2006豐田scion xa維修手冊英有電路collision repair

1、IN-18INTRODUCTIONABBREVIATIONS USED IN THIS MANUALFor convenience, the following abbreviations are used in this manual.ABSlock Brake System A/ CAir ConditionerassyassemblyECTElectronic Controlled Transmission ECUElectronic Control Unite.g. Exempli Gratia (for Example)Ex.ExceptFWDFront Wheel Drive Ve

2、hicles 4WDFour Wheel Drive Vehicles in.inchLHLeft-handLHDLeft-hand DriveMIGMetal Inert GasM/ YM YearPPSProgressive Power Steering RHRight-handRHDRight-hand DriveSRSSupplemental Restraint System SSMSpecial Service Materialsw/withw/ owithoutFOREWORDThis repair manual has been prepared to provide essen

3、tial in- formation on body panel repair methods (including cutting and welding operations, but excluding painting) for the SCION xA.Applicable ms: NCP61 seriesThis manual consists of body repair methods, exploded dia- grams and illustrations of the body components and other in- formation relating to

4、 body panel replacement such as handling precautions, etc. However, it should be noted that the front fend- ers of the SCION m is bolted on and require no welding.When repairing, dont cut and join areas that are not shown in this manual. Only work on the specified contents to maintain body strength.

5、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 compone

6、nts 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.INTRODUCTIO

7、NIN-1GENERAL REPAIR INSTRUCTIONS1. WORK PRECAUTIONSGlass CoverSeat CoverF10001A(a) VEHICLE (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fire-proof covers.WRONGF10002A(b) SAFETY(1) Never stand in direct line with the chain when using a puller on the b

8、ody or frame, and be sure to attach a safety cable.WRONGF10003A(2) Before perfor repair work, check for fuel leaks. If a leak is found, be sure to 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.F10004(c) SAFETY WOR

9、K CLOTHES(1) In addition to the usual mechanics 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.CodeNameADust-Prevention MaskBFace ProtectorCEye ProtectorDSafety ShoesEWelders G

10、lassesFEar PlugsGHead ProtectorHWelders GlovesIN-2INTRODUCTION2. 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

11、 body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint- ing etc.), consideration must be given to the property of the plastic.CodeMaterial nameHeat* resistant temperature limit C ( F) to alcohol or gasolineNotesAASAcrylonitrile Acrylic Styrene80(176)Alcohol is harmless i

12、f applied only for short time in small amounts (e.g., quick wi to remove grease).Avoid gasoline and organic or aromatic solvents.ABSAcrylonitrile Butadiene Styrene80(176)Alcohol is harmless if applied only for short time in small amounts (e.g., quick wi to remove grease).Avoid gasoline and organic o

13、r aromatic solvents.AESAcrylonitrile Ethylene Styrene80(176)Alcohol is harmless if applied only for short time in small amounts (e.g., quick wi to remove grease).Avoid gasoline and organic or aromatic solvents.ASAAcrylonitrile Styrene Acrylate80(176)Alcohol is harmless if applied only for short time

14、 in small amounts (e.g., quick wi to remove grease).Avoid gasoline and organic or aromatic solvents.CABCellulose Acetate80(176)Alcohol is harmless if applied only for short time in small amounts (e.g., quick wi to remove grease).Avoid gasoline and organic or aromatic solvents.EPDMEthylene Propylene1

15、00(212)Alcohol is harmless.Gasoline is harmless if applied only for short time in small amounts.Most solvents aarmless but avoid dipin gasoline, solvents, etc.FRPFiber Reinforced Plastics180(356)Alcohol and gasoline aarmless.Avoid alkali.EVAEthylene Acetate70(158)Alcohol is harmless if applid only f

16、or short time in small amounts (e.g., quick wito remove grease).Avoid gasoline and organic or aromatic solvents.PAPolyamide (Nylon)80(176)Alcohol and gasoline aarmless.Avoid battery acid.PBTPolybutylene Terephthalate160(320)Alcohol and gasoline aarmless.Most solvents aarmless.PCPolycarbonate120(248)

17、Alcohol is harmless.Avoid gasoline brake fluid, wax, wax removers and organic solvents. Avoid alkali.*Temperatures higher than those listed here may result in material deformation during repair.INTRODUCTIONIN-3CodeMaterial nameHeat* resistant temperature limit C ( F) to alcohol or gasolineNotesPEPol

18、yethylene80(176)Alcohol and gasoline aarmless.Most solvents aarmless.PETPolyethylene Terephthalate75(167)Alcohol and gasoline aarmless.Avoid dip in water.PMMAPolymethyl Methacrylate80(176)Alcohol is harmless if applied only for short time in small amounts.Avoid dip or immersing in alcohol, gasoline,

19、 solvents, etc.POMPolyoxymethylene (Polyacetal)100(212)Alcohol and gasoline aarmless.Most solvents aarmless.PPPolypropylene80(176)Alcohol and gasoline aarmless.Most solvents aarmless.PPOModified Polyphenylene Oxide100(212)Alcohol is harmless.Gasoline is harmless if applied only for quick wi to remov

20、e grease.PSPolystyrene60(140)Alcohol and gasoline aarmless if applied only for short time in small amounts.Avoid dip or immersing in alcohol, gasoline, solvents, etc.PURPolyurethane80(176)Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wi to remove grease).Avoid

21、 dip or immersing in alcohol, gasoline, solvents, etc.PVCPolyvinylchloride (Vinyl)80(176)Alcohol and gasoline aarmless if applied only for short time in small amounts (e.g., quick wi to remove grease).Avoid dip or immersing in alcohol, gasoline, solvents, etc.SANStyrene Acrylonitrile80(176)Alcohol i

22、s harmless if applied only for short time in small amounts (e.g., quick wi to remove grease).Avoid dip or immersing in alcohol, gasoline, solvents etc.TPOThermoplastic Olefine80(176)Alcohol is harmless.Gasoline is harmless if applied only for short time in small amounts.Most solvents aarmless but av

23、oid dipin gasoline, solvents, etc.TPUThermoplastic Polyurethane80(176)Alcohol is harmless if applied only for short time in small amounts (e.g., quick wi to remove grease).Avoid dip or immersing in alcohol, gasoline, solvents, etc.TSOPTOYOTASuperOlefine Polymer80(176)Alcohol and gasoline aarmless.Mo

24、st solvents aarmless.UPUnsaturated Polyester110(233)Alcohol and gasoline aarmless.Avoid alkali.*Temperatures higher than those listed here may result in material deformation during repair.IN-4INTRODUCTION3. LOCATION OF PLASTIC BODY PARTSParts NameCodeRadiator GrilleTSOPFront Bumper CoverTSOPFront Bu

25、mper Hole CoverTSOPHeadlightPP/ PCFog lightTSOPSide Turn Signal LightPMMA / ABSFender Panel MudguardTSOPFront Fender MudguardPP/ EPDMCowl Top Ventilator LouverTSOPOuter Rear View MirrorABS/ PAFront Pillar Upper CoverAESSide MudguardTSOPFront Door Outside HandlePC / PARear Door Outside HandlePC / PAQ

26、uarter Panel Rear MudguardTSOPRear Wheel House PlatePP/ EPDMBack Door Outside GarnishABSBack Door Outside HandlePAHigh Mount Stop LightPMMA / ABSRear Bumper CoverTSOPRear Combination LightPMMA / AASLicense Plate LightPMMA / ABSRear Fog LightPC/ ABSRear SpoilerABS Resin material differs with m./ up o

27、f 2 or more kinds of materials.INTRODUCTIONIN-15HANDLING PRECAUTIONS ON RELATED COMPONENTS1. BRAKE SYSTEMThe 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 m when handling brake sys

28、tem parts.NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC sys- tem.2. DRIVE TRAIN AND CHASSISThe drive train and chassis are components that can have great effects on the running performance and vibration of the vehicle. After installing components in t

29、he 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-

30、en in the repair manual for the relevant m during alignment and section DI of this section.Component to be alignedSection of repair manual for relevant mFront WheelsFront Suspension (26) sectionRear WheelsRear Suspension (27) section3. COMPONENTS ADJACENT TO THE BODY PANELSVarious types of component

31、 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. Before repairing the body panels, remove their components or apply protective covers over the com- ponents. Before

32、 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. Before removing components from the outer surface of the body, attach protective tape to the body to ensure no damage to painted areas

33、.HINT: Apply touch-up paint to any damaged paint surfaces. 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

34、 ECUs. 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 mem

35、orized 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

36、 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. 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)

37、 or more, remove the ECUs from the vehicle before starting work. Be careful not to drop the ECUs and not to apply physical shocks to them.HOW TO USE THIS MANUALINTRODUCTIONIN-51. BODY PANEL REPLACEMENT THIS MANUALBP-34BODY PANEL REPLACEMENTQUARTER PANEL (CUT)REPLACEMENTREMOVALPOINT1 Remove the A at

38、the same time.PART NAMEA Fuel Filler Opening LidA : REPLACEMENT PART AND METHODQUARTER 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)Replace

39、ment partB : REMOVAL CONDTIONSC : PART LOCATIOND : REMOVAL DIAGRAMDescribes in removal of the damaged part involving repair by cutting.E : REMOVAL GUIDEProvides additional information to more efficiently help you perform the removal.F13890AIN-6INTRODUCTIONBODY PANEL REPLACEMENTBP-35INSTALLATION Temp

40、oraily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fiting of the related parts around the new parts before welding. This affects the appearance of theFfinish. After welding, apply the polyure

41、thane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply-rust agent to the inside of the necked section structural weld spots.IJGI5mmPOINT1 Before temporarily installing the new parts, apply body se

42、aler 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.H3) For other sealing points, refer to section PC.PART NAMEA Fuel Filler Opening LidB Waterproof RivetF : INSTALLATION CONDITI

43、ONS G : INSTALLATION DIAGRAMDescribes in installation to the new part involving repair by welding and / or cutting, but excluding painting.H : INSTALLATIOLN GUIDEProvides additional information to more efficiently help you perform the installation.I : SYMBOLS(See page IN-7)J : ILLUSTRATION OF WELD P

44、OINTSWeld method and panel position symbols (See page IN-9)K : PART NAMEF13891AINTRODUCTIONIN-72. SYMBOLSThe following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the types of weld required.SYMBOLSMEANINGILLUSTRATIONCUT AND JOIN LOCATION (SAW C

45、UT)CUT AND JOIN LOCATION(Cut Location for Supply Parts)CUT LOCATIONCUT WITH DISC SANDER, ETC.BRAZE(Removal)BRAZE(Installation) WELD POINTSSPOT WELD OR MIG PLUG WELD(See Page IN-9)CONTINUOUS MIG WELD (BUTT WELD)CONTINUOUS MIG WELD (TACK WELD)BODY SEALERF13893AIN-8INTRODUCTIONSYMBOLSMEANINGILLUSTRATIO

46、NAssembly MarkBODY SEALER(Flat Finishing)BODY SEALER(No flat Finishing)F13894AINTRODUCTIONIN-93. ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE:REMOVALINSTALLATIONWeld pointsWeld pointsRemove weld point and panel positionWeld method and panel positionSYMBOLSMEANINGILLUSTRATIONSYMBOLSMEANINGILLUSTRATIONR

47、emove Weld Points(Outside)(Middle)(Inside)HINT: Panel position symbols are as seen from the working posture.Spot WeldMIG Plug WeldSpot MIG WeldF13892AIN-16INTRODUCTIONPRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS1. HEAT REPAIR FOR BODY STRUCTURE PANELSToyota prohibits the use of the heat repair me

48、thod 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 rus

49、t preventive steel sheets on the body.High tensile steel sheets are 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 aeat rep

50、aired 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 an

51、d the steel sheet surface is oxidized.2. STRUCTURE PANEL KINKSA 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

52、 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.INTRODUCTIONIN-173. IMPACT BEAM REPAIRThe impact beam and bracket are

53、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 r