Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Scion 2006-2007 xA xB tC Approved Toyota_Scion_xA-2006 Collision Repair Collision Repair
<< Back | HomeMost service manuals and schematics are PDF files, so You will need Adobre Acrobat Reader to view : Acrobat Download Some of the files are DjVu format. Readers and resources available here : DjVu Resources
For the compressed files, most common are zip and rar. Please, extract files with Your favorite compression software ( WinZip, WinRAR ... ) before viewing. If a document has multiple parts, You should download all, before extracting.
Good luck. Repair on Your own risk. Make sure You know what You are doing.
Image preview - the first page of the document
>> Download Collision Repair documenatation <<
Text preview - extract from the document
IN-18 INTRODUCTION
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
FWD Front Wheel Drive Vehicles
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
SSM Special Service Materials
w/ with
w/o without
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 xA.
Applicable models: NCP61 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 xA 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.
INTRODUCTION IN-1
GENERAL REPAIR INSTRUCTIONS
1. WORK PRECAUTIONS
(a) VEHICLE PROTECTION
Glass Cover
(1) When welding, protect the painted surfaces, windows,
seats and carpet with heat resistant, fire-proof covers.
Seat Cover
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.
WRONG
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.
WRONG 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
F10004 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).
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)
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 TSOP
Front Bumper Cover TSOP
Front Bumper Hole Cover TSOP
Headlight PP/PC
Fog light TSOP
Side Turn Signal Light PMMA/ABS
Fender Panel Mudguard TSOP
Front Fender Mudguard PP/EPDM
Cowl Top Ventilator Louver TSOP
Outer Rear View Mirror ABS/PA
Front Pillar Upper Cover AES
Side Mudguard TSOP
Front Door Outside Handle PC/PA
Rear Door Outside Handle PC/PA
Quarter Panel Rear Mudguard TSOP
Rear Wheel House Plate PP/EPDM
Back Door Outside Garnish ABS
Back Door Outside Handle PA
High Mount Stop Light PMMA/ABS
Rear Bumper Cover TSOP
Rear Combination Light PMMA/AAS
License Plate Light PMMA/ABS
Rear Fog Light PC/ABS
Rear Spoiler ABS
S Resin material differs with model.
/ Made up of 2 or more kinds of materials.
INTRODUCTION IN-15
HANDLING PRECAUTIONS ON RELATED COMPONENTS
1. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in brake (32) section of the repair manual for the relevant model when handling brake system
parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC sys-
tem.
2. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance and
vibration resistance of the vehicle. After installing components in the sections listed in the table below,
perform alignments to ensure correct mounting angles and dimensions. Particularly accurate repair of
the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions giv-
en in the repair manual for the relevant model during alignment and section DI of this section.
Section of repair manual
Component to be aligned
for relevant model
Front Wheels Front Suspension (26) section
Rear Wheels Rear Suspension (27) section
3. COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to the body panels. Strictly ob-
serve the following precautions to prevent damaging these components and the body panels during han-
dling.
S Before repairing the body panels, remove their components or apply protective covers over the com-
ponents.
S Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.
S Before removing components from the outer surface of the body, attach protective tape to the body to
ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.
S Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
4. ECU (ELECTRONIC CONTROL UNIT)
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.
S Before starting electric welding operations, disconnect the negative (-) terminal cable from the bat-
tery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are
all equipped with memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.
S Do not expose the ECUs to ambient temperatures above 80_C (176_F).
NOTICE: If it is possible the ambient temperature may reach 80_C (176_F) or more, remove the ECUs
from the vehicle before starting work.
S Be careful not to drop the ECUs and not to apply physical shocks to them.
INTRODUCTION IN-5
HOW TO USE THIS MANUAL
1. BODY PANEL REPLACEMENT THIS MANUAL
BP-34 BODY PANEL REPLACEMENT
QUARTER PANEL (CUT)
REPLACEMENT
REMOVAL
POINT
1 Remove the [A] at the same time.
PART NAME
[A] Fuel Filler Opening Lid
A : REPLACEMENT PART AND METHOD
QUARTER PANEL (CUT)
Replacement method
(ASSY) ... Assembly replacement
(CUT) ... Major cutting (less than 1 / 2 of part used)
(CUT-H) ... Half cutting (about 1 / 2 of part used)
(CUT-P) ... Partial cutting (most of part used)
Replacement part
B : REMOVAL CONDTIONS
C : PART LOCATION
D : REMOVAL DIAGRAM
Describes in detail removal of the damaged part involving repair by cutting.
E : REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
F13890A
IN-6 INTRODUCTION
BODY PANEL REPLACEMENT BP-35
INSTALLATION
S Temporaily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
S Inspect the fiting of the related parts around the new parts before welding. This affects the appearance of the F
finish.
S After welding, apply the polyurethane foam to the corresponding parts.
S After welding, apply body sealer and under-coating to the corresponding parts.
S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
I
J
G
I
5mm
POINT
1 Before temporarily installing the new parts, apply body sealer to the wheel arch.
HINT:
1) Apply body sealer about 5mm (0.20in.) front the flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4mm (0.12 - 0.16in.) in diameter. H
3) For other sealing points, refer to section PC.
PART NAME
[A] Fuel Filler Opening Lid [B] Waterproof Rivet
F : INSTALLATION CONDITIONS
G : INSTALLATION DIAGRAM
Describes in detail installation to the new part involving repair by welding and / or
cutting, but excluding painting.
H : INSTALLATIOLN GUIDE
Provides additional information to more efficiently help you perform the installation.
I : SYMBOLS
(See page IN-7)
J : ILLUSTRATION OF WELD POINTS
Weld method and panel position symbols (See page IN-9)
K : PART NAME
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.
SYMBOLS MEANING ILLUSTRATION
CUT AND JOIN LOCATION
(SAW CUT)
CUT AND JOIN LOCATION
(Cut Location for
Supply Parts)
CUT LOCATION
CUT WITH DISC
SANDER, ETC.
BRAZE
(Removal)
BRAZE
(Installation)
-- WELD POINTS
SPOT WELD OR
-- MIG PLUG WELD
(See Page IN-9)
CONTINUOUS
MIG WELD
(BUTT WELD)
CONTINUOUS
MIG WELD
(TACK WELD)
BODY SEALER
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:
REMOVAL INSTALLATION
Weld points Weld points
Remove weld point and panel position Weld method and panel position
SYMBOLS MEANING ILLUSTRATION SYMBOLS MEANING ILLUSTRATION
Remove
Weld
Spot Weld
Points
(Outside)
MIG Plug
Weld
(Middle)
(Inside)
Spot MIG
Weld
HINT: Panel position symbols are as seen from
the working posture.
F13892A
IN-16 INTRODUCTION
PRECAUTIONS FOR REPAIRING BODY
STRUCTURE PANELS
1. HEAT REPAIR FOR BODY STRUCTURE
PANELS
Toyota prohibits the use of the heat repair method on body
structure panels when repairing a vehicle damaged in a col-
lision.
Panels that have high strength and rigidity, as well as a long
life span for the automobile body are being sought after.
At Toyota, in order to fulfill these requirement, we use high
tensile strength steel sheets and rust preventive steel
sheets on the body.
High tensile steel sheets are made with alloy additives and
a special heat treatment in order to improve the strength.
To prevent the occurrence of rust for a long period of time,
the surface of the steel is coated with a zinc alloy.
If a body structure parts are heat repaired with an acetylene
torch or other heating source, the crystalline organization of
the steel sheet will change and the strength of the steel
sheet will be reduced.
The ability of the body to resist rust is significantly lowered
as well since the rust resistant zinc coating is destroyed by
heat and the steel sheet surface is oxidized.
2. STRUCTURE PANEL KINKS
A sharp deformation angle on the panel that cannot be re-
turned to its original shape by pulling or hammering is
called a kink.
Since structure parts were designed to exhibit a 100% per-
formance when they were in their original shape, if they are
deformed in an accident, or if the deformed parts are re-
paired and reused, they become unable to exhibit the same
performance as intended in the design.
It is necessary to replace the part where the kink has oc-
curred.
INTRODUCTION IN-17
3. IMPACT BEAM REPAIR
The impact beam and bracket are necessary and important
parts in maintaining a survival space for passengers in a
side collision.
For impact beam, we use special high tensile strength
steel.
The high tensile strength steel maintains its special crystal-
line organization by heat treatment or alloy additives.
Since these parts were designed to exhibit a 100% perfor-
mance when they were in their original shape, if they are
deformed in an accident, or if the deformed parts are re-
paired and reused, they become unable to exhibit the same
performance as intended in the design.
It is necessary to replace the door assembly when impact
beam or bracket is damaged.
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.
F10007
(b) CUTTING AREA
Cutting Okay
(1) Always cut in a straight line and avoid reinforced area.
Reinforcement
Corners
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.
WRONG 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.
F10010
INTRODUCTION IN-11
2. PREPARATION FOR INSTALLATION
(a) SPOT WELD POINTS
(1) When welding panels with a combined thickness of
Less than over 3mm (0.12in.), use a MIG (Metal Inert Gas) weld-
3mm
er for plug welding.
HINT: Spot welding will not provide sufficient durability
for panels over 3mm (0.12in.) 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.
F10012
(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
1.0 (0.04) under 5 (0.20) ◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo