Page 617 of 4770
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-20
Page 618 of 4770

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.
ASAAcrylonitrile
Styrene
Acrylate80
(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.
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.
FRPFiber
Reinforced
Plastics180
(356)Alcohol and gasoline are
harmless.Avoid alkali.
EVAEthylene
Acetate70
(158)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease.)Avoid gasoline and
organic oraromatic
solvents.
PAPolyamide
(Nylon)80
(176)Alcohol and gasoline are
harmless.Avoid battery acid.
PBTPolybutylene
Terephthalate160
(320)Alcohol anal gasoline are
harmless.Most solvents are
harmless.
PC Polycarbonate120
(248)Alcohol is harmless.Avoid gasoline brake
fluid, wax, wax removers
and organic solvents.
Avoid alkali.
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 619 of 4770

CodeMaterial
nameHeat*
resistant
temperature
limit °C (°F)Resistance to
alcohol or gasolineNotes
PE
Polyethylene80
(176)Alcohol and gasoline are harmless.Most solvents are
harmless.
PETPolyethylene
Terephthalate75
(167)Alcohol and gasoline are
harmless.Avoid dipping in water.
PMMAPolymethyl
Methacrylate80
(176)Alcohol is harmless if applied
only for short time in small
amounts.Avoid dipping or
immersing in alcohol,
gasoline, solvents, etc.
POMPolyoxymethylene
(PolyacetaI)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
Polystyrene60
(140)Alcohol and gasoline are
harmless if applied only for
short time in small amounts.Avoid dipping or
immersing 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
immersing 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
immersing 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
immersing in alcohol,
gasoline, solvents etc.
TPOThermoplastic
Olefine80
(176)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.
TPUThermoplastic
Polyurethane80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease.)Avoid dipping or
immersing in alcohol,
gasoline, solvents, etc.
TSOPTOYOTA
Super
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
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Parts NameCode
Front Bumper CoverTSOP
Radiator Grille (Models Except USA & CANADA)ABS
Headlight (For USA & CANADA)PC/PP
Front Turn Signal LightPMMA/ASA
Front Fog Light (Models Except USA & CANADA)PC/PP
Side Turn Signal Light (Models Except USA & CANADA)SAN/AAS
Outer Rear View MirrorABS
Outside Handle (Front, Rear)PC/PBT
Front Fender Outside MouldingPVC
Door Outsider Moulding (Front, Rear)PVC
Quarter Panel Outside Moulding (Front, Rear) (For Europe)PVC
Front Fender Mudguard (For USA & CANADA)PP/PMMA
Front Fender Mudguard (Models Except USA & CANADA)PP/EPDM
Quarter Panel Mudguard (For USA & CANADA)PP/PMMA
Quarter Panel Mudguard (Models Except USA & CANADA)PP/EPDM
Rear Bumper Cover (For USA & CANADA)PUR
Rear Bumper Cover (Models Except USA & CANADA)TSOP
Rear Combination Light (For USA & CANADA) PMMA/ASAPMMA/ABS/PC
Rear Combination Light (Models Except USA & CANADA)PMMA/ASA
Licence Plate LightPC
Back±up Light (Rear Light)PMMA/ASA
LOCATION OF PLASTIC BODY PARTS
HINT:
Resin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPP-4
Page 621 of 4770
High Strength Sheet 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 weld-
ing should be done with MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other
than specified.
BODY PANEL CONSTRUCTIONCN-2
Page 622 of 4770

RUST±RESISTANT SHEET STEEL PARTS
Rust±Resistant Sheet 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 further
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 quality
Zn±Fe Alloy
(Zinc±Rich)
Zn±Fe Alloy (Zinc Rich) improves
rust±resistant performance
Bass Metal Base
Metal
Galvannealed Sheet Steel Excelite II
The handling 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-3
Page 623 of 4770
Zinc±iron Alloy Double Layer
Galvannealed Sheet Steel Galvannealed Sheet Steel
BODY PANEL CONSTRUCTIONCN-4
Page 624 of 4770
RADIATOR UPPER SUPPORT (ASSY)
REMOVAL
BODY PANEL REPLACEMENTRE-2