Explanation Of Structural (Frame/Unibody) Damage - Toyota All Models Inspection Standards Manual

EXPLANATION OF STRUCTURAL
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FRAME/UNIBODY
to be anchored by using some form of clamp to secure the pinch
weld flange, and clamping may require the removal of factory-
applied PVC chip-resistant coatings. High-quality repair shops
will repair and re-coat the damaged area with chip-resistant
primer, but most shops will generally leave this area untreated.
In time, the exposed metal will rust. Clamp marks are usually
obvious. Even if coated, replacement coatings may be a different
color or texture than the originally installed product.
• Inspect the front and rear bumper mounting areas for signs of
distortion or straightening. Check the crush beads (depressions
in the side members) for distortion or collapse. These crush zones
should have smooth bends and folds.
• Check for the presence of shims or washers. Toyota vehicles
are manufactured to tolerances of approximately ±0.5 mm;
consequently, Toyota does not use shims when installing body
components. Inspect for any hole that looks like it was slotted to
align a component. Compare both sides of the vehicle.
• Check the alignment of the exhaust system by looking at the
rubber mounts. There should be no uneven stress.
• Look for signs of freshly applied undercoating. Look for paint
overspray on hoses, clamps, brackets, wiring harnesses and
exhaust components. Undercoating is not applied in the engine
compartment during the manufacturing process, so any
undercoating in this area may be covering up repaired sheet
metal. However, it may have been a dealer-installed up-sell.
• From inside of the engine compartment, look at the vertical joint
between the front wheel house apron and the core support
baffle. If the core support was replaced, damaged paint or bent
metal may be seen in this area. Mechanical components — such as
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DAMAGE
21
the washer reservoir, battery and air cleaner housing — usually
hide this type of damage.
• Look at the tie-rod adjusters on the front steering linkage.
There should be approximately the same number of threads
exposed on the tie-rod adjusters on the right and left side of
the vehicle. Small variations are normal. Large variations may
indicate suspension component damage only. But, it could
indicate steering rack misalignment, or a damaged steering
rack mounting, or damaged suspension cross member.
• Check the fit and operation of the doors, hood and deck lid. Note
any sticking or binding. Watch for a door that drops or springs
upward when opened or closed. It may be hinge damage or
adjustment, but incorrect body alignment may also be the cause.
• Remove the interior trim from the trunk area and inspect the
inner quarter panels for signs of repair or replacement. Look at
the trunk floor/spare tire well and check for signs of repair. Reach
up into the C-pillar area (between the rear wheel housing and
the quarter panel) to see if the quarter panel has been cut and
seam-welded in this area. Wear gloves.
EXISTING DAMAGE
Most structural damage that will affect vehicle performance and
certification will usually be visible when inspected from below the
vehicle, but minor structural damage is difficult to determine without
dimensional measuring. Most of the previous items should be inspected.
Minor scratches to the underbody or suspension components do not
necessarily indicate structural damage, but they should be a tip-off
that more inspection is required.

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