1997 TOYOTA SUPRA lock

mm in.
100
2003.94
7.87
QUARTER PANEL (CUT)
(Cut and Join Location)
Normal RoofBODY PANEL. REPLACEMENT RE-34
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.
REMOVAL
(Cut and Join Location)
(Cut and Join Location) 200 mm
Cut and Join Location
100 mm
Cut and Join
Location
(Cut and Join Location)
Sport Roof Cut and Join Location
(Cut Location for Supply Parts)
1. Cut and join the parts at the location shown above.
REPLACEMENT PARTS AND METHOD
(CUT)
QUARTER PANEL
Replacement method
(ASSY) Assembly replacement. . . . .
(CUT) Major cutting (less than 1/2 of parts used). . . . . .
(CUT-H) Half cutting (about 1/2 of parts 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.
INTRODUCTIONIN-2

Steering Wheel Pad
(with Airbag) Junction Block No. 1Center Airbag Sensor Assembly Front Airbag Sensor LHFront Passenger Airbag Assembly Front Airbag Sensor RHSRS Warning Light
Spiral Cable
Locations of SRS Components
HANDLING PRECAUTIONS ON RELATED COMPONENTS
1. SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Servicing vehicle with a Supplemental Restraint System (referrerd to as the SRS in the remainder of this
manual) installed.
When handling SRS components (removal, installation or inspection, etc.), always follow the directions
given in the repair manual for the relevant model year to prevent the occurrence of accidents and airbag
malfunction.
Also take the following precautions when repairing the body:

Work must be started after 90 seconds or longer from the time the ignition switch is set to the LOCK
position and the negative (-) terminal cable is disconnected from the battery.
(The airbag system is equipped with a backup power source so that if work is started within 20 seconds
of disconnecting the negative (-) terminal cable of the battery, the airbag may be deployed.)
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat, outside rear view mirror and power shoul-
der belt anchorage, which are all equipped with memory function, it is not possible to make a record of
the memory contents. So when the operation is finished, it will be necessary to explain this fact to the
customer, and request the customer to adjust the features and reset the memory.

When using electric welding, first disconnect the SRS connector (yellow color and 2 pins) under the
steering column near the combination switch connector on the glove compartment finish plate and lower
the front scuff plate before starting work.
INTRODUCTIONIN-6

Front Fender Area

Before repairing the body, remove the SRS parts if, during repair, shocks are likely to be applied to
the sensors due to vibrations of the body or direct tapping with tools or other parts.

Do not expose the SRS parts directly to hot air or flames.
NOTICE:
1) The maximum ambient temperature tolerance is 120
°C (248°F) for the front airbag sensor,
105
°C (221°F) for the center airbag sensor assembly and 93°C (200°F) for the steering wheel
pad, and front passenger airbag assembly. If it is possible that the ambient temperature may
reach or exceed the temperature limit, remove the sensors and the steering wheel pad from
the vihicle or protect them with a hot insulation material before starting work.
2) Prior to welding, remove adjacent SRS parts from the vehicle or protect there with fire-proof
covers.

If the front fender or periphery of the vehicle is damaged, visually inspect for damage to the front
airbag sensor using the inspection procedures described in section RS of the repair manual for the
relevant model year.
Also check that the dimensions of the body where the front airbag sensor is installed match those
in the body dimension drawings.
(The airbag may malfunction, or may not work, if the mounting angle or dimensions of the sensor
mount are not correct.)

If the vehicle is damaged, visually inspect for damage to the steering wheel pad using the inspection
procedures described in section RS of the repair manual for the relevant model year.

When removing or handling the steering wheel pad, and front passenger airbag assembly keep the
pad upper surface facing upward. Also, lock the lock lever of the twin lock type connector at the rear
of the pad and take care not to damage the connector.
(Storing the pad or front passenger airbag assembly with its metalic surface up may lead to a serious
accident if the airbag inflates for some reason.)

Store the steering wheel pad and the front passenger airbag assembly where the ambient tempera-
ture remains below 93°C (200°F), without high humidity and away from electrical noise.

Be careful not to let painting materials contact the SRS parts.

Information labels are attached to the periphery of the SRS components. Follow the NOTICES.

Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high
humidity and away from electrical noise.
INTRODUCTIONIN-7

Shift Lock ECUEngine Control
Module
(Engine ECU)Center Airbag
Sensor Assembly ABS
Deceleration
Sensor ABS and Traction ECU
(for 2JZ-GTE)Stereo Power
Amplifier Integration
RelayJ/B No. 1Traction ECU
(for 2JZ-GTE)
R/B No. 4 Daytime Running
Light Relay (Main)
(for Canada)Blower Control
RelayPPS ECU A/C AmplifierTheft Deterrent
ECU Cruise Control ECU Auto Antenna Control Relay
ABS ECU
(for 2JZ-GE)
Component to be alignedSection of repair manual
for relevant model year
Front Wheels
Suspension and Axle (SA) section
Rear Wheels
Suspension and Axle (SA) section
Propeller Shaft
Propeller Shaft (PR) section
3. DRIVE TRAIN AND CHASSIS2. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in section BR of the repair manual for the relevant model year when handling brake
system parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC
system.
The drive train and chassis are components-that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions
given in the repair manual for the relevant model year during alignment and section DI of this manual.
4. ECU (ELECTRONIC CONTROL UNIT)
Locations of ECUs
INTRODUCTIONIN-8

Light Failure Sensor Fuel Pump ECURear Wiper Relay
5. COMPONENTS ADJACENT TO THE BODY PANELS Locations of ECUs (Cont'd)
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all
equipped with memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80°C (176°F).
NOTICE: if it is possible the ambient temperature may reach 80°C (176°F) or more, remove the ECUs
from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.
Various types of component parts are mounted directly on or adjacently to the body panels.
Strictly observe the following precautions to prevent damaging these components and the body panels
during handling.

Before repairing the body panels, remove their components or apply protective covers over the
components.

Before prying components off using screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components an the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body
to ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
INTRODUCTIONIN-9

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

PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER
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
.

INSTALLATION
1. Temporarily install the new parts and mea-
sure each part in accordance with the body
dimension diagram.
HINT: First install the hood lock support.
BODY PANEL REPLACEMENTRE-3