Toyota Tacoma User Manual

Manual Name Pub. No.

7M−GE Engine Repair Manual

TOYOTA SUPRA Chassis and Body

Repair Manual

TOYOTA SUPRA Chassis and Body

Repair Manual Supplement

TOYOTA SUPRA Electrical Wiring

Diagram Manual

TOYOTA SUPRA Repair Manual

(USA and Canada)

TOYOTA SUPRA Electrical Wiring

Diagram Manual (USA and Canada)

Fundamental Body Repair Procedures

Fundamental Painting Procedures

BRM002E

36438E

M/Y Version

M/Y Version

EWD013E

RM036E

RM029E

RM027E

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 SUPRA.

Applicable models: MA70 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, tools, equipment, etc. However, it should be noted that
the front fenders of all TOYOTA models are bolted on and re­quire no welding.

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 service of specifications and repair procedures other
than collision−damaged body components of the TOYOTA
SUPRA, 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 proce­dures are subject to change without prior notice.

TOYOTA MOTOR CORPORATION

1

mm

in.

87

3.15

200

7.87

QUARTER PANEL

Cut and Join Location

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.

RE−26

BODY PANEL REPLACEMENT−Rear Body Components

QUARTER PANEL (CUT)

REMOVAL

Cut and Join Location

200 mm

80 mm

[Cut and Join Location]

Front

Braze

Rear

1. Cut and join the quarter panel as shown above.

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). . . .

Replacement part

BODY VARIATIONS AND PART LOCATION

Body variations: Non All 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.

5

0.20

1. Before temporarily installing the new part, apply
body sealer to the wheel arch portion.

NOTE:

1) Apply sealer approx. 5 mm (0.20 in.) from the
flange, avoiding any oozing.

2) Apply evenly, approx. 3 − 4 mm (0.12 − 0.16 in.)
in diameter.

3) For other sealing points, refer to section SU.

BODY PANEL REPLACEMENT−Rear Body Components

RE−27

INSTALLATION

Butt Weld

Butt Weld

Body Sealer

Braze

Body Sealer

About 5 mm

2. Temporarily installing the new part and check the fit of
the front door, luggage compartment door and rear
combination lamp.

INSTALLATION DIAGRAM

Describes in detail installation of the new part 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−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

GENERAL REPAIR INSTRUCTIONS

Work Precautions

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.

SAFETY
Never stand in direct
line with the chain when
using a puller an the
body or frame, and be
sure to attach a safety
cable.

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.

Welder’s
Glasses

Body
Mechanic
Stand

Dust−
Prevention
Mask

Face
Protector

Ear
Plugs

Head
Protector Welder’s

Gloves

HAND TOOLS
Keeping your hand tools
in neat order will have
an effect on your work
efficiency.

Safety
Shoes

Cotton
Gloves

INTRODUCTION

IN-6

REMOVAL OF ADJACENT
PART S
When removing adjacent parts
by avoid accidental marring,
etc., wrapping the tools used
and surrounding body parts in
protective tape.

NOTE:

1) Take particular care not
to damage any screw or
clip holes.

2) If you do scratch a
painted surface, retouch
immediatly after. Even a
small scratch will result
in rust and corrosion.

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, ap­ply touch−up paint immediately. Even
the slightest scratch may result in cor­rosion or appearance of rust.

NO. OF SPOT WELDS
Make a note of the
number of spot welds
for later reference.

NOTE: The number
of spot welds may
vary depending on
the vehicle.

PRE−REMOVAL MEASURING
Before removal or cutting opera­tions, take measurements in ac­cordance with the dimension dia­gram. Always use a puller to
straighten a damaged body or
frame.

CUTTING AREA
Always cut in a straight
line and avoid reinforced
areas.

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 Okay

Corners

Reinforcement

WRONG

INTRODUCTION

IN-7

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.

POST−WELDING REFINISH­ING

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.

PRE−WELDING MEASUREMENTS
Always take measurements before
installing underbody or engine com­ponents to insure correct assembly.
After installation, confirm proper fit.

WRONGOKAY

Seal

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 PRECAUTIONS

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.

SPOT WELD LOCATIONS
Try to avoid welding over
previous spots.

Old
Spot
Locations

New Spot
Locations

Tip Cutter

INTRODUCTION

IN-8

Thickness of
welded portion

Size of plug hole

1.0 (0.04) under

5 (0.20)

φ over

1.0 (0.04) over

6.5 (0.26)

φ over

REFERENCE:

mm (in.)

PREPARATION FOR INSTALLATION

SPOT WELD POINTS

APPLICATION OF WELD−THROUGH PRIMER

Less than
3 mm

When welding panels with a
combined thickness of over 3
mm (0.12 in.), use a MIG
(Metal Inert Gas) welder for
plug welding.

NOTE: Spot welding will
not provide sufficient dura­bility for panels over 3 mm
(0.12 in.) thick.

For treatment
against corrosion,
remove the paint
from the portion of
the new part and
body to be welded,
and apply weld−
through primer.

Air Saw

WRONG

20 − 30 mm

Puncher

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
he used, use a puncher or drill to make
holes for plug welding.

INTRODUCTION

IN-9

ANTI−CORROSIVE TREATMENT

When replacing body panels, always apply body sealer, anti−rust treatment or undercoating according to
the requirements of your country.

CHASSIS RUST−PROOFING

Anti−rust treatment for weld­ing spots or inside brazed
areas (torque box).

BODY SEALER
Apply body sealer to the
required areas.

Nozzle

Tube
Type

Air Gun

Cartridge
Type

UNDERCOATING
Anti−rust treatment for underbody welding
spots and wheel housings.

Spray Gun

Undercoating
(Water base)

Undercoating
(Oil base)

INTRODUCTION

IN-10

IN0088
IN0089

SUPPORT POSITION

PANTOGRAPH JACK POSITION

Front Center of front suspension crossmember. . . . . . . . .

Rear Center of differential carrier. . . . . . . . . .

JACK POSITION

Safety stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front

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
M/Y Model Year
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

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, measure­ments 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
welding.

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

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
damaged 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.

Surforrn Tool

For rough finishing of panels.

GRINDING AND POLISHING TOOLS (Cont’d)

TOOLS AND EQUIPMENT

TE-7

Master Gauge

Plate Looseness

Two−dimensional
distance

Center−to−center
Horizontal distance in
forward/rearward

Wrong

Correct

GENERAL INFORMATION

1. BASIC DIMENSIONS

(a) There are two types of dimensions in the diagram.

(Three−dimensional distance)

S Straight−line distance between the centers of two

measuring points.

(Two−dimensional distance)
S Horizontal distance in forward/rearward between

the centers of two measuring points.

S The height from an imaginary standard line.

(b) In cases in which only one dimension is given, left

and right are symmetrical.

(c) The dimensions in the following drawing indicate

actual distance. Therefore, please use the dimen­sions as a reference.

2. 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.

HINT:

1. The height of the left and right pointers must be equal.

2. Always calibrate the tracking gauge before measuring or
after adjusting the pointer height.

3. Take care not to drop the tracking gauge or otherwise
shock it.

4. Confirm that the pointers are securely in the holes.

(c) When using a tape measure, avoid twists and

bends in the tape.

(d) When tracking a diagonal measurement from the

front spring support inner hole to the suspension
member upper rear installation hole, measure
along the front spring support panel surface.

Pointer

Center−to−center
straight−line
distance

Vertical distance
in lower surface

Vertical distance
in center

Body Looseness

Pointer

Pointer Looseness

Three−dimensional
distance

Imaginary Standard Line

Front Suspension Member Rear Side
Upper Installation Hole

Along Body
Surface

Front Spring Support Inner Hole

Tape Measure

BODY DIMENSIONS

DI-2

mm (in.)

ENGINE COMPARTMENT

Symbol

Nomenclature

Hole dia.

BO1788

A, a

Front fender installation nut−front

8 (0.31)

B, b

Front spring support hole−rear

11 (0.43)

C, c

Front fender installation nut−rear

8 (0.31)

D

Cowl top panel center mark

E, e

Front side member standard hole

15 (0.59)

F, f Suspension member rear installation hole−upper

17 (0.67)

G, g Retractable light bracket installation nut−upper

11 (0.43)

H, h

Radiator seal installation hole−lower

7 (0.28)

I, i Front fonder aide installation hole 8 (0.31)
J, j

Cowl top panel standard hole

10 (0.39)

K

Hood lock support brace installation nut 7 (0.28)

BODY DIMENSION DRAWINGS

BODY DIMENSIONS

DI-3

mm (in.)

Front

X, x Point

LUGGAGE COMPARTMENT

Symbol

Nomenclature

Hole dia.

BO1790

V

Back door opening frame center mark

2 (0.08)

W, w

Rear suspension spring support hole−inner

9 (0.35)

X, x

Rear floor pan bumper installation hole−front

40 (1.57)

BODY DIMENSIONS

DI-3

BO1789

Wheel base 2,595 (102.17)

Imaginary
Standard
line

UNDER BODY

mm (in)

Hole dia.

10 (0.39)

19 (0.75)

18 (0.71)

25×18(0.98×0.71)

18 (0.71)

Nomenclature

Front floor No. 2 reinforcement standard hole

Suspension member front installation hole−outer

Center floor side member standard hole
Suspension member rear installation hole
Rear floor side member standard hole

Symbol

Q,q

R, r

S, s

T, t
U, u

Hole dia

15 (0.59)

17×15 (0.67×0.59)

11 (0.43)

17 (0.67)

17 (0.67)

10 (0.39)

Nomenclature

Front side member bumper front installation hole−Lower

Front side member bumper front installation hole−Lower
Stabilizer front installation nut

Suspension member front installation hole−lower
Suspension member rear installation hole−lower

Front floor under reinforcement standard hole

Symbol

L

I

M, m

N, n
O,o

P, p

BODY DIMENSIONS

DI-3

mm in.

2

0.08

7

0.28

10

φ

0.39

l0

φ

l0φ

l0φ

2R

Center Mark

STANDARD BODY MARKS

LIFTBACK

Assembly Mark

Center Mark

(7

φ)

Center Mark

Assembly MarkAssembly Mark

Assembly Mark

Assembly Mark

l0

φ

BODY PANEL CONSTRUCTION

CN-2

Door Side Impact
Protection Beam
(USA, Canada, Saudi Arabia and
Australia)

Front Bumper Reinforcement

Front Apron to Cowl
Side Upper Member

Front Body
Outer Pillar

Front side Member

Front Floor Under
Reinforcement

Front Crossmember
No. 2 Reinforcement

Rear Bumper
Reinforcement

Belt Anchor
Reinforcement

Rear Floor
Side Member

Rear Suspension
Spring Support

Front Spring
Support Plate

Belt Anchor to Roof
Side Inner Reinforcement

Cowl Top to
Apron Brace

Quarter Pillar Inner
Reinforcement

Back Door Hinge
Reinforcement

Quarter Wheel
Housing No. 1 Gusset

Front Body Pillar Upper
Inner Reinforcement

Hood Stopper
Reinforcement

Back Door Lower
Outer Panel

Engine Hood Panel

Back Door Upper
Outer Panel

The handling of HSS is the same as for mild steel, but the following should be observed.

HIGH−STRENGTH STEEL (HSS) PARTS

Generally, High−Strength Steel (HSS) is that which has an intensity value of at least 35 kg f/mm2, and
distinguished from mild steel.

1. Panel Hammering; Because HSS is thinner than mild steel, care should be taken to avoid warping
during hammering operations.

2. Removing Stop Welds: Because HSS is tougher than mild steel, damage will occur more easily to a
regular drill. Therefore, an HSS Spot Cutter is recommended.
Also, use a high−torque drill at low speed, and supply grinding oil to the drill during use.

3. Panel Welding: Panel welding procedures for HSS are exactly the same as for mild steel. Plug
welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at
areas other than specified.

BODY PANEL CONSTRUCTION

CN-3