LAND CRUISER J100 Body Repair BRM080U All (EN)

FOREWORD This repair manual has been prepared to provide essential infor- mation on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA LAND CRUISER. Applicable models: UZJ100, FZJ10_ series HDJ10_, HZJ105 series This manual consists of body repair methods, exploded dia- grams and illustrations of the body components and other infor- mation relating to body panel replacement such as handling pre- cautions, etc. However, it should be noted that the front fenders of the TOYOTA model is bolted on and require no welding. When repairing, don’t cut and join areas that are not shown in this manual.

Only work on the specified contents to maintain body strength. Body construction will sometimes differ depending on specifica- tions and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations. For the repair procedures and specifications other than collision- damaged body components of the TOYOTA LAND CRUISER refer to the repair manuals. If you require the above manuals, please contact your TOYOTA Dealer. All information contained in this manual is the most up-to-date at the time of publication. However, specifications and proce- dures are subject to change without prior notice. TOYOTA MOTOR CORPORATION

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INTRODUCTION IN-2 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 REMOVAL Cut and Join Location Cut and Join Location QUARTER PANEL (CUT) 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 QUARTER PANEL (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) . . . . . . Replacement Parts 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. mm in. 150 250 5.91 9.84

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INTRODUCTION IN-3 INSTALLATION Butt Weld Butt Weld RE-29 BODY PANEL REPLACEMENT Foamed Material Application Areas Butt Weld Body Sealer Body Sealer about 5 mm 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. 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. 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 . mm in, 5 0.20

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INTRODUCTION IN-4 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. SYMBOLS MEANING ILLUSTRATION SAW CUT OR ROUGH CUT REMOVE BRAZE WELD POINTS SPOT WELD OR MIG PLUG WELD (See page IN-5 ) CONTINUOUS MIG WELD (BUTT WELD OR TACK WELD) BRAZE BODY SEALER

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