Precaution

PRECAUTION

1. WORK PRECAUTIONS
a. VEHICLE PROTECTION

1. When welding, cover glass, seats, carpets, etc. with heat resistant fireproof covers to protect them.

b. SAFETY

1. Never stand in the path of the chain when using a puller on the body or frame, and be sure to attach a safety cable.

2. If it is necessary to use a flame in the area of the fuel tank, first remove the tank and plug the fuel line.

c. SAFETY WORK CLOTHES

1. In addition to the usual mechanic's wear, cap and safety shoes, the appropriate gloves, head protector,welder's glasses, ear plugs, face protector, dust mask, etc. should be worn as the situation demands.

2. PRECAUTIONS WHEN REPAIRING BODY FRAME PARTS (INCLUDING CRUSH BOX)
a. PROHIBITION OF HEAT REPAIR FOR BODY FRAME PARTS

1. Rustproof high strength steel sheets are used for the body frame. Therefore, if these parts are heat repaired using an acetylene torch or equivalent, the crystalline structure changes, causing the strength of the steel sheets to decrease. Also, the zinc coating which is used to protect the body from rust will be damaged. This causes the surface of the steel sheets to become oxidized, which reduces their ability to resist rust.

b. WHEN TO REPLACE FRAME PARTS

NOTICE: Replace frame parts that have kinks.

HINT: What is kink?

A deformation on a steel sheet that cannot be returned to its original shape by pulling or hammering due to the deformation angle being sharp.

c. REPAIR OF DOOR SIDE IMPACT BEAM IS PROHIBITED

1. The impact beam is designed so that it performs at 100% in its original shape. However, if the impact beam is repaired, its performance may not be the same as before the accident.

PARTS WHICH ARE PROHIBITED TO BE REPAIRED: Door side impact beam

d. REPAIR OF BUMPER REINFORCEMENT IS PROHIBITED

1. The bumper reinforcement is designed so that it performs at 100% in its original shape. However, if the bumper reinforcement is repaired, its performance may not be the same as before the accident.

PARTS WHICH ARE PROHIBITED TO BE REPAIRED: Bumper reinforcement

3. PRECAUTIONS FOR CORRECT REPAIR
a. REMOVAL OF ADJACENT COMPONENTS

1. When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage.

NOTICE: If the paint film is damaged, make sure to refinish the paint.

b. ANTI-RUST TREATMENT BEFORE WELDING

1. Apply welding primer to the contact surfaces of the welding areas to protect them from rust.

NOTICE: Do not apply welding primer outside of the contact surfaces.

c. MAKING HOLES FOR PLUG WELDING

1. For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding.

d. WELDING PRECAUTIONS

1. The number of welding spots should be as follows.

Spot weld: 1.3 X No. of manufacturer's spots
Plug weld: More than No. of manufacturer's plugs

2. Spot weld locations Avoid welding over previously welded areas.

4. ANTI-RUST TREATMENT AFTER INSTALLATION

a. BODY SEALER APPLICATION

PURPOSE: For water-proofing and anti-rust measures, always apply the body sealer to the body panel seams and hems of the doors, hood, etc.

NOTICE: Apply body sealer neatly to parts that require a high quality appearance.

b. UNDERCOAT APPLICATION

PURPOSE: To prevent corrosion and protect the body from gravel, always apply a sufficient undercoating to the areas indicated.

c. VEHICLE BODY ANTI-RUST AGENT APPLICATION

PURPOSE: The purpose is to protect areas from rust which are difficult to paint such as the backside of the box-shaped cross section frame parts.

METHOD: Apply anti-rust agent through the service holes and/or installation holes of the parts.

5. CAUTIONARY POINTS WHEN REPAIRING ALUMINUM ALLOY PANELS
a. PORTIONS WHERE ALUMINUM ALLOY PANELS ARE USED

b. WORK SAFETY
Although aluminum is a nontoxic material, it is very light in weight, which can easily cause metal particles to become airborne during sanding. It is important for technicians to protect their lungs and eyes from these particles. It is the personal responsibility of the technicians to be aware of the dangers involved, and to protect themselves by using proper safety equipment. It is also necessary to provide adequate lighting and ventilating facilities in the workshop. Please follow the recommended safety precautions below when repairing aluminum panels.
- Always wear protective glasses, ear plugs, dust masks, and other protective equipment to protect your eyes, ears, and respiratory system.
- Make sure to wear protective gloves when conducting heat repairs and when sanding or using organic solvents.
- As safety equipment for an emergency, have fire extinguishers, first aid kits, and an eye wash area at the workplace.

c. DIFFERENCE BETWEEN 5000 SERIES AND 6000 SERIES ALUMINUM ALLOY PANELS

NOTICE: There is a marked decrease in the panel strength if heated over the heating temperature limit.

d. CHARACTERISTICS OF ALUMINUM ALLOY
1. If the base metal of aluminum alloy is left untreated, it will naturally develop an oxide film that will protect against corrosion. As a result, an anti-rust agent does not need to be used even when aluminum alloy is exposed to heat during shrinking.
2. Aluminum alloy conducts heat very well so a wide area will become heated when heat is applied to one area.

3. Aluminum alloy does not become magnetized.

e. PRECAUTIONS WHEN CONDUCTING REPAIRS
1. If aluminum comes into contact with another type of metal (especially steel), galvanic corrosion will cause the base metal to corrode. If tools used to repair steel panels are not cleaned before they are used on aluminum alloy surfaces, the tools will leave behind steel particles and corrode the base metal.
Therefore make sure to completely clean off iron particles on the surface of tools if using them to repair steel parts before use, or prepare a separate set of tools (hammers, dollies, chisels, air sander, carbon electrode, etc.) for use on aluminum alloys only.

HINT: Galvanic corrosion is rusting that is created by a potential difference between two metals that is produced when they come in to contact together. This phenomenon occurs with any type of metal, and the aluminum causes the corrosion when the base metal surfaces of aluminum and steel are put together.

2. An oxide film forms on an aluminum alloy within a matter of minutes when the base metal is exposed to the air.
This oxide film has a negative effect on putty and paint adhesion, so it is important to immediately treat the base metal after sanding and degreasing.

3. Aluminum is brittle and easily develops work hardening and cracks. Heating aluminum when restoring a deformed portion improves workability and prevents work hardening and cracking so it is an effective method when repairing. However, heating at the optimal heating temperature provides the very best results and any increase in temperature above this will result in a corresponding decrease in strength. (There is a marked decrease in strength if the optimal heating temperature is exceeded.)

f. CHOOSING THE REPAIR METHOD

g. THE WORK PROCEDURE OF EACH REPAIR METHOD

- Repair by Pulling.

NOTICE: Make sure to completely clean off iron particles on the surface of the tools above if using them to repair steel parts before use, or prepare a separate set of tools for use on aluminum alloys only (to prevent galvanic corrosion of the aluminum).

a. CHECK OF THE DAMAGE

1. Inspect visually and brush your hand across the damaged surface to determine the condition of the damaged area and whether there is any stretching. Also, check for any cracking and paint peeling. In cases where no paint defects are found, conduct the work starting from (C).

b. PAINT REMOVAL (NOT NECESSARY IN CASES WHERE THERE ARE NO PAINT DEFECTS)

1. Completely remove the paint at the points where bonding chips will be attached.

c. DEGREASING WHERE THE BONDING CHIP WILL BE ATTACHED

1. After air blowing the surface, apply the degreaser cleaning solution that comes with the puller set to a cloth and degrease the area to be repaired.

HINT: If there are no paint defects present, scuff with the extra fine compound and then degrease.

d. PREPARING THE PLATE HOOK

1. Heat the plate hook with an industrial heater gun and attach the bonding chip before it cools off.

e. SETTING THE PLATE HOOK

1. Attach two-sided tape (or masking tape folded over on itself) on the back of the magnet for positioning and set the plate hook on the panel surface to secure it in place.

HINT: The magnet must be attached with tape because aluminum does not magnetize.

f. ATTACHING THE PLATE HOOK

1. Heat the bonding chip with an industrial heater gun. Then use a handle of a hammer or the like to apply pressure on the plate hook and adhere it to the surface.
2. Next, air blow to cool down the panel surface and plate hook.

g. SETTING THE PULLER

1. Fasten the magnet rubber plate attachment under the arm of the puller (with tape or the like) to prevent secondary damage.
2. Attach the eye nut to the plate hook and then attach the puller hook to the eye nut. Pull outward to about 1 to 2 mm (0.04 to 0.08 in.) past the height of the undamaged surface.

h. PULLING

1. While keeping the puller pulled outward, lightly strike the convex surrounding area with a body line chisel or wood piece.

HINT: Perform procedures (d) to (i) for areas a, b and c in alphabetical order. Pull so that each area is -1 to -2 mm (-0.04 to -0.08 in.) in relation to the undamaged surface.

i. REMOVING THE PLATE HOOK

1. After pulling, use an industrial heater gun to heat the bonding chip until it melts and then remove the plate hook.
2. Heat the leftover bonding chip and use a spatula to quickly remove it from the panel. Then apply the degreaser cleaning solution to degrease the panel surface.

NOTICE: After the above work has been completed, conduct the following shrinking work if the tension of the repaired panel surface is inadequate.

j. SHRINKING

1. Shrink areas that are elevated due to stretching with a carbon electrode to ensure tension.
2. After shrinking, remove the burn mark in the same way as when repairing regular steel panels.

NOTICE:
- There is a negative effect on putty adhesion of the exposed panel portions due to oxidization.
- Create a featheredge on the previous coat, and apply primer and putty immediately after the shrinking work.

- Repairing with a Hammer and Dolly by Heating

1. Inspect visually and brush your hand across the damaged surface to determine the condition of the damaged area and whether there is any stretching.

b. PREPARATION FOR HEAT REPAIRS

1. Cover the undamaged paint coating with a wet cloth so that it will not be burned by the flame of the burner while heating.
2. Put the temperature indication label at a position approximately 50 mm (1.97 in.) away from the heated area.

HINT: Position the temperature indication label so that it is not directly exposed to the burner flame.

c. HEAT REPAIRING

1. Evenly heat the bent portion.

NOTICE:
- Do not directly expose the temperature indication label to the flame.
- Stop heating before the temperature indication label color changes.

NOTICE:
- Measure the painted surface when using a noncontact thermometer. (The aluminum base metal surface cannot be precisely measured.)
- Apply a guide coat or a lacquer coat (white or black) on the base metal surface and then measure the surface to be painted when measuring the aluminum base metal surface.
- The temperature will rise immediately after heating so make sure to frequently measure the temperature. (There is a large marked decrease in strength if the heating limit temperature is exceeded.)

d. REPAIRING BY HAMMERING

1. Rough Repairing
Aluminum quickly cools down after being heating so hammer the backside of panel with a plastic- faced or wooden hammer immediately after heating.

2. Guidelines for Finishing Rough Repair
Even if there is unevenness in the surface, the repair is complete if the edge lines are restored.

3. Repair with a Hammer and Dolly
- Smooth the surface repeatedly using an on-dolly and an off-dolly on the surface.
- Restore the panel edge line with an on-dolly.

e. CHECK OF THE REPAIRED SURFACE

1. Check the following two conditions and repair by shrinking using a carbon electrode if either applies.
- There is an area that is higher than normal.
- There is inadequate tension.

f. REPAIRING DENTS ON THE INNER PANEL PORTION

1. If there are no high points, repair by putty shaping.

2. If there are high points, place the nozzle of an industrial heater gun close to the high point, and heat it for 30 seconds.

3. Repair the shape of the surface with a fine smoothening hammer before the heated portion cools off.

HINT: Alternate between heating and hammering.

g. PROCEDURE AFTER PANEL REPAIR (PUTTY SHAPING, PAINTING, ETC.)
1. Conduct the procedure based on the work process below. (The basic work process is the same as for repairs on steel panels.)

HINT: Perform the procedure with the paint manufacture specified primer and putty. Also, when using the primer and putty, make sure to follow the paint manufacturer's instructions.

6. REPAIR PROCEDURE OF HEADLIGHT RETAINER
a. INSTALL UPPER HEADLIGHT PROTECTOR RETAINER

HINT: If the installation area of the headlight is damaged, use the supply retainer for low-cost repair. Ensure that the headlight is not damaged.

1. Cut off the part shaded in the illustration and smooth with sandpaper.

NOTICE: After cutting off the part, place the headlight protector retainer against the bosses, and gradually file away the old bracket if it interferes with the installation of the supply retainer.

2. Install the headlight protector retainer with the screw.

b. INSTALL LOWER HEADLIGHT PROTECTOR RETAINER

HINT: If the installation area of the headlight is damaged, use the supply retainer for low-cost repair. Ensure that the headlight is not damaged.

2. Install the headlight protector retainer with the screw.

7. PROCEDURES NECESSARY WHEN BATTERY TERMINAL IS DISCONNECTED/RECONNECTED
a. THE WORK LIST

NOTICE: After the power switch is turned OFF, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the power switch OFF, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.

8. PROCEDURES NECESSARY WHEN ECU OR OTHER PARTS ARE REPLACED
a. THE WORK LIST: USA, Canada

b. THE WORK LIST: Except USA, Canada

9. DESCRIPTION OF THE DELIVERABLE PAINT FINISHING QUALITY AND REPAIR POINTS TO REMEMBER
a. DESCRIPTION OF THE DELIVERABLE PAINT FINISHING QUALITY
1. Wet sanding is conducted after applying the intermediate coat and after applying the color base or the first clear coat to create a paint appearance with the texture and luster consistent with the quality of the Lexus brand. This improves the smoothness and luster of the clear coat and ensures an appearance quality that is one level above the Toyota brand. In addition, a double clear coat should be used for deeper paint colors to improve the appearance quality.
2. Although there is a difference in the appearance quality in the texture and luster compared to Toyota brand vehicles, there is no change in the type of paint used.

b. POINTS TO REMEMBER WHILE REPAIRING
1. Although it is possible to repair using the same repair procedure as used previously, it is necessary to apply a clear coat and sand with an emphasis on recreating the smoothness of the texture and creating a coat of the appropriate thickness.
- Before repairing, after confirming the texture of the surrounding panels, sand and paint the panel to match the texture.
- For deeper colors, make sure to apply a coat of the appropriate thickness and to match up the texture with surrounding panels (undamaged areas).

HINT: In certain cases, matching up the texture and luster by applying a double clear coat based on the number of panels (area) to be painted will reduce the work time because sanding requires additional work time.

10. PRECAUTIONS FOR SRS AIRBAG SYSTEM
a. Handling of a vehicle that has been damaged in a collision.
1. Refer for the SRS airbag system inspection procedures.
2. When using an electric welder, first remove all airbags and seat belt pretensioners.
3. If impacts are likely to occur to the front airbag sensors, side airbag sensors, rear side airbag sensors, center airbag sensor or seat position sensor, remove each sensor as necessary beforehand.
4. Do not allow the front airbag sensors, side airbag sensors, rear side airbag sensors, center airbag sensor or seat position sensor to become heated to high temperatures.
5. Check the wire harnesses and connectors for damage and/or melting, as some areas of airbags and seat belt pretensioners may heat up to several hundred degrees when they operate.

11. PRECAUTIONS FOR RESIN PARTS
a. PLASTIC PROPERTIES CHART
1. When repairing, some parts may be deformed by the heat. Therefore, confirm the properties of the plastic parts, and remove parts beforehand as necessary.

b. THE PLASTIC BODY PARTS MATERIAL LIST