diagram TOYOTA LAND CRUISER 1998 Factory Repair Manual

INSTALLATION
PRE-WELDING MEASUREMENTS
Always take measurements before
installing underbody or engine com-
ponents to insure correct assembly.
After installation, confirm proper
fit.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 grind-
er, be careful not to grind off
too much as this would
weaken the weld.
WRONG
WRONG
OKAY
2. Plug welding should be done
with a MIG (Metal Inert Gas)
welder. Do not gas weld or
braze panes 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.New Spot
Locations
Old
Spot
Locations
Tip Cutter
INTRODUCTIONIN-13

mm in.
150
2505.91
9.84
QUARTER PANEL (CUT)
Replacement Parts
QUARTER PANEL
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
RE-28
REMOVALCut and Join Location
Cut and Join Location
150 mm
250 mm
[Cut and Join Location]
Cut and Join
Location
(Cut Location for
Supply Parts)
[Cut and Join Locations]
1. Cut and join the parts at the locations as shown
above.
REPLACEMENT PARTS AND METHOD
(CUT)
Replacement method
(ASSY) Assembly replacement. . . . . . .
(CUT) Major cutting (less than 1/2 of parks used). . . . . . . .
(CUT-H) Half cutting (about 1/2 of parks used). . . . . .
(CUT-P) Partial cutting (most of parts used). . . . . .
PARTS LOCATION
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.
INTRODUCTIONIN-2

mmin,
50.20RE-29 BODY PANEL REPLACEMENT
INSTALLATIONButt Weld
Butt Weld
Foamed Material
Application Areas
Body Sealer
Butt Weld
Body Sealer
about 5 mm
2. Temporarily install the new parts and check the
fit of the rear door, back door, tail gate and rear
combination light.
3. After installing the new parts, apply foamed ma-
terials. 1. Before temporarily installing the new parts,
apply body sealer to the wheel arch.
HINT:
1) Apply body sealer about 5 mm (0.20 in.) from
the flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4 mm (0.12 -
0.16 in.) in diameter.
3) For other sealing points, refer to section AR.
INSTALLATION DIAGRAM
Describes in detail installation of the new parts 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 POINTS
Weld method and panel position symbols.
See page IN-5.
INTRODUCTIONIN-3

SYMBOLSMEANINGILLUSTRATION
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.
INTRODUCTIONIN-4

INSTALLATION
Butt Weld
Pillar Reinforcement
Inner Pillar
Rocker Panel
Reinforcement
Butt Weld
Butt Weld
Foamed Material
Application Area
Butt Weld
Butt Weld
Butt Weld
1. Temporarily install the new parts and mea-
sure each part in accordance with the body
dimension diagram.
2. Temporarily install the new parts and check
the fit of the front door and rear door.3. After welding inner pillar and rocker panel
reinforcement and pillar reinforcement to the
vehicle install the outer pillar.
4. After installing the new parts, apply foamed
materials.
BODY PANEL REPLACEMENTRE-19

mm in.
20
0.79 Foamed Material
Application Area
Butt Weld
Butt Weld
Butt Weld
Butt Weld
Tack Weld (20 mm)
Butt Weld
6. Apply foamed material to the pillar section. 4. Temporarily install the new parts and measure
each part in accordance with the body dimen-
sion diagram.
5. Before welding the new parts, check the fit of
the front door, front fender and windshield
glass.
BODY PANEL REPLACEMENTRE-17

INSTALLATION
1. Temporarily install the new parts and measure
each part in accordance with the body dimen-
sion diagram.
BODY PANEL REPLACEMENTRE-7

INSTALLATION
1. Temporarily install the new parts and measure
each part in accordance with the body dimen-
sion diagram.2. Temporarily install the front fender and hood,
and check the fit.
BODY PANEL REPLACEMENTRE-13

(Without Battery Carrier Support): RH (With Battery Carrier Support):
INSTALLATION
LH:
RH (With Battery Carrier Support):
[RH only]
LH:
Intercooler Mounting Retainer
1. Temporarily install the new parts and measure
each part in accordance with the body dimen-
sion diagram.
HINT: First install the radiator upper support.
BODY PANEL REPLACEMENTRE-5

GENERAL INFORMATION
1. BASIC DIMENSIONS
(a) There are two types of dimensions in the diagram.
(Three-dimensional distance)

Straight-line distance between the centers of two
measuring points.
(Two-dimensional distance)

Horizontal distance in forward/rearward between
the centers of two measuring points.

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 dimen-
sions 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.
Center-to-center
straight-line
distance Three-dimensional
distance
Front Spring Support Inner Hole
Tape Measure
Along Body
Surface
Front Suspension Member Rear Side
Upper Installation HoleMaster Gauge PointerPointer LoosenessBody LoosenessPlate Looseness Two-dimensional
distanceCenter-to-center
Horizontal distance in
forward/rearward
Vertical distance
in lower surface Vertical distance
in center
Imaginary Standard Line
WrongCorrect
Pointer
BODY DIMENSIONSDI-2