Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Scion 2006-2007 xA xB tC Approved Toyota_Scion_tC-2007 Collision Repair Manual Collision Repair Manual
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FOREWORD
This repair manual has been prepared to provide essential in-
formation on body panel repair methods (including cutting and
welding operations, but excluding painting) for the SCION tC.
Applicable models: ANT10 series
This manual consists of body repair methods, exploded dia-
grams and illustrations of the body components and other in-
formation relating to body panel replacement such as handling
precautions, etc. However, it should be noted that the front fend-
ers of the SCION model is bolted on and require no welding.
When repairing, don't cut and join areas that are not shown in
this manual. Only work on the specified contents to maintain
body strength.
Body construction will sometimes differ depending on specifica-
tions and country of destination. Therefore, please keep in mind
that the information contained herein is based on vehicles for
general destinations.
For the repair procedures and specifications other than collision-
damaged body components of the SCION tC refer to the repair
manuals.
If you require the above manuals, please contact your SCION
Dealer.
All information contained in this manual is the most up-to-date at
the time of publication. However, specifications and procedures
are subject to change without prior notice.
VIEWS OF THIS TEXT
Scope of the repair work explanation
D This text explains the welding panel replacement instructions from the vehicle's white body condi-
tion. We have abbreviated the explanations of the removal and reinstallation of the equipment parts
up to the white body condition and of the installation, inspection, adjustment and final inspection of
equipment parts after replacing the weld panel.
Section categories
D Each section has been divided as shown below.
Section Title Contents Examples
Explanation of general body repair. Cautionary items.
INTRODUCTION
Views of weld panel replacement instructions. Views of weld panel replacement instructions.
Instructions for replacing the weld panels Front side member replacement.
from the white body condition, from which Quarter panel replacement.
BODY PANEL REPLACEMENT
bolted parts have been removed, with
individual supply parts.
BODY DIMENSIONS Body aligning measurements. Dimension diagrams.
Scope and type of anti-rust treatment, etc. Under coat.
PAINT D COATING
together with weld panel replacement. Body sealer.
Abbreviation of contents in this text.
D The following essential procedures have been abbreviated. When actually working, conduct this
work properly.
(1) Jack and lift operations.
(2) Clean and wash removed parts, if necessary.
(3) Visual inspection.
INTRODUCTION IN-1
GENERAL REPAIR INSTRUCTIONS
1. WORK PRECAUTIONS
(a) VEHICLE PROTECTION
(1) When welding, protect the painted surfaces, windows,
seats and carpet with heat resistant, fire-proof covers.
F10001A
(b) SAFETY
(1) Never stand in direct line with the chain when using a
puller on the body or frame, and be sure to attach a
safety cable.
F10002A
(2) Before performing repair work, check for fuel leaks.
If a leak is found, be sure to close the opening totally.
(3) If it is necessary to use a flame in the area of the fuel
tank, first remove the tank and plug the fuel line.
F10003A
(c) SAFETY WORK CLOTHES
(1) In addition to the usual mechanic's wear, cap and
safety shoes, the appropriate gloves, head protector,
glasses, ear plugs, face protector, dust-prevention
mask, etc. should be worn as the situation demands.
Code Name
A Dust-Prevention Mask
B Face Protector
F10004A C Eye Protector
D Safety Shoes
E Welder's Glasses
F Ear Plugs
G Head Protector
H Welder's Gloves
IN-2 INTRODUCTION
2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS
(1) The repair procedure for plastic body parts must conform with the type of plastic material.
(2) Plastic body parts are identified by the codes in the following table.
(3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint-
ing etc.), consideration must be given to the property of the plastic.
Heat*
Material resistant Resistance to
Code Notes
name temperature alcohol or gasoline
limit _C (_F)
Alcohol is harmless if applied only for
Acrylonitrile 80 Avoid gasoline and organic
AAS short time in small amounts (e.g., quick
Acrylic Styrene (176) or aromatic solvents.
wiping to remove grease).
Alcohol is harmless if applied only for
Acrylonitrile 80 Avoid gasoline and organic
ABS short time in small amounts (e.g., quick
Butadiene Styrene (176) or aromatic solvents.
wiping to remove grease).
Alcohol is harmless if applied only for
Acrylonitrile 80 Avoid gasoline and organic
AES short time in small amounts (e.g., quick
Ethylene Styrene (176) or aromatic solvents.
wiping to remove grease).
Acrylonitrile Alcohol is harmless if applied only for
80 Avoid gasoline and organic
ASA Styrene short time in small amounts (e.g., quick
(176) or aromatic solvents.
Acrylate wiping to remove grease).
Alcohol is harmless if applied only for
Cellulose 80 Avoid gasoline and organic
CAB short time in small amounts (e.g., quick
Acetate (176) or aromatic solvents.
wiping to remove grease).
Alcohol is harmless. Most solvents are harmless
Ethylene 100
EPDM Gasoline is harmless if applied only for but avoid dipping in gasoline,
Propylene (212)
short time in small amounts. solvents, etc.
Fiber
180
FRP Reinforced Alcohol and gasoline are harmless. Avoid alkali.
(356)
Plastics
Alcohol is harmless if applid only for short
Ethylene 70 Avoid gasoline and organic
EVA time in small amounts (e.g., quick wiping
Acetate (158) or aromatic solvents.
to remove grease).
Ethylene /
Vinyl Alcohol is harmless if applid only for short
70 Avoid gasoline and organic
E / VAC Acetate time in small amounts (e.g., quick wiping
(158) or aromatic solvents.
Copolymer to remove grease).
Resin
Polyamide 80
PA Alcohol and gasoline are harmless. Avoid battery acid.
(Nylon) (176)
Polybutylene 160
PBT Alcohol and gasoline are harmless. Most solvents are harmless.
Terephthalate (320)
Avoid gasoline brake fluid,
120
PC Polycarbonate Alcohol is harmless. wax, wax removers and
(248)
organic solvents. Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.
INTRODUCTION IN-3
Heat*
Material resistant Resistance to
Code Notes
name temperature alcohol or gasoline
limit _C (_F)
80
PE Polyethylene Alcohol and gasoline are harmless. Most solvents are harmless.
(176)
Polyethylene 75
PET Alcohol and gasoline are harmless. Avoid dipping in water.
Terephthalate (167)
Avoid dipping or immersing
Polymethyl 80 Alcohol is harmless if applied only for
PMMA in alcohol, gasoline,
Methacrylate (176) short time in small amounts.
solvents, etc.
Polyoxymethylene 100
POM Alcohol and gasoline are harmless. Most solvents are harmless.
(Polyacetal) (212)
80
PP Polypropylene Alcohol and gasoline are harmless. Most solvents are harmless.
(176)
Composite
80
PPF Reinforced Alcohol and gasoline are harmless. Most solvents are harmless.
(176)
Polypropylene
Modified Gasoline is harmless if
100
PPO Polyphenylene Alcohol is harmless. applied only for quick wiping
(212)
Oxide to remove grease.
Alcohol and gasoline are harmless if Avoid dipping or immersing
60
PS Polystyrene applied only for short time in small in alcohol, gasoline,
(140)
amounts. solvents, etc.
Alcohol is harmless if applied only for very Avoid dipping or immersing
80
PUR Polyurethane short time in small amounts (e.g., quick in alcohol, gasoline,
(176)
wiping to remove grease). solvents, etc.
Alcohol and gasoline are harmless if
Avoid dipping or immersing
Polyvinylchloride 80 applied only for short time in small
PVC in alcohol, gasoline,
(Vinyl) (176) amounts (e.g., quick wiping to remove
solvents, etc.
grease).
Alcohol is harmless if applied only for Avoid dipping or immersing
Styrene 80
SAN short time in small amounts (e.g., quick in alcohol, gasoline, solvents
Acrylonitrile (176)
wiping to remove grease). etc.
Alcohol is harmless. Most solvents are harmless
Thermoplastic 80
TPO Gasoline is harmless if applied only for but avoid dipping in gasoline,
Olefine (176)
short time in small amounts. solvents, etc.
Alcohol is harmless if applied only for Avoid dipping or immersing
Thermoplastic 80
TPU short time in small amounts (e.g., quick in alcohol, gasoline,
Polyurethane (176)
wiping to remove grease). solvents, etc.
TOYOTA
80
TSOP Super Alcohol and gasoline are harmless. Most solvents are harmless.
(176)
Olefine Polymer
Unsaturated 110
UP Alcohol and gasoline are harmless. Avoid alkali.
Polyester (233)
*Temperatures higher than those listed here may result in material deformation during repair.
IN-4 INTRODUCTION
3. LOCATION OF PLASTIC BODY PARTS
Parts Name Code
Radiator Grille ABS
Radiator Lower Grille TSOP
Front Bumper Cover TSOP
Front Bumper Hole Cover TSOP
Front Bumper Guard Cover TSOP
Headlight PC/PP
Cowl Top Ventilator Louver TSOP
Outer Rear View Mirror ASA/ABS
Front Door Outside Handle PC/PBT
Side Mudguard TSOP
Center Stop Light PMMA/ABS
Back Door Outside Garnish ABS
License Plate Light PC
Rear Combination Light PMMA/PC /ASA
Rear Bumper Cover TSOP
HINT:
D Resin material differs with model.
/ Made up of 2 or more kinds of materials.
INTRODUCTION IN-5
HOW TO USE THIS MANUAL
1. BODY PANEL REPLACEMENT THIS MANUAL
F13890A
IN-6 INTRODUCTION
F13891A
INTRODUCTION IN-7
2. SYMBOLS
The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas
and the types of weld required.
F13893A
IN-8 INTRODUCTION
SYMBOLS MEANING ILLUSTRATION
-- Assembly Mark --
BODY SEALER
-- (Flat Finishing)
BODY SEALER
-- (No flat Finishing)
F13894A
INTRODUCTION IN-9
3. ILLUSTRATION OF WELD POINT SYMBOLS
EXAMPLE:
F13892A
IN-10 INTRODUCTION
PROPER AND EFFICIENT WORK
PROCEDURES
1. REMOVAL
(a) PRE-REMOVAL MEASURING
(1) Before removal or cutting operations, take measure-
ments in accordance with the dimension diagram. Al-
ways use a puller to straighten a damaged body or
frame.
F10007A
(b) CUTTING AREA
(1) Always cut in a straight line and avoid reinforced area.
F10008A
(c) PRECAUTIONS FOR DRILLING OR CUTTING
(1) Check behind any area to be drilled or cut to insure
that there are no hoses, wires, etc., that may be dam-
aged.
HINT: See "Handling Precautions on Related Compo-
nents" on page IN-15.
F10009A
(d) REMOVAL OF ADJACENT COMPONENTS
(1) When removing adjacent components, apply protec-
tive tape to the surrounding body and your tools to pre-
vent damage.
HINT: See "Handling Precautions on Related Compo-
nents" on page IN-15.
F10010A
INTRODUCTION IN-11
2. PREPARATION FOR INSTALLATION
(a) SPOT WELD POINTS
(1) When welding panels with a combined thickness of
over 3 mm (0.12 in.), use a MIG (Metal Inert Gas)
welder for plug welding.
HINT: Spot welding will not provide sufficient durability
for panels over 3 mm (0.12 in.) thick.
F10011A
(b) APPLICATION OF WELD-THROUGH PRIMER
(SPOT SEALER)
(1) Remove the paint from the portion of the new parts
and body to be welded, and apply weld-through prim-
er.
F10012A
(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.
REFERENCE: mm (in.)
Thickness of welded portion Size of plug hole
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