Training - Locate Your OEM Toyota Parts Here
Training - Locate Your OEM Toyota Parts Here
Training - Locate Your OEM Toyota Parts Here
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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.