Roof Panel Assy Sun Roof

REMOVAL

[If resusing the roof panel reinforcement]

^ Hemming Location

Disc Sander

^ Hemming Location

Disc Sander

Toyota Celica Sunroof Repair

Cloth Tape

Cloth Tape

Wooden Hammer

Wooden Hammer

[Foamed Material Apprication Areas]

Body Sealer

[Foamed Material Apprication Areas]

Body Sealer

Cruiser Windshield Header Panel

1. Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel reinforcement and back window frame.

HINT:

1) Apply just enough sealer for the new parts to make contact.

2. Bend the flange hem with a wooden hammer and dolly.

HINT: Perform hemming three steps, being careful not to warp the panel.

ROCKER OUTER PANEL (CUT)

REMOVAL

Hydro Operated Lift
[Cut and Join Location]

mm

in.

20

0.79

ROCKER OUTER REAR PANEL (CUT)

REMOVAL

i#33P

[Foamed Material Application Area]

Body Sealer about 5 mm

A - A

mm

in.

5

0.20

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.) in diameter.

2. Temporarily install the new parts and check the fit of the front door and slide door.

3. Apply foamed material to the quater section.

/T^ Mandrel

RIVET REMOVAL AND INSTALLATION

PARTS NAME AND VARIETY OF RIVET

Flange

0X mm >/

Rivet Size

Steel-Rivet

Waterproof-Rivet

T-Rivet p p

Before installation

After installation

Outer

Inner

Before installation

After installation

Outer

Inner

Before installation

After installation

Waterproof Seal

Outer

Waterproof Seal

Inner

Outer

Inner

Before installation

After installation Mandrel

After installation Mandrel

Outer

Inner

Outer

Small nonwaterproof rivet

No magnetic adherence

Small nonwaterproof rivet

Magnetic adherence

Small waterproof rivet

Waterproof seal

Large waterproof rivet

Mandrel sticks out after installation

RIVET REMOVAL

1. SELECTION OF CUTTING TOOL

Cutting tool

Note

Aluminum-Rivet Steel-Rivet

T-Rivet with 06.4 mm

Drill blade

Rivet size

Blade size

04 mm

04 mm

04.8 mm

05 mm

06.4 mm

06.5 mm

Waterproof special-Rivet with 04.0 mm

Drill blade with 04.0 mm

Cutting can be done with drill blade or rivet cutter for an aluminum-rivet with 04.8 mm.

When a rivet cutter is used for an aluminum-rivet (except 04.8 mm), a steel-rivet, or a T-rivet with 06.4 mm, it is possible that the drill will spin abnormally damaging the rivet hole and breaking the rivet cutter.

Aluminum-Rivet with 04.8 mm Waterproof-Rivet with 04.8 mm or 06.0 mm

Rivet Cutter (P/N 09060-60350)

When a ordinary cutter is used for a waterproof-rivet with 04.8 mm or 06.O mm, the rivet can not be cut as it spins with the cutter.

T.—RIVET1 REMOVAL-

Using a ponch with 05 mm, stamp out the mandrel.

Vacuum Hose 'ÜÜil^—

(2) Put tape around the drill blade 5 mm (0.20 in.) from the tip or insert a vacuum hose.

NOTE: Use of tape or a vacuum hose prevents damage to the rivet hole.

(3) Attach the drill blade or a rivet cutter to the drill.

Tape

Tape

(4) Gently and vertically put the drill to the rivet, and cut the rivets flange. NOTE:

• While upward drilling, wear a protective glasses.

• If a drill is strongly pushed deeply in to a rivet, the rivet can't be cut as it spins together with the drill.

• Prizing the hole with a drill can lead to damage to the rivet hole or the breaking of the rivet cutter.

(5) Aluminum-Rivet and Waterproof-Rivet with 04.8 mm or 06.O mm:

Even if flange is taken off, continue drilling and push out remaining fragments with the drill.

If the flange is taken off, stop drilling and pull out the remaining fragments with a pliers.

If the flange is taken off, stop drilling and push out the remaining fragments with a ponch with 05 mm or pull out the remaining fragments with pliers.

INTRODUCTION - Rivet Removal and Installation

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