Automobile training 48 collision repair manual

Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual Automobile training 48 collision repair manual

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 YARIS Applicable models: KSP90 series Applicable models: NCP90, 91 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 YARIS 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 : 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 : 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 : COATING Scope and type of anti-rust treatment, etc together with weld panel replacement Under coating Body sealer Contents omitted in this manual : Make sure to perform the following essential procedures, although they are omitted in this manual (1) Jack and lift operations (2) Clean and wash removed parts, if necessary (3) Visual inspection INTRODUCTION IN-1 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 F10001A (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 F10002A (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 F10003A (c) F10004A 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 C Eye Protector D Safety Shoes E Welder’s Glasses F Ear Plugs G Head Protector H Welder’s Gloves INTRODUCTION IN-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, painting etc.), consideration must be given to the properties 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) Avoid gasoline and organic or aromatic solvents 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 or aromatic solvents E / VAC Ethylene / Vinyl Acetate Copolymer Resin 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 or aromatic solvents PA Polyamide (Nylon) 80 (176) Alcohol and gasoline are harmless Avoid battery acid PBT Polybutylene Terephthalate 160 (320) Alcohol and gasoline are harmless Most solvents are harmless PC Polycarbonate 120 (248) Alcohol is harmless Avoid gasoline, brake fluid, wax, wax removers and organic solvents Avoid alkali *Temperatures higher than those listed here may result in material deformation during repair INTRODUCTION Code Material name Heat* resistant temperature limit _C (_F) Resistance to alcohol or gasoline IN-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 PPF Composite Reinforced 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) Alcohol and gasoline are 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 SAN Styrene Acrylonitrile 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 TPO Thermoplastic Olefine 80 (176) 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 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 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 TSOP UP *Temperatures higher than those listed here may result in material deformation during repair INTRODUCTION IN-4 LOCATION OF PLASTIC BODY PARTS Parts Name Code Front Bumper Cover TSOP Radiator Grille TSOP Headlight PC/PP Fog Light TSOP Front Pillar Upper Cover AES Side Turn Signal Light PMMA/PC/ABS Cowl Top Ventilator Louver TSOP/PP/PE Rear Body Mudguard PP Door Outside Handle PA/PC/PBT Outer Rear View Mirror PP/PA/ABS : ASA Front Door Window Frame Front Moulding ASA Front Spoiler Cover TSOP Front Fender Mudguard PP Back Door Outside Handle PA License Plate Light PC Rear Combination Light PMMA/ASA Rear Bumper Cover TSOP HINT: : Resin material differs depending on model / Made up of or more kinds of materials INTRODUCTION IN-5 HOW TO USE THIS MANUAL BODY PANEL REPLACEMENT IN THIS MANUAL BODY PANEL REPLACEMENT QUARTER PANEL (CUT) REPLACEMENT REMOVAL POINT Remove the [A] at the same time PART NAME [A] Fuel filler opening lid 200 mm (7.87 in.) 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 REMOVAL CONDITIONS PART LOCATION REMOVAL DIAGRAM Describes in detail the removal of the damaged part involving repair by cutting REMOVAL GUIDE Provides additional information to more efficiently help you perform the removal F13890A INTRODUCTION IN-6 BODY PANEL REPLACEMENT INSTALLATION Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish After welding, apply the polyurethane foam to the corresponding parts After welding, apply body sealer and under-coating to the corresponding parts After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots POINT Before temporarily installing the new parts, apply sealer to the wheel arch HINT 1) Apply body sealer about mm (0.20 in.) front the flange, avoiding any oozing 2) Apply sealer evenly, about 3−4 mm (0.12−0.16 in.) in diameter 3) For other sealing points, refer to section PC INSTALLATION CONDITIONS INSTALLATION DIAGRAM Describes in detail the installation of the new parts involving repair by welding and/or cutting, but excluding painting INSTALLATION GUIDE Provides additional information to more efficiently help you perform the installation SYMBOLS (See page IN-7) INSTALLATION OF WELD POINTS Weld method and panel position symbols (See page IN-9) PART NAME F13891A INTRODUCTION IN-7 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 CUT AND JOIN LOCATION (Saw Cut) CUT AND JOIN LOCATION (Cut Location for Supply Parts) CUT LOCATION CUT WITH DISC SANDER, ETC BRAZE (Removal) BRAZE (Installation) WELD POINTS SPOT WELD OR MIG PLUG WELD (See page IN-9) CONTINUOUS MIG WELD (BUTT WELD) CONTINUOUS MIG WELD (TACK WELD) BODY SEALER F13893A BODY PANEL REPLACEMENT BP-79 INSTALLATION : Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram (See the body dimension diagram) : Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish : After welding, apply polyurethane foam to the corresponding parts : After welding, apply body sealer and undercoating to the corresponding parts : After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points mm Spot Tip mm F24836-1 POINT Inspect the fitting of the rear door, luggage compartment door, rear combination light and other related parts before welding as this affects the appearance of the finish Apply adhesive (3MTM AutomixTM Panel Bonding Adhesive #8115) to the area indicated by *1 in illustration HINT: 1) Apply enough adhesive for the panels to sick to each other Perform spot-welding on the flange indicated by *2 in the illustration Modify/ cut the spot tip as shown in the illustration (*3) so that it can fit into the narrow flange mm (0.12 in.) mm (0.20 in.) BODY PANEL REPLACEMENT BP-80 mm F24837-1 POINT Before temporarily installing the new parts, apply body sealer to the wheel arch HINT: 1) Apply body sealer evenly about mm (0.20 in.) form the flange, avoiding any oozing 2) Apply sealer evenly, about − mm (0.12 − 0.16 in.) in diameter mm (0.20 in.) BODY PANEL REPLACEMENT BP-81 (13 mm) F24838-1 PART NAME [A] Fuel Filler Opening Lid 13 mm (0.51 in.) [B] Rivets BP-98 BODY PANEL REPLACEMENT LOWER BACK UPPER GUSSET (ASSY): Hatchback REPLACEMENT F22859A REMOVAL F22859 BODY PANEL REPLACEMENT BP-99 INSTALLATION : Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram (See the body dimension diagram) : Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish : After welding, apply the polyurethane foam to the corresponding parts : After welding, apply body sealer and under-coating to the corresponding parts : After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots F22860 BP-100 BODY PANEL REPLACEMENT LOWER BACK UPPER QUSSET (ASSY): Sedan REPLACEMENT F24843A REMOVAL F24843-1 BODY PANEL REPLACEMENT BP-101 INSTALLATION : Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram (See the body dimension diagram) : Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish : After welding, apply polyurethane foam to the corresponding parts : After welding, apply body sealer and undercoating to the corresponding parts : After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points F24843-2 BP-102 BODY PANEL REPLACEMENT BODY LOWER BACK PANEL (ASSY): Hatchback REPLACEMENT F22861A REMOVAL F23325 BODY PANEL REPLACEMENT BP-103 INSTALLATION : Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram (See the body dimension diagram) : Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish : After welding, apply polyurethane foam to the corresponding parts : After welding, apply body sealer and undercoating to the corresponding parts : After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points F23326 POINT Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish BP-104 BODY PANEL REPLACEMENT BODY LOWER BACK PANEL (ASSY): Sedan REPLACEMENT F24844A REMOVAL F24844-1 BODY PANEL REPLACEMENT BP-105 INSTALLATION : Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram (See the body dimension diagram) : Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish : After welding, apply polyurethane foam to the corresponding parts : After welding, apply body sealer and undercoating to the corresponding parts : After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points F24844-2 POINT Inspect the fitting of the back door and rear combination light and other related parts before welding as this affects the appearance of the finish BP-106 BODY PANEL REPLACEMENT BACK DOOR OPENING TROUGH (ASSY): Hatchback REPLACEMENT With the quarter panel and body lower back panel removed F22865A REMOVAL F22865 POINT Remove [A] at the same time PART NAME [A] Back Door Opening Lower Reinforcement BODY PANEL REPLACEMENT BP-107 INSTALLATION : Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram (See the body dimension diagram) : Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish : After welding, apply polyurethane foam to the corresponding parts : After welding, apply body sealer and undercoating to the corresponding parts : After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points F22866 POINT Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish PART NAME [A] Back Door Opening Lower Reinforcement [B] Rear Bumper Side Retainer BP-108 BODY PANEL REPLACEMENT LUGGAGE DOOR OPENING FRONT TROUGH (ASSY): Sedan REPLACEMENT F24845A REMOVAL F24845-1 BODY PANEL REPLACEMENT BP-109 INSTALLATION : Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram (See the body dimension diagram) : Inspect the fitting of the related parts around the new parts before welding This affects the appearance of the finish : After welding, apply polyurethane foam to the corresponding parts : After welding, apply body sealer and undercoating to the corresponding parts : After applying the top, apply anti-rust agent to the internal panel portion of the closed section structural weld points (13 mm) F24845-2 POINT Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish 13 mm (0.51 in.) ... FOR REPAIRING BODY STRUCTURE PANELS 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 collision. .. Body repair must be particularly accurate to ensure correct alignment HINT: Correct procedures and special tools are required for alignment Always follow the directions given in the repair manual. .. directions and notes given in the brake (32) section of the repair manual for the relevant model when handling brake system parts NOTICE: When repairing the brake master cylinder or TRAC system, bleed