Bumper Handling and Refinishing

Quick Training Guide – QLB12A

This QTG aids in understanding the 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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION 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., 2013
 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Receiving handling storage staging transportation

Dealer Bumper Cover Quality Standards

• Lexus TSOP bumpers are packaged in protective material to prevent damage during shipping.

• Following Lexus’ recommended handling procedure can reduce the occurrence of deformation
and abrasion damage.

©Toyota Motor Sales, U.S.A., Inc., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Receiving handling 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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Receiving handling 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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Receiving handling 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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Receiving handling 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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Receiving handling 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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

ScrATCHES on Deformation or
Scuffs & Scratches ScraTCHES & Gouges Repair VS. Replace
Textured Surfaces Broken Tabs

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 Excessive Deformation

Scuffs and Scratches or Broken Tabs
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 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

ScraTCHES on Deformation or
Scuffs & Scratches ScraTCHES & Gouges Repair VS. Replace
Textured Surfaces Broken Tabs

Minor Surface Scuffs and Scratches

• Packaging and occasional contact may scuff • Fingernail will not catch in scuff.
the raw bumper surface.
• Because 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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

SCRATCHES on Deformation or
Scuffs & Scratches scratches & Gouges Repair VS. Replace
Textured Surfaces Broken Tabs

Deep Scratches and Gouges

• Scratches and gouges that cause your fingernail • These may be eligible for repair reimbursement
to catch require additional attention during or return.*
preparation.

*Per guideline outlined in the parts policy manual.

©Toyota Motor Sales, U.S.A., Inc., 2013
 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

SCRATCHES on Deformation or
Scuffs & Scratches ScraTCHES & Gouges Repair VS. Replace
Textured Surfaces Broken Tabs

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., 2013
 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

SCRATCHES on Deformation or
Scuffs & Scratches ScraTCHES & Gouges Repair VS. Replace
Textured Surfaces Broken Tabs

Excessive Deformation or Broken Tabs

• Inspect for excessive damage. • These examples may be eligible for return.*

Deformation Broken tabs

*Per guideline outlined in the parts policy manual.

©Toyota Motor Sales, U.S.A., Inc., 2013
 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

SCRATCHES on Deformation or
Scuffs & Scratches ScraTCHES & Gouges Repair VS. Replace
Textured Surfaces Broken Tabs

Repair vs. Replace POLICY / PROGRAM UPDATE

SERVICE & PARTS OPERATIONS COMMUNICATIONS
• TMS Damaged Part Policy provides DAMAGED PART REPAIR PROCEDURES POLICY
reimbursement for repairs up to 05 – 07 – 2009 Bulletin 2009 – 05 Page 1 of 2

50% of the value of the part.
• Return policy details are contained
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.

in PANT Bulletin 2009-05. 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 Lexus Parts Policy and Procedures Manual, Section 4, Transportation and
Receiving, pages 4.3 through 4.5 and Section 6, Parts Return Programs, pages 6.14 and 6.15
 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.

©Toyota Motor Sales, U.S.A., Inc., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Adhesion De-Nib &

Washing Dry & Inspect SCUFFING Spot Repair Anti-Static Sealer COlor COat Clear Coat
Promoter Polish

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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Adhesion De-Nib &

Washing Dry & Inspect SCUFFING Spot Repair Anti-Static Sealer COlor COat Clear Coat
Promoter 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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Adhesion De-Nib &

Washing Dry & Inspect SCUFFING Spot Repair Anti-Static Sealer COlor COat Clear Coat
Promoter 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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Adhesion De-Nib &

Washing Dry & Inspect SCUFFING Spot Repair Anti-Static Sealer COlor COat Clear Coat
Promoter 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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Adhesion De-Nib &

Washing Dry & Inspect SCUFFING Spot Repair Anti-Static Sealer COlor COat Clear Coat
Promoter 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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Adhesion De-Nib &

Washing Dry & Inspect SCUFFING Spot Repair Anti-Static Sealer COlor COat Clear Coat
Promoter Polish

Anti-Static
• Move the bumper into the booth and apply with a suitable anti-static product.

©Toyota Motor Sales, U.S.A., Inc., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Adhesion De-Nib &

Washing Dry & Inspect SCUFFING Spot Repair Anti-Static Sealer COlor COat Clear Coat
Promoter Polish

Adhesion Promoter
• Apply an adhesion promoter designed for use on plastic surfaces.

©Toyota Motor Sales, U.S.A., Inc., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Adhesion De-Nib &

Washing Dry & Inspect SCUFFING Spot Repair Anti-Static Sealer COlor COat Clear Coat
Promoter Polish

Sealer
• Apply a sealer per the paint manufacturer’s directions.

©Toyota Motor Sales, U.S.A., Inc., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Adhesion De-Nib &

Washing Dry & Inspect SCUFFING Spot Repair Anti-Static Sealer COlor COat Clear Coat
Promoter Polish

Color Coat
• Apply the color coat to the bumper following the paint manufacturer’s mixing directions.

©Toyota Motor Sales, U.S.A., Inc., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Adhesion De-Nib &

Washing Dry & Inspect SCUFFING Spot Repair Anti-Static Sealer COlor COat Clear Coat
Promoter 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., 2013

 Bumper Handling and Refinishing
Quick Training Guide – QLB12A

DAMAGE 10 Step
INTRODUCTION STANDARDS
IDENTIFICATION Refinishing Method

Adhesion De-Nib &

Washing Dry & Inspect SCUFFING Spot Repair Anti-Static Sealer COlor COat Clear Coat
Promoter 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., 2013