TOYOTA SUPRA 1997 Service Repair Manual

SPOT WELD LOCATIONS
Try to avoid welding over pre-
vious spots.
New Spot
Locations
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.
INSTALLATION
POST-WELDLNG REFINISH-
ING
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.
WRONG
WRONG
OKAY
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.
Oil
spot
Locations
Tip Cutter
INTRODUCTIONIN-13

Cartridge Type
ANTI-RUST TREATMENT
When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the
requirements of your country.
HINT: For further details, see the description given in section AR of this manual.
BODY SEALER
Apply body sealer to the
required areas.ANTI-RUST AGENT (WAX)
Apply anti-rust agent to
following sections.

Inside of the hems of the
doors and hood.

Around the hinges of the
doors and hood.

Inside of the welded parts
with boxed cross-section.
Tube Type
UNDERCOAT
Apply undercoat to the underbody and
wheel housings.
spray Gun
Undercoating
(Oil base)Undercoating
(Water base)
INTRODUCTIONIN-14

SUPPORT POSITIONPANTOGRAPH JACK POSITION
CAUTION: Before jacking-up the rear and front, make sure the car is
not carrying any extra weight.
Front Front crossmember. . . . . . . .
Rear Rear axle beam. . . . . . . . .
JACK POSITION
Front
Safety stand and swing arm type lift . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE LIFT AND SUPPORT LOCATIONS
INTRODUCTIONIN-15

ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
FWD Front Wheel Drive Vehicles
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
w/ with
w/o without
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
INTRODUCTIONIN-16

FOR THE TOYOTA DEALER
COLLISION REPAIR INFORMATION
TITLE: ANTI±CORROSION TREATMENT PAGE 1 of 4
SECTION: GENERAL INFORMATION BULLETIN #82
MODELS: ALL
DATE: DECEMBER 1997
To prevent corrosion and reduce interior noise when replacing body panels, always apply
corrosion inhibiting and sound dampening materials such as body sealer, cavity wax,
undercoating and body foam according to Toyota recommendations.
These recommendations can be found in the Anti±Rust Treatment (AR) section of the
model specific Repair Manual for Collision Damage publication. Collision repair manuals
can be obtained through a Toyota dealership parts department.
BODY SEALER
For waterproofing and corrosion protection measures, always apply body sealer to the
seams and hems of the doors, hoods, etc.
Apply body sealer to required areas:
Door seams (Illustration A.)
Underhood seams (Illustration B.)
Wherever body sealer has been removed during a repair
Illustration A.
Illustration B.

ANTI±CORROSION TREATMENT (cont'd) PAGE 2 of 4
CAVITY WAX
To provide corrosion resistance, always apply cavity wax to the inside of the hemming
areas of the doors and hoods, around the hinges, and to the welded surfaces inside the
boxed cross±section structure of the side member, body pillar, etc.
Apply cavity wax to required areas:
Inside of the hems of the doors and hoods (Illustration A.)
Around the hinges of the doors and hood (Illustration B.)
Wherever the original cavity wax was disturbed during a repair
Illustration A. Illustration B.
UNDERCOATING
To protect the body from damage by flying stones, always apply chip resistant materials to
the bottom surfaces of the underbody and inside of the wheel housing.
Apply chip resistant materials to all welded areas and panel joints (Illustration A.); then
apply to the entire area (Illustration B.).
Illustration A. Illustration B.

ANTI±CORROSION TREATMENT (cont'd) PAGE 3 of 4
BODY FOAM
Apply body foam to all areas where foam was damaged or removed during a repair. This
will restore sound deadening characteristics and corrosion protection.
Apply body foam to all required areas:
ªAº, ªBº and ªCº pillar
Rocker panels
Wherever foam was disturbed or removed during a repair
The information on the application of all anti±corrosion materials is contained in the
Anti±Corrosion Treatment section (AR), and throughout the Body Panel Replacement
section of the Toyota Repair Manual for Collision Damage Publications. Information on
anti±corrosion material application can also be found in the Fundamental Body Repair
Procedures manual and the Noise, Vibration, and Harshness manual.
These publications may be obtained through your local Toyota dealership parts department
or by obtaining the part number and calling:
1±800±622±2033 Mon±Fri 7:00 a.m. to 4:30 p.m. Pacific Standard Time
This information can also be obtained by attending Toyota Collision Repair and Refinish
training courses:

Non±Structural Body Repair Techniques

Structural Body Repair Techniques

ANTI±CORROSION TREATMENT (cont'd) PAGE 4 of 4
MANUFACTURERS LIST
Provided is a list of manufacturers. Call them directly to obtain a list of their products or a
product demonstration brochure.
Phone Web site
3M: 1±800±877±9344 N/A
Kent: 1±800±654±6333 http://www.farnell.co.uk
Dominion: 1±800±265±0790 http://www.dominionsureseal.com
SEM: 1±800±831±1122 N/A
Crest: 1±800±822±1400 http://www.crestauto.com
Wurth:
Western area 1±800±346±4198 http://www.wurthwest.com
Illinois 1±800±99±WURTH http://www.wurthillinois.com
Florida 1±800±829±8316 http://www.wurthflorida.com
All other states 1±800±526±5228 http://www.wurthusa.com

mm (in.)NO8903
NO8971
HINT: For symbols, capital letters indicate
right side of vehicle, small letters indicate
left side of vehicle (Seen from rear).
1,617
(63.66) 263
(10.35)652
(25.67) A-L, a-l C-l, c-L G-g
Vehicle Dimensions
(Three-Dimensional Distance)
Symbol Name Hole dia. Symbol Name Hole dia.
A, a Front fender apron standard hole 10 (0.39) J, j Front side member reinforcement standard hole 8 (0.31)
B, b Front spring support hole-front 11 (0.43) Cooling fan installation nut 6 (0.24) nut
C, c Cowl top side panel standard hole 10 (0.39) L, l Front fender installation nut 6 (0.24) nut
Cowl top panel center mark M, m Hood hinge installation nut 8 (0.31) nut
E, e Front side member working hole 18 (0.71) N, n Headlight installation nut 6 (0.24) nut
F, f Front side member standard hole 13 (0.51) O, o Headlight installation hole
14x10.6
(0.55x0.42)
G, g Radiator duct installation hole 7.2 (0.283) P, p Headlight installation hole
H, h Radiator support apron brace standard hole 10 (0.39) Q, q Headlight installation hole
I, i Apron fender side extension standard hole 9 (0.35)
BODY DIMENSION DRAWINGS
ENGINE COMPARTMENT
D
14x9
(0.55x0.35)
14x9
(0.55x0.35)
K
BODY DIMENSIONSDI-3

BODY LOWER BACK PANEL (ASSY)
REMOVAL
Braze
Braze
BODY PANEL REPLACEMENTRE-48