Toyota ZZT230 Series Manual
  1. Manuals
  2. Brands
  3. Toyota Manuals
  4. Automobile
  5. ZZT230 series
  6. Manual
Toyota ZZT230 Series Manual

Toyota ZZT230 Series Manual

Hide thumbs Also See for ZZT230 Series:
Table of Contents

Advertisement

Quick Links

Download this 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 CEL-
ICA.
Applicable models: ZZT230 series
Applicable models:
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 TOY-
OTA 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 CELICA 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.
ZZT231 series

Advertisement

Table of Contents
loading

Related Manuals for Toyota ZZT230 Series

Summary of Contents for Toyota ZZT230 Series

  • Page 1 For the repair procedures and specifications other than collision- damaged body components of the TOYOTA CELICA refer to the repair manuals. If you require the above manuals, please contact your TOYOTA Dealer.
  • Page 2 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.

  • Page 3: General Repair Instructions

    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. F10001A (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.
  • Page 4 SS-2 INTRODUCTION 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.
  • Page 5 Avoid dipping or immersing Thermoplastic short time in small amounts (e.g., quick in alcohol, gasoline, Polyurethane (176) wiping to remove grease). solvents, etc. TOYOTA TSOP Super Alcohol and gasoline are harmless. Most solvents are harmless. (176) Olefine Polymer Unsaturated Alcohol and gasoline are harmless.
  • Page 6 SS-4 INTRODUCTION 3. LOCATION OF PLASTIC BODY PARTS Parts Name Code Radiator Grille Front Bumper Cover (Upper & Lower) TSOP Headlight PC/PP Side Turn Signal Light PMMA/ABS Radiator Lower Grille TSOP Front Door Outside Handle PC/PBT Hood Bulge Side Madguard TSOP Rear Bumper Cover TSOP...

  • Page 7: How To Use This Manual

    INTRODUCTION SS-5 HOW TO USE THIS MANUAL 1. BODY PANEL REPLACEMENT THIS MANUAL F10113...
  • Page 8 SS-6 INTRODUCTION F10114A...
  • Page 9 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...
  • Page 10 SS-8 INTRODUCTION 3. ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE: F10005A...
  • Page 11 INTRODUCTION SS-9 PROPER AND EFFICIENT WORK PROCEDURES 1. REMOVAL (a) PRE-REMOVAL MEASURING (1) Before removal or cutting operations, take measure- ments in accordance with the dimension diagram. Al- ways use a puller to straighten a damaged body or frame. F10007 (b) CUTTING AREA (1) Always cut in a straight line and avoid reinforced area.

  • Page 12: Preparation For Installation

    SS-10 INTRODUCTION 2. PREPARATION FOR INSTALLATION (a) SPOT WELD POINTS (1) When welding panels with a combined thickness of over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) weld- er for plug welding. HINT: Spot welding will not provide sufficient durabili- ty for panels over 3 mm (0.12 in.) thick.

  • Page 13: Installation

    INTRODUCTION SS-11 3. INSTALLATION (a) PRE-WELDING MEASUREMENTS (1) Always take measurements before installing under- body or engine components to insure correct assem- bly. After installation, confirm proper fit. F10016A (b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld: 1.3 X No.
  • Page 14 SS-12 INTRODUCTION 4. ANTI-RUST TREATMENT (a) BODY SEALER APPLICATION (1) For water-proofing and anti-corrosion measures, al- ways apply the body sealer to the body panel seams and hems of the doors, hoods, etc. F10021A (b) UNDERCOAT APPLICATION (1) To prevent corrosion and protect the body from dam- age by flying stones, always apply sufficient undercoat to the bottom surface of the under body and inside of the wheel housings.
  • Page 15 INTRODUCTION SS-13 6. ANTI-RUST TREATMENT BY PAINTING REFERANCE: Painting prevents corrosion and protect the sheet met- al from damage. In this section, anti-chipping paint only for anti-corrosion purpose is described. (a) ANTI-CHIPPING PAINT (1) To prevent corrosion and protect the body from dam- age by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, valance panel, etc.
  • Page 16 SS-14 INTRODUCTION HANDLING PRECAUTIONS ON RELATED COMPONENTS 1. BRAKE SYSTEM The brake system is one of the most important safety components. Always follow the directions and notes given in section BR of the repair manual for the relevant model year when handling brake system parts. NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC sys- tem.
  • Page 17 STRUCTURE PANELS 1. 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 col- lision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are being sought after.
  • Page 18 SS-16 INTRODUCTION 3. IMPACT BEAM REPAIR The impact beam and bracket are necessary and important parts in maintaining a survival space for passengers in a side collision. For impact beam, we use special high tensile strength steel. The high tensile strength steel maintains its special crystal- line organization by heat treatment or alloy additives.

  • Page 19: Abbreviations Used In This Manual

    INTRODUCTION SS-17 ABBREVIATIONS USED IN THIS MANUAL For convenience, the following abbreviations are used in this manual. Antilock Brake System Air Conditioner assy assembly Electronic Controlled Transmission Electronic Control Unit e.g. Exempli Gratia (for Example) Except Front Wheel Drive Vehicles Four Wheel Drive Vehicles inch Left-hand...

  • Page 20: Radiator Support (Assy)

    BODY PANEL REPLACEMENT BP-1 RADIATOR SUPPORT (ASSY) REPLACEMENT REMOVE RADIATOR SUPPORT (a) Replace the headlamp inner bracket at the same time. F10301A...
  • Page 21 BP-2 BODY PANEL REPLACEMENT INSTALL RADIATOR SUPPORT (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: First install the radiator upper support. F10302 MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-72) 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.
  • Page 22 BODY PANEL REPLACEMENT BP-3 FRONT CROSSMEMBER FRONT (ASSY) REPLACEMENT REMOVE FRONT CROSSMEMBER FRONT F10303...
  • Page 23 BP-4 BODY PANEL REPLACEMENT INSTALL FRONT CROSSMEMBER FRONT (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: First install the radiator upper support and hood lock support. F10304...
  • Page 24 BODY PANEL REPLACEMENT BP-5 MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-72) MEASURING THE UNDERBODY DIMENSIONS (See page BP-72) 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.

  • Page 25: Front Crossmember (Assy)

    BP-6 BODY PANEL REPLACEMENT FRONT CROSSMEMBER (ASSY) REPLACEMENT REMOVE FRONT CROSSMEMBER F10305A...
  • Page 26 BODY PANEL REPLACEMENT BP-7 INSTALL FRONT CROSSMEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: First install the radiator upper support and hood lock support. F10306A...
  • Page 27 BP-8 BODY PANEL REPLACEMENT MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-72) MEASURING THE UNDERBODY DIMENSIONS (See page BP-72) 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.
  • Page 28 BODY PANEL REPLACEMENT BP-9 RADIATOR SUPPORT (ASSY) REPLACEMENT REMOVE RADIATOR SUPPORT F10307A...
  • Page 29 BP-10 BODY PANEL REPLACEMENT INSTALL RADIATOR SUPPORT (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10308A...
  • Page 30 BODY PANEL REPLACEMENT BP-11 MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-72) MEASURING THE UNDER BODY DIMENSIONS (See page BP-72) 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.

  • Page 31: Front Fender Front Apron (Assy)

    BP-12 BODY PANEL REPLACEMENT FRONT FENDER FRONT APRON (ASSY) REPLACEMENT REMOVE FRONT FENDER FRONT APRON F10309...
  • Page 32 BODY PANEL REPLACEMENT BP-13 INSTALL FRONT FENDER FRONT APRON (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10310 APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING UNDERCOATING (See page PC-5) 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.

  • Page 33: Cowl Top Side Panel (Assy)

    BP-14 BODY PANEL REPLACEMENT COWL TOP SIDE PANEL (ASSY) REPLACEMENT REMOVE COWL TOP SIDE PANEL F10311A...
  • Page 34 BODY PANEL REPLACEMENT BP-15 INSTALL COWL TOP SIDE PANEL F10312A 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.

  • Page 35: Front Fender Apron (Assy)

    BP-16 BODY PANEL REPLACEMENT FRONT FENDER APRON (ASSY) REPLACEMENT REMOVE COWL TOP SIDE PANEL (See page BP-14) REMOVE FRONT FENDER APRON F10313...
  • Page 36 BODY PANEL REPLACEMENT BP-17 INSTALL FRONT FENDER APRON HINT: Inspect the fitting of the front fender and hood, etc. before welding, since this affects the appearance of the finish. (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Make sure each measurement is correct, as this parts affects the front wheel alignment.
  • Page 37 BP-18 BODY PANEL REPLACEMENT MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-72) INSTALL COWL TOP SIDE PANEL (See page BP-14) APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING UNDER COATING (See page PC-5) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural...

  • Page 38: Front Side Member (Cut-P)

    BODY PANEL REPLACEMENT BP-19 FRONT SIDE MEMBER (CUT-P) REPLACEMENT REMOVE RADIATOR SUPPORT (See page BP-1) REMOVE FRONT CROSSMEMBER (See page BP-6) REMOVE FRONT SIDE MEMBER (a) Cut and join the parts at the locations as shown below. F10315A...
  • Page 39 BP-20 BODY PANEL REPLACEMENT INSTALL FRONT SIDE MEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10316A...
  • Page 40 BODY PANEL REPLACEMENT BP-21 MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-72) MEASURING THE UNDER BODY DIMENSIONS (See page BP-72) INSTALL FRONT CROSSMEMBER (See page BP-6) INSTALL RADIATOR SUPPORT (See page BP-1) 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.

  • Page 41: Front Side Member (Assy)

    BP-22 BODY PANEL REPLACEMENT FRONT SIDE MEMBER (ASSY) REPLACEMENT REMOVE RADIATOR SUPPORT (See page BP-1) REMOVE FRONT CROSSMEMBER (See page BP-6) REMOVE COWL TOP SIDE PANEL (See page BP-14) REMOVE FRONT FENDER APRON (See page BP-16) REMOVE FRONT SIDE MEMBER (a) Leave the steering gear box support member extension to the vehicle, remove the front side member.
  • Page 42 BODY PANEL REPLACEMENT BP-23 F10318A...
  • Page 43 BP-24 BODY PANEL REPLACEMENT INSTALL FRONT SIDE MEMBER (a) Remove the steering gear box support member extension from the new parts of front side member. (b) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Make sure each measurement is correct, as this parts affects the front wheel alignment.
  • Page 44 BODY PANEL REPLACEMENT BP-25 F10319...
  • Page 45 BP-26 BODY PANEL REPLACEMENT 7. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-72) 8. MEASURING THE UNDER BODY DIMENSIONS (See page BP-72) 9. INSTALL FRONT FENDER APRON (See page BP-16) 10. INSTALL COWL TOP SIDE PANEL (See page BP-14) INSTALL FRONT CROSSMEMBER (See page PB-6) 12.

  • Page 46: Front Body Pillar (Cut)

    BODY PANEL REPLACEMENT BP-27 FRONT BODY PILLAR (CUT) REPLACEMENT REMOVE COWL TOP SIDE PANEL (See page BP-14) REMOVE FRONT BODY PILLAR (a) Cut and join the parts at the locations as shown below. HINT: Shift the each cut and join locations of the outer pillar, inner pillar and rocker outer panel. F10321A...
  • Page 47 BP-28 BODY PANEL REPLACEMENT INSTALL FRONT BODY PILLAR HINT: Inspect the fitting of the front door, front fender and windshield glass, etc., before welding, since this af- fects the appearance of the finish. (a) Cut the new parts for the outer pillar and rocker outer panel at the locations as shown below. HINT: Install the rocker panel section of the outer pillar after cutting the supply part about 150 mm (5.91 in.) from the front of the cut line and butt welding the rocker outer panel.
  • Page 48 BODY PANEL REPLACEMENT BP-29 0.59 F10323A...
  • Page 49 BP-30 BODY PANEL REPLACEMENT F10324A 4. MEASURING THE OPENING PORTION DIMENSIONS (See page BP-72) 5. INSTALL COWL TOP SIDE PANEL (See page BP-14) 6. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) 7. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 8.

  • Page 50: Front Door Outer Panel (Assy)

    BODY PANEL REPLACEMENT BP-31 FRONT DOOR OUTER PANEL (ASSY) REPLACEMENT REMOVE FRONT DOOR OUTER PANEL (a) After grinding off the hemming location, remove the outer panel. F10363...
  • Page 51 BP-32 BODY PANEL REPLACEMENT INSTALL FRONT DOOR OUTER PANEL (a) Before temporarily installing the new parts, apply body sealer to the reinforcement side impact protection beam and back side of the new parts. HINT: D Apply sealer evenly about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter to the outer panel and apply just enough sealer for the side impact protection beam to make contact.
  • Page 52 BODY PANEL REPLACEMENT BP-33 APPLYING SEALER TO THE DOOR PARTS (See page PC-1) 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.
  • Page 53 BP-34 BODY PANEL REPLACEMENT ROCKER OUTER PANEL (CUT) REPLACEMENT REMOVE ROCKER OUTER PANEL (a) Cut and join the parts at the locations as shown below. HINT: This part is reused to cut from the front of the supply part cut point, behind the front pillar side and at the quarter panel side.
  • Page 54 BODY PANEL REPLACEMENT BP-35 INSTALL ROCKER OUTER PANEL HINT: Inspect the fitting of the front door, etc., before welding, since this affects the appearance of the finish. (a) Cut the new parts for rocker panel at the location as shown below. (b) After welding the rocker panel to the vehicle install the outer panel.
  • Page 55 BP-36 BODY PANEL REPLACEMENT MEASURING THE OPENING PORTION DIMENSIONS (See page BP-72) APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 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.
  • Page 56 BODY PANEL REPLACEMENT BP-37 QUARTER PANEL (CUT) REPLACEMENT REMOVE QUARTER PANEL (a) Cut and join the parts at the locations as shown below. (b) Replace the quarter panel end housing, back door opening trough and fuel filler opening lid at the same time.
  • Page 57 BP-38 BODY PANEL REPLACEMENT F10328A...
  • Page 58 BODY PANEL REPLACEMENT BP-39 INSTALL QUARTER PANEL HINT: Inspect the fitting of the front door, back 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: D Apply body sealer about 5 mm (0.20 in.) from the flange, avoiding any oozing.
  • Page 59 BP-40 BODY PANEL REPLACEMENT F10330A MEASURING THE OPENING PORTION DIMENSIONS (See page BP-72) APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) CHARGINE THE POLYURETHANE FOAM (See page PC-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.
  • Page 60 BODY PANEL REPLACEMENT BP-41 QUARTER WHEEL HOUSING OUTER PANEL (ASSY) REPLACEMENT REMOVE QUARTER PANEL (See page BP-37) REMOVE QUARTER WHEEL HOUSING OUTER PANEL (a) Cut and join the rocker panel No.2 reinforcement at the location as shown below. (b) After removing the roof side inner to wheel housing brace, remove the quarter wheel housing outer panel. F10331A...
  • Page 61 BP-42 BODY PANEL REPLACEMENT F10332...
  • Page 62 BODY PANEL REPLACEMENT BP-43 INSTALL QUARTER WHEEL HOUSING OUTER PANEL HINT: Temporarily install the quarter panel and inspect the fitting before welding, since this affects the appear- ance of the finish. (a) Determine the position of the new parts by the assembly marks of the inner and outer panels. F10333A...
  • Page 63 BP-44 BODY PANEL REPLACEMENT F10334A...
  • Page 64 BODY PANEL REPLACEMENT BP-45 INSTALL QUARTER PANEL (See page BP-37) APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) APPLYING UNDER COATING (See page PC-5) 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.
  • Page 65 BP-46 BODY PANEL REPLACEMENT ROCKER PANEL NO.2 REINFORCEMENT (ASSY) REPLACEMENT REMOVE QUARTER PANEL (See page BP-37) REMOVE ROCKER PANEL NO.2 REINFORCEMENT (a) Cut the rocker outer panel at the location shown in the below figure and remove the rocker panel No.2 reinforcement.
  • Page 66 BODY PANEL REPLACEMENT BP-47 INSTALL ROCKER PANEL NO.2 REINFORCEMENT HINT: Temporarily install the quarter panel and inspect the fitting before welding, since this affects the appear- ance of the finish. (a) Cut the new parts for the rocker outer panel at the locations as shown below. 0.59 19.88 F10336A...
  • Page 67 BP-48 BODY PANEL REPLACEMENT INSTALL QUARTER PANEL (See page BP-37) APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) APPLYING UNDER COATING (See page PC-5) 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.
  • Page 68 BODY PANEL REPLACEMENT BP-49 BODY LOWER BACK PANEL (ASSY) REPLACEMENT REMOVE BODY LOWER BACK PANEL F10337...
  • Page 69 BP-50 BODY PANEL REPLACEMENT INSTALL BODY LOWER BACK PANEL HINT: Inspect the fitting of the back door and rear combination light, etc., before welding, since this attacts the appearance of the finish. F10338...
  • Page 70 BODY PANEL REPLACEMENT BP-51 APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) APPLYING UNDER COATING (See page PC-5) 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.
  • Page 71 BP-52 BODY PANEL REPLACEMENT REAR FLOOR CENTER CROSSMEMBER (ASSY) REPLACEMENT REMOVE REAR FLOOR CENTER CROSSMEMBER (a) After removing the rear absorber mounting No.1 bracket, remove the rear floor center crossmember. F10343A...
  • Page 72 BODY PANEL REPLACEMENT BP-53 INSTALL REAR FLOOR CENTER CROSSMEMBER F10344A...
  • Page 73 BP-54 BODY PANEL REPLACEMENT APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING UNDER COATING (See page PC-5) REPLACEMENT SILENCER SHEET (See page PC-8) 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.
  • Page 74 BODY PANEL REPLACEMENT BP-55 REAR FLOOR PAN (ASSY) REPLACEMENT REMOVE BODY LOWER BACK PANEL (See page BP-49) REMOVE REAR FLOOR CENTER CROSSMEMBER (See page BP-52) REMOVE REAR FLOOR PAN (a) Replace the rear floor pan reinforcement at the same time. F10339A...
  • Page 75 BP-56 BODY PANEL REPLACEMENT INSTALL REAR FLOOR PAN F10340A...
  • Page 76 BODY PANEL REPLACEMENT BP-57 5. INSTALL REAR FLOOR CENTER CROSSMEMBER (See page BP-52) 6. INSTALL BODY LOWER BACK PANEL (See page BP-49) 7. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 8. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 9.
  • Page 77 BP-58 BODY PANEL REPLACEMENT REAR FLOOR PAN EXTENSION (ASSY) REPLACEMENT REMOVE BODY LOWER BACK PANEL (See page BP-49) REMOVE REAR FLOOR PAN EXTENSION F10341...
  • Page 78 BODY PANEL REPLACEMENT BP-59 INSTALL REAR FLOOR PAN EXTENSION F10342 INSTALL BODY LOWER BACK PANEL (See page BP-49) APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) APPLYING UNDER COATING (See page PC-5) REPLACEMENT SILENCER SHEET (See page PC-8) APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural...
  • Page 79 BP-60 BODY PANEL REPLACEMENT QUARTER INNER REAR PANEL (ASSY) REPLACEMENT REMOVE QUARTER PANEL (See page BP-37) REMOVE QUARTER INNER REAR PANEL (a) Replace the back door opening side reinforcement at the same time. F10347...
  • Page 80 BODY PANEL REPLACEMENT BP-61 INSTALL QUARTER INNER REAR PANEL HINT: Temporarily install the quarter panel and inspect the fitting before welding, since this affects the appear- ance of the finish. F10348 INSTALL QUARTER PANEL (See page BP-37) APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) APPLYING UNDER COATING (See page PC-5) APPLYING ANTI-RUST AGENT...
  • Page 81 BP-62 BODY PANEL REPLACEMENT REAR FLOOR SIDE REAR MEMBER (ASSY) REPLACEMENT REMOVE BODY LOWER BACK PANEL (See page BP-49) REMOVE REAR FLOOR SIDE REAR MEMBER F10349...
  • Page 82 BODY PANEL REPLACEMENT BP-63 3. INSTALL REAR FLOOR SIDE REAR MEMBER (a) When temporarily installing the new parts, determine the installation position by the assembly mark. Then measure each part in accordance with the body dimension diagram. F10350A 4. MEASURING THE UNDER BODY DIMENSIONS (See page BP-72) 5.
  • Page 83 BP-64 BODY PANEL REPLACEMENT REAR FLOOR NO.2 CROSSMEMBER (ASSY) REPLACEMENT REMOVE REAR FLOOR NO.2 CROSSMEMBER F10345...
  • Page 84 BODY PANEL REPLACEMENT BP-65 INSTALL REAR FLOOR NO.2 CROSSMEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10346...
  • Page 85 BP-66 BODY PANEL REPLACEMENT MEASURING THE UNDER BODY DIMENSIONS (See page BP-72) APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING UNDER COATING (See page PC-5) 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.
  • Page 86 BODY PANEL REPLACEMENT BP-67 ROOF PANEL (ASSY) REPLACEMENT REMOVE ROOF PANEL F10351...
  • Page 87 BP-68 BODY PANEL REPLACEMENT F10352A...
  • Page 88 BODY PANEL REPLACEMENT BP-69 INSTALL ROOF PANEL: w / o Moon Roof (a) Before temporarily installing the new parts, apply body sealer to the windshield header inner panel, roof panel reinforcement and back door opening frame. HINT: D Apply just enough sealer for the new parts to make contact. D For other sealing points, refer to section PC.
  • Page 89 BP-70 BODY PANEL REPLACEMENT INSTALL ROOF PANEL: w / Moon Roof (a) Before temporarily installing the new parts, apply body sealer to the windshield header inner panel, roof panel reinforcement and back door opening frame. HINT: D Apply just enough sealer for the new parts to make contact. D For other sealing points, refer to section PC.
  • Page 90 BODY PANEL REPLACEMENT BP-71 APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) CHARGING THE POLYURETHANE FOAM (See page PC-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.

  • Page 91: General Information

    BP-72 BODY PANEL REPLACEMENT GENERAL INFORMATION BASIC DIMENSIONS (a) There are two types of dimensions in the diagram. (1) (Three-dimensional distance) Straight-line distance between the centers of two mea- suring points. F10115A (2) (Two-dimensional distance) Horizontal distance in forward/rearward between the centers of two measuring points.
  • Page 92 BODY PANEL REPLACEMENT BP-73 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. (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers.
  • Page 93 BP-74 BODY PANEL REPLACEMENT BODY DIMENSION DRAWINGS ENGINE COMPARTMENT...
  • Page 94 BODY PANEL REPLACEMENT BP-75 BODY OPENING AREAS (Side View)
  • Page 95 BP-76 BODY PANEL REPLACEMENT BODY OPENING AREAS (Rear View)
  • Page 96 BODY PANEL REPLACEMENT BP-77 UNDER BODY...
  • Page 97 BP-78 BODY PANEL REPLACEMENT UNDER BODY (Cont’d)

  • Page 98: Engine Compartment

    PAINT COATING PC-1 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 ap- plying body sealer.
  • Page 99 PC-2 PAINT COATING 2. INSIDE F10357A...

  • Page 100: Rear Luggage Compartment

    PAINT COATING PC-3 3. REAR LUGGAGE COMPARTMENT F10358A...

  • Page 101: Door Parts

    PC-4 PAINT COATING 4. DOOR PARTS F10359A...
  • Page 102 PAINT COATING PC-5 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.
  • Page 103 PC-6 PAINT COATING 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 acci- dently applied to other areas.
  • Page 104 PAINT COATING PC-7 FOAMED MATERIAL APPLICATION AREAS The sections shown in the figure below are filled with foamed material to provide noise insullation. After repairing these sections or their peripheries, refill with foamed materials. HINT: Use the service holes located on the reverse side of the body panel to refill with foamed materials. When handling foamed material, follow the directions of the material’s manufacturer.
  • Page 105 PC-8 PAINT COATING SILENCER SHEET INSTALLATION AREAS F10361A...
  • Page 106 PAINT COATING PC-9 BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS HINT: Anti-chipping paint should be applide 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.

This manual is also suitable for:

Zzt231 series

Table of Contents