Bumper Handling and Refinishing
Quick Training Guide – QTB12A
This QTG aids in understanding the Toyota/Lexus
approved refinishing process for new raw bumper covers.
ENTER
Click the ENTER button to view the Quick Training Guide.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
STANDARDS
DAMAGE
IDENTIFICATION
10 Step
Refinishing Method
Introduction
• New bumpers are manufactured from TSOP, Toyota Super Olefin Plastic and are engineered to be
durable yet flexible.
• Refinishing replacement bumper covers requires attention to detail during each step to ensure a
durable long lasting finish that resists peeling and abrasion over the vehicle’s lifetime.
Click the tabs at the top to view each section
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Receiving
handling
10 Step
Refinishing Method
DAMAGE
IDENTIFICATION
STANDARDS
storage
staging
transportation
Dealer Bumper Cover Quality Standards
• Lexus and Toyota TSOP bumpers are packaged in protective material to prevent damage
during shipping.
• Following Toyota’s recommended handling procedure can reduce the occurrence of deformation
and abrasion damage.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Receiving
handling
10 Step
Refinishing Method
DAMAGE
IDENTIFICATION
STANDARDS
storage
staging
transportation
Receiving
• DO: Inspect bumpers at the point of receipt to
identify any obvious damage.
•D
ON’T: Improper stacking or failure to perform
visual quality verification upon receipt may result in
damage being passed on to the customer.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Receiving
handling
10 Step
Refinishing Method
DAMAGE
IDENTIFICATION
STANDARDS
storage
staging
transportation
Handling
• DO: Carrying in the center or using a stable
cart will help protect the bumper.
•D
ON’T: Dragging bumpers can cause
un-repairable damage.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Receiving
handling
10 Step
Refinishing Method
DAMAGE
IDENTIFICATION
STANDARDS
storage
staging
transportation
Storage
• DO: Store horizontally on a flat surface (in Car
Position) with enough space to easily move parts
in and out of location.
•D
ON’T: Forcing parts into locations, and excessive
stacking can cause damage and deformation.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Receiving
handling
10 Step
Refinishing Method
DAMAGE
IDENTIFICATION
STANDARDS
storage
staging
transportation
Staging
• DO: Stage in an area that will not result in parts
being hit, kicked or struck.
•D
ON’T: High traffic areas increase potential
for damage.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Receiving
handling
10 Step
Refinishing Method
DAMAGE
IDENTIFICATION
STANDARDS
storage
staging
transportation
Transportation
• DO: Transport in horizontal position (Car Position)
and avoid stacking and/or contact with other
objects.
•D
ON’T: Contact with sharp edges can cause
scratches, gouges or dents.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Scuffs & Scratches
DAMAGE
IDENTIFICATION
STANDARDS
ScraTCHES & Gouges
ScrATCHES on
Textured Surfaces
10 Step
Refinishing Method
Deformation or
Broken Tabs
Repair V.S. Replace
Damage Identification
• Scuffing or other minor scratch marks caused during the handling process are normal,
and will be corrected during the approved paint preparation process.
• Use the following guide to determine the extent of the damage.
Minor Surface
Scuffs and Scratches
Excessive Deformation
or Broken Tabs
28
09Pag
Deep Scratches
and Gouges
Scratches on
Textured Surfaces
e1
of 2
Repair vs. Replace
d
on
age
dam a claim r
htly
u 0%
slig filing y o
ing y for entiall ceed 5
n
r
retu s polic . Ess ot ex
n
re
with
ry
cy
ted cedu delive sts do
r
Poli
o
ocia pro
ass repair dling o pair c
es
r
ts
u
s
n
r
re
p
rs
ced
e co ce ou ring ha if the
e
o
sho
iz
r
g
r
P
im
t
ody
ana
009
info e du par
min
pair
eb
1, 2
nd nd re amag able
ts M
t Re
utsid
y1
ea
a
d
ir
Par
Ma
Par
rvic duce imal repa
or o
e
r
d
s
er intro d min e any
eale
age
e
tom
ed
re
c
:
Dam
cus ke to r incur repla
y th
TO
d b ses
ely
e
li
T:
lete
n
hav than
t tim uld
mp expe
JEC
por S wo t may ather
o
B
p
c
u
g
s
be agin
SU
, TM tha air r
t to
can
ck
and
ffor nt parts n parts to rep
pair repa PDC
arts
ne
IV-4
s re and rn to tion
of p
In a ceme collisioealers t.
-3,
g
ea
la
r
rity
tu
c
e:
e
es IV
teg
rep irable for d he pa
lac cle tim andlin for re redu eplac
g
p
a
in
e
a
t
R
rm
cy ery, h part
me rsus r
n, p
d
fi
s
ti
rep uest is e of
o
e
ir
n
u
ti
g
a
d
d
o
s
v
e
a
p
c
of
orta
ver
age h lea air v
deli
r re
req he valu
dam days
and
nsp
pair tome curring ss dam throug gh rep
tly
age
Tra
of t
e
c
uen ess
f Re cus
am
0
nd
rou
tion
roc
s o uces of reo
e3
ic a
freq usin
ny d
to p tisfac ent th
efit
d
raff
n
hav
for (3) b
te a
T
e
u
ta
g
o
Ben • Re ductio s need er sa ironm
e
IV
o
a hre
y
to
am
t
to n
tion
Re inate ustom n env
hen
d D ithin
ged
:
eipt ers
Sec -12
o
y, t nt
c
a
le
s
•
m
l
c
r
t
it
e
a
li
s
a
e
u
c
r
w
r
d
e
e
m
E
u
c
nu 1, V pon usto
C
pa
mo eme enco
rov
•
ced Ma
1
Con PD
u
Imp uces im
com burs ongly
Pro Parts ges V- ment party c “R9” acing
d
d
r
d
•
e
r
tr
im
n
ta , pa
a
ag ir re are s
Re
s fo
ship third age o our f
s
cy
oyo
am
a
ure
•
Poli nce T rogram n parts arts to r Dam tact y imate ent d r rep t, you
ced
r
e
im
o
n
u
t
o
pro
Cla Refer port P heck iting p Carrie en co air es n-freq laim f the pa
im
air.
la
ir
c
a
p
t
c
p
f
rep
o
ed
th
y:
gc
ge
Rep Polic n V Su quality exp Freigh low), g a re for n mage alue o
win
ma if
r to
tio
3”
follo
da
it v
be
m
uin
age
(
r da
the
Sec Perfor nt prio e is “R chart purs Dam file a the un w
.
t fo eceipt
e
n
s
e
lo
e
d
e
g
f
u
d
vice
m
a
o
le
n
ar
ee
be
e
•
ry r
sem
Ser
ship rt dam ies (s you oncea ate a 50% ribed
leas
bur elive
ery
e
d
c
a
le, p
eliv
reim e d
If p modit advis “R9” C ir estim excee s des
irab
ng y of th
dD
a
a
t
ti
m
a
•
e
o
is
p
t
o
s
it
o
d
p
t
c
ers
ue cop
age a re
tten
es n lace
ut re
eip
tom
req
a
db
rec rt dam rsue ate do n rep
Una
cus
are ill and
age
a
u
a
op
ime
ou
.
If p s to p estim ther th
dam
y sh dures
at y epair b
ht-T .
d
ir
ly
th
ig
y
•
o
a
a
e
te
da e rep art r
r N hours
er
visib
as b proc
p
dica of th
d fo
t is
well and
If th ir the
C
d in
uire to 48
.
tha
a
•
art
l, as policy
y an ing PD elivery ot req in 24
rep
ap
n
nne
c
h
d
Dail
rso repair
ler our fa e of age is air wit
eive nt.
e
a
c
p
e
t
e
y
r
e
p
D
tim
m
par
vice
via can to ge at ng da t of re
you ursem
ser mage
b
a
ti
s
uld
os
laim
nd
0
Sho ir reim dures age c end a s dam t nota r the c
ts a MS da
()0
a
s
ip
par
T
rep Proce e dam py or t notatey rece edit fo
our ing of
y
il
r
r
o
a
c
F
h
c
e
wit stand
9
1. Fax a able) th f deliv claim
n
)
r
o
(
ti
e
o
10
2. applic Copy n issue
rma und
(X) 00
:
info lear
e
this ve a c
Note will th
()0
6
C
a
iew
PD
rev lved h
(X)
u
o
3.
at y s invo
()7
t th
e
ues ll parti
()8
©Toyota Motor
f
req
a
()4 g
We nsure
4
)
(
to e
O:
N
4c
()5
Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Scuffs & Scratches
DAMAGE
IDENTIFICATION
STANDARDS
ScraTCHES & Gouges
ScraTCHES on
Textured Surfaces
Deformation or
Broken Tabs
10 Step
Refinishing Method
Repair V.S. Replace
Minor Surface Scuffs and Scratches
• Packaging and occasional contact may scuff
the raw bumper surface.
• Fingernail will not catch in scuff.
•B
ecause the bumper requires washing and
scuffing during the refinish process, these issues
will be eliminated by the refinish technician.
Acceptable
scuffing due
to contact with
packaging
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Scuffs & Scratches
DAMAGE
IDENTIFICATION
STANDARDS
scratches & Gouges
SCRATCHES on
Textured Surfaces
Deformation or
Broken Tabs
10 Step
Refinishing Method
Repair V.S. Replace
Deep Scratches and Gouges
• Scratches and gouges that cause your fingernail
to catch require additional attention during
preparation.
•T
hese may be eligible for repair reimbursement
or return.*
*Per guideline outlined in the parts policy manual.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Scuffs & Scratches
DAMAGE
IDENTIFICATION
STANDARDS
ScraTCHES & Gouges
SCRATCHES on
Textured Surfaces
Deformation or
Broken Tabs
10 Step
Refinishing Method
Repair V.S. Replace
Scratches on Textured Surfaces
• Inspect for scratches on textured surfaces.
• Scratches of any type on textured surfaces may be eligible for return.*
Scrape on bumper (white)
Gouge on bumper
*Per guideline outlined in the parts policy manual.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Scuffs & Scratches
DAMAGE
IDENTIFICATION
STANDARDS
ScraTCHES & Gouges
SCRATCHES on
Textured Surfaces
10 Step
Refinishing Method
Deformation or
Broken Tabs
Repair V.S. Replace
Excessive Deformation or Broken Tabs
• Inspect for excessive damage.
Deformation
• These examples may be eligible for return.*
Broken tabs
*Per guideline outlined in the parts policy manual.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Scuffs & Scratches
DAMAGE
IDENTIFICATION
STANDARDS
ScraTCHES & Gouges
SCRATCHES on
Textured Surfaces
10 Step
Refinishing Method
Deformation or
Broken Tabs
Repair V.S. Replace
Repair vs. Replace
• TMS Damaged Part Policy provides
reimbursement for repairs up to
50% of the value of the part.
09- 28
May 11, 2009
• Return policy details are contained
in PANT Bulletin 09-28.
Page 1 of 2
TO:
Parts Managers
SUBJECT:
Damaged Part Repair Procedures Policy
In an effort to support timely customer service and minimize costs associated with returning slightly damaged
replacement parts, TMS would like to reintroduce and reinforce our repair procedures policy for filing a claim on
repairable collision parts that may have incurred minimal damage during handling or delivery. Essentially our
request is for dealers to repair rather than replace any repairable part if the repair costs do not exceed 50%
of the value of the part.
Benefits of Repair versus Replace:
• Reduces customer repair cycle time as repair can be completed by the dealer or outside body shop
• Reduction of reoccurring delivery, handling and repackaging expenses
• Eliminates need to process damaged part for return to PDC
• Improves customer satisfaction through lead time reduction
• Reduces impact on environment through repair versus replace
Repair Claim Policy and Procedures:
Policy: Reference Toyota Parts Manual Section IV Traffic and Transportation, pages IV-3, IV-4 and
Section V Support Programs, pages V-11, V-12
• Perform quality check on parts shipment upon receipt to notate any damage and confirm integrity of parts
shipment prior to expediting parts to third party customers
• If part damage is “R3” Freight Carrier Damage or “R9” Concealed Damage for frequently damaged
commodities (see chart below), then contact your facing PDC within three (3) business days of
receipt to advise you are pursuing a repair estimate
• If part damage is “R9” Concealed Damage for non-frequent damaged commodity, then you have 30
days to pursue a repair estimate and file a damage claim for repair reimbursement
• If the repair estimate does not exceed 50% of the unit value of the part, you are strongly encouraged to
repair the part rather than replace it as described below
Should you receive a part that is visibly damaged but repairable, please use the following claim procedures for
repair reimbursement.
Procedures
1. File damage claim via Dealer Daily and indicate that you are requesting reimbursement for damage repair.
2. Fax a copy or send a scan to your facing PDC of the repair bill and a copy of the delivery receipt (if
applicable) that notates damage at time of delivery.
Note: Copy of delivery receipt notating damage is not required for Night-Time Unattended Delivery Service.
3. PDC will then issue claim credit for the cost of repair within 24 to 48 hours.
We request that you review this information with your parts and service personnel, as well as body shop customers
to ensure all parties involved have a clear understanding of TMS damage part repair policy and procedures.
DISTRIBUTION LIST NO:
(X) 1
(X) 4
( ) 4c
(X) 2
( ) 4a
( ) 4d
()3
( ) 4b
( ) 4e
( ) 4f
( ) 4g
()5
(X) 6
()7
()8
()9
(X) 10
( ) 000
( ) 00
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Washing
Dry & Inspect
DAMAGE
IDENTIFICATION
STANDARDS
SCUFFING
Spot Repair
Anti-Static
Adhesion
Promoter
Sealer
10 Step
Refinishing Method
COlor COat
Clear Coat
De-Nib &
Polish
Toyota/Lexus 10 Step Method for TSOP Bumper Cover Refinishing
1 Washing
6 Adhesion Promoter
2 Dry & Inspect
7 Sealer
3 Scuffing
8 Color Coat
4 Spot Repair
9 Clear Coat
5 Anti-Static
10 De-Nib & Polish
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Washing
Dry & Inspect
DAMAGE
IDENTIFICATION
STANDARDS
SCUFFING
Spot Repair
Anti-Static
Adhesion
Promoter
Sealer
10 Step
Refinishing Method
COlor COat
Clear Coat
De-Nib &
Polish
Washing
• New bumper manufacturing uses a release agent during the molding process.
• This release agent must be washed off the bumper with soap and water before the scuffing
process can begin.
• Failure to remove this release agent before scuffing will embed it into the plastic and
prevent paint adhesion.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Washing
Dry & Inspect
DAMAGE
IDENTIFICATION
STANDARDS
SCUFFING
Spot Repair
Anti-Static
Adhesion
Promoter
Sealer
10 Step
Refinishing Method
COlor COat
Clear Coat
De-Nib &
Polish
Dry and Inspect
• After washing, dry and inspect the bumper.
• Look for areas that will require attention during the scuffing step.
Washing
Inspect
Alcohol
Wax &
Grease
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Washing
Dry & Inspect
DAMAGE
IDENTIFICATION
STANDARDS
SCUFFING
Spot Repair
Anti-Static
Adhesion
Promoter
Sealer
10 Step
Refinishing Method
COlor COat
Clear Coat
De-Nib &
Polish
Scuffing
• Thoroughly scuff the bumper with sanding paste and a pad.
• Clean, dry and inspect the paintable surface for a uniform dull appearance that will promote
paint application and adhesion.
Paste on Scotch Brite
Rubbing
Inspect
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Washing
Dry & Inspect
DAMAGE
IDENTIFICATION
STANDARDS
SCUFFING
Spot Repair
Anti-Static
Adhesion
Promoter
Sealer
10 Step
Refinishing Method
COlor COat
Clear Coat
De-Nib &
Polish
Spot Repair
• If the bumper requires a minor repair perform the repair using fillers and primers formulated
for flexible surfaces.
Staged w/o filler bead
with bead of filler
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Washing
Dry & Inspect
DAMAGE
IDENTIFICATION
STANDARDS
SCUFFING
Spot Repair
Anti-Static
Adhesion
Promoter
Sealer
10 Step
Refinishing Method
COlor COat
Clear Coat
De-Nib &
Polish
Anti-Static
• Move the bumper into the booth and apply with a suitable anti-static product.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Washing
Dry & Inspect
DAMAGE
IDENTIFICATION
STANDARDS
SCUFFING
Spot Repair
Anti-Static
Adhesion
Promoter
Sealer
10 Step
Refinishing Method
COlor COat
Clear Coat
De-Nib &
Polish
Adhesion Promoter
• Apply an adhesion promoter designed for use on plastic surfaces.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Washing
Dry & Inspect
DAMAGE
IDENTIFICATION
STANDARDS
SCUFFING
Spot Repair
Anti-Static
Adhesion
Promoter
Sealer
10 Step
Refinishing Method
COlor COat
Clear Coat
De-Nib &
Polish
Sealer
• Apply a sealer per the paint manufacturer’s directions.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Washing
Dry & Inspect
DAMAGE
IDENTIFICATION
STANDARDS
SCUFFING
Spot Repair
Anti-Static
Adhesion
Promoter
Sealer
10 Step
Refinishing Method
COlor COat
Clear Coat
De-Nib &
Polish
Color Coat
• Apply the color coat to the bumper following the paint manufacturer’s mixing directions.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Washing
Dry & Inspect
DAMAGE
IDENTIFICATION
STANDARDS
SCUFFING
Spot Repair
Anti-Static
Adhesion
Promoter
Sealer
10 Step
Refinishing Method
COlor COat
Clear Coat
De-Nib &
Polish
Clear Coat
• Apply a clear coat when applicable per the paint manufacturer’s directions and bake
the required time.
©Toyota Motor Sales, U.S.A., Inc., 2012
Bumper Handling and Refinishing
Quick Training Guide – QTB12A
INTRODUCTION
Washing
DAMAGE
IDENTIFICATION
STANDARDS
Dry & Inspect
SCUFFING
Spot Repair
Anti-Static
Adhesion
Promoter
Sealer
10 Step
Refinishing Method
COlor COat
Clear Coat
De-Nib &
Polish
De-nib and Polish
• If needed, perform de-nibbing to remove dust and imperfections then polish.
De-Nib tool
3in buffer
©Toyota Motor Sales, U.S.A., Inc., 2012