Toyota Avalon GSX30 Series User manual

FOREWORD
This repair manual has been prepared to provide essential in-
formation on body panel repair methods (including cutting and
welding operations, but excluding painting) for the TOYOTA
AVALON.
Applicable models: GSX30 series
This manual consists of body repair methods, exploded dia-
grams and illustrations of the body components and other in-
formation relating to body panel replacement such as handling
precautions, etc. However, it should be noted that the front fend-
ers 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 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 repair procedures and specifications other than collision-
damaged body components of the TOYOTA AVALON 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 condi-
tion. 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
Each section 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 coat. Body sealer.
Abbreviation of contents in this text.
The following essential procedures have been abbreviated. When actually working, conduct this
work properly.
(1) Jack and lift operations.
(2) Clean and wash removed parts, if necessary.
(3) Visual inspection.

F10004A
F10001A
F10002A
F10003A
Glass Cover
Seat Cover
WRONG
WRONG
INTRODUCTION IN-1
GENERAL REPAIR INSTRUCTIONS
1. WORK PRECAUTIONS
(a) VEHICLE PROTECTION
(1) When welding, protect the painted surfaces, windows,
seats and carpet with heat resistant, fire-proof covers.
(b) SAFETY
(1) 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.
(2) Before performing repair work, check for fuel leaks.
If a leak is found, be sure to close the opening totally.
(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.
(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 Name
ADust-Prevention Mask
B Face Protector
CEye Protector
DSafety Shoes
EWelder’s Glasses
FEar Plugs
GHead Protector
HWelder’s Gloves

INTRODUCTION
IN-2
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, paint-
ing etc.), consideration must be 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).
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 applid 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 applid 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 IN-3
Code Material
name
Heat*
resistant
temperature
limit C (F)
Resistance to
alcohol or gasoline 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.
POM 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.
PS 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.
TSOP TOYOTA
Super
Olefine Polymer
80
(176) Alcohol and gasoline are harmless. Most solvents are harmless.
UP Unsaturated
Polyester 110 (233) Alcohol and gasoline are harmless. Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.

INTRODUCTION
IN-4
3. LOCATION OF PLASTIC BODY PARTS
Parts Name Code
Radiator Grille ABS
Front Bumper Cover TSOP
Front Bumper Hole Cover PC/ABS
Headlight PP/PC
Foglight PC/PE
Cowl Top Ventilator Louver TSOP
Door Window Frame Moulding ASA
Door Outside Handle PA
Outer Rear View Mirror ABS PPO
Door Outside Moulding TPO
Body Rocker Panel Moulding TPO
Rocker Panel Moulding Protector PP
License Plate Light PC
Rear Combination Light PMMA/ASA
Rear Light PMMA/ASA
Rear Bumper Cover TSOP
HINT:
Resin material differs with model.
/ Made up of 2 or more kind of materials.

INTRODUCTION
F13890A
IN-5
HOW TO USE THIS MANUAL
1. BODY PANEL REPLACEMENT THIS MANUAL

INTRODUCTION
F13891A
IN-6

F13893A
INTRODUCTION IN-7
2. 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.

INTRODUCTION
F13894A
SYMBOLS MEANING ILLUSTRATION
Assembly Mark
BODY SEALER
(Flat Finishing)
BODY SEALER
(No flat Finishing)
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IN-8