Page 481 of 1807
ROOF PANEL (ASSY): Normal Roof
REMOVAL
Braze
(both sides)
Braze
(both sides)
1. Heat the brazed area of the front body pillar
and quarter panel and scrape off the brazing
with a wire brush
HINT: Be careful not to overheat the pillar sides.
BODY PANEL REPLACEMENTRE-62
Page 482 of 1807
2. Braze the front body pillar and quarter panel
connection.
HINT: Before performing these operations, place
a wet rag on the roof panel to protect it from
damage.
INSTALLATION
Body Sealer
Braze
(both sides)
Braze
(both sides)
1. Before temporarily installing the new parts,
apply body sealer to the windshield header
panel, roof panel reinforcement and back
door opening frame.
HINT:
1) Apply just enough sealer for the new parts to
make contact.
2) For other sealing points, refer to Section AR.
BODY PANEL REPLACEMENTRE-63
Page 483 of 1807

Galvannealed Sheet Steel Excelite II
RUST-RESIST ANT SHEET STEEL PARTS
Rust-Resistant Sheet Steel have zinc, tin or aluminum etc, plating over the base metal surface in order to
improve the corrosion resistance of the sheet metal. For the vehicle's body panels, galvannealed sheet
steel is widely used.
Body panel on TOYOTA models are made of two different galvannealed sheet steel. The ordinary galvan-
nealed sheet steel has a zinc-iron alloy plating over the base metal surface. Zinc-iron alloy double-layer
galvannealed sheet steel has zinc-iron alloy plating on both the outside and the back surface, plus a fur-
ther iron-rich zinc-iron alloy plating which has good paint adhesion. These two galvannealed sheet steels
are used selectively according to need.
Zn-Fe Alloy (Iron Rich) improves
paint qualityZn-Fe Alloy
(Zinc-Rich)
Zn-Fe Alloy (Zinc Rich) improves
rust-resistant performance
Base Metal Base
Metal
Galvannealed Sheet Steel
Excelite II
The handing of Rust-Resistant Sheet Steel is the same as for ordinary sheet steel, but the following
should be observed.
1. Panel Welding: The paint as well as the zinc portion must be removed completely from the welding
area to guarantee good welding integrity.
2. Anti-Rust Treatment: Since the zinc plating is lost after welding, anti-rust treatment of the welded
area must be thoroughly performed (refer to section AR).
BODY PANEL CONSTRUCTIONCN-4
Page 484 of 1807

FOR THE TOYOTA DEALER
COLLISION REPAIR INFORMATION
TITLE: SCRATCH±RESISTANT PAINT PAGE 1 of 2
SECTION: REFINISH BULLETIN #78
MODELS: JAPAN PRODUCED VEHICLES (AS LISTED)
DATE: AUGUST 1997
Some Toyota models produced in Japan are finished with a Scratch±Resistant paint
technology. This type of coating provides improved resistance to minor scratching. Vehicles
produced with this type of coating can be identified by referring to the chart below and by
the Vehicle Identification Number (VIN). The first character in the VIN of Japan±built
vehicles is a ªJº (J=Japan).
NOTE:U.S. manufactured vehicles do not use this type of paint technology.
ModelColor CodeDate of Introduction
Camry202August 1992
Celica202August 1991
MR2202December 1989
LandCruiser202December 1995
RAV4202January 1995
Supra202April 1993
Color code 202 (Black) is a single±stage paint as applied by the factory. During refinish
work however, two±stage (basecoat/clearcoat) refinishing utilizing the appropriate
materials is recommended.
REFINISH RECOMMENDATIONS
Refinish materials that provide similar scratch±resistant qualities have been developed by
your respective paint vendor. Listed are the refinish materials (basecoat, clearcoat,
reducer, hardener/activator) recommended by Toyota and your paint vendor for refinishing
vehicles originally manufactured with scratch±resistant paint.
Page 485 of 1807

SCRATCH±RESISTANT PAINT (cont'd) PAGE 2 of 2
ManufacturerBasecoatClearcoatReducerHardener/Activator
Akzo±NobelAutobaseAutocoat LV HSAutocoat LVHardener HS±BSR
BASF54/55 line923±43none929±76
DuPontChroma±base9700S1085S3575S
ICI Autocolor2K/AquabaseP190±639P850±1692/3/4P210±839
PPGDeltron 2000
Global BCDCU 2021
D894DT±Series
D807DCX8
D897
Sherwin±Williams
Martin SenourUltra±7000
Tec/BaseCC±830 HS
8895 HSCCR±837
8879UH±100 HS
8874
Spies±HeckerPermacron
293/295Permasolid 8030
HSPermacron
Series3120 Super Hardener
StandoxBasecoat2K HS Clear2K ThinnerScratch±Resistant
Check with your paint vendor for VOC compliance information and product availability.
Contact your paint vendor for additional information on application procedures, material
availability and VOC compliant materials. For paint vendor technical service information
telephone numbers, refer to Collision Repair Information Bulletin #77.
POLISHING TIPS
Follow paint vendor recommended baking or air dry times prior to sanding and polishing.
Since this type of paint technology resists scratches, it is important to understand that
sanding and polishing to remove dirt nibs may require additional time.
Use a fine grit sand paper (2000±2500 grit) soaked in a soapy water solution for a
minimum of 1±hour (overnight preferred) to prevent deep scratches and use polishing
materials designed for urethane±type clearcoats.
Page 486 of 1807
SILENCER SHEET INSTALLATION AREAS
Thickness of Asphalt Sheet
1.5 mm . . . . . . .
(0.059 in.)
APPENDIXAP-3
Page 487 of 1807

FOR THE TOYOTA DEALER
COLLISION REPAIR INFORMATION
TITLE: SRS AIRBAG COMPONENT REPLACEMENT PAGE 1 of 6
SECTION: ELECTRICAL BULLETIN #79
MODELS: ALL
DATE: AUGUST 1997
After an airbag has been deployed during a collision, it will be necessary to replace certain
components of the airbag system. Technicians can identify these parts by using the
attached matrix.
If the airbag does not deploy, yet the combination meter (airbag warning light) stays on for
more that 10 seconds after the key is turned to the ªACCº or ªONº position, it is necessary
to perform a diagnostic test. Always refer to the Toyota repair manual for the correct repair
procedure.
The attached information includes:
A matrix indicating components requiring replacement (pages 2±4).
Parts replacement note (page 5).
An example repair manual page outlining the diagnostic procedure available in
each model specific repair manual (page 6).
Toyota recommends the use of electrical repair kit (P/N 00002±04200±01) for any wiring
repairs. This kit includes a selection of numerous repair connectors, terminal ends, a repair
procedures manual and special tools specific to Toyota. The
replacement electrical wire
and connector (from the wire harness to the front sensors) is P/N 82988±24010.
Toyota also offers a video package which shows the operation of the SRS airbag system
(P/N 00401±42994).
CAUTION: SRS Airbag service work can be performed only AFTER 90 SECONDS
from the time the ignition switch is turned to the ªlockº position and the
negative (±) terminal cable is disconnected from the battery.
NOTE: PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER
MANAGER!
Page 488 of 1807
SRS AIRBAG COMPONENT REPLACEMENT (cont'd) PAGE 2 of 6