Toyota TechDoc 86 / ZN6

Outline OFF Top Back New (BM2090E)

BODY LOWER BACK PANEL > ASSEMBLY REPLACEMENT

BODY LOWER BACK
PANEL > ASSEMBLY
REPLACEMENT

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

INSTALLATION

Symbol meaning

Plug Weld

INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
3. After welding, apply body sealer to the corresponding parts. (See the painting / coating)
4. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

CAUTION LABEL > ATTACHMENT POSITION

CAUTION LABEL >
ATTACHMENT
POSITION 1. After using a degreasing agent to clean the surfaces of the body where the caution labels
will be attached, attach the caution labels to the positions shown in the illustration.

HINT:

Make sure the caution label is not attached over a spot weld.
When attaching the caution label, make sure not to touch the label's
adhesive surface.
To prevent the edges of the caution label from peeling, apply extra
pressure to the label's periphery.
If the work area's temperature is 5°C or less, the caution label's
adhesive will deteriorate. It is recommended that you heat the label to
20 to 40°C.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

CENTER BODY PILLAR > CUT AND JOIN REPLACEMENT SECTIONS

CENTER BODY PILLAR
> CUT AND JOIN
REPLACEMENT
SECTIONS With the quarter panel removed.

Weld work for 980 MPa ultra high

strength steel

REMOVAL
Follow the welding conditions below
when welding ultra high strength
INSTALLATION steel to assure sufficient weld
strength. (When repairing this
model)
*1: When welding 2 panels together
including 980 MPa ultra high strength
steel.

Plug diameter 10 mm (0.39 in.)

Plug weld Wire type AWS A5.18 ER70S-3
Shield gas Metal active gas

*2: When welding more than 3 panels together including 980 MPa ultra high strength steel.
(When plug welding a third panel to 2 panels which are welded under the conditions
described above.)

Same as the standard method (See the

Plug diameter
introduction)
Plug weld
Wire type AWS A5.18 ER70S-3
Shield gas Metal active gas

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

Cut with Disc Sander etc.

Cut and Join Location

REMOVAL POINT
1. Do not butt weld or heat repair because the heat decreases the strength of areas where
ultra high strength steel is used. (See the introduction)
2. *3 is reused.
INSTALLATION

Symbol meaning

Plug Weld

Plug Weld
 Cut and Join Location

Fillet Weld

Butt Weld

INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
3. If the entire supply part is not needed, remove the part of the supply part that is needed.
4. Follow the welding conditions when welding *1 and *2 to assure sufficient weld strength.
(See the introduction)
5. Before temporarily installing the new parts, weld the center body pillar reinforcement sub-
assembly and rocker reinforce sub-assembly outer with the standard number of welding
points.
6. After welding the No.1 inner pillar sub-assembly the vehicle side, install the center body
pillar reinforcement sub-assembly and rocker reinforce sub-assembly outer.
7. After welding the No.1 inner pillar sub-assembly, center body pillar reinforcement sub-
assembly and rocker reinforce sub-assembly outer the vehicle side, install the *3.
8. After welding, apply body sealer to the corresponding parts. (See the painting / coating)
9. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

COWL TOP TO APRON BRACE > ASSEMBLY REPLACEMENT

COWL TOP TO APRON
BRACE > ASSEMBLY
REPLACEMENT

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

Cut with Disk Sander etc.

REMOVAL POINT
1. *1: Bolts.
2. After removing the front fender apron patch No.4 and front fender apron patch, remove the
cowl top side panel sub-assembly.
INSTALLATION

Symbol meaning

Plug Weld

Plug Weld
 Fillet Weld

INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimension diagram)
3. *1: Bolts.
4. After welding the cowl top side panel sub-assembly to the vehicle side, install the front
fender apron patch No.4 and front fender apron patch.
5. After welding, apply body sealer to the corresponding parts. (See the painting / coating)
6. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

FIT STANDARD / ADJUSTMENT METHOD > ADJUSTMENT

FIT STANDARD /
ADJUSTMENT METHOD
> ADJUSTMENT INSPECT HOOD SUB-ASSEMBLY

INSPECT HOOD SUB-

ASSEMBLY

ADJUST HOOD SUB-

ASSEMBLY

INSPECT FRONT DOOR

ADJUST FRONT DOOR

GLASS

ADJUST FRONT DOOR

INSPECT LUGGAGE
COMPARTMENT DOOR
PANEL SUB-ASSEMBLY

ADJUST LUGGAGE
COMPARTMENT DOOR
PANEL SUB-ASSEMBLY

a. Check that the clearance measurements of areas *a through *e are within each standard
range.

Reference Value
Area Measurement Area Measurement
*a 5.8 to 9.8 mm (0.2283 to 0.3858 in.) *b 3.0 to 7.0 mm (0.1181 to 0.2756 in.)
*c -2.0 to 2.0 mm (-0.0787 to 0.0787 in.) *d 2.0 to 5.0 mm (0.0787 to 0.1969 in.)
*e -2.0 to 1.0 mm (-0.0787 to 0.0394 in.) - -

HINT:

Use the same procedure for the LHD and RHD vehicles.
The procedure listed below is for the LHD vehicles.
Centering bolts are used to mount the hood hinge and hood lock. The hood and
hood lock cannot be adjusted with the centering bolts installed. Substitute the
centering bolts with standard bolts when making adjustments.

ADJUST HOOD SUB-ASSEMBLY

a. Horizontally and vertically adjust the

hood.
 i. Loosen the 4 hinge bolts of the
hood.

ii. Adjust the clearance between

the hood and front fender by
moving the hood.

iii. Tighten the 4 hinge bolts after

the adjustment.

Torque:
25 N*m{ 255 kgf*cm ,
18 ft.*lbf }

b. Adjust the height of the front end of the

hood using the cushion rubbers.

i. Adjust the 2 cushion rubbers

so that the heights of the hood
and fender are aligned.

HINT:

Raise or lower the front end

of the hood by turning the 2
cushion rubbers.

c. Adjust the hood lock.

i. Loosen the 3 bolts.

ii. Adjust the hood lock position

so that the striker can enter it
smoothly.

iii. Tighten the 3 bolts after the

adjustment in the order shown
in the illustration.

Torque:
33 N*m{ 337 kgf*cm ,
24 ft.*lbf }

iv. Check that the striker can

 engage smoothly with the hood
lock.

INSPECT FRONT DOOR

a. Check that the clearance measurements of areas *a through *j are within each standard
range.

Reference Value
Area Measurement Area Measurement
*a 0.5 mm (0.0197 in.) *b 7.0 mm (0.2756 in.)
*c 5.0 mm (0.1969 in.) *d 6.7 mm (0.2638 in.)
13.5 to 16.5 mm (0.5315 to 0.6496
*e *f 2.5 to 5.5 mm (0.0984 to 0.2165 in.)
in.)
*g 0.0 to 1.5 mm (0.0 to 0.0591 in.) *h 4.8 to 7.8 mm (0.1890 to 0.3071 in.)
-1.0 to 1.5 mm (-0.0394 to 0.0591
*i 3.1 to 5.6 mm (0.122 to 0.220 in.) *j
in.)
Text in Illustration
*1 Front Glass *2 Front Door

HINT:

Use the same procedure for both the RH and LH sides.

The following procedure is for the LH side.
Centering bolts are used to mount the door hinge to the vehicle body and door.
The door cannot be adjusted with the centering bolts installed on it. Substitute the
centering bolts with standard bolts when making adjustments.

ADJUST FRONT DOOR GLASS

a. Using a SST, check that the clearance

measurements of areas "a" to "b" are
within each standard range

SST
09812-18010  

Text in Illustration
*1 SST
Reference Value
Area Measurement
*a 5.0 mm (0.1969 in.)
*b 6.7 mm (0.2638 in.)

b. Adjust the front door glass so that the

fitting dimensions come within the
reference values.

c. Loosen the nut on the front door sush

stopper and front door rear sush
stopper, and adjust the glass position.

d. After the adjustment, tighten the nut on

the front door sush stopper and front
door rear sush stopper.

Torque:
7.5 N*m{ 76 kgf*cm , 66
in.*lbf }
e. Loosen the 2 nuts on the front door rear
lower frame sub-assembly, and adjust
the glass position.

f. After the adjustment, tighten the 2 nuts

on the front door rear lower frame sub-
assembly.

Torque:
14 N*m{ 143 kgf*cm , 10
ft.*lbf }

g. Loosen the bolt on the door glass inner

stabilizer and adjust the glass position.

h. After the adjustment, tighten the bolt

on the door glass inner stabilizer.

Torque:
7.5 N*m{ 76 kgf*cm , 66
in.*lbf }

i. Loosen the 2 nuts on the front door rear

lower frame sub-assembly.

j. Using a screwdriver, rotate the bolts

and then adjust the position of the front
door glass in lateral direction.

k. After the adjustment, tighten the 2 nuts

on the front door rear lower frame sub-
assembly.

Torque:
14 N*m{ 143 kgf*cm , 10
ft.*lbf }

l. Using a SST, check that the clearance

measurements of areas "a" to "b" are
within each standard range .

SST
09812-18020  
 Text in Illustration
*1 SST
Reference Value
Area Measurement
2.5 to 5.5 mm (0.0984 to
*a
0.2165 in.)
5.2 to 8.2 mm (0.2047 to
*b
0.3228 in.)

m. Adjust the front door sush so that the

fitting dimensions come within the
reference values.

n. Loosen the nut on the front door sush

and adjust the front door sush position.

o. After the adjustment, tighten the nut on

the front door sush.

Torque:
14 N*m{ 143 kgf*cm , 10
ft.*lbf }

ADJUST FRONT DOOR

a. Loosen the hinge bolts on the vehicle

body and adjust the door position.

b. After the adjustment, tighten the hinge

bolts on the vehicle body.

Torque:
30 N*m{ 306 kgf*cm , 22
ft.*lbf }

c. Loosen the hinge bolts on the door and

adjust the door position.
 d. After the adjustment, tighten the hinge
bolts on the door.

Torque:
25 N*m{ 255 kgf*cm , 18
ft.*lbf }

e. Adjust the striker position by slightly

loosening the striker mounting screws
and hitting the striker with a plastic-
faced hammer.

f. After the adjustment, tighten the striker

mounting screws.

Torque:
18 N*m{ 184 kgf*cm , 13
ft.*lbf }

INSPECT LUGGAGE COMPARTMENT DOOR PANEL SUB-ASSEMBLY

 a. Check that the clearance measurements of areas *a to *f are within each standard range.

Reference Value
Area Measurement Area Measurement
*a 8.2 mm (0.3228 in.) *b 2.0 to 5.0 mm (0.0787 to 0.1969 in.)
*c -2.0 to 1.0 mm (-0.0787 to 0.0394 in.) *d 5.8 to 10.2 mm (0.2283 to 0.4016 in.)
-2.0 to 1.0 mm (-0.0787 to 0.0394
*e 4.3 to 7.3 mm (0.1693 to 0.2874 in.) *f
in.)

HINT:

Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be
adjusted with the centering bolts on. Substitute the centering bolts with standard bolts when making
adjustments.

ADJUST LUGGAGE COMPARTMENT DOOR PANEL SUB-ASSEMBLY

a. Horizontally and vertically adjust the

door by loosening the door side hinge
bolts.

Torque:
18 N*m{ 184 kgf*cm , 13
ft.*lbf }
b. When adjusting the rear edge of the
doors left or right, or adjusting the
luggage door closer assembly, loosen
the bolts before making adjustments.

c. Using a brass bar and a hammer, hit the

striker to adjust its position.

d. After the adjustment, tighten the 2 bolts

on the luggage door closer assembly.

Torque:
7.5 N*m{ 76 kgf*cm , 66
in.*lbf }
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

FRONT BODY PILLAR LOWER GUSSET > ASSEMBLY REPLACEMENT

FRONT BODY PILLAR
LOWER GUSSET >
ASSEMBLY
REPLACEMENT With the cowl top to apron brace
removed.

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

Remove Weld Points

Cut with Disk Sander etc.

INSTALLATION

Symbol meaning

Plug Weld

Plug Weld
 Plug Weld

INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
3. When welding *1, make a hole on a new part for plug welding and weld the panel with the
panel behind completely.
4. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

FRONT BODY PILLAR > CUT AND JOIN REPLACEMENT SECTIONS

FRONT BODY PILLAR >
CUT AND JOIN
REPLACEMENT
SECTIONS With the front body pillar lower gusset
removed.

Weld work for 980 MPa ultra high

strength steel
REMOVAL
Follow the welding conditions below
INSTALLATION when welding ultra high strength
steel to assure sufficient weld
strength. (When repairing this
model)
*1: When welding 2 panels together
including 980 MPa ultra high strength
steel.

Pressure 2940 N (300 kgf, 661 lbf)

Spot weld Weld current 10000 A
Weld time 18 Cyc. (0.30 Sec.)
Plug diameter 10 mm (0.39 in.)
Plug weld Wire type AWS A5.18 ER70S-3
Shield gas Metal active gas

*2: When welding more than 3 panels together including 980 MPa ultra high strength steel.
(When plug welding a third panel to 2 panels which are welded under the conditions
described above.)

Same as the standard method (See the

Plug diameter
introduction)
Plug weld
Wire type AWS A5.18 ER70S-3
Shield gas Metal active gas

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

Remove Weld Points

Cut with Disc Sander etc.

Cut and Join Location

REMOVAL POINT
1. Do not butt weld or heat repair because the heat decreases the strength of areas where
ultra high strength steel is used. (See the introduction)
INSTALLATION

Symbol meaning

Spot Weld

Plug Weld
 Plug Weld

Plug Weld

Cut and Join Location

Fillet Weld

Butt Weld

Body Sealer

INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
3. If the entire supply part is not needed, remove the part of the supply part that is needed.
4. Before installing a new part, apply body sealer.

HINT:

Apply body sealer in an even, continuous bead.

5. Follow the welding conditions when welding *1 and *2 to assure sufficient weld strength.
(See the introduction)
6. Before temporarily installing the new parts, weld the front body pillar sub-assembly inner
and front pillar extension lower with the standard number of welding points.
7. When welding *3, make a hole on a new part for plug welding and weld the panel with the
panel.
8. After welding the front body lower inner pillar the vehicle side, install the front body pillar
sub-assembly inner and front pillar extension lower.
9. After welding the front body lower inner pillar, front body pillar sub-assembly inner and
front pillar extension lower the vehicle side, install the rocker reinforce sub-assembly outer.
10. After welding the front body lower inner pillar, front body pillar sub-assembly inner, front
pillar extension lower and rocker reinforce sub-assembly outer the vehicle side, install the
front body pillar reinforce sub-assembly lower.
11. After welding the front body lower inner pillar, front body pillar sub-assembly inner, front
pillar extension lower, rocker reinforce sub-assembly outer and front body pillar reinforce
sub-assembly lower the vehicle side, install the front body pillar upper outer and rocker
panel outer rear.
12. After welding, apply body sealer to the corresponding parts. (See the painting / coating)
13. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

FRONT FENDER APRON > ASSEMBLY REPLACEMENT

FRONT FENDER APRON
> ASSEMBLY
REPLACEMENT
With the front fender mounting bracket
and front body pillar lower gusset
removed.

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

Cut with Disk Sander etc.

INSTALLATION

Symbol meaning

Plug Weld

Plug Weld
 Fillet Weld

INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimension diagram)
3. Make sure to attach correctly in accordance with the body dimension diagram as this part
affects the front wheel alignment.
4. After welding, apply body sealer and undercoating to the corresponding parts. (See the
painting / coating)
5. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

FRONT FENDER MOUNTING BRACKET > ASSEMBLY REPLACEMENT

FRONT FENDER
MOUNTING BRACKET
> ASSEMBLY
REPLACEMENT With the radiator side support
removed.

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

REMOVAL POINT
1. *1: Bolts.
INSTALLATION

Symbol meaning

Plug Weld

Plug Weld
INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimension diagram)
3. *1: Bolts.
4. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

FRONT SIDE MEMBER > CUT AND JOIN REPLACEMENT SECTIONS (SMALL
FRONT SIDE MEMBER AREAS)
> CUT AND JOIN
REPLACEMENT
SECTIONS (SMALL
AREAS) With the radiator support and front
fender mounting bracket removed.

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Cut and Join Location

REMOVAL POINT
1. Carefully cut the member so not to damage *1.

Reference Value
Area Measurement Area Measurement
*a 135 mm (5.31 in.) *b 271 mm (10.67 in.)
*c 410 mm (16.14 in.) *d 135 mm (5.31 in.)
*e 271 mm (10.67 in.) *f 410 mm (16.14 in.)
INSTALLATION

Symbol meaning

Plug Weld

Butt Weld
INSTALLATION POINT
1. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
2. After welding, apply body sealer and undercoating to the corresponding parts. (See the
painting / coating)
3. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

FRONT SIDE MEMBER > ASSEMBLY REPLACEMENT (PATTERN 1)

FRONT SIDE MEMBER
> ASSEMBLY
REPLACEMENT
(PATTERN 1) With the radiator support and front
fender mounting bracket removed.

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

Cut with Disk Sander etc.

REMOVAL POINT
1. After removing the front side member reinforcement No.1, remove the front side member
sub-assembly.
INSTALLATION

Symbol meaning

Plug Weld

Plug Weld
 Fillet Weld

INSTALLATION POINT
1. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
2. After welding the front side member sub-assembly to the vehicle side, install the front side
member reinforcement No.1.
3. Make sure to attach correctly in accordance with the body dimension diagram as this part
affects the front wheel alignment.
4. After welding, apply body sealer and undercoating to the corresponding parts. (See the
painting / coating)
5. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

FRONT SIDE MEMBER > ASSEMBLY REPLACEMENT (PATTERN 2)

FRONT SIDE MEMBER
> ASSEMBLY
REPLACEMENT
(PATTERN 2) With the radiator support and front
fender apron removed.

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

REMOVAL POINT
1. After removing the front side member reinforcement No.1, remove the front side member
sub-assembly.
INSTALLATION

Symbol meaning

Plug Weld

INSTALLATION POINT
1. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
2. After welding the front side member sub-assembly to the vehicle side, install the front side
member reinforcement No.1.
3. Make sure to attach correctly in accordance with the body dimension diagram as this part
affects the front wheel alignment.
4. After welding, apply body sealer and undercoating to the corresponding parts. (See the
painting / coating)
5. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

QUARTER PANEL END HOUSING > ASSEMBLY REPLACEMENT

QUARTER PANEL END
HOUSING > ASSEMBLY
REPLACEMENT

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

Cut with Disc Sander etc.

REMOVAL POINT
1. Cut the quarter panel and fold it upward as shown in *1. Then cut through the welded area
of the quarter panel inner rear and quarter inner panel rear, and remove the quarter panel
extension rear lower.
INSTALLATION

Symbol meaning

Plug Weld

Plug Weld
 Butt Weld

INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
3. After welding, apply body sealer to the corresponding parts. (See the painting / coating)
4. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

QUARTER PANEL > CUT AND JOIN REPLACEMENT SECTIONS

QUARTER PANEL >
CUT AND JOIN
REPLACEMENT
SECTIONS

REMOVAL

INSTALLATION

Quarter Panel Replacement Using Adhesive

Work Procedure
1. Cut the wheel arch portion.
2. Heat the quarter panel adhesive area and remove the quarter panel.

HINT:

Using an industrial heater gun or gas burner, heat the quarter panel to 110 to 140°C.
Make sure the quarter panel does not warp.

3. Clean off any adhesive that remains on the vehicle.

HINT:

Using an industrial heater gun or gas burner, heat the adhesive to 110 to
140°C.
Using a scraper, scrape away the adhesive.
If adhesive remains, the strength of any subsequently applied adhesive
will be weak.

4. Using a disc grinder or belt sander, scuff and sand any adhesive that remains on the
vehicle.

HINT:

Scuff at a width of approximately 10 mm (0.39 in.) over the previous adhesive coating.

5. Apply adhesive to the exposed metal areas on the vehicle. Using a spatula, spread the
adhesive evenly.
6. Apply adhesive to the vehicle again.
7. Using #60-120 grit sandpaper, scuff the adhesive application area on the new quarter
panel.
8. Apply adhesive to the new quarter panel. Using a spatula, spread the adhesive evenly.
9. Using a vise grip or the palms of your hands, press the quarter panel so that the thickness
of the adhesive is even.
10. Complete installation the new quarter panel.
11. Dry the adhesive areas of the new quarter panel.

HINT:

With dryer or equivalent (60°C): 60 minutes (complete hardening: 90

minutes)
Ambient temperature (25°C): 12 hours (complete hardening: 24 hours)

REMOVAL

Symbol meaning
 Remove Weld Points

Remove Weld Points

Remove Weld Points

Cut and Join Location

Cut Location for Supply Parts

REMOVAL POINT
1. *1 in illustration above indicates where the adhesive is located.
2. Roughly cut open the panel so that the adhesive can be reached. Cut through the adhesive
with a cut chisel to remove the panel.

HINT:

In cases where the adhesive cannot be removed with a cut chisel, heat the adhesive with
an industrial heater gun or gas burner taking care not to cause panel deformation by
overheating.
INSTALLATION

Symbol meaning

Spot Weld

Plug Weld
 Plug Weld

Plug Weld

Butt Weld

INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
3. When welding *1, make a hole on a new part for plug welding and weld the panel with the
panel behind completely.
4. Apply adhesive (3MTM AutomixTM Panel Bonding Adhesive #8115) to the area indicated by
*2 in the illustration.

HINT:

Apply enough adhesive for the panels to stick to each other.

5. Perform spot-welding on the flange indicated by *3 in the illustration. Modify/cut the spot
tip as shown in the illustration*4 so that it can fit in to the narrow flange.
6. After welding, apply body sealer to the corresponding parts. (See the painting / coating)
7. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

QUARTER WHEEL HOUSING OUTER PANEL > ASSEMBLY REPLACEMENT

QUARTER WHEEL
HOUSING OUTER
PANEL > ASSEMBLY
REPLACEMENT With the quarter panel removed.

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

Remove Weld Points

Cut and Join Location

REMOVAL POINT
1. *1 and *2 is reused.
2. After removing the *1, *2 and quarter lock pillar extension sub-assembly, remove the
quarter wheel house panel outer.
INSTALLATION

Symbol meaning

Spot Weld

Plug Weld
 Plug Weld

Plug Weld

Butt Weld

Assembly Mark

INSTALLATION POINT
1. When welding *1, make a hole on a new part for plug welding and weld the panel with the
panel behind completely.
2. For positioning of the new parts, align the installation standard holes of the outer panel and
the inner panel.
3. After welding the quarter wheel house panel outer to the vehicle side, install the quarter
lock pillar extension sub-assembly, *1 and *2.
4. After welding, apply body sealer and undercoating to the corresponding parts. (See the
painting / coating)
5. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

RADIATOR LOWER SUPPORT > ASSEMBLY REPLACEMENT

RADIATOR LOWER
SUPPORT > ASSEMBLY
REPLACEMENT

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

REMOVAL POINT
1. *1: Bolts.
INSTALLATION

Symbol meaning

Plug Weld

Plug Weld
INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
3. *1: Bolts.
4. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

RADIATOR SIDE SUPPORT > ASSEMBLY REPLACEMENT

RADIATOR SIDE
SUPPORT > ASSEMBLY
REPLACEMENT

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

REMOVAL POINT
1. *1: Bolts.
INSTALLATION

Symbol meaning

Plug Weld

INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
3. *1: Bolts.
4. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

RADIATOR SUPPORT > ASSEMBLY REPLACEMENT

RADIATOR SUPPORT >
ASSEMBLY
REPLACEMENT

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

INSTALLATION

Symbol meaning

Plug Weld

Plug Weld
INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
3. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
4. Measure the dimensions before installing the headlights.

Reference Value
Area Measurement Area Measurement
*a 1360 mm (53.54 in.) *b 1278 mm (50.31 in.)
*c 1097 mm (43.19 in.) *d 888 mm (34.96 in.)
*e 881 mm (34.68 in.) *f 889 mm (35.00 in.)
*g 805 mm (31.69 in.) - -
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

REAR FLOOR PAN > CUT AND JOIN REPLACEMENT SECTIONS

REAR FLOOR PAN >
CUT AND JOIN
REPLACEMENT
SECTIONS With the body lower back panel
removed.

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

Remove Weld Points

Cut with Disc Sander etc.

Cut Location

REMOVAL POINT
1. After removing the rear floor side panel and rear bumper bracket, remove the rear floor
pan.
INSTALLATION

Symbol meaning

Plug Weld

Plug Weld
 Plug Weld

Cut Location

Fillet Weld

Body Sealer

INSTALLATION POINT
1. Cut the new part so that it overlaps the previous cut location.
2. When welding *2, make a hole on a new part for plug welding and weld the panel with the
panel behind completely.
3. *1: Perform plug-welding in the area where the panel are overlapped. Apply body sealer to
both sides of each panel.

HINT:

Confirm that the panels are securely welded together.

Apply body sealer in an even, continuous bead.

4. After welding the rear floor pan to the vehicle side, install the rear floor side panel and rear
bumper bracket.
5. After welding, apply body sealer and undercoating to the corresponding parts. (See the
painting / coating)
6. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

REAR FLOOR SIDE MEMBER > ASSEMBLY REPLACEMENT

REAR FLOOR SIDE
MEMBER > ASSEMBLY
REPLACEMENT
With the body lower back panel
removed.

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

Remove Weld Points

Cut with Disc Sander etc.

REMOVAL POINT
1. After removing the rear floor side panel and rear bumper bracket, remove the rear floor
side member reinforcement sub-assembly rear.
INSTALLATION

Symbol meaning

Plug Weld

Plug Weld
 Plug Weld

INSTALLATION POINT
1. When welding *1, make a hole on a new part for plug welding and weld the panel with the
panel behind completely.
2. After welding the rear floor side member reinforcement sub-assembly rear to the vehicle
side, install the rear floor side panel and rear bumper bracket.
3. After welding, apply body sealer and undercoating to the corresponding parts. (See the
painting / coating)
4. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

REAR FLOOR SIDE PANEL > ASSEMBLY REPLACEMENT

REAR FLOOR SIDE
PANEL > ASSEMBLY
REPLACEMENT
With the body lower back panel
removed.

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Remove Weld Points

Remove Weld Points

Cut with Disc Sander etc.

REMOVAL POINT
1. After removing the rear floor side panel and rear bumper bracket, remove the rear floor pan
to quarter panel extension.
INSTALLATION

Symbol meaning

Plug Weld

Plug Weld
 Plug Weld

INSTALLATION POINT
1. When welding *1, make a hole on a new part for plug welding and weld the panel with the
panel behind completely.
2. After welding the rear floor pan to quarter panel extension to the vehicle side, install the
rear floor side panel and rear bumper bracket.
3. After welding, apply body sealer to the corresponding parts. (See the painting / coating)
4. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

ROCKER OUTER PANEL > CUT AND JOIN REPLACEMENT SECTIONS (SMALL
ROCKER OUTER PANEL AREAS)
> CUT AND JOIN
REPLACEMENT
SECTIONS (SMALL
AREAS)

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

Cut and Join Location

Cut Location for Supply Parts

INSTALLATION

Symbol meaning

Plug Weld

Butt Weld
INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
3. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

ROOF PANEL > ASSEMBLY REPLACEMENT

ROOF PANEL >
ASSEMBLY
REPLACEMENT

REMOVAL

INSTALLATION

REMOVAL

Symbol meaning

Remove Weld Points

INSTALLATION

Symbol meaning

Spot Weld

Plug Weld
 Body Sealer

INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the
appearance of the finish.
2. Temporarily install the new parts and measure each part of the new parts in accordance
with the body dimension diagram. (See the body dimensions)
3. Before temporarily installing the new parts, apply body sealer to the windshield header
panel and roof panel reinforcement.

HINT:

Apply just enough body sealer for the new parts to make contact.

4. After welding, apply body sealer to the corresponding parts. (See the painting / coating)
5. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed
section structural weld points.
 Toyota TechDoc 86 / ZN6
Outline OFF Top Back New (BM2090E)

SPECIFIED TORQUE > COMPONENTS

SPECIFIED TORQUE >
COMPONENTS