Page 441 of 1807

CodeMaterial
nameHeat*
resistant
temperature
limit °C (°F)Resistance to
alcohol or gasolineNotes
AASAcrylonitrile
Acrylic Styrene80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).Avoid gasoline and
organic or aromatic
solvents.
ABSAcrylonitrile
Butadiene Styrene80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).Avoid gasoline and
organic or aromatic
solvents.
AESAcrylonitrile
Ethylene Styrene80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).Avoid gasoline and
organic or aromatic
solvents.
BMCBulk
Moulding
Compound150
(302)Alcohol and gasoline are
harmless.Most solvents are
harmless.
CABCellulose
Acetate80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).Avoid gasoline and
organic or aromatic
solvents.
EPDMEthylene
Propylene100
(212)Alcohol is harmless.
Gasoline is harmless if applied
only for short time in small
amounts.Most solvents are
harmless but avoid
dipping in gasoline,
solvents, etc.
PAPolyamide
(Nylon)80
(176)Alcohol and gasoline are
harmless.Avoid battery acid.
PBTPolybutylene
Terephthalate160
(320)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PCPolycarbonate120
(248)Alcohol is harmless.Avoid gasoline, brake
fluid, wax, wax removers
and organic solvents.
Avoid alkali.
PEPolyethylene80
(176)Alcohol and gasoline are harmless.Most solvents are
harmless.
PETPolyethylene
Terephthalate75
(176)Alcohol and gasoline are
harmless.Avoid dipping in water.
HANDLING PRECAUTIONS
1. The repair procedure for plastic body parts must conform with the type of plastic material.
2. Plastic body parts are identified by the codes in the following chart.
3. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding,
painting etc.), consideration must given to the property of the plastic.
* Temperatures higher than those listed here may result in material deformation during repair.
PLASTIC BODY PARTSPP-2
Page 442 of 1807

CodeMaterial
nameHeat*
resistant
temperature
limit
°C (°F)Resistance to
alcohol or gasolineNotes
PMMAPolymethyl
Methacrylate80
(176)Alcohol is harmless if applied
only for short time in small
amounts.Avoid dipping or im-
mersing in alcohol,
gasoline, solvents,
etc.
POMPolyoxymethylene
(Polyacetal)100
(212)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PP Polypropylene80
(176)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PPOModified
Polyphenylene
Oxide100
(212)Alcohol is harmless.Gasoline is harmless if
applied only for quick
wiping to remove
grease.
PS Polystyrene
60
(140)Alcohol and gasoline are
harmless if applied only for
short time in small amounts.Avoid dipping or im-
mersing in alcohol,
gasoline, solvents,
etc.
PUR
Polyurethane80
(176)Alcohol is harmless if applied
only for very short time in small
amounts (e.g., quick wiping to
remove grease).Avoid dipping or im-
mersing in alcohol,
gasoline, solvents,
etc.
PVCPolyvinylchloride
(Vinyl)80
(176)Alcohol and gasoline are harmless
if applied only for short time in small
amounts (e.g., quick wiping to re-
move grease).Avoid dipping or im-
mersing in alcohol,
gasoline, solvents,
etc.
SANStyrene
Acrylonitrile80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).Avoid dipping or im-
mersing in alcohol,
gasoline, solvents,
etc.
SMCSheet
Moulding
Compound180
(356)Alcohol and gasoline are
harmless.Avoid alkali.
TPOThermoplastic
Olefine80
(176)Alcohol is harmless.
Gasoline is harmless if applied
only for short tune in small
amounts.Most solvents are
harmless but avoid dip-
ping in gasoline, sol-
vents, etc.
TPUThermoplastic
Polyurethane80
(176)Alcohol is harmless if applied
only for very short time in small
amounts (e.g., quick wiping to
remove grease).Avoid dipping or im-
mersing in alcohol,
gasoline, solvents,
etc.
TSOPTOYOTA
Supper
Olefine Polymer80
(176)Alcohol and gasoline are
harmless.Most solvents are
harmless.
UPUnsaturated
Polyester11 0
(233)Alcohol and gasoline are
harmless.Avoid alkali.
* Temperatures higher than those listed here may result in material deformation during repair.
PLASTIC BODY PARTSPP-3
Page 443 of 1807
High-Strength Steel
HIGH-STRENGTH STEEL (HSS) PARTS
Generally, High-Strength Steel (HSS) is that which has an intensity value of at 35 kgf/mm2
(343 MPa),
and distinguished from mild steel.
The handling of HSS is the same as for mild steel, but the following should be observed.
1. Panel Hammering: Because HSS is thinner than mild steel, care should be taken to avoid warping
during hammering operations.
2. Removing Spot Welds: Because HSS is tougher than mild steel, damage will occur more easily to
a regular drill. Therefore, an HSS Spot Cutter is recommended.
Also, use a high-torque drill at low speed, and supply grinding oil to the drill during use.
3. Panel Welding: Panel welding procedures for HSS are exactly the same as for mild steel. Plug
welding should be done with MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at
areas other than specified.
BODY PANEL CONSTRUCTIONCN-3
Page 444 of 1807
LOCATION OF PLASTIC BODY PARTS
Outer Rear View Mirror (ABS)
Front Door Outside Handle (PC)
Instrument Panel Safety Pad (PVC/PUR)
Rear Spoiler (SMC/UP)
Cowl Top Ventilator Louver (PP)
Hood Bulge (BMC)
Headlamp (PC/PP)
Quarter Lower
Moulding (PP)
Quarter Panel Air Inlet
Garnish (PUR)
Body Rocker Panel Moulding (PP) Front Bumper Extension
Mounting Bracket (PP)
Front Fender Moulding (PP)
Side Turn Signal Lamp (SAN/ABS)
Front Spoiler Cover (PUR)
Front Side Marker Lamp (PMMA/ABS)
Front Turn Signal Lamp (PMMA/PP)
Front Bumper Cover (PUR)
Front Active Spoiler (PUR)
HINT:
w Resin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPP-4
Page 445 of 1807
Roof Side Inner Garnish (PP)
Rear Speaker Grille (ABS/PET)
Quarter Inside Trim Board (PP)
Front Pillar Garnish (PP)
Cowl Side Trim (PP/PE)
Radiator Upper Air
Deflector (PP/PE)
Front Door Scuff Outside Plate (PP)
Front Fender Liner (PE) Radiator
Reserver Tank (PP)
Windshield Washer Jar (PP)
Front Fender splash shield (PE)
Engine Under No. 1 Cover (PP/PE)Engine Under No. 4 Cover (PE)
Engine Under No. 2 Cover (PE)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPP-5
Page 446 of 1807
Steering Wheel Pad (PUR)
Quarter Wheel Housing Inner Cover (PP)
Rear Combination Lamp (PMMA/PC/PP)
Instrument Panal Passenger
Air Bag (PVC/PUR)
Center Stop Lamp (PMMA/ABS)
Deck Trim Side Board (PP)
Quarter Vent Duct (PP)
Front Fender
Mudguard (PP)
Air Conditioner Unit (PP)
Licence Plate Lamp (PC/PP)
Rear Bumper Cover (PUR) Fuel Filler Opening Lid (PBT)
Rear Side Marker
Lamp (PMMA/ABS)
Fuel Tank Filler
Pipe Protector
(PE)
Back Door Trim Board (PP/PE) Fuel Tank (PE)
Deck Trim Rear Cover (PP/PE)
HINT:
w Resin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPP-6
Page 447 of 1807
QUARTER PANEL (CUT-P)
REMOVAL
Cut and Join
Location
Cut and Join
Location
1. Cut and join the parts at the location shown
above.
BODY PANEL REPLACEMENTRE-38
Page 448 of 1807
mm in.
5
0.20
2. Temporarily install the new parts and check
the fit of the back door and rear combination
lamp.
3. Before welding, cut the lining away from the
weld seams a little.
INSTALLATION
Butt Weld
Body Sealer
Braze
Butt Weld
Braze
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) Apply sealer evenly, about 3 - 4 mm (0.12 -
0.16 in.) diameter.
3) For other sealing points, refer to section AR.
BODY PANEL REPLACEMENTRE-39