid battery acid Polybutylene Terephthalate 160 (320) Alcohol and gasoline are harmless Most solvents are harmless Polycarbonate 120 (248) Alcohol is harmless Avoid gasoline, brake fluid, wax, wax removers and organic solvents Avoid alkali PA PBT PC Avoid gasoline and organic or aromatic solvents *Temperatures higher than those listed here may result in material deformation during repair PLASTIC BODY PARTS Code Material name Heat* resistant temperature limit °C (°F) Resistance to alcohol or gasoline PP-3 Notes PE Polyethylene 80 (176) Alcohol and gasoline are harmless Most solvents are harmless PET Polyethylene Terephthalate 75 (167) Alcohol and gasoline are harmless Avoid dipping in water PMMA Polymethyl Methacrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts Avoid dipping or immersing in alcohol, gasoline, solvents, etc Polyoxymethylene (Polyacetal) 100 (212) Alcohol and gasoline are harmless Most solvents are harmless PP Polypropylene 80 (176) Alcohol and gasoline are harmless Most solvents are harmless PPO Modified Polyphenylene Oxide 100 (212) Alcohol is harmless Gasoline is harmless if applied only for quick wiping to remove grease Polystyrene 60 (140) Alcohol and gasoline are harmless if applied only for short time in small amounts Avoid dipping or immersing in alcohol, gasoline, solvents, etc PUR Polyurethane 80 (176) Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wiping to remove grease) Avoid dipping or immersing in alcohol, gasoline, solvents, etc PVC Polyvinylchloride (Vinyl) 80 (176) SAN Styrene Acrylonitrile 80 (176) TPO Thermoplastic Olefine 80 (176) TPU Thermoplastic Polyurethane 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease) Avoid dipping or immersing in alcohol, gasoline, solvents, etc TSOP TOYOTA Super Olefine Polymer 80 (176) Alcohol and gasoline are harmless Most solvents are harmless Unsaturated Polyester 110 (233) Alcohol and gasoline are harmless Avoid alkali POM PS UP Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease) Alcohol is harmless Gasoline is harmless if applied only for short time in small amounts Avoid dipping or immersing in alcohol, gasoline, solvents, etc Avoid dipping or immersing in alcohol, gasoline, solvents etc Most solvents are harmless but avoid dipping in gasoline, solvents, etc *Temperatures higher than those listed here may result in material deformation during repair INTRODUCTION IN-6 HANDLING PRECAUTIONS ON RELATED COMPONENTS FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The TOYOTA LAND CRUISER is equipped with an SRS (Supplemental Restraint System), such as the driver airbag and front passenger airbag and seat belt pretensioners Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing, possibly leading to a serious accident Further, if a mistake is made in servicing the supplemental restraint system, it is possible the SRS may fail to operate when required Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in this manual S Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important source of information when troubleshooting When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery S Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery (The supplemental restraint system is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable from the battery, the SRS may deploy.) When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled So before starting work, make a record of the contents memorized by the audio memory system Then when work is finished, reset the clock and audio systems as before To avoid erasing the memory of each memory system, never use a back-up power supply from outside the vehicle S Even in cases of a minor collision where the SRS does not deploy, the passenger’s airbag assembly, the steering wheel pad and seat belt pretensioners should be inspected Never use SRS parts from another vehicle When replacing parts, replace them with new parts S Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs S Never disassemble and repair the airbag sensor assembly, steering wheel pad in order to reuse it S If the airbag sensor assembly, steering wheel pad have been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones S Do not expose the airbag sensor assembly, steering wheel pad directly to hot air or flames S Use a volt/ohmmeter with high impedance (10 kW/V minimum) for troubleshooting of the electrical circuit S Information labels are attached to the periphery of the SRS components Follow the instructions on the notices S After work on the supplemental restraint system is completed, check the SRS warning light S Before repairing the body, remove the SRS parts if, during repair, shocks are likely to be applied to the sensors due to vibrations of the body or direct tapping with tools or other parts S Do not expose the SRS parts directly to hot air or flames NOTICE: 1) The maximum ambient temperature tolerance is 120°C (248°F) for the front airbag sensor, 105°C (221°F) for the center airbag sensor assembly and 93°C (200°F) for the steering wheel pad, and front passenger airbag assembly If it is possible that the ambient temperature may reach or exceed the temperature limit, remove the sensors and the steering wheel pad from the vehicle or protect them with a hot insulation material before staring work 2) Prior to welding, remove adjacent SRS parts form the vehicle or protect them with fire-proof covers S If the vehicle is damaged, visually inspect for damage to the steering wheel pad using the inspection procedures described in section RS of the repair manual for the relevant model year BODY DIMENSIONS DI-2 Three-dimensional distance Center-to-center straight-line distance GENERAL INFORMATION BASIC DIMENSIONS (a) There are two types of dimensions in the diagram (Three-dimensional distance) S Straight-line distance between the centers of two measuring points Two-dimensional distance (Two-dimensional distance) S Horizontal distance in forward/rearward between the centers of two measuring points Center-to-center Horizontal distance in forward/rearward S The height from an imaginary standard line (b) In cases in which only one dimension is given, left and right are symmetrical Vertical distance in lower surface Vertical distance in center (c) Imaginary Standard Line Plate Looseness Body Looseness The dimensions in the following drawing indicate actual distance Therefore, please use the dimensions as a reference 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 Pointer Looseness Pointer (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers Master Gauge Correct Wrong HINT: The height of the left and right pointers must be equal Always calibrate the tracking gauge before measuring or after adjusting the pointer height Take care not to drop the tracking gauge or otherwise shock it Confirm that the pointers are securely in the holes Pointer Front Spring Support Inner Hole Tape Measure Along Body Surface Front Suspension Member Rear Side Upper Installation Hole (c) When using a tape measure, avoid twists and bends in the tape (d) When tracking a diagonal measurement from the front spring support inner hole to the suspension member upper rear installation hole, measure along the front spring support panel surface AR-10 ANTI-RUST TREATMENT BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS HINT: Anti-chipping paint should be applied to some areas before the second coat and to others after the top coat If other areas are accidentally coated, wipe of the paint immediately with a rag soaked in grease, wax and silicone remover Anti-Chipping Paint PVC Chipping Paint ANTI-RUST TREATMENT AR-11 BODY PANEL UNDERCOATING AREAS HINT: First wipe off any dirt, grease or oil with a rag soaked in a grease, wax and silicone remover Cover the surrounding areas with masking paper to avoid coating unnecessary areas If other areas are accidently coated, wipe off the coating immediately Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over the entire area Do not coat parts which become hot, such as the tailpipe, or moving parts, such as the propeller shaft Besides the locations described below, apply undercoating to all weld points under the body to insure corrosion prevention Be sure to seal the edge of the flange of the member and bracket with undercoating If undercoat is damaged by peeling, cracks, etc., be sure to repair as necessary Before the undercoat apply sealer allowing rust prevention to be attained REFERENCE: Referring to the notes above, undercoating should be applied according to the specifications for your country ANTI-RUST TREATMENT AR-12 BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS HINT: Whenever adjusting the doors and hoods, apply anti-rust agent (wax) around the hinges Even if partially repairing a part, apply anti-rust agent (wax) over the entire application area of the part Wipe off the anti-rust agent immediately with a rag soaked in a grease, wax and silicone remover, if accidently applied to other areas LIFT-UP TYPE BACK DOOR Back Door Hinge Tail Gate Hinge Tail Gate Hinge Back Door, Tail Gate Hood Hinge Door Hood Door Hinge Door Hinge ANTI-RUST TREATMENT AR-13 SWING TYPE BACK DOOR Back Door Hinge Back Door Hood Hinge Door Hood Door Hinge Door Hinge AR-4 ANTI-RUST TREATMENT BODY PANEL SEALING AREAS HINT: Prior to applying body sealer, clean the area with a rag soaked in a grease, wax and silicone remover If weld-through primer was used, first wipe off any excess and coat with anti-corrosion primer before applying body sealer Wipe off excess body sealer with a rag soaked in a grease, wax and silicone remover If body sealer is damaged by peeling, cracks, etc., be sure to repair as necessary Flat Surfacing Flat Surfacing All Hinge Flat Surfacing ANTI-RUST TREATMENT AR-5 Flat Surfacing Flat Surfacing AR-6 ANTI-RUST TREATMENT Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing ANTI-RUST TREATMENT Flat Surfacing Lift-Up Type Back Door Lift-Up Type Back Door AR-7 ANTI-RUST TREATMENT AR-8 Swing Type Back Door Flat Surfacing Flat Surfacing ANTI-RUST TREATMENT AR-9 Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing ANTI-RUST TREATMENT AR-2 GENERAL INFORMATION Anti-rust treatment is necessary before welding and before and after the painting process ANTI-RUST TREATMENT BEFORE WELDING WELD-THROUGH PRIMER (SPOT SEALER) APPLICATION For anti-corrosion measures, always apply the weld-through primer (spot sealer) to welding surfaces where the paint film has been removed HINT: Apply the weld-through primer (spot sealer) so that it does not ooze out from the joining surfaces Weld-Through Primer (Spot Sealer) WELD-THROUGH PRIMER (SPOT SEALER) APPLICATION ANTI-RUST TREATMENT BEFORE PAINTING PROCESS BODY SEALER APPLICATION For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams and hems of the doors, hoods, etc UNDERCOAT APPLICATION Sealer Gun BODY SEALER APPLICATION To prevent corrosion and protect the body from damage by flying stones, always apply sufficient undercoat to the bottom surface of the under body and inside of the wheel housings UNDERCOAT APPLICATION ANTI-RUST TREATMENT AR-3 ANTI-RUST TREATMENT AFTER PAINTING PROCESS ANTI-RUST AGENT (WAX) APPLICATION 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 hoods, and around the hinges, or the welded surfaces inside the boxed cross-section structure of the side member, body pillar, etc ANTI-RUST AGENT (WAX) APPLICATION REFERENCE: ANTI-RUST TREATMENT BY PAINTING Painting prevents corrosion and protects the sheet metal from damage In this section, anti-chipping paint only for anti-corrosion purpose is described ANTI-CHIPPING PAINT To prevent corrosion and protect the body from damage by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, valance 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 S Apply the anti-chipping paint after the top coat Anti-Chipping Paint To Coat Second Coat S Apply the anti-chipping paint before the second coat Top Coat Second Coat Anti-Chipping Paint Under coat (ED Primer) Under coat (ED Primer) Steel Metal Steel Metal AP-4 APPENDIX SILENCER SHEET INSTALLATION AREAS + SEATER MODELS Thickness of Asphalt Sheet 0.8 mm (0.031 in.) 1.5 mm (0.059 in.) 2.0 mm (0.079 in.) 3.0 mm (0.118 in.) 3.5 mm (0.138 in.) 3.7 mm (0.146 in.) *1 *2 *1 For 2UZ-FE Engine: 3.7 mm (0.146 in.) Except 2UZ-FE Engine: 2.0 mm (0.079 in.) *2 2UZ-FE, 1FZ-FE, 1HZ Engine: 3.0 mm (0.118 in.) 1HD-FE, 1HD-T Engine: 5.0 mm: (0.197 in.) APPENDIX AP-5 + SEATER MODELS Thickness of Asphalt Sheet 0.8 mm (0.031 in.) 1.5 mm (0.059 in.) 2.0 mm (0.079 in.) 3.0 mm (0.118 in.) 3.5 mm (0.138 in.) 3.7 mm (0.146 in.) *1 *2 *1 For 2UZ-FE Engine: 3.7 mm (0.146 in.) Except 2UZ-FE Engine: 2.0 mm (0.079 in.) *2 2UZ-FE, 1FZ-FE, 1HZ Engine: 3.0 mm (0.118 in.) 1HD-FE, 1HD-T Engine: 5.0 mm (0.197 in.) ... repair procedures and specifications other than collisiondamaged body components of the TOYOTA LAND CRUISER refer to the repair manuals If you require the above manuals, please contact your TOYOTA. .. 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 LAND CRUISER. .. 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