Toyota 1991 CAMRY Body Section Operating instructions

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

200
300
mm in.
7.87
11.81
QUARTER PANEL (CUT)
QUARTER PANEL
Replacement part
RE-34
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.
BODY PANEL REPLACEMENT-Rear Body Components
REMOVAL
200 - 300 mm
200 - 300 mm
Cut and Join
Location
[Cut and Join Location]
Front
Braze
Rear
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
(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). . . .
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-2

mm in.
50.20
2. Temporarily install the new part and check fit for
the rear door, luggage compartment door and
rear combination light.
RE-35
BODY PANEL REPLACEMENT-Rear Body Components
INSTALLATION
Butt Weld Body Sealer
Braze
Body Sealer
About 5 mm
1. Before temporarily installing the new part, apply
body sealer to the wheel arch.
NOTE:
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 .
INTRODUCTION IN-3

SYMBOLS MEANING ILLUSTRATION
SAW CUT OR
ROUGH CUT
REMOVE BRAZE
(See page IN-5 )
SPOT WELD OR
MIG PLUG WELD
WELD POINTS
BRAZE
CONTINUOUS MIG
WELD (BUTT WELD
OR TACK WELD)
BODY SEALER
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.
INTRODUCTION
IN-4

Remove weld point and panel position
Weld points
REMOVAL
Weld method and panel position
Weld points
INSTALLATION
SYMBOL MEANING ILLUSTRATION SYMBOL
Spot Weld
MEANING ILLUSTRATION
Remove
Weld
Points
(Outside)
Mig Plug
Weld
(Middle)
(Inside)
Spot MIG
Weld
HINT: Panel position syrnbols are as seen from the
working posture.
Illustration of Weld Point Symbols
EXAMPLE:
INTRODUCTION IN-5

IN0102
SUPPORT POSITION
PANTOGRAPH JACK POSITION
Front Center of engine mounting center member. . . . . . . . .
Rear Jack up support of rear suspension member. . . . . . . . . .
JACK POSITION
Front
Safety stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE LIFT AND SUPPORT LOCATIONS
INTRODUCTION IN-11

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
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual
INTRODUCTION
IN-12

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.
SAFETY
1. Before performing repair work, check
for fuel leaks. If a leak is found, be sure
to close the opening totally.
2. If it is necessary to use a frame in the
area of the fuel tank, first remove the
tank and plug the fuel line.
VEHICLE PROTECTION
When welding, protect the
painted surfaces, windows,
seats and carpet with heat-
resistant, fire-proof covers.
WRONG
Glass Cover
Safety Cable
Seat Cover
WRONG
SAFETY
Before performing repair work,
disconnect the battery cables.
SAFETY WORK CLOTHES
In addition to the usual mechanic wear, cap and safety shoes,
the necessary gloves, head protector, glasses, ear plugs, face
protector, dust-prevention mask, etc. should be worn as the
situation demands.
Dust-
Prevention
Mask Welder’s
Glasses Body
Mechanic
Stand
Face
Protector Ear
Plugs
Head
Protector Welder’s
Gloves
Cotton
Gloves
HAND TOOLS
Keeping your hand tools
to neat order will have
an effect on your work
efficiency.
Safety
Shoes
INTRODUCTION
IN-6

Proper and Efficient Work Procedures
REMOVAL REMOVAL OF ADJACENT COMPONENTS
When removing adjacent components,
apply protective tape to the surrounding
body and your tools to prevent damage.
CAUTION:
1. Be especially careful not to damage
screw or clip holes.
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.
NO. OF SPOT WELDS
Make a note of the num-
ber of spot welds for lat-
er reference.
NOTE: The number of
spot welds may vary
depending on the
vehicle.
PRE-REMOVAL MEASURING
Before removal or cutting opera-
tions, take measurements in ac-
cordance with the dimension dia-
gram. Always use a puller to
straighten a damaged body or
frame.
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.
CUTTING AREA
Always cut in a straight
line and avoid reinforced
areas.
Cutting Okay
Corners
Reinforcement
WRONG
INTRODUCTION IN-7

Thickness of
welded portion Size of plug hole
1.0 (0.04) under 5 (0.20) φover
1.0 (0.04) over 6.5 (0.26) φover
REFERENCE: mm (in.)
PREPARATION FOR INSTALLATION
SPOT WELD POINTS APPLICATION OF WELD-THROUGH PRIMER
For treatment
against corrosion,
remove the paint
from the portion of
the new part and
body to be welded,
and apply weld-
through primer.
Less than
3 mm
When welding panels with a
combined thickness of over 3
mrn (0.12 in.), use a MIG
(Metal Inert Gas) welder for
plug welding.
NOTE: Spot welding will
not provide sufficient dura-
bility for panels over 3 mm
(0.12 in.) thick.
Air Saw
WRONG
20 - 30 mm
Overlap
ROUGH CUTTING OF JOINTS
For joint areas, rough cut the
new part, 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.
INTRODUCTION
IN-8

POST-WELDING REFINISH-
ING
1. Always check the welded
spots to insure they are
secure.
2. When smoothing out the
weld spots with a disc
grinder, be careful not to
grind off too much as this
would weaken the weld.
Seal
INSTALLATION 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.
PRE-WELDING MEASUREMENTS
Always take measurements before
installing underbody or engine
components to insure correct
assembly. After installation, confirm
proper fit.
WRONG
OKAY
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 WELDING PRECAUTIONSSPOT WELD LOCATIONS
Try to avoid welding over
previous spots. 1. The shape of the welding
tip point has an effect on
the strength of the weld.
2. Always insure that the
seams and welding tip are
free of paint.
Old
Spot
Locations
New Spot
Locations
Tip Cutter
INTRODUCTION IN-9

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
Apply body sealer to the
required areas.
ANTI-RUST AGENT (WAX)
Apply anti-rust agent to
following sections.
Inside of the hems of the
doors and hood.
Around the hinges of the
doors and hood.
Inside of the welded parts
with boxed cross-section.
Nozzle
Tube
Type
Cartridge
Type Air Gun
UNDERCOAT
Apply undercoat to the underbody and
wheel housings.
Spray Gun
Undercoat
(Water base)
Undercoat
(Oil base)
INTRODUCTION
IN-10

Air-powered
Drill
For separating spot welds and making
holes in the body.
Electric-
powered
Drill
For separating spot welds and making
holes in the body.
Spot Cutter
For separating spot welds.
Air-powered
Cutter
For cutting panels.
Air-powered
Chuck Grinder
For separating spot and plug welds
and grinding off traces of plug welds.
Tracking Gauge
For measuring body dimensions
Frame Centering
Gauge
When 3 or 4 are used together, measure-
ments of twists, bends or warps in the
body and frame are possible.
MEASURING INSTRUMENTS
SEPARATING TOOLS
TOOLS AND EQUIPMENT
TE-2

Air-powered
Chisel
For rough cutting and rough flattening
of panels.
Hammer Tool
Flat Chisel
Panel Cutter
For rough flattening in hard-to-reach
areas.
For separating spot welds.
For rough cutting of panels.
Air-powered
Saw
For rough cutting of pillars, rocker
panels, etc.
Air-powered
Saw
For rough cutting of pillars, rocker
panels, etc.
Hacksaw
For rough cutting of pillars, rocker
panels, etc.
SEPARATING TOOLS (Cont’d)
TOOLS AND EQUIPMENT TE-3

Seat Cover
For protecting the seats from welding
sparks, etc.
Glass Cover
For protecting the glass from welding
sparks, etc.
Vise Grip
Wrench
For temporary installation of panels and
holding of portions to be welded.
Flanging Tool
For making flanges in overlapping
panels.
Hemming Tool
For hemming door outer panels, etc.
Hole Punch
For making holes for MIG plug weld-
ing.
INSTALLATION ASSISTANCE TOOLS
BODY PROTECTORS
TOOLS AND EQUIPMENT
TE-4

MIG Welder
(Metal Inert Gas)
For panel welding.
Spot Welder
For panel welding.
Gas Welder Torch
Gas Cutter Torch
For rough cutting of panels,
members, etc.
Acetylene Gas
Torch
For soldering and peeling of
paint.
Straightening
Machine
For straightening distorted
panels.
Panel
Extractor
For extraction of closed-in
panels.
WELDING INSTRUMENTS
TOOLS AND EQUIPMENT TE-5

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. . . . . .
RE-1

Air-powered
Disc Grinder
For grinding plug welds, butt welds
and door hems.
Electric-
powered
Disc Sander
For grinding plug welds, butt welds
and door hems.
Belt Sander
For removing paint around weld
areas.
Double-action
Sander
For rough grinding and polishing, and
feather edging.
Body Pullers
For straightening lightly dam-
aged panels.
LIGHT BODY REPAIR TOOLS
GRINDING AND POLISHING TOOLS
TOOLS AND EQUIPMENT
TE-6

Straight-line
Sander
For rough polishing of panel putty.
Air-powered
Orbital Sander
For removing putty over a wide area,
resurfacing and refinishing.
Air-powered
Disc Sander
For peeling paint.
File Holder
For paint removal.
Flexible File
Holder
For correction of soldering spots
and resurfacing of panels.
Surform Tool
For rough finishing of panels.
GRINDING AND POLISHING TOOLS (Cont’d)
TOOLS AND EQUIPMENT TE-7

RADIATOR SUPPORT (ASSY)
REMOVAL
BODY PANEL REPLACEMENT
RE-2