Toyota ZZW30 Series Operating instructions

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 MR2.
Applicable models: ZZW30 series
This manual consists of body repair methods, exploded diagrams and il-
lustrations 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 collision-damaged
body components of the TOYOTA MR2 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 for the removal and reinstallation of the equipment parts
up to the white body condition and for 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
Body aligning measurements and 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.
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.

F10004
F10001A
F10002A
F10003A
Glass Cover
Seat Cover
WRONG
WRONG
INTRODUCTION SS-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 frame 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 safe-
ty 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
BFace Protector
CEye Protector
DSafety Shoes
EWelder’s Glasses
FEar Plugs
GHead Protector
HWelder’s Gloves

INTRODUCTIONSS-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 chart.
(3) 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).
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 Acylonitrile
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 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.
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
oraromatic 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 SS-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.
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 wip-
ing 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.

INTRODUCTIONSS-4
3. LOCATION OF PLASTIC BODY PARTS
Parts Name Code
Front Bumper Cover TSOP
Headlight PC/PP
Side Turn Signal Light SAN/ABS
Outer Rear View Mirror ABS
Front Door Outside Handle PC/PBT
Front Fender Mudguard PP/EPDM
Rear Bumper Cover TSOP
Quarter Panel Mudguard PP/EPDM
Rear Combination Light PMMA/PP
License Plate Light PC
Center Stop Light PC
HINT:
Resin material differs with model.
/ Made up of 2 or more kinds of materials.

INTRODUCTION SS-5
F10113
REPLACEMENT PARTS
QUARTER PANEL (CUT) Replacement method
(ASSY) Assembly replacement. .
(CUT) Major cutting (less than 1/2 of parts used). . .
(CUT-H) Half cutting (about 1/2 parts used).
(CUT-P) Partial cutting (most of parts used).
Replacement Parts
REMOVAL DIAGRAM
Describes in detail removal of the damaged parts involving repair by cutting.
REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
BODY PANEL REPLACEMENT
QUARTER PANEL (CUT)
REPLACEMENT
1. REMOVE QUARTER PANEL
(a)Cut and join the part at the location as shown below.
Cut and Join Location
[Cut and Join Loca-
tion]
Cut and Join Location
[Cut Location for supply
parts]
[Cut and Join Location]
Braze
HOW TO USE THIS MANUAL
1. BODY PANEL REPLACEMENT THIS MANUAL

3. MEASURING THE OPENING PORTION DIMENSIONS (See page BP-XX)
4. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-XX)
5. APPLYING SEALER TO THE REAR, LUGGAGE COMPARTMENT (See page PC-XX)
6. CHARGING THE POLYURETHANE FOAM (See page PC-XX)
7. APPLYING ANTI-RUST AGENT
(a).After applying the top coat layer, apply the anti-rust agent to the inside of the necked section
structural weld spots.
F10114A
INSTALLATION GUIDE
Provides additional information to more efficiently help you perform the installation.
INSTALLATION DIAGRAM
Describes in detail installation of the new parts involving repair by welding and/or cutting, but excluding
painting.
SYMBOLS
See page SS-7.
ILLUSTRATION OF WELD POINTS
Weld method and panel position symbols.
See page SS-8.
BODY PANEL REPLACEMENT
2. INSTALL QUARTER PANEL
HINT:
Inspect the fitting of the rear door, luggage compartment door and rear combination light, etc.,
before welding, since this affects the appearance of the finish, (a) Before temporarily installing
the new parts, apply body sealer to the wheel arch.
HINT:
Apply body sealer about 5 mm (0.20 in.) from the flange, avoiding any oozing.
Apply sealer evenly, about 3 – 4 mm (0.12 – 0.16 in.) in diameter.
For other sealing points, refer to section PC.
Butt Weld
Butt Weld
Body
Sealer
about 5
mm
Braze
Body Seal-
er
INTRODUCTIONSS-6

F10005A
SYMBOLS MEANING ILLUSTRATION
SAW CUT OR
ROUGH CUT
REMOVE BRAZE
WELD POINTS
SPOT WELD OR
MIG PLUG WELD
(See Page SS-8)
CONTINUOUS MIG
WELD (BUTT WELD
OR TACK WELD)
BRAZE
BODY SEALER
INTRODUCTION SS-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.

F10005A
REMOVAL INSTALLATION
SYMBOL MEANING ILLUSTRATION SYMBOL MEANING ILLUSTRATION
Remove
Weld
Points
(Outside)
(Middle)
(Inside)
HINT: Panel position symbols are as seen from
the working posture.
Spot Weld
Mig Plug
Weld
Spot MIG
Weld
Braze
Weld points
Remove weld point and panel position Weld method and panel position
Braze
Weld points
INTRODUCTIONSS-8
3. ILLUSTRATION OF WELD POINT SYMBOLS
EXAMPLE: