G. MASKING AROUND WORK STALL
NOTE:
Depending on the shop layout, it may be necessary to put barriers to prevent accidental over spray
Masking on the floor is unnecessary. (if wax falls from the frame, clean the spill right away to avoid a
fall hazard)
1.

VEHICLE MASKING
NOTE:
In this work, masking needs to be done only partially as
the drips and scattering are few.
Using an infrared thermometer ensure the exhaust has
cooled.
Cover the holes from which wax can spill out using shop
cloths or the likes.

Protect each brake tube as the wand may hit them.
(LH Side Only)

28

2.

PLUG HOLES IN THE FRAME
Apply all the plugs other than the ones indicated with stars (★) on Hole Plugs Installation Check Sheet found
in appendix.
DO NOT install the plugs indicated with stars (★) until the wax application is completed. Those
plug holes will be used when inserting a wand to apply wax.
NOTE:
• You may have to remove certain stickers to install optional equipment.
• Some vehicles may not have plug holes or may have plugs already installed depending on the
vehicle specification or model year.
• Make sure all the plugs are flush with the frame.
• Make sure the surface of the frame is clean before you apply stickers.
Apply masking tape to the holes shown in the illustration from which wax can spill out.
NOTE:
The masking tape has to be applied on both LH and RH side of the frame even when the illustrations
show only one side.

29

H. APPLY WAX WITH SHORT WAND

Before starting this process, review the SCK0D E-Learning Spray
Application section for key details
1.

PREPARE FOR WAX APPLICATION
CHECK THE REMAINING WAX AMOUNT
1. Check that more than 1/3 of wax is in the wax pail.
If not, add NEW wax to fill up the can.
The wax level must NOT be less than
1/4 as the pump starts suctioning air.
NOTE :
1 wax pail (18 Liters) is for 3 to 4 vehicles.
CHECK PUMP CYCLE RATE
Standard Value: 7 - 10 times/mins
NOTE:
If the pump cycle rate is faster or slower than the
standard value, turn the back pressure regulator to
adjust the rate within the range.
CHECK EACH PRESSURE
Standard Value:
• Pump output pressure: 14MPa (2031 psi)
• High pressure: 12 MPa (1741 psi)
• Sealer pressure: 0.5 - 4 MPa (73 - 580 psi)
NEVER set the pressures to be over
the specified values.

CHECK WAX TEMPERATURE
Standard Value: 40 ºC (104 ºF)
DO NOT warm up the wax temperature
higher than 50 ºC (122 ºF)

30

CHECK SPRAY PATTERN
1. Connect the short wand to the high pressure spray gun.
2. Weigh the empty cup and zero the scale
3. Spray 1 shot of wax on Paint Prep cup (Φ 10 - 15 cm (3.94 - 5.91 in.) for paint work).
4. Visually inspect the wax discharged from 5 orifices is continuously connected.
(Refer to XII. C. WAND SPECIFICATION)

CHECK WAX DISCHARGE AMOUNT
1. Measure the weight of the empty Paint Prep cup.
2. Spray 10 shots of wax into Paint Prep cup and measure the entire weight.
NOTE:
• Fully pull the spray gun trigger to stabilize the discharge amount of wax per shot.
• You may need to practice to be able to spray 10 g (0.353 oz.) of wax per shot.
• DO NOT spray 10 shots continuously as the pressure lowers.
3. Subtract the weight of Paint Prep cup and calculate the weight of 1 shot.
Standard Value: 100 – 120 g (3.53 - 4.23 oz.) [10 - 12 g (0.353 - 0.423 oz.) per shot]

• When replacing the high pressure wands (short or long), make sure to perform the checks
shown above every time.
• If the gun trigger is pulled when the pump is operating, wax cannot be applied properly.
In such a case, redo the procedure to check properly.
• DO NOT DISCARD INITIAL SPRAY CHECK CUP. You will need to upload an image of the spray
cup at a later step
CHECK WAND TOP MARKS
1. Confirm that the TOP marks on the wand are on the
upper side when using the high pressure spray gun
with short or long wand.
(Refer to XII. C. WAND SPECIFICATION)

31

2.

INSERT FROM THE INNER APPLICATION HOLE TOWARDS FRONT
* The illustrations show RH side only. Use the same procedure for LH side.

If the gun trigger is pulled when the pump is operating, wax cannot be applied properly.
In such a case, spray wax again at the same place.
Insert the short wand forward up to mark 1 so that the wand
touches the middle of the side of the application hole.
Spray 1 shot to apply wax.

Pull back the wand 1 notch and spray 1 shot.
Repeat step c) until the gun hits the frame crossmember
sub-assembly No.3.

Change the wand angle upward at the position where the
gun hit the frame crossmember sub-assembly No.3.
NOTE:
• Place the wand so that it touches the opposing
corners of the application hole.
• Be cautious as the spraying interval will change
because the notch will be at every 5 mm (0.197 in.)
at the last part of the wand.

32

Spray 1 shot and repeat step c) until Mark 5 appears.
When spraying the last few shots, cover the application hole
with your hand so that wax does not splash out.
Apply masking tape on the application hole.

3.

REINSTALL THE FRONT SUSPENSION MEMBER
BRACKET (IF EQUIPPED)
Reinstall the front suspension member bracket.
Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf)
Be sure to install at this step.

33

4.

INSERT FROM THE INNER OPENING TOWARDS FRONT
* The illustrations show RH side only. Perform the same procedure for LH side.

If the gun trigger is pulled when the pump is operating, wax cannot be applied properly.
In such a case, spray wax again at the same place.
Insert the short wand into the gap above the bulkhead forward, up to Mark 2.
NOTE:
The wand should be placed at the center of the gap.
Spray 2 shots.

Pull back the wand 10 mm (0.394 in.) and spray 2 shots.

34

Repeat step c) until Mark 4 comes to the reference line.

Insert the short wand into the gap below the bulkhead forward, up to Mark 2.
NOTE:
The wand should be placed at the center of the gap.
Spray 2 shots.

Pull back the wand 10 mm (0.394 in.) and spray 2 shots.

Repeat step g) until Mark 4 comes to the reference line.

35

Insert the short wand into the center hole of the bulkhead forward, up to Mark 2.
Spray 1 shot.

Pull back the wand 10 mm (0.394 in.) and spray 1 shot.
Repeat step k) until the wand comes out of the bulkhead center hole.
NOTE:
DO NOT spray wax at each 5 mm (0.197 in.) notch. Spray every 10 mm (0.394 in.) though the notches
are at both 10 mm (0.394 in.) and 5 mm (0.197 in.) intervals.

Once the wand comes out of the bulkhead center hole, place the wand as close to the center as possible and
keep spraying 1 shot at every 10 mm (0.394 in.) until Mark 5 appears.

36

5.

FROM THE BOTTOM SQUARE HOLE TO THE TOP
* The illustrations show RH side only. Perform the same procedure for LH side.

If the gun trigger is pulled when the pump is operating, wax cannot be applied properly.
In such a case, spray wax again at the same place.
Remove the masking tape applied to the application hole.
Set the guide on the wand according to the mark.
(The guide is supplied for LH and RH respectively.)

Insert the wand until it hits the frame inner top.

Spray 4 shots to apply wax.
NOTE:
Spray 4 shots at one spot.
Apply masking tape to the application hole

6.

REPEAT THE PROCEDURE ON THE OTHER SIDE
Repeat from the step 2 to 7 on the other side of the frame side rail.

37

I.

APPLY WAX WITH LONG WAND
* The illustrations show RH side only. Perform the same procedure for LH side.
• Wax temperature
Confirmation
• Spray pattern
Before wax application
(Refer to XII. H. 1. PREPARE FOR WAX APPLICATION) • Wax Discharge Amount
• TOP mark positions

If the gun trigger is pulled when the pump is operating, wax cannot be applied properly.
In such a case, spray wax again at the same place.
1.

FROM THE OUTER SQUARE HOLE TO THE FRONT
Peel the masking tape half way back on the application hole.
Insert the wand forward until the wand hits the bulkhead and spray 1 shot

38

Pull back the wand 1 notch and spray 1 shot.
NOTE:
Be cautious as the spraying interval will change because the notches are at both 5 mm (0.197 in.) and
10 mm (0.394 in.) intervals.

Repeat step c) until Mark 2 appears.
When spraying the last few shots, cover the application hole with your hand so that wax does not splash out.
Apply masking tape on the application hole.

2.

REPEAT THE PROCEDURE ON THE OTHER SIDE
Repeat the step 1 on the other side of the frame side rail.

39

J. APPLY WAX WITH SEALER GUN
* The illustrations show RH side only. Perform the same procedure for LH side.
Confirmation
Before wax application
• Wax temperature
(Refer to XII. H. 1. PREPARE FOR WAX APPLICATION)

1.

AROUND THE REINFORCEMENT AND CROSSMEMBER
Apply wax to the gap and edge between the reinforcement and side rail.
NOTE :
The amount of wax can be visually controlled.
The distance between the crossmember and the reinforcement may vary depending on the vehicle

40

Fill wax into the gap between the side rail and reinforcement.
NOTE :
Cover the top of the gun with your hand as shown in the illustration and fill wax enough until it comes
out from between the fingers.
Fill wax from the upper side of the gap.
NOTE :
Make sure to fill the wax as much as they come out.

Apply wax to the gap and edge between reinforcement and side rail.

41

Apply wax to the gap and edge between reinforcement and side rail.
Apply wax to the gap and edge between crossmember and side rail.
NOTE:
• Insert the sealer gun tip from the front and rear hole of the crossmember to apply wax inside the
crossmember properly.
• These steps e) and f) are not needed for short wheel base vehicle configuration.

Apply wax to the gap and edge between reinforcement and side rail.

42

Apply wax to the gap and edge between reinforcement and side rail.
Apply wax to the gap and edge between front inner channel and side rail.

Apply wax to the gap and edge between front inner channel and side rail.

43

2.

INSIDE CAB MOUNT
Insert the sealer gun tip from the holes which are on the bottom surface of the cab mount and apply wax to
the gap between the cab mount and side rail.

3.

REPEAT THE PROCEDURE ON THE OTHER SIDE
Repeat the steps 1 and 2 on the other side of the frame side rail.

44

4.

INSTALL THE BODY PLUGS
Remove the masking tape and scrape out the wax applied around the inside of the plug hole, and then install
the NEW plug (90950-01A24).
The plug must be installed with the openings facing the side of the vehicle and the tabs
facing the front a rear to ensure road spray does not enter the frame through the plug.
Remove the masking tape and install the NEW plugs (90950-01991, 90950-01987).

45

XIII.
1.

CHECKSHEET AND RECORD KEEPING
COMPLETE POST-SPRAY CHECK SHEET (THIS MUST BE DONE FOR EVERY VEHICLE)
a. Click the link below to access the frame check sheet (USE IE FOR ALL SUBMISSIONS)
https://one.tis.toyota.com/t3Portal/frameSprayCheck?l=tis_frame_spray&campaignCode=K0D&vin=&c
ampaignId=5&source=tech
NOTE: VEHICLES FOUND WITH AFTERMARKET WAX
Vehicles that come into dealership that already have wax applied from the plant can be determined by
using the parts look up site mentioned on page 3. Any vehicle that has had wax application from the
plant do NOT require a Checksheet.

Vehicles found with an aftermarket wax sprayed over K0D coverage areas will need a Checksheet
completed to determine wax application coverage. Below are examples of aftermarket wax coverage. If
you find a vehicle with aftermarket wax send an email to Quality_Compliance@toyota.com for further
instruction.
Examples of aftermarket CRC

46

b. Answer the questions and enter your initials throughout
the check sheet
c. Upload photos to the check sheet
Note:
-All the photos must be taken and have the required parts
as shown in the steps below
-All photos must be less than 3MB each
-All photos must be uploaded before the check sheet is
completed.
d. Spray Cup Image
- Photo must be taken from the top view and show a
completed wax ring in the cup
- R.O. Number must be in the picture

e. Left/Right Inner Box Section Image
- Photo must be taken at the opening of the box
section and show the top, bottom, and side walls of
the box section
- R.O. number must be in the picture
NOTE: It is recommended you either use a camera flash or
back light to clearly show the interior of the box section
f.

Left/Right Open Section Image
- Photo must be taken from a distance where the
entire wax application along the open section can
be seen.
- The R.O. must be in the picture

g. Left/Right Wheel Well Image
- Photo must be taken from an angle that has all the
plugs installed on the outer rail of the frame
- The R.O. must be in the picture

h.
i.
j.
k.

Sign the check sheet
Have your Service Manager or Shop Forman sign the check sheet.
Submit the check sheet.
Using the print function, attached the completed check sheet to the R.O.
A check sheet must be completed for each vehicle sprayed

47

XIV.

INSTALLATION OF FRAME SEAL
* The illustrations show LH side only. Perform the same procedure for RH side.
1. INSTALL FRAME RAIL SEAL
Using Template C and D, modify both the left and right side
frame seal by drilling a (3/8”) hole in the location shown.

Install the bolt through the frame and torque the flange nut.
Torque: 18.5 N*m (189 kgf*cm, 14 ft.*lbf)
Install the washer onto the bolt.
Install the frame seal second washer and locking nut onto
the frame and torque to spec.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
Plug Hole Kit CRC Application 2 (2016-2017MY)
Part #
94183-00831
94611-10800

Part Name
Nut, Lock
Washer, Plate

Qty
2
4

Plug Hole Kit CRC Application 4 (2016-2017MY)
Part #
90178-A0112
90105-A0356
5114A-04010
5114B-04010

Part Name
Nut, Flange
Bolt, Flange
Seal, Frame Side Rail, RH
Seal, Frame Side Rail, LH

Qty
2
2
1
1

XV.
RESTORATION WORKS
1. RESTORE THE VEHICLE
Remove all the remaining masking materials.
Wipe off all the unnecessary wax remaining on the vehicle.
Reinstall all the removed parts.
Reinstall wheels and torque to spec.
Steel Wheel / Aluminum Wheel
Torque: 113 N*m (1152 kgf*cm, 83 ft.*lbf)
Lower the vehicle.
RECORD-KEEPING AND OTHER REQUIREMENTS
To make sure that your dealership can satisfy specific state and local requirements, please refer to your
specific state Dealer Information Packet.
XVI.
A.
B.
C.

APPENDIX
WAND TIP CLEANING
PLUG CHECKSHEET AND FISHTALE COVER TEMPLATES
NOX-RUST 712THV-T SDS

48

A. WAND TIP CLEANING
* The illustrations show the short wand tip; However, the process can be used for the long wand tip as
well.
1.

REMOVE TIP
Remove tip from the wand by using wrench.

Wipe off the wax on outer surface of the tip

2.

REMOVE WAX
a) Blow air into each orifice to remove wax and any foreign
material
b) Repeat air-blow until as much material can be removed as
possible

3.

RE-ASSEMBLE WAND
a) Tape the wand thread by sealant tape.
Reference: Tape the thread twice
The sealant tape should not be applied near
the end of the threads to avoid sealant tape
entering the wand.
b) Assemble the tip and wand by wrench until the end of tip is
24mm from 1st notch. (See picture)
c) Adjust the tip angle to meet the top mark on the tip and top
mark on the wand. (the long wand tip may not have marks to
align. In that case adjust the end of the tip to be 24mm from
the first notch)
Note : Only adjust the tip angle when tightening
The 24mm distance between the end of the tip
and the first notch is critical for a proper spray
pattern

End of tip

1st notch
24mm

d) Check spray pattern to confirm tip is no longer clogged. If
clogged repeat step one through 3.
Note: If the tip cannot be unclogged after multiple attempts
call the Bosch Technical Assistance Line - 1-800-933-8335
(Option 4) to order a new wand.
35
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