TECHNICAL
REPORT
LET’S LOOK AT THE
TOYOTA HILUX
52 PanelTalk
TECHNICAL
REPORT
I-CAR New Zealand is currently developing the Toyota Collision Repair Course for 23 vehicles of the current
Toyota fleet. This course will be delivered in two packages, the first covering commercial and recreational vehicles
and the second delivery will cover passenger vehicles.
There are a large number of Hilux vehicles around the country and as a result collision damage is common place,
unlike the city driven SUVs, many are often used in the rugged or off road conditions they are designed for. Many
accidents in these conditions often result in more extensive and sometimes a different type of damage than that
commonly seen with city driven vehicles. Roll-over repairs are common place for the Hilux and other similar type
vehicles in rural regions around NZ, however detailed repair methods for this type of repair will not always be
covered in the body repair manuals.
Before safety features and construction methods for utility type vehicles became the same as any regular type
passenger vehicle, the repairer could carry out repairs as he had always done but this is not the case anymore, it is
equally as important that these safety features are reinstated like any other passenger vehicle.
We will look at some repair methods for the
Hilux that are not always easy to find in the
standard repair manual, but first we will look
at the body structure of the cab. All three cab
configurations have a four star ANCAP safety
rating and use High-Strength Sheet Steel
(HSSS) for the A, B and C Pillar reinforcements
plus the floor cross beams; they do have
sectioning methods for the side reinforcements,
however make sure you always follow the
correct repair specifications if doing this type of
repair.
Fig 1: shows the upper staggered joint for
sectioning the double cab B Pillar. The repair
manual also states that Toyota prohibits the
use of the heat repair method when repairing
collision damage and that parts that are kinked
should be replaced.
Fig 1. B Pillar reinforcement upper joint
Fig 2 and 3: show the cut options available for the double and extended cab outer side panels; these cut locations are
similar for all three models of cab. Note!! This illustration is only an example; you will need the full specifications for accurate
cut measurements.
Fig 2 and 3. Outer panel cut options
Toyota Hilux Technical Information July – August 2013 - I-CAR
www.i-car.co.nz/wp-content/uploads/.../Toyota-Hilux-JulyAug-20131.p...
Hilux that are not always easy to find in the standard repair manual, but first we will look at the body structure of the cab. All three cab configurations have a four ...
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