Toyota ZZW30 Series User Manual

FOREWORD
This repair manual has been prepared to provide essential information on
body panel repair methods (including cutting and welding operations, but
excluding painting) for the TOYOTA MR2.
Applicable models: ZZW30 series
This manual consists of body repair methods, exploded diagrams and il-
lustrations of the body components and other information relating to body
panel replacement such as handling precautions, 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 specifications 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 MR2 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 procedures are subject to
change without prior notice.

Toyota ZZW30 Series Specifications

General

Brand	Toyota
Model	ZZW30 Series
Category	Automobile
Language	English

Summary

FOREWORD

INTRODUCTION

GENERAL REPAIR INSTRUCTIONS

Essential repair information and work precautions for body panel repair.

HANDLING PRECAUTIONS OF PLASTIC BODY PARTS

Guidelines for repairing plastic body parts, material properties, and resistance.

LOCATION OF PLASTIC BODY PARTS

Identifies plastic body parts and their corresponding material codes.

HOW TO USE THIS MANUAL

Guidance on interpreting manual sections, symbols, and procedures.

BODY PANEL REPLACEMENT

Detailed procedures and diagrams for replacing various body panels.

SYMBOLS

Explains symbols used in welding diagrams for cutting and welding operations.

ILLUSTRATION OF WELD POINT SYMBOLS

Visual guide to symbols representing weld points and their methods.

PROPER AND EFFICIENT WORK PROCEDURES

Procedures for efficient panel removal, including measuring and cutting.

PREPARATION FOR INSTALLATION

Steps for preparing parts and equipment before installing new body panels.

INSTALLATION

Procedures for installing new body panels, including measurements and precautions.

ANTI-RUST TREATMENT

Methods for applying anti-rust measures, including sealers and undercoats.

HANDLING PRECAUTIONS ON RELATED COMPONENTS

Precautions for handling vehicle components during body repair.

PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS

HEAT REPAIR FOR BODY STRUCTURE PANELS

Toyota prohibits heat repair on body structure panels due to strength reduction.

STRUCTURE PANEL KINKS

Explains that kinked structure panels must be replaced to maintain performance.

IMPACT BEAM REPAIR

Importance of replacing damaged impact beams and brackets for passenger safety.

ABBREVIATIONS USED IN THIS MANUAL