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Dedicated to promoting quality collision repair of <strong>Toyota</strong> vehicles<br />

<strong>Parts</strong> and Repair Organization Support<br />

<strong>Training</strong><br />

The Next Generation<br />

Pros Tips<br />

2003 Corolla<br />

On Time<br />

Eliminating the Hurdles<br />

Summer 2002


Table of<br />

Contents<br />

To produce quality<br />

repairs you need to<br />

use quality parts<br />

and materials.<br />

Summer 2002<br />

3 Guide to Success<br />

The Collision Repair Reference<br />

Guide contains all the information<br />

an experienced technician requires<br />

to start a repair.<br />

4 <strong>Training</strong> the Next Generation<br />

Several <strong>Toyota</strong> initiatives are<br />

helping to educate new collision<br />

repair technicians.<br />

6 Paint Technician <strong>Training</strong><br />

<strong>Toyota</strong> courses help experienced<br />

painters improve their skills and<br />

productivity.<br />

8 On Time—Eliminating<br />

the Hurdles<br />

The <strong>Toyota</strong> On Time Collision<br />

Repair System is a great way<br />

to increase quality, productivity<br />

and profits.<br />

10 Pros Tips—2003 Corolla<br />

The all-new 2003 Corolla features<br />

improvements and refinements—<br />

making it more rigid and quieter<br />

on the road. This article gives<br />

you background information<br />

on how they’re built and proper<br />

repair procedures.<br />

Collision Pros<br />

Editor: Doug Stein Managing Editor: Karl Krug Copywriting and Design: Liehr Marketing & Communications Refer all<br />

correspondence to: Collision Pros, <strong>Toyota</strong> Motor Sales, U.S.A., Inc., 19001 S. Western Ave., H211, Torrance, California 90509. Fax: (310)<br />

974-5908 E-mail: collisionpros@toyota.com. Collision Pros is published four times a year by The <strong>Toyota</strong> Customer Services, Product<br />

Management Department. Contents may be reprinted with permission. ©2002 Collision Pros. MDC# 00117-00601-JULY02


Guide to Success<br />

Collision Repair Reference Guide is a handy<br />

manual for experienced technicians<br />

A wealth of information is available to help<br />

collision repairers achieve <strong>Toyota</strong> owners’<br />

expectations of having vehicles fixed right the first<br />

time. One of the key publications in this effort is the<br />

Collision Repair Reference Guide, a helpful manual that contains<br />

important information on recent vehicles in the <strong>Toyota</strong> lineup.<br />

The guide is a quick-look reference manual intended for the experienced<br />

technician. The publication includes basic information a seasoned technician requires<br />

to get a collision repair started.<br />

To help estimators properly identify <strong>Toyota</strong> models dating back to 1990, the guide<br />

provides a complete vehicle identification section with production dates, model numbers<br />

and engine numbers. The guide also includes a helpful explanation of vehicle identification<br />

numbers to help technicians locate color codes, axle codes, transmission codes and other<br />

important details.<br />

Another important area of the guide is the jacking and hoisting section. Detailed illustrations<br />

show the correct jack positions for each model along with support positions to help technicians<br />

support a vehicle on a frame rack without causing frame damage. This section also details the<br />

correct lift locations for <strong>Toyota</strong> models.<br />

Body technicians can use the Collision Repair Reference Guide to identify <strong>Toyota</strong> dimensions<br />

of all models dating from 1990 through the 2001 Camry. Helpful illustrations indicating assembly<br />

marks and other information are included alongside the dimension details. Technicians can also<br />

find SRS air bag information in the guide. A detailed matrix explains what parts should be<br />

replaced or inspected after air bag deployment.<br />

Paint technicians can use the guide to determine proper paint codes and refinish formulas.<br />

The guide includes <strong>Toyota</strong> paint names and codes along with a translation guide to identify the<br />

corresponding paint code for most major paint manufacturers.<br />

Collision repair centers should use the full range of <strong>Toyota</strong> resource materials to help ensure<br />

proper repairs. Collision Repair Information Bulletins offer <strong>Toyota</strong>’s position on the latest developments<br />

in the collision repair industry and offer information on new procedures and materials.<br />

Collision Repair Manuals provide detailed information on structural repairs. The Collision Repair<br />

Reference Guide is a quick reference that technicians can use when beginning repairs or doublechecking<br />

other repair information.<br />

The Collision Repair Reference Guide is an invaluable resource that helps experienced technicians<br />

perform timely and accurate repairs.<br />

To Order:<br />

Independent collision repair<br />

shops can order copies<br />

of the Collision Repair<br />

Reference Guide and CD<br />

(Material #: 00117-00540-01)<br />

through a <strong>Toyota</strong> dealership<br />

or directly from the <strong>Toyota</strong><br />

Materials Distribution<br />

Center at 1-800-622-2033.<br />

3


4<br />

TRAINING<br />

The Next<br />

Generation<br />

Several <strong>Toyota</strong> Programs aim to Educate New Collision<br />

Repair Technicians. As the number of <strong>Toyota</strong> and Lexus vehicles on<br />

the road increases, the demand for skilled collision repair technicians to fix<br />

those vehicles also continues to rise. <strong>Toyota</strong> is working on several fronts to<br />

meet that demand and to train technicians with the knowledge and skills to<br />

provide quality repairs. By collaborating with high schools, community colleges<br />

and vocational schools in several innovative programs, <strong>Toyota</strong> is helping<br />

to groom the collision repair workforce of the future.


Three <strong>Toyota</strong> initiatives are already preparing the next generation of collision repair technicians.<br />

<strong>Here</strong> are the programs that are in place and how they work:<br />

(1)T-TEN:<strong>Toyota</strong> Technical Education Network<br />

During the past 16 years, T-TEN has trained thousands of skilled technicians.<br />

The network forges a partnership between <strong>Toyota</strong>, community<br />

colleges and career training schools. Using a <strong>Toyota</strong> and I-CAR curriculum,<br />

the schools provide a quality, hands-on automotive education.<br />

Created in 1986 to train service technicians, T-TEN added collision<br />

repair to the program three years ago. Five campuses across the country<br />

offer T-TEN collision repair and the program’s popularity has grown<br />

with students, schools and collision repair centers.<br />

At the Pennsylvania College of Technology, more than a dozen students<br />

are learning collision repair through the T-TEN program. The school’s program<br />

is so popular that plans are in place to double enrollment beginning<br />

this Fall.<br />

“We’ve been very pleased with the support we’ve received from<br />

<strong>Toyota</strong>—it’s been a good marriage,” reports Alfred Thomas, the T-TEN<br />

Collision Repair Program Coordinator at Pennsylvania College in<br />

Williamsport. “<strong>Toyota</strong> and Lexus provide us vehicles, parts and training<br />

material, so we’re able to provide a great service to our students.<br />

To broaden the pool of skilled<br />

entry-level employees, T-TEN<br />

recently forged a strategic alliance<br />

with UTI, a private career training<br />

school that has produced skilled<br />

automotive graduates since 1965.<br />

The <strong>Toyota</strong>/UTI Collision Repair<br />

Technician <strong>Training</strong> Program features<br />

a comprehensive curriculum<br />

at the school’s Houston, Texas,<br />

campus. During the 51-week program,<br />

students complete a series<br />

of I-CAR courses in addition to<br />

<strong>Toyota</strong>-specific classes.<br />

“It is estimated that in the one<br />

year students are at UTI, they gain<br />

what it would have taken them<br />

years to learn if they were simply<br />

working in the field,” says Rick<br />

Jazwin, Director of Industry<br />

Development at the school. While<br />

the training is conducted in<br />

Houston, students are recruited<br />

from across the country. Most students<br />

are willing to relocate following<br />

graduation, meaning the program<br />

serves more than just the<br />

Houston area.<br />

Students like it because they get training that can help lead to good jobs.”<br />

Fairfield Auto Group in Williamsport hired its first T-TEN collision repair<br />

technician last year and was impressed. “The technician we got was<br />

pretty skilled; he knew what he was doing,” says Tony Pilger, Fairfield’s<br />

Body Shop Manager. After his initial experience, Pilger is eager to add<br />

more T-TEN graduates to his staff. “I’d hire another one in a heartbeat.”<br />

The T-TEN collision repair program covers two years and can lead to an<br />

Associate’s Degree. In addition to taking regular automotive courses, students<br />

enroll in four <strong>Toyota</strong> collision repair and refinishing courses taught by<br />

<strong>Toyota</strong>-trained instructors. Students must pass two ASE certification tests<br />

as part of the program and complete a 640-hour (16-week) paid internship.<br />

The program has important benefits for everyone involved. Collision<br />

centers reduce their training expenses and develop a pipeline for<br />

<strong>Toyota</strong>/Lexus-trained collision repair professionals. Schools receive support<br />

from <strong>Toyota</strong> and Lexus in the form of vehicles, parts, equipment and<br />

training support. Students get a state-of-the-art education, internship<br />

opportunities and a good start on a rewarding career.<br />

(2)UTI:Universal Technical Institute (3)AYES: Automotive Youth Educational Systems<br />

Want more information<br />

about T-TEN,UTI or AYES?<br />

You can find more details and locate participating schools on the<br />

Web at www.T-TEN.com, www.uticorp.com and www.ayes.org.<br />

<strong>Toyota</strong> is one of 10 manufacturers<br />

working with dealerships and<br />

high schools to encourage bright<br />

students to choose automotive<br />

careers. The AYES program funnels<br />

high school students into<br />

automotive courses, which continue<br />

through their senior year. Along<br />

the way, students take internships<br />

where they are mentored by seasoned<br />

technicians.<br />

Originally started in 1995 to train<br />

service technicians, AYES recently<br />

created a pilot program for collision<br />

repair and refinish. The program<br />

provides hands-on coursework in<br />

paint and refinish, non-structural<br />

repairs, and plastics and adhesives.<br />

The program will be rolled<br />

out within the next 18 months, providing<br />

the potential for several hundred<br />

new entry-level collision repair<br />

technicians annually.<br />

“The pilot students are now doing<br />

very well,” reports Roger Tadajewski,<br />

National Manager for the AYES collision<br />

repair and refinish program.<br />

“The students get the skills they<br />

need and the program helps<br />

improve the image and awareness<br />

of collision repair careers.”<br />

Through efforts such as T-TEN<br />

and AYES, <strong>Toyota</strong> is working hard<br />

to meet the growing demand for<br />

new collision repair technicians.<br />

You can help by supporting these<br />

and other similar programs and<br />

the students involved in them.<br />

5


6<br />

Paint Technician <strong>Training</strong> Hands-on<br />

tTechnicians who complete <strong>Toyota</strong>’s trio of training<br />

courses learn the techniques required to restore vehicles<br />

to original <strong>Toyota</strong> and Lexus condition. They also put<br />

themselves on the path to earning <strong>Toyota</strong> Master Paint<br />

Technician Certification, recognition that increases<br />

their market value along with their skill level. Collision<br />

repair centers sending technicians to courses enjoy the<br />

benefits of higher overall shop knowledge and get access<br />

to the most current paint and refinish techniques.<br />

“I’ve been doing this for 19 years and I got a lot<br />

out of the class,” says Al Estrada, Paint Shop Director<br />

at Fletcher Jones Collision Center in Las Vegas,<br />

Nevada. “The class was very practical and informative.<br />

I was able to come back to this shop and apply what<br />

I learned.”<br />

Some of those applications resulted in better quality<br />

repairs, Estrada notes. “We were taught some better<br />

<strong>Toyota</strong><br />

courses help<br />

technicians improve<br />

their skills<br />

Highly skilled painters and refinishers<br />

play a crucial role in providing<br />

total customer satisfaction on collision<br />

repairs. To help paint technicians<br />

achieve this high standard<br />

while enhancing their career potential,<br />

<strong>Toyota</strong> offers a trio of training<br />

courses. As a student attending<br />

these courses, you’ll develop and<br />

refine your skills to consistently perform<br />

quality refinish repairs. You<br />

will also learn color principles to<br />

accurately tint paint and enhance<br />

color-matching skills.<br />

methods for creating color hues to make more accurate<br />

color matches,” he explains. “The class was so good<br />

that we’ve decided to send our other painters to the<br />

<strong>Toyota</strong> training.”<br />

The classes are offered at <strong>Toyota</strong> training centers in<br />

Torrance, California, and West Caldwell, New Jersey,<br />

using <strong>Toyota</strong> vehicles and Genuine <strong>Toyota</strong> <strong>Parts</strong>. By<br />

participating, you gain a better understanding of paint<br />

principles and the effects of light sources. You also get<br />

practical hands-on experience with high-volume/lowpressure<br />

paint guns and learn techniques to avoid common<br />

defects.<br />

Body shops that have sent technicians to the courses<br />

report increased customer satisfaction and a more productive<br />

and efficient environment. Course graduates<br />

emerge with the latest information about state-of-the-art<br />

technology, tools and applications. They also get on the


path to receiving the <strong>Toyota</strong> Emblem,<br />

which requires a combination of <strong>Toyota</strong><br />

work experience, ASE certification, I-CAR<br />

course credit and <strong>Toyota</strong> training.<br />

John Saia, Technical & Body <strong>Training</strong><br />

Development Manager, <strong>Toyota</strong> Motor<br />

Sales, U.S.A., Inc., says ongoing training<br />

should be a part of all collision repair<br />

technicians’ careers: “We’ve created courses<br />

that offer something for everyone.<br />

Painting is a profession that requires lifelong<br />

learning. Materials change, techniques<br />

change, and new problems and<br />

solutions crop up all the time. These<br />

courses cover all of those areas.”<br />

THE THREE TOYOTA<br />

PAINT CLASSES ARE:<br />

<strong>Toyota</strong> Paint Finish<br />

Repair (T100):<br />

A one-day class<br />

designed for new car<br />

detailing specialists and<br />

paint repair specialists.<br />

It provides detail<br />

technicians with the<br />

skills to properly evaluate and perform<br />

paint finish repairs. Technicians learn to<br />

identify basic paint types, evaluate paint<br />

surface damage and perform paint finish<br />

repairs without painting. In addition, they<br />

receive instruction on measuring paint<br />

coating thickness, selecting appropriate<br />

tools and equipment, and performing correct<br />

buffing and polishing techniques.<br />

Technicians learn how to repair <strong>Toyota</strong><br />

paint surfaces damaged by scratches, acid<br />

rain, rail dust, hard water spots or environmental<br />

fallout. Detailers can use<br />

course techniques to remove minor flaws<br />

in urethane finishes and clearcoats.<br />

<strong>Toyota</strong> Color Matching<br />

for Painters (T200):<br />

A two-day course intended for painters<br />

with urethane paint system experience who<br />

wish to develop a systematic approach to<br />

color matching <strong>Toyota</strong> vehicles. The train-<br />

ing provides experienced technicians with<br />

the color principles to accurately tint paints<br />

and also enhances their paint matching<br />

skills. The course covers the procedures<br />

required before tinting, an explanation<br />

of the three dimensions of color and the<br />

effects of light sources. It also provides<br />

hands-on instruction<br />

on applying<br />

color principles<br />

in the tinting<br />

process and creating<br />

a blendable<br />

color match.<br />

Course graduates<br />

gain a more<br />

thorough under-<br />

“We’ve developed<br />

the classes to really<br />

enhance an experienced<br />

painter’s knowledge, We<br />

know that they know<br />

how to spray and prep.<br />

But we can give them<br />

the tools to help<br />

consistently achieve a<br />

perfect paint job.”<br />

Shawn Hart,<br />

Collision Repair <strong>Training</strong> Instructor,<br />

<strong>Toyota</strong> Motor Sales, U.S.A., Inc.<br />

standing of Original Equipment<br />

Manufacturer (<strong>OEM</strong>) coatings, a greater<br />

ability to precisely match unique <strong>Toyota</strong><br />

colors and increased expertise on color<br />

blend preparation techniques.<br />

<strong>Toyota</strong> Advanced Painting<br />

Techniques (T250):<br />

A two-day course open to experienced<br />

painters who have completed the other<br />

two <strong>Toyota</strong> painting courses. This class<br />

covers a wide range of advanced paint<br />

technology and skills, such as performing<br />

correct plastic preparation and the use of<br />

high-volume/low-pressure (HVLP) paint<br />

guns. It also alerts technicians about how<br />

to avoid common paint defects and apply<br />

low-VOC refinish paint products.<br />

This hands-on course instructs painters<br />

about the preparation and refinishing of<br />

bumper covers along with procedures for<br />

refinishing new body panels with corrosion-resistant<br />

coatings.<br />

“We’ve developed the classes to really<br />

enhance an experienced painter’s knowledge,”<br />

says Shawn Hart, Collision Repair<br />

<strong>Training</strong> Instructor, <strong>Toyota</strong> Motor Sales,<br />

U.S.A., Inc. “We know that they know<br />

how to spray and prep. But we can give<br />

them the tools to help consistently<br />

achieve a perfect paint job.”<br />

Alex Gonzales, Manager of Puente Hills<br />

Autobody in California has been painting<br />

for six years but says the color-matching<br />

course was extremely useful. “I’ve taken a<br />

lot of paint courses in different places<br />

before, but the <strong>Toyota</strong> class really took<br />

things to a new level,” he says. “I discovered<br />

some new techniques and different<br />

approaches. It really opens your eyes to<br />

what’s possible.”<br />

Course schedules are published quarterly.<br />

To learn more about <strong>Toyota</strong> training,<br />

contact your local <strong>Toyota</strong> dealer or local<br />

<strong>Toyota</strong> region, or send an e-mail to<br />

collisionpros@toyota.com.<br />

7


8<br />

Since its introduction, the <strong>Toyota</strong> On Time<br />

Collision Repair (OTCR) system has earned a repu-<br />

tation for helping improve efficiency and reduc-<br />

ing waste in most collision shops. As an added<br />

value, OTCR shops have also been able to dimin-<br />

ish cycle time on many collision repair jobs.<br />

Getting vehicles through the shop more efficient-<br />

ly though, is only a small part of the On Time sto-<br />

ry. The system’s most significant advantages are<br />

dramatically higher productivity, reduced waste<br />

and improvements in repair quality—all adding<br />

up to greater profitability.<br />

On Time–Eliminating<br />

On Time Collision Repair is based upon the<br />

principles of the <strong>Toyota</strong> Production System. One<br />

of the guiding principles behind the On Time system<br />

is that a repair shop organized into two distinct<br />

areas operates more efficiently because the<br />

On Time line can concentrate on specific types of<br />

repair jobs. By adopting proven <strong>Toyota</strong> Production<br />

System manufacturing principles, bottlenecks are<br />

reduced along with the “stop and start” nature of<br />

some repairs.<br />

Since the On Time area is dedicated to repairs<br />

requiring three or fewer days, damaged bumpers<br />

or scraped fenders are no longer treated as “filler<br />

jobs” that distract technicians from larger repairs.<br />

This leads to quicker, quality repairs, pleasing customers<br />

and insurance companies, as well as the<br />

repair shop. But that benefit represents only a<br />

fraction of the On Time advantages.<br />

Three body shop managers explain how<br />

the On Time system has helped deliver quality<br />

repairs, a more productive shop and a healthier<br />

bottom line.


Multiple makes are no problem<br />

The On Time approach works at collision centers dealing with multiple manufacturer lines of vehicles like the Clair<br />

Collision Center in Boston, Massachusetts. “Just one of five vehicles going through the busy center is a <strong>Toyota</strong>, but the<br />

On Time approach works well even with a mixture of other lines,” says John Assini, Clair’s Body Shop Director.<br />

“We’ve got multiple vehicle lines coming through but the On Time system works with all of them,” Assini explains.<br />

“We’ve become more efficient, reduced mistakes and become more productive. Plus, our technicians love it.”<br />

Since adopting the system in November 2001, gross margins have jumped significantly without a dramatic increase in<br />

severity. As small jobs are no longer dispatched around the center, quality has also improved, says Assini. “Our On Time<br />

team of technicians and painters meet each morning and plan what’s coming and how to handle the work. Quality went<br />

up as cycle time went down. Now, I’ve adopted a lot of the On Time principles to the rest of the shop and we’ve seen<br />

improvements there too.<br />

“When we first started looking into On Time, I was concerned that it would not work in Massachusetts where there<br />

are no insurance company direct repair programs,” adds Assini. “But since installing it in our shop, we find that it works<br />

great. Rather than focus on things beyond our control, we<br />

look for efficiencies in the things that we have direct control<br />

the Hurdles<br />

over. We do not need an insurance company’s approval to<br />

become a more efficient shop. In fact, many companies now<br />

see the benefit in reduced cycle time and happier customers.”<br />

Continued on page 12<br />

The <strong>Toyota</strong> On Time Collision Repair System helps provide quality repairs and productivity<br />

<strong>Toyota</strong> Production System concepts that everyone can adopt<br />

Taichi Ohno is considered to be<br />

one of the founding fathers of the<br />

<strong>Toyota</strong> Production System. Ohno<br />

described what he calls the Seven<br />

Sins of “Muda.” Muda can be defined<br />

as anything that consumes resources<br />

yet produces nothing of value to the<br />

customer. Shop owners and managers<br />

should look at their operation<br />

and start reducing or eliminating<br />

waste in these areas:<br />

1. Over-production Ahead of<br />

Demand: Have we anticipated the<br />

needs of our market and assured<br />

that production capacity matches<br />

demand for our product?<br />

2. Waiting for the Next Step: Do<br />

our technicians stand around<br />

waiting for something to happen?<br />

Is paint shop production matched<br />

to body shop production?<br />

3. Unnecessary movement of<br />

materials, parts, vehicles: Are our<br />

shop and our systems designed to<br />

minimize movement and maximize<br />

productivity?<br />

4. Over-processing: Do we regularly<br />

perform unneeded labor operations?<br />

For example, do your<br />

painters remove electrodeposition<br />

primers by machine sanding a<br />

new sheet metal panel when many<br />

paint vendors suggest scuffing<br />

with a plastic abrasive pad?<br />

5. Excessive inventories: How<br />

many days supply of Paint and<br />

Materials do you have on hand?<br />

Do you use Just-in-Time delivery<br />

for sheet metal parts?<br />

6. Unnecessary movement of people:<br />

Are we deploying our most<br />

expensive resource in the best<br />

way possible?<br />

7. Production of Defective<br />

Products: How much work do we<br />

need to redo?<br />

<strong>Toyota</strong> believes in the concept of<br />

Kaizen (constant improvement). Remember<br />

that to produce quality<br />

repairs you need to use quality parts<br />

and materials. Review the list and start<br />

to apply the concepts of Kaizen to<br />

your shop today. <strong>Your</strong> customers will<br />

love you for it.<br />

9


10<br />

Tips<br />

Pros Tips–2003 Corolla<br />

In the automotive world, few<br />

vehicles have a pedigree as<br />

long as the <strong>Toyota</strong> Corolla.<br />

Originally introduced in 1968,<br />

over 20 million Corollas have<br />

been built. This latestgeneration<br />

Corolla is bound<br />

to be an equally popular<br />

model, featuring all-new<br />

exterior sheet metal as well<br />

as many refinements that<br />

make it quieter on the road.<br />

If a new Corolla is involved in<br />

a collision, proper attention<br />

to detail is important when<br />

returning it to pre-loss condition.<br />

This article provides fundamental<br />

information needed<br />

when repairing a new Corolla.<br />

High-Strength Steel<br />

Anti-Chipping Application<br />

Only for models without mud guard<br />

High-Strength Steel (HSS) is used to help<br />

ensure body rigidity while providing a lightweight<br />

body. Changes in the structural configuration and<br />

galvanization of the steel can take place when it’s<br />

heated during repairs. Do not heat HSS components.<br />

Using heat to stress-relieve structural steel<br />

can result in:<br />

• Destruction of corrosion-resistant coatings<br />

• Decreased impact energy absorption capacity<br />

• Brittleness of the metal<br />

• Cracking of the metal<br />

“Cold straightening” (stress-relieving) is the only<br />

approved repair method. If the structural member<br />

or perimeter frame cannot be satisfactorily<br />

restored to original dimensions during this<br />

process, it should be replaced.<br />

Removing spot welds also requires special<br />

handling. Use an HSS spot-weld bit with a hightorque<br />

drill at low speeds and lubricate the bit<br />

Soft Chip Primer<br />

Urethane Chipping Pa<br />

PVC Coating<br />

with a small amount of drilling oil. Also, be sure to<br />

check the ’03 Corolla Repair Manual for Collision<br />

Damage to determine if the welds are inside, outside<br />

or middle prior to drilling.<br />

Reinforcements<br />

The new Corolla features numerous new reinforcements<br />

on the rocker panels, roof side rails,<br />

lower front pillars, inside the center pillars, and the<br />

roof panel. To reinforce the area from the front<br />

A-pillar to the front suspension tower, a cowl top<br />

inner reinforcement is placed inside the cowl top<br />

panel. A brace joins the front pillars.<br />

• When repairing these areas, be sure to consult<br />

the ‘03 Corolla Repair Manual for Collision<br />

Damage to identify the location of these<br />

reinforcements and <strong>Toyota</strong>-recommended cut<br />

and join locations prior to repairing the vehicle.<br />

Corolla body parts should not be cut in a<br />

location other than described in the repair<br />

manual.<br />

Impact-Absorbing Body<br />

The structure of the Corolla has been designed to<br />

help absorb and distribute the impact force during<br />

a collision, channeling energy away from the driver<br />

and passengers. This was accomplished by creating<br />

a high-strength body structure that minimizes<br />

the deformation of the cabin itself. Be sure to carefully<br />

inspect the body structure for damage, as the<br />

force of the impact may cause deformations in<br />

areas away from the actual impact.<br />

• The left and right front side members are joined<br />

by a cross member, and the rear side members<br />

are connected to the rocker. After a collision, be<br />

sure to inspect these areas for any deformation.<br />

• Differential-thickness sheet metal is used in the


front end of the front side members—the<br />

thinner front portion and the thicker rear<br />

portion enable the front end of the side<br />

members to collapse efficiently to absorb<br />

the energy of an impact. Differentialthickness<br />

sheet metal is also used in the<br />

center pillar. These areas should be<br />

inspected and repaired according to<br />

<strong>Toyota</strong>-recommended repair procedures.<br />

• Corolla features a Head Impact<br />

Protection Structure—with this type of<br />

construction, if the occupant’s head<br />

impacts the roof side rail and pillar in<br />

reaction to a collision, the inner panels<br />

are designed to help absorb the force of<br />

the impact. If this structure is damaged,<br />

it must be replaced to help ensure proper<br />

performance in subsequent collisions.<br />

Anti-Corrosion Sheet Steel<br />

Anti-corrosion sheet steel is used in the<br />

construction of both fenders, the hood and<br />

many other external components other than<br />

the roof and interior parts.<br />

•“Cold straightening” is the only approved<br />

repair method; <strong>Toyota</strong> does not recommend<br />

the use of open flame heating to<br />

stress-relieve HSS components.<br />

• Body fillers and two component polyputties<br />

applied over bare anti-corrosion steel<br />

may not adhere adequately. Blistering or<br />

peeling may result. An epoxy primer must<br />

first be applied to the bare metal before<br />

application of body filler.<br />

Wax and Sealer<br />

Wax and sealer are applied to the<br />

hemmed portions of the hood, door panels,<br />

rocker panels and luggage compartment<br />

door to improve rust resistance. Be sure to<br />

reapply the wax and sealer on these areas<br />

during repairs to help maintain proper corrosion<br />

protection.<br />

Anti-Chipping Application<br />

Polyvinyl Chloride (PVC) coating is applied<br />

to the underside of the body, the bottom side<br />

of the cowl panel, the fender apron and various<br />

other areas that are subject to stone<br />

chipping. In addition, soft-chip primer is<br />

Anti-Corrosion<br />

Sheet Steel<br />

applied to the front hood area and the lower<br />

door panel area to help protect them from<br />

stone chipping. Follow all paint manufacturer<br />

recommendations when refinishing these<br />

areas, and be sure to restore these areas to<br />

pre-loss condition.<br />

Low Noise Body<br />

Various measures are employed to help<br />

reduce vibrations and suppress road noise<br />

before it reaches the passenger cabin.<br />

• Asphalt sheeting panels are used for the<br />

floor to reduce booming.<br />

• Foamed urethane sponge and foamed<br />

seal material are applied inside the roof<br />

pillars and to the roof panel to reduce<br />

wind and road noise.<br />

• A dash panel silencer and hood silencer<br />

help keep engine and road noise from<br />

reaching the cabin.<br />

• Felt is used on the floor and roof to help<br />

ensure a quiet interior (Roof Felt not used<br />

on models equipped with the optional<br />

moonroof).<br />

Anti-Corrosion<br />

Sheet Steel<br />

When a vehicle sustains a severe side<br />

or rear impact, the noise reduction materials<br />

may become dislodged, torn or broken.<br />

These materials are important in helping to<br />

maintain the quietness of these vehicles.<br />

Proper installation of these materials can<br />

help reduce unwanted noise that may be<br />

transmitted into the cabin. In addition,<br />

apply the appropriate body foam to all<br />

areas where foam was damaged or<br />

removed during a repair; this can help<br />

restore sound-deadening characteristics<br />

and corrosion protection.<br />

Seatbelts<br />

• The driver’s seat and front passenger<br />

seat have a 3-point Emergency Locking<br />

Retractor (ELR) seatbelt, an electrical<br />

sensing type seatbelt pretensioner and a<br />

seatbelt force limiter. After a collision,<br />

inspect these components and replace<br />

if necessary.<br />

Continued on page 12<br />

11


12<br />

Record sales<br />

Since adopting the On Time system at the end of<br />

2001, <strong>Toyota</strong> of Hollywood’s collision repair center<br />

has set monthly efficiency records. “Our shop is no<br />

longer like a parking lot,” says Larry Cummings,<br />

Manager of the Hollywood, Florida, dealership’s body<br />

shop. “We get vehicles in and out. Technicians get to<br />

work on one job from start to finish without being<br />

interrupted. They can focus on their tasks and have<br />

become more productive. They’re not on and off jobs<br />

anymore.”<br />

Pre-managing a job to ensure that all needed parts<br />

are on hand and that all supplemental estimates have<br />

been approved makes for a consistent flow of vehicles<br />

through the shop. That paves the way for a more<br />

profitable shop.<br />

“We now have the room to process a lot more vehicles,”<br />

Cummings says. “We’re much more organized,<br />

our labor costs have improved because we’re more productive and our technicians<br />

don’t have to worry about four or five jobs at once. While it’s not for<br />

everybody, I’ve been using On Time in the shop since 1999 and it really<br />

does work.”<br />

On Time<br />

Collision Repair<br />

Productivity boost<br />

On Time continued from page 9<br />

“A key advantage of the On Time system is that it maximizes technician<br />

productivity,” says Jeff Debner, Collision Center Director at Fred Haas<br />

<strong>Toyota</strong> World in Spring, Texas. “The On Time method’s organizational<br />

advantages show up directly on the bottom line,” he adds.<br />

“You have the right people doing the right work,” Debner explains. “The<br />

technicians perfect their techniques because they are familiar with the<br />

repairs they are doing. A technician who is constantly hanging fenders on a<br />

Camry or replacing bumpers on a Corolla can get very good at it and the<br />

repetition increases the quality.”<br />

In addition, the On Time system liberates technicians working on bigger<br />

or more complex jobs to concentrate on their tasks. “You don’t want your<br />

highest paid frame technician stopping what he’s doing to put a new headlight<br />

on a vehicle. That can sometimes happen without this system,”<br />

Debner says. “It’s like in a service area where you wouldn’t have your highest<br />

skilled diagnostic technician stopping to do oil changes.”<br />

Thanks to the system, Fred Haas <strong>Toyota</strong> World’s collision center is enjoying<br />

strong results. “Our margins are higher<br />

and our customers are very satisfied,”<br />

Debner says. “Quality and profitability go<br />

hand in hand.”<br />

Tips<br />

Pros Tips continued from page 11<br />

• The right- and left-rear seats have<br />

3-point ELR and Automatic Locking<br />

Retractor (ALR) seatbelts.<br />

• A 3-point ELR and ALR seatbelt with<br />

its retractor enclosed in the seatback is<br />

provided for the center seatbelt of the<br />

rear seat.<br />

In the event of a collision, air bag<br />

components should be inspected.<br />

In the event of a collision, all seatbelt and<br />

air bag components should be inspected<br />

and replaced according to <strong>Toyota</strong> recommendations.<br />

For more information, consult<br />

the appropriate Collision Repair Information<br />

Bulletin (CRIB).<br />

Reusable Clips<br />

Retaining stays for the headlights have<br />

been provided separately from the headlight<br />

housing to help protect them from<br />

severe damage in a minor collision.<br />

Complete collision repair information is<br />

available in the ’03 Corolla Repair Manual<br />

for Collision Damage (P/N00117-BRM11-<br />

2U), available through any <strong>Toyota</strong> dealership,<br />

or by calling the <strong>Toyota</strong> Material<br />

Distribution Center at 1-800-622-2033.

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