Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Collision Damage Repair Precautions - Crib # 161 (T-CRIB-161)
Reference number: T-CRIB-161
COLLISION DAMAGE REPAIR PRECAUTIONS - CRIB # 161
COLLISION REPAIR INFORMATION
| TOYOTA: | All Toyota, Lexus, Scion |
| SECTION: | Structural |
REVISION HISTORY
February 2022: Document formatting updated.
April 2022: Document content updated.
The following collection of precautions is intended to reinforce Toyota's position on some key collision repair topics. They should not be considered all-inclusive or a substitute for training.
Heat Repair for Body and Frame Components is Prohibited
High strength sheet steel is used for structural body and frame components. If these components are repaired with heat the crystalline structure changes, causing a significant decrease in strength. Heat also damages the zinc coating reducing corrosion resistant properties.
Intrusion Beam Repair is Prohibited
Intrusion beams are designed to absorb, channel, and dissipate collision energy. If they are damaged and repaired, they will no longer perform as intended. Damaged intrusion beams require complete door replacement.
Bumper Reinforcement Repair is Prohibited
Bumper reinforcements are designed to absorb, channel, and dissipate collision energy. If they are damaged and repaired, they will no longer perform as intended. Damaged bumper reinforcements require replacement.
When to Replace Damaged Body and Frame Components
Body and frame deformations that cannot be returned to original shape by pushing, pulling, or hammering (known as cold straightening) are classified as kinks. Kinks require component replacement. Deformations that can be returned to original shape by cold straightening methods are classified as bends.
Frame Component Replacement is Limited to New Genuine OE Service Parts Only
Welded components may be installed using Gas Metal Arc Welding/Metal Inert Gas (MIG) techniques. Ensure proper weld settings and penetration with practice welds. Do not weld over factory weld beads. Be sure to clean effected repair surfaces and apply epoxy primer and matching topcoat.
Butt Joint Without Backing is the Approved Cut and Join Welding Method
Sleeves and inserts will have a negative effect on crash energy management designs. Therefore, butt joint without backing is the only approved welding method unless otherwise specified. Ensure proper root-gap, weld settings, and penetration with practice welds. Adhere to specified cut and join locations.
Always Observe the Following Electric Welding Precautions
Before performing any electric welding, turn off the ignition, disconnect the negative terminal of the 12V battery. Remove any ECU's within 18 inches of weld sites and disconnect the main SRS computer connector. Wait 90 seconds before start of welding.
For more information on this and other important collision repair topics visit the Toyota Technical Information System (TIS)
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
Affiliate disclosure: We may earn a commission at no extra cost to you.
When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.