TOYOTA SUPRA 1997 Service Repair Manual

Flat Surfacing
Normal Roof
Flat Surfacing
Flat Surfacing
Sport Roof
Flat Surfacing
Flat Surfacing
Flat Surfacing
ANTI-RUST TREATMENTAR-6

Flat Surfacing
Flat Surfacing
All Around
Flat Surfacing
Flat Surfacing
Flat Surfacing
Flat Surfacing
Flat Surfacing
ANTI-RUST TREATMENTAR-7

COWL TOP SIDE PANEL (ASSY)
REMOVAL
(Right Side)(Left Side)
Cut with disc
Sander etc.
Cut with disc sander etc.
Cowl Top to Apron Brace
Cowl Top to Apron Brace
Cut with disc
Sander etc.
1. After removing the cowl top to apron brace,
remove the cowl top side panel.
BODY PANEL REPLACEMENTRE-20

mm in.
15
200.59
0.79
INSTALLATION
(Left Side)
(Right Side)
Tack Weld (20 mm each)Tack Weld
(20 mm each)
Assembly Mark
Tack Weld
(15 mm each)
1. 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.
BODY PANEL REPLACEMENTRE-21

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COLLISION REPAIR INFORMATION
FOR THE TOYOTA DEALER


TITLE: PAINTLESS DENT REPAIR

SECTION: EXTERIOR BULLETIN # 146

MODELS: TOYOTA, SCION AND LEXUS

DATE: SEPTEMBER 2006


Toyota has developed the following guidelines for the use of “Paintless Dent
Repair” (PDR) procedures on all Toyota, Scion and Lexus vehicles.

PDR is used to reduce the cost of repairing minor dents and to avoid color match
and refinish issues that may arise. Be sure to choose your PDR service provider
carefully and always review their professional qualifications to ensure they are up
to date on the latest PDR techniques and procedures.


Repair Precautions


• Always refer to the specific vehicle schematic (available from your PDR provider)
for locations where PDR is possible.
• Pay close attention to the locations of accessories and subassemblies that may
utilize wire harnesses or drain hoses, etc.
• PDR is often complicated by panel contour, placement of reinforcements, and
location of electrical and mechanical components.
• PDR Technicians should be aware of and take the necessary precautions to
prevent damage to electrical and mechanical components while performing
PDR repairs.

General Repair Guidelines


• The PDR process should only be considered when the exterior paint surface
is not broken or cracked. A 30X power hand held microscope (available from
most body shop jobbers) should be used to determine if the paint surface
shows evidence of cracking.
• Pushing and prying on the back side of body panels can disrupt the factory
rust and corrosion protective coatings. PDR technicians must take steps to
prevent corrosion coating damage or restore it with approved equivalent
materials. PDR service companies performing PDR repairs should be
knowledgeable and capable of restoring corrosion protective coatings
damaged during PDR repairs.

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MANAGER AND COLLISION REPAIR TECHNICIANS

00408-03000-146
• Prying, pushing, or pulling on body panels may cause stretching beyond the
flexible limits of the paint coatings causing delamination (paint coating
separation) or micro-cracking. These conditions may not be immediately
detectable (use a 30X magnifying hand-held microscope to inspect for
cracks).

Important
: The PDR process uses special tools to access otherwise
inaccessible areas. Drilling of holes, prying away or cutting
reinforcements or welded structural components to gain access to perform
a PDR is strictly prohibited and, if done, may void the manufacturer’s
corrosion protection warranty.

• Using blocks or wedges between window moldings and door glass (for tool
access) is also prohibited. This process can damage window moldings and
reduce the factory designed-in pressure of the inner belt molding on the base of
the door glass.
• Window guard protectors must be used to protect window glass during PDR
operations.

Specific Repair Guidelines


• Panels with multiple dents, including hail damage, may be considered for
PDR as long as the original panel integrity (strength) is maintained. If a panel
exhibits any evidence of loss of strength due to the number of dents, the
panel should not be considered for PDR. If after performing a PDR repair the
panel exhibits evidence of loss of strength, the panel must be repaired using
conventional body shop processes.
• Round/oval dents may be removed if they are 2 inches or more away from
panel edges or body lines and are no larger than the diameter of a soft ball.
• Creases that are up to 4” long
may be considered for removal.

Note
: sharp creases cannot be removed using PDR.

• Dents or protrusions, of up to 6mm, from the reverse side, on hoods, trunks,
fenders, and quarter panels may be considered, but extreme caution must be
used during this type of repair due to the higher potential of damaging the
paint surface. Remember no broken paint
.

mm in.
4.5
4.6
5.0
6.5
9.20.177
0.181
0.197
0.256
0.362
FIT STANDARDS
After doors and the engine hood are installed, be sure to perform fit adjustment to prevent abnormal wind
noise and ensure a good appearance.
5.0 mm
4.5 mm
4.5 mm
4.6 mm
9.2 mm
6.5 mm
5.0 mm
APPENDIXAP-2

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 periph-
eries, refill with foamed materials.
HINT:
1. Use the service holes located on the
reverse side of the body panel to refill
with foamed materials.
2. When handling foamed material, follow
the directions of the material's manufac-
turer.
NORMAL ROOFAPPENDIX
AP-4

SPORT ROOFAPPENDIX
AP-5

FRONT FENDER APRON (ASSY)
REMOVAL (With the radiator upper support removed.)
Cut with disc
sander etc.
BODY PANEL REPLACEMENTRE-10