TSF0902G P 2

PROTECTED Do Not Reproduce
TOYOTA ENGINEERING STANDARD
NO.: TSF0902G
Test methods for the nonmetal material properties of rear-body products
TITLE: and their quality requirements
CLASS: C1
Established/Revised: Rev. 2 ( Mar. 2021 )
This standard has been revised as a result of the following changes:

(1) descriptions of quality requirements have been clarified (Table 7);
(2) description of the properties of the thermal cycle test has been clarified (Table 8);
(3) drop weight impact test conditions have been added (Table 21); and
(4) descriptions have been clarified [Section 6.1.2 (1)].
Prepared and Written by: Design Quality Innovation Dept.

Resin & Paint Design Dept. TOYOTA MOTOR CORPORATION
Mobility Material Engineering Div.
Copyright TOYOTA MOTOR CORPORATION
HP PELZER PIMSA AUTOMOTIVE A.S.

2021/03/31 21:06:37 TBE0000@EUG0128 Tolga BENGI 2021/03/31 21:06:37 TBE0000@EUG0128 Tolga BENGI 2021/03
CLASS
TOYOTA ENGINEERING STANDARD TSF0902G C1
Test methods for the nonmetal material properties of rear-body products and
their quality requirements
1. Scope
This standard covers the methods for testing the compatibility of the nonmetal material properties of
rear-body interior and exterior products [hereinafter referred to as the “product(s)”] (Fig. 1) with the
working environment, and their quality requirements. The functions, performance and design
qualities of each product, whether installed in a vehicle or as a single unit, shall conform to the
specifications in the drawings provided separately from this standard. Standard test conditions and
quality requirements are provided in this standard. If test conditions and quality requirements differ
according to the vehicle model, installed location, destination etc., applicable test conditions and
quality requirements shall be specified in drawings.
NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 2
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.
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TOYOTA ENGINEERING STANDARD TSF0902G
Fig. 1 Rear Body (Nonmetal Products in the Target Zone)
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For reference, Table 1 gives typical products installed in the vehicle rear body. Products other than
those in Table 1 may be subject to this standard depending on the rear-body design.
Table 1 Target Products (Reference)

Location Target products
Luggage-compartment front trim cover
Luggage-compartment side trim cover
Luggage-compartment floor board
Luggage-compartment floor mat
Luggage-compartment trim rear cover
Deck side trim
Quarter trim
Interior
Deck trim rear cover
Deck board
Deck mat
Rear floor board
Rear floor mat
Tonneau cover
Package tray trim
Rear bumper cover
Rear bumper spoiler
Exterior Rear mudguard
Rear wheelhousing liner
Rear fender flare
Remark: This standard sets regional criteria for the items shown in Table 2. The regional criteria shall
be applied if there is an instruction in the drawing etc. Regional criteria shall not be applied
unless otherwise instructed.
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Table 2 Regional Criteria

Applicable
Criteria Item Test item Regional criteria
region
Vibration
6.1.4
durability test
Falling weight
Temperature 6.1.5
According to impact test It has been changed to
Asia (Low temperature
Table 3 Impact durability -10 .
side) 6.1.6
test
Bending
6.1.7
durability test
Snow melting agent
Snow (calcium chloride
Fluid resistance
(Snow melting 6.2.27 solution, etc.) has been
test
agent) removed from the test
fluid
Table 3 Applicable Region ( : Applicable)

Temperature Snow Temperature Snow
(Low (Snow (Low (Snow
Country / region Country / region
temperature melting temperature melting
side) agent) side) agent)
Brunei Afghanistan --- ---
Cambodia Armenia --- ---
East Timor Azerbaijan ---
Indonesia Bahrain ---
Laos Cyprus ---
ASEAN Malaysia Georgia ---

Myanmar
Iran --- ---
(Burma)
Philippines Iraq ---
Singapore GCC/ Jordan ---

west
Thailand Asia Kuwait ---
Vietnam Lebanon ---
Bangladesh Oman ---
Bhutan --- Qatar ---

Saudi
India ---
Arabia
South Maldives Syria ---
Asia
United Arab
Nepal ---
Emirates
Pakistan --- Yemen ---
Sri Lanka Taiwan
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2. Shape, Design, and Material Marking

The material, shape, dimensions and secondary processing method shall conform to the
specifications in the drawings. Material marking shall be in accordance with TSZ6005G.
3. Test Items
For rear bumper cover, rear bumper spoiler, rear mudguard, and rear fender flare, the tests given in
Tables 4 to 6 shall be carried out. Appropriate tests shall be selected according to the material used.
For products that use any plastic material other than those given in Tables 4 to 6, appropriate tests
shall be determined through consultation with related departments. For products other than rear
bumper cover, rear bumper spoiler, rear mudguard, and rear fender flare, all tests specified for each
target product in Table 7 shall be carried out.
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Table 4 Test Items for Rear Bumper Cover and Rear Bumper Spoiler
Material(1)
TSM5608G-1, TSM5608G-6,
Test item
TSM5608G-7, TSM5708G-1,
TSM5708G-2
Heat resistance (method A)
Heat resistance (method B)
Thermal cycle
Vibration resistance
Accelerated weatherability
Outdoor weatherability
Note (1): “Material” refers to the primary material used in each product. Each target product shall
undergo each test, with the component parts mounted, and shall satisfy the quality
requirements specified in Table 7.
Remarks:
: Requisite
: Discretionary
With regard to the discretionary tests marked with , consult with related departments to determine
whether or not to carry out the tests.
Table 5 Test Items for Rear Mudguard

Material(1)
EPDM rubber (TSM1500G-N708O5P)
Test item EVA resin (TSM5505G-2, TSM5505G-3)
Polyethylene elastomer (TSM5518G-1)
Polypropylene elastomer (TSM5601G-4C)
Thermal cycle
Impact resistance
Flex resistance
Fluid resistance
Remark:
: Requisite
: Discretionary
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Table 6 Test Items for Rear Fender Flare

Material(1)
TSOP SMC
Test item BMC
(TSM5608G-6, (TSM6506G-3,
(TSM6508G-2)
TSM5608G-7) TSM6506G-4)
Heat resistance (method A)
Thermal cycle
Accelerated weatherability --- ---
Outdoor weatherability --- ---
Deformation strength ---
Insert/outsert-molding strength ---
Tapping-screw-tightening-area strength ---
Remarks:
: Requisite
: Discretionary
4. Quality
4.1 Appearance
Products shall be free from any abnormalities detrimental to appearance, such as color irregularity,
uneven surface, puckering, scratches, stain, gloss, peeling, and pinholes.
4.2 Materials
Halogen-based additive (such as chlorinated adhesive) shall not be used for interior products.
4.3 Properties
Products shall be tested by the methods specified in Section 6, and shall meet the quality
requirements provided in Table 7. The design appearance quality requirements of surface-treated or
ornamented area shall be determined through consultation with related departments. Heat
resistance, thermal cycle, vibration resistance, impact resistance, drop weight impact, deformation
resistance, and flex resistance tests shall be carried out on each target product in an assembly with
other rear-body products. Other tests shall be carried out on each target product as a single unit or
on a specimen cut from the product.
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Table 7 Quality Requirements

Test item Products to be tested Quality requirements
Assembly test
Method A All target products(2) No remarkable abnormalities in appearance(3) shall occur.
Deck side trim
Quarter trim
No remarkable abnormalities in appearance(3) shall occur.
Heat resistance Tonneau cover
Method B Deck side trim and quarter trim shall meet the quality
Package tray trim
Rear bumper cover
Rear bumper spoiler
No remarkable abnormalities in appearance(3) shall occur.
Thermal cycle All target products Deck side trim and quarter trim shall meet the quality
Rear bumper cover
Rear bumper spoiler
No abnormalities such as breakage, cracking, rattling and
Rear mudguard
Vibration resistance detachment shall occur including the design surface and
Rear wheelhousing
mounting portion.
liner
Rear fender flare
Luggage-compartment
No breakage or cracking shall occur under an impact load of
trim rear cover
1.23 N m or lower.
The lower general portion and lower speaker grill shall not
Quarter trim break or crack under an impact load of 2.94 N m or lower
Drop weight impact and 1.72 N m or lower, respectively.
Rear wheelhousing No breakage or crack shall occur under an impact load of
liner 7.35 N m or lower.
No breakage or crack shall occur under an impact load of
Rear fender flare
1.72 N m or lower.
Impact resistance Rear mudguard Breakage shall not occur.
As compared with the condition before the test, no
remarkable deformation, crack, wear, or the like
Flex resistance test Rear mudguard abnormalities in appearance shall occur during or after the
test. Abrasion mark produced by the sliding rod is
permitted.
Notes:
(2) Rear mudguard shall be excluded. It is not necessary to carry out the method-A test on products
that have undergone the method-B test.
(3) Deformation, discoloration/fading, gap, height difference between products, warpage, corrugation,
bulge, concavity, wrinkle, floating, peeling, breakage, cracking, uneven gloss, irregular color,
stickiness, mealy state, run-over, play, splotch, abraded part, detachment etc.
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Table 7 (Continued)
Test item Products to be tested Quality requirements
Single-unit or Specimen Test
Original state Shall not burn at a rate faster than 100 mm/min max., or shall
Flammability
After heat aging All target interior products(5) be nonflammable or self-extinguishing.
VOC(4) Shall conform to the specifications in the drawings.
Fogging 10 % max. (method A) or 90 % min. (method B)
DRY Intensity 3.0 max.
Initial and after Hedonic scale -1.5 min.
aging Type of smell “Irritating,” “disgusting”; 1.0 max.
WET Intensity 3.5 max.
Initial and after Hedonic scale -2.0 min.
aging Type of smell “Irritating,” “disgusting”; 1.0 max.
Water Intensity ---
Smell
All target interior products

extraction Hedonic scale ---
(Type 1 A)(6) Type of smell ---
Water Intensity 3.0 max.
extraction Hedonic scale -1.5 min.
(Type 2 A)(6) Type of smell “Irritating,” “disgusting”; 1.0 max.
Water Intensity 2.0 max.
extraction Hedonic scale -1.0 min.
(Type 2 B)(6) Type of smell “Irritating,” “disgusting”; 1.0 max.
Discoloration grade of 4 min.; Color fading grade of 3 min.;
Change in color
E* = 3.0 max.(7)
Light exposure All target interior products(5)
No abnormalities in appearance, such as pile falling, base
Deterioration
blushing, or surface breakage, shall occur.
No abnormalities in appearance, such as surface peeling,
Heat aging Deck side trim
puckering or lift, or base deformation, shall occur.
Quarter trim
Deck side trim and quarter trim shall meet the quality
Humidity aging Package tray trim
Report any abnormalities in appearance, such as surface
High-temperature aging Package tray trim
peeling, puckering or lift, or base deformation.
4.9 min., or the surface or base layer shall break.
Original state Deck side trim and quarter trim shall meet the quality
Deck side trim
Peeling strength requirements specified in Table 8.
Quarter trim
(N/25 mm) After heat aging 3.92 min., or the surface or base layer shall break.
Package tray trim
After humidity Deck side trim and quarter trim shall meet the quality
aging requirements specified in Table 8.
Creep resistance (Peeling length) (mm)
Deck side trim
Method A
Puckering resistance Quarter trim As per Table 8
Method B
Scratch resistance
Quarter trim
Oil resistance Grade 4 min.
Deck side trim
Humidity resistance As per Table 8
Quarter trim
Rear bumper cover
Rear bumper spoiler
Rear mudguard
No abnormalities in appearance, such as remarkable
Rear fender flare
discoloration, noticeable color fading, or crack, shall occur.
Rear bumper cover
Outdoor weatherability Rear bumper spoiler
Rear fender flare
Deformation strength
Insert/outsert-molding strength Rear fender flare Design strength requirement shall be met.
Tapping-screw-tightening-area strength
No abnormalities in appearance, such as remarkable
Fluid resistance Rear mudguard
discoloration and deformation, or crack, shall occur.
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Notes:
(4) VOC stands for volatile organic compounds.
(5) For the products inside the luggage compartment of sedan and coupe vehicles, such as
luggage-compartment front trim cover, luggage-compartment side trim cover,
luggage-compartment floor board, luggage-compartment floor mat and luggage-compartment trim
rear cover, determine whether the test will be carried out or not after due consultation with the
departments concerned.
(6) Refer to drawing notes when choosing a water-extraction type among the types of 1 A, 2 A, and 2
B.
(7) Visual inspection is sufficient to evaluate fabrics.
Table 8 Quality Requirements of Deck Side Trim and Quarter Trim

Description
Surface layer Surface layer
Test item
entirely bonded to Genuine leather partially bonded or No surface layer
base layer as surface layer welded to base layer
Heat resistance (method B) Deck side trim: No remarkable abnormalities(3) in

appearance shall occur. Deformation
Quarter trim: Deformation grade shall be 4 min. Surface grade of 4 min.
Thermal cycle lift or peeling shall not occur.
Heat aging No abnormalities, such as surface lift and peeling, shall

---
Humidity aging occur.
Surface peeling strength
As per Table 9
(N/25 mm)(8)
---
Creep resistance (Peeling 10 max. in peeling length. The condition of peeling shall
length) (mm) be reported.
Puckering Method A Appearance grade of
--- ---
resistance Method B 3 min.
Scratch resistance(9) Surface-layer penetration load shall be 3.92 N min. Grade 3 min.
No abnormali-
ties, such as
surface lift and
peeling, shall
Humidity resistance --- ---
occur.
Puckering:
appearance
grade of 4 min.
Notes:
(8) This test shall be carried out on product portions that require surface peeling strength from design
perspective. For any portions other than those given in Table 9, if surface peeling strength
measurement is considered necessary, determine the quality requirements through consultation
with related department.
(9) This test is not necessary for deck side trims.
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Table 9 Quality Requirements for Surface Peeling Strength of Deck Side Trim and Quarter Trim
Description
Partial
Entire surface bonding High frequency welding
bonding
Portion
Test item Condition
General,
Surface layer Surface layer
General Ornamented Carpeted ornamented
× Surface × Base
portion portion portion and carpeted
portions layer layer
Surface Original state
9.8 min., or 1.96 min., or Material shall break.
peeling After heat aging 9.8 min., or material shall
material shall material shall Peeling strength shall be
strength After humidity break.
break. break. reported.
(N/25 mm) aging
5. General Test Conditions

5.1 Standard Conditions of Test Environment
Tests shall be carried out by the method specified in Section 6, in a laboratory under the standard
condition of 23±2 and 50±5 %RH unless otherwise specified. If the standard laboratory
condition cannot be maintained, the actual temperature and humidity used for the test shall be
reported in the test result.
5.2 Test Samples

Finished products(10) equivalent to mass-production ones shall be used as test samples. If it is
inevitable to use products different from the corresponding mass-production products for the reason of
test conditions, the condition used in processing the test samples, as well as their difference from the
corresponding mass-production products, shall be reported in the test result.
Note (10): Referring to moldings finished as products, including those undergoing secondary
processing and those combined in an assembly, which meet the process, material and
dimensional specifications for the corresponding mass-production parts.
5.3 Conditioning of Test Samples

Test samples shall be conditioned as specified in Section 6.(11) For tests for which the test-sample
conditioning method is not specified in Section 6, test samples shall be taken from products aged 12 h
or longer after production. Before being tested, each test sample shall be conditioned for at least 4 h
in the atmospheric condition specified in Section 5.1. For plated products, products aged 48 h or
longer after plating shall be used as test samples.
Note (11): Test-sample conditioning is requisite for flammability, VOC, and smell tests. Condition
each test sample as specified in Section 6.
5.4 Quantities of Test Samples

The required quantities of test samples shall be determined through consultation with related
departments.
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5.5 Reporting
The following information shall be recorded in the test result for reporting:
(1) Name and material of test sample, as well as material manufacturer and grade
(2) Type and condition of molding and/or processing
(3) Date of test
(4) Classification of test sample
(5) Quantities of test sample
(6) Temperature and humidity of the laboratory during testing
(7) The condition of test sample before, during and after each test
6. Test Methods
Standard test conditions are specified for each test. If it is necessary to carry out test under different
conditions according to the vehicle model, installed location, destination etc., the test condition and
criteria specified separately in the drawings shall be applied.
6.1 Assembly Tests

This section describes the tests to be carried out, as a rule, with all target rear-body products installed
in the form of an assembly in a cut body or white body. If it is difficult to carry out test on the
assembly in a cut body or white body, test may be carried out on each test sample installed on a
testing jig after consultation with related departments. For a cut body, the standard pattern C40-AB,
C03-ABC or C03-ABG provided in TSF0300G shall be used. If a cut body other than the standard
pattern is to be used, the appropriate pattern to be used shall be determined through consultation with
related departments, with the vehicle structure taken into consideration. Products to be combined in
an assembly are shown in Table 10. In the case of products that constitute a storage space or
loading platform, the load to be assumed for each test shall be determined through consultation with
related departments.
Table 10 Products to Be Combined in an Assembly (Reference)

Name Purpose
Rear sun shade
Roof side pillar garnish
Roof side inner garnish
To confirm the mating precision
Roof head lining
Opening trim
Rear combination-lamp assembly
Luggage-compartment under tray
Under box
To secure test sample
Tool box
Spare tire
Convenience hook
To confirm the mating precision and secure test sample
Luggage-compartment lamp
Tools
Standard
Warning triangle To apply the same load as in an actual vehicle on test sample
accessories
First-aid kit
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6.1.1 Test Preparation

(1) Installing method
Install test samples on a cut or white body or on a test stand or jig, using the specified tightening
torque(12) so that the same assembling load as in an actual vehicle is applied on the test samples.
When rear bumper cover, rear bumper spoiler, and rear fender flare are installed, select
appropriate temperature condition from Table 11 after consultation with related departments.
Install other test samples at room temperature.
Note (12): Use retightening torque.
Table 11
Atmospheric Condition during Installing Test Samples
--- Description
Install each test sample in the atmosphere at 23±2 and
Room-temperature installation
50±5 %RH.
After holding each test sample for 8 h in a thermostat
chamber at 80±2 to dry, immediately transfer it into a
Low-temperature installation
thermostat chamber at 5±2 for conditioning for 8 to 16 h,
and install it in the atmosphere at 5±2 .
After conditioning each test sample for 8 to 16 h in a
thermo-hygrostatic chamber at 35±2 and 75±5 %RH,
High-temperature installation
install it in the atmosphere at the same temperature and
humidity.
(2) Measuring dimensions

Before and after each test, set each test sample on a surface plate or a horizontal rack, and
measure the dimensions using a 3D layout machine or the like measuring instrument. In the
appearance check conducted after each test, if any abnormal gap or abnormal difference in level
is found between mating parts, measure the gap or level difference using a steel rule, clearance
gage or level gage block. Determine required measuring points and accuracy through
consultation with related departments.
6.1.2 Heat Resistance Test

(1) Method A
Carry out the test on test samples installed in a cut body or white body, in accordance with
method A in Section 4.1.1 of TSM0502G. Table 12 shows the standard test conditions for
typical products. Also, check for abnormalities in appearance at high temperatures during the
test. If the test conditions differ according to the vehicle model, installed location, destination
etc., determine applicable test conditions through consultation with related departments.
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Table 12 Test Conditions for Heat Resistance Test (Method A)

Location Product Test conditions
Luggage-compartment
trim rear cover Leave each test sample to stand for 24 h at 80±2 .
Interior
Other interior products As per method A in Section 4.1.1 of TSM0502G.
Rear bumper cover
Leave each test sample to stand for 48 h at 80±2 .
Rear bumper spoiler
Exterior Rear fender flare Leave each test sample to stand for 20 h at 80±2 .
Rear wheelhousing liner Leave each test sample to stand for 20 h at 70±2 .
Other exterior products As per method A in Section 4.1.1 of TSM0502G.
(2) Method B
Carry out the test on test samples installed in a cut body or white body, in accordance with
method B specified in Section 4.1.1 of TSM0502G. Table 13 shows the standard test conditions
for typical products. If the test conditions differ according to the vehicle model, installed location,
destination etc., determine applicable test conditions through consultation with related
departments. For the deck side trim and quarter trim, carry out the test only if the upper portion
of these products is exposed to direct sunlight. Irradiate the portion to be exposed to direct
sunlight (upper portion of each product) with an infrared lamp. If the upper portion is not
trimmed or is not exposed to direct sunlight, carry out the test in accordance with method A
specified in item (1) above. In that case, leave test samples to stand for 20 h at 80±2 . For
the criteria for quarter trim deformation, use the rating grades given in Table 19.(13)
Note (13): If it is difficult to determine a proper rating grade, report the result, attaching
photograph(s) taken after the test to the result, or determine the rating grade through
Table 13 Test Conditions for Heat Resistance Test (Method B)

Cycle (Time)
Product
a (1 h) b (3 h) c (0.5 h)
Atmospheric temperature: 80±2
Package tray trim
Surface temperature: 110±2
Deck side trim Atmospheric temperature: Atmospheric temperature: 80±2
Interior Room
Quarter trim 80±2 Surface temperature: 100±2 temperature
As per Method B in Section 4.1.1 of (23±2 )
Tonneau cover
TSM0502G
Rear bumper cover Atmospheric temperature: Atmospheric temperature: 50±2
Exterior
Rear bumper spoiler 50±2 Surface temperature: 90±2
Temperature setting
(Repeat the b-to-c cycle four times)
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(3) Procedures for heat resistance test (Methods A and B)

(a) Set each test sample in a thermostat chamber, and start the test.
(b) Carry out the test under the test conditions specified in Table 12 or 13.
(c) After the test, leave each test sample to stand for 1 h min. Then, measure the dimensions of
each test sample and check the sample for any abnormality in appearance.
Remark: For the criteria for deformation, refer to Section 7.
6.1.3 Thermal Cycle Test

Carry out the test on test samples installed in a cut body or white body, in accordance with Table 15
and method A in Section 4.1.3 of TSM0502G. The standard test conditions for typical products are
shown in Tables 14 and 15. After four continuous cycles of the test, leave the test samples to stand
for 1 h min. at 23±2 , and check each sample for any difference in level between mating parts,
sag/warp, and any abnormality in appearance. If the test conditions differ according to the vehicle
model, installed location, destination etc., determine applicable test conditions through consultation
with related departments. For the criteria for quarter trim deformation, use the rating grades given in
Table 19.(13) Check each test sample for appearance, after high-temperature, low-temperature and
humidity exposures for each cycle of the test.
Table 14 Thermal Cycle Test Conditions

Test High Low
Test
Location Product condition tempera- tempera- Humidity
method
class ture ture
Deck side trim
Quarter trim
Package tray trim
Tonneau cover
Luggage-compartment floor board
Interior Luggage-compartment floor mat Conditions given in Table 15
Deck board
Deck mat
Rear floor board
Rear floor mat
Other interior products
Rear bumper cover
Rear bumper spoiler
Rear fender flare Conditions given in Table 16 if not influenced by humidity
Exterior
Rear mudguard Conditions given in Table 18 if influenced by humidity
Other exterior products
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Table 15 Humidity and Thermal Cycle Test

Step in each cycle Condition Time (h)
1 50±2 , 95±5 %RH 23.5
2 Leave to stand at room temperature (23±2 ). 0.5
3 -30±2 7.5
5 80±2 15.5
Table 16 Thermal Cycle Test Conditions if Not Influenced by Humidity

High temperature Low temperature
Product Test method
( ) ( )
Rear bumper cover
Rear bumper spoiler 80±2
Rear fender flare
Rear mudguard
As per Table 17 70±2 -30±2
Shall conform to the
Other exterior products specifications in the
drawings.
Table 17 Thermal Cycle Test without Humidity Influence: Test Procedure and Sequence
High Normal Low Normal Number of
temperature temperature temperature temperature cycles
15.5 h 0.5 h 4.5 h 0.5 h 3
Table 18 Thermal Cycle Test Conditions if Influenced by Humidity

Test
High temperature Low temperature
Product Test method condition Humidity
( ) ( )
class
Rear bumper cover
Rear bumper spoiler 80±2
Rear fender flare Method B in
Rear mudguard Section 50±2
a 70±2 -30±2
Rear wheelhousing liner 4.1.3 of 95±5 % RH
TSM0502G Shall conform to
Other exterior products the specifications
in the drawings.
Table 19Rating Grades

Grade Description
5 Not observable at all
4 Slightly observable but hardly noticeable
3 Obvious but not conspicuous
2 Obvious and rather conspicuous
1 Very conspicuous
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(1) Test procedures

(a) Set test samples in a thermostat chamber, and start the test.
(b) Carry out the test under the test conditions specified in Tables 14 and 15.
(c) After the test, measure the dimensions of each test sample and check each test sample for
any abnormality in appearance.
Remark: For the criteria for deformation, refer to Section 7. For the criteria for quarter trim
deformation, use the rating grades shown in Table 19.
6.1.4 Vibration Resistance Test

Carry out the test on test samples installed in a cut body or white body, in accordance with Section 4.4
of TSM0502G. Table 20 shows the standard test conditions. If the test conditions differ according
to the vehicle model, installed location, destination etc., determine applicable test conditions through
consultation with related departments. Carry out the test following the temperature pattern shown in
Fig. 2. Measure the vibration acceleration on the product surface.
Table 20 Vibration Resistance Test Conditions

Test temperature Vibration Full
Number of vibrations
Product ( ) acceleration amplitude
(times)
High Low (m/s2) (mm)
Rear bumper cover
Rear bumper spoiler
1500000 at each
Rear mudguard 55±2 -30±2 34.3 2 to 2.5
temperature
Rear fender flare
Fig. 2
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6.1.5 Drop Weight Impact Test

Carry out the test in accordance with Section 4.5.2 of TSM0502G. Table 21 shows the standard test
conditions. If the test conditions differ according to the vehicle model, installed location, destination
etc., determine applicable test conditions through consultation with related departments. For the
quarter trim, drop a weight on the lower area (including the speaker grill portion) indicated in Fig. 3.
For other products, drop a weight on the area most prone to impact when the product is installed in a
vehicle. For a product having a convex portion or thinner-wall portion considered less resistant to
impact, determine additional areas on which to drop a weight through consultation with related
departments. After leaving test samples to stand for 3 h or longer in a thermostat chamber at the test
temperature shown in Table 21 carry out the test and check for cracks or breakage(14).
Note (14): “Breakage or cracks” means cracks and breakage occurring on the products’ designed
surface. Check for them visually and tactilely with fingers.
Table 21 Drop Weight Impact Test Conditions

Minimum
Test Weight Height breakage
Location Part
temperature (g) (cm) energy
(N m)
Quarter Lower general area 60 2.94
trim Speaker grill area 35 1.72
Interior 500
Luggage trim rear cover
-30±2 25 1.23
Rear wheelhousing liner 1000 75 7.35
Exterior
Rear fender flare 500 35 1.72
Fig. 3 Lower Area of Quarter Trim
6.1.6 Impact Resistance Test

Carry out the impact resistance test of rear mudguard in accordance with Section 2.1 of TSH1504G.
Use the thinnest portion of product as a test sample. Carry out the test at -30±2 , using a 1 kg
weight and an impact needle 1.59 mm (1/16 inch) in tip diameter. Drop the weight from the height of
5 cm.
Mar. 2021
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6.1.7 Flex Resistance Test

Positioning a sliding rod (a round rod 15 mm in diameter), with its lower end aligned with the lower
edge of the rear mudguard, move the rod back and forth 100 times in the longitudinal direction of
vehicle in the atmosphere at a room temperature, and then another 100 times in the atmosphere at
-30 . Reciprocation stroke shall be such that the rod moves across the test sample (Fig. 4). As
the test sample, use the rear mudguard that underwent the vibration resistance test.
Fig. 4
6.2 Single-unit or Specimen Tests

This section describes the tests to be carried out on each target product shown in Table 1 as a single
unit or on a specimen cut from the target product.
6.2.1 Flammability Test

Carry out the test in accordance with TSM0500G.
6.2.2 VOC Test

Carry out the test in accordance with TSM0508G and TSM0512G.
6.2.3 Fogging Test

Carry out the test in accordance with TSM0503G, preferably method B unless there is a good reason
to use method A. Table 22 shows the standard test conditions for typical products. If the test
conditions differ according to the vehicle model, installed location, destination etc., determine
applicable test conditions through consultation with related departments. The quarter trim is divided
into the upper and lower areas as shown in Fig. 5.
Table 22 Heating Temperature

Product Heating temperature ( )
Package tray trim 100±2
Tonneau cover 85±2
Upper 90±2
Quarter trim
Lower 80±2
Other interior products As per TSM0503G
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Fig. 5
Remarks: “Upper” refers to the area above A-A line, and “lower” the area below A-A line.
Heat the upper area at 90 even when there is ornament fabric above A-A line for the
reason of structure.
For a quarter trim whose structure is substantially different from that shown in Fig. 5,
determine appropriate heating temperatures through consultation with related departments.
6.2.4 Smell Test

Carry out the test in accordance with TSM0505G.
6.2.5 Light Exposure Test

Set a specimen cut from a target product on a fade-o-meter, and carry out the test using the exposure
conditions specified in Table 23. Take out the specimen, and compare it with another specimen not
exposed to light with regard to change in color and deterioration. For the criteria for change in color,
use the rating grades given in Table 24. In the case of a quarter trim, use the rating grades given in
Table 19.
Table 23 Test Method and Conditions

Product Test method Test conditions
As per method A Exposure time (h)
Package tray trim(15) in Section 5.1 of Change in color Deterioration
TSL0601G 200 min. 400 min.
As per
Other interior products As per TSL0601G
TSL0601G
Note (15): Surface layer alone may be used as a specimen if test result is anticipated to be the same
as for the package tray trim finished as a product.
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Table 24
Rating Grades
Grade Description
5 Fading to the level of Discoloration/Fading Gray Scale(16) No. 5
1 Fading to the level of Discoloration/Fading Gray Scale(16) No. 1 or more
Note (16): As per JIS L 0804 or ISO 105-A02
6.2.6 Heat Aging Test

After leaving each test sample to stand for at least 400 h in a thermostat chamber at 80±2 , take
out the sample and check for any abnormalities in appearance.
6.2.7 Humidity Aging Test

After leaving each test sample to stand for at least 400 h in a thermo-hygrostatic chamber at 50±2
and 95±5 %RH, take out the sample and check for any abnormalities in appearance.
If the carpet or ornament surface layer of quarter trim is bonded to PVC cover material, leave the test
sample to stand for at least 400 h in a thermo-hygrostatic chamber at 80±2 and 95±5 %RH
before checking for any abnormalities in appearance.
6.2.8 High-temperature Aging Test

After leaving each test sample to stand for at least 400 h in a thermostat chamber at 110±2 , take
out the sample and check for any abnormalities in appearance.
6.2.9 Peeling Strength Test

(1) Original state
Cut 25 mm wide specimens from general, ornamented, high-frequency welded, and carpeted
portions of target products. For specimens in which the surface layer is entirely bonded to the
base layer, peel the surface layer by appropriate length in the direction perpendicular to the
shorter side of the specimen (Fig. 6). Set the specimen (with the surface layer partly peeled
from the base layer) in the grips of an Instron tensile tester, and peel the surface layer at the rate
of 200 mm/min. Based on the recorded chart, calculate an average of maximum values
(excluding abnormal values) to determine the peeling strength (N/25 mm). During the test,
maintain the standard condition in the laboratory. Report the test result as well as the condition
of each layer broken during the test.
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Fig. 6
(2) After heat aging

portions of target products that have been left to stand for 24 h under the standard condition after
undergoing the heat aging test of Section 6.2.6. Carry out the test on these specimens following
the same procedure as in (1) above to determine the peeling strength (N/25 mm) of heat-aged
products.
(3) After humidity aging
portions of target products that have been left to stand for 24 h under the standard condition after
undergoing the humidity aging test of Section 6.2.7. Carry out the test on these specimens
following the same procedure as in (1) above to determine the peeling strength (N/25 mm) of
humidity-aged products.
6.2.10 Creep Resistance Test

Cut 25 mm wide specimens from target products’ general, ornamented, carpeted and other portions
where the surface layer is entirely bonded to the base layer. Peel the surface layer by appropriate
length in the direction perpendicular to the shorter side of the specimen. Leave each specimen (with
the surface layer partly peeled from the base layer) to stand for 24 h in a thermostat chamber at 80±
2 , with a load of 0.98 N applied to the specimen as shown in Fig. 7, and then measure the peeling
length (mm).
Fig. 7
Mar. 2021
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6.2.11 Puckering Resistance Test

(1) Method A
After leaving a test sample for 10 min in a hot air dryer at 60±2 , visually check for puckering
and other abnormalities in appearance in the 60±2 atmosphere in the dryer. For the criteria
for puckering, use the rating grades shown in Table 19.
(2) Method B
After leaving a test sample for 20 min in a thermo-hygrostatic chamber at 30±2 and 95±
5 %RH, visually check for puckering and other abnormalities in appearance. For the criteria for
puckering, use the rating grades shown in Table 19.
6.2.12 Scratch Resistance Test

Sample specimens from the flat portion of the product. Adhere a specimen on the turn table of a
tabar scratch tester shown in Fig. 8. Carry out the test under conditions specified in Table 25. After
the test, check the specimen for the occurrence of cut penetrating through the surface layer when the
product has a surface layer. When the product does not have a surface layer, evaluate the damage
with an applicable grade among those shown in Table 26.
Fig. 8 Taber Scratch Tester
Table 25 Scratch Resistance Test Conditions

--- With surface layer Without surface layer
Orientation of cutting blade (Fig. 9) Ordinary Reverse
Load (N) 3.92 0.98
Rotation speed (r/min) 0.5 or 1.0
Scratch length (mm) 15 min.
Mar. 2021
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Fig. 9 Cutting Blade (Unit: mm)
Table 26
Scratch Resistance Grades
Grade Description of damage
5 No gloss, whitening and flattened grain are observed.
Gloss, whitening or flattened grain is barely discernible at certain viewing angle but is not
4
conspicuous.
3 Gloss, whitening or flattened grain is clearly discernible at any viewing angle.
2 Gloss, whitening or flattened grain is fairly conspicuous.
1 Gloss, whitening or flattened grain is significantly conspicuous.
6.2.13 Oil Resistance Test

This test shall be applied to a test sample that uses thermoplastic olefin (TPO) or genuine leather as
the surface layer. From each product portion shown in Table 27, cut surface layer to an appropriate
size that can be mounted on the testing jig shown in Fig. 10. Set the specimen on the testing jig (Fig.
10), place a 38 mm across spacer ring on the specimen, and drip paraffin oil(17) within the ring as
specified in Table 27. After heat-aging the specimen under the condition given in Table 27, take out
the specimen, and check for the surface condition. Report the result using the rating grades shown
in Table 28.
Note (17): Nacalai Tesque’s soft liquid paraffin (No. 261-32, specific gravity of 0.820 to 0.845) or its
equivalent
Table 27 Oil Resistance Test Conditions

Location Drip amount of paraffin oil (g) Heat-aging condition
Upper and armrest portions 1.5
80 24 h
Lower and other portions 0.1
Mar. 2021
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Fig. 10 Testing Jig for Oil Resistance Test (Unit: mm)
Table 28 Rating Grades

Grade Appearance of specimen (Condition of puckering)
5 No puckering or other abnormalities in appearance. No oil stain
Shallow surface roughness partly along lines of lattice pattern.
4
Grain pattern faded due to absorbed oil
Puckering in a wide range independently of lattice pattern.
3
Depressed puckering. Loss of grain pattern
Deep or depressed puckering over the entire surface, with
2
remarkable surface roughness
6.2.14 Humidity Resistance Test

Leave a test sample to stand for 48 h in a thermo-hygrostatic chamber at 28±3 and 95±5 %RH,
and immediately after taking the test sample out of the chamber, check for any abnormalities in
appearance, such as surface lift, peeling and puckering. Also after leaving a test specimen to stand
for 24 h in the atmosphere of standard condition (23±2 and 50±5 %RH in principle; if the
standard condition cannot be maintained, record the temperature and humidity used for the test in the
test result), check for any abnormalities in appearance, such as surface lift, peeling and puckering.
For the criteria for puckering, use the rating grades given in Table 19.
6.2.15 Accelerated Weatherability Test

This test shall be applied only to mold-in-color products.
(1) Accelerated weatherability test of rear bumper cover and rear bumper spoiler
Carry out the test in accordance with Section 9.20 of TSM0501G. Test time shall be at least 800
h with a Suga xenon lamp weather-o-meter SX-75, or at least 1800 h with an Atlas xenon lamp
weather-o-meter Ci4000. (The test should use a xenon lamp weather-o-meter as a rule. If it is
unavoidable, however, a sunshine weather-o-meter may be used after consultation with related
departments. In that case, the black panel temperature shall be 83±2 , and the test time
shall be at least 1000 h.)
(2) Accelerated weatherability test of rear mudguard and rear fender flare
Carry out the test on each test sample as a single unit in accordance with Section 4.7.3 of
TSM0502G. Irradiate the designed surface of the test sample in a weather-o-meter under the
test conditions shown in Table 29.
Mar. 2021
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Table 29 Accelerated Weatherability Test Conditions

Product Black panel temperature ( ) Exposure time (h)
Rear mudguard 63±2 300 min.
Rear fender flare 83±2 400 min.
6.2.16 Outdoor Weatherability Test

This test shall be applied only to mold-in-color products. Carry out the test in accordance with
Section 4.7.1 of TSM0502G. Standard test duration is one year.
6.2.17 Deformation Strength Test

Carry out the test on a rear fender flare in accordance with Section 4.10.1 of TSM0502G. Test points
shall be bosses and the area between bosses. If it is considered necessary to carry out the test on
other points, determine necessary test points through consultation with related departments.
6.2.18 Insert/Outsert-Molding Strength Test

Carry out the test in accordance with Section 4.10.3 of TSM0502G.
6.2.19 Tapping-Screw-Tightening-Area Strength Test

For the test to determine the strength against screw removal, follow method B in Section 4.10.3 (1) of
TSM0502G. For the test to determine the strength against screw tightening, follow the method in
Section 4.10.3 (3) of TSM0502G.
6.2.20 Fluid Resistance Test

Carry out the test in accordance with method A (wiping test) in Section 4.8.2 of TSM0502G. As
testing fluid, use car cleaning agent, car wax fluid, windshield washer fluid and brake fluid. If the test
conditions differ according to the vehicle model, installed location, destination etc., determine
applicable test conditions through consultation with related departments.
7. Criteria for Deformation (Reference)

Table 30 shows the standard acceptance criteria for appearance-affecting deformation of products
after heat resistance test and thermal cycle test. Referring to Table 30, determine the acceptance
criteria most suitable for the vehicle model, installed location, destination etc. through consultation
with related departments.
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Table 30 Acceptable Amount of Deformation (Unit: mm)

Mating joints Movable product’s
Mating joints where Surfaces whose
where gap or mating joints where
gap or difference in sag or warp is
Location difference in level gap or difference in
level is noticeable noticeable by
is not noticeable level is noticeable by
by passengers passengers
by passengers passengers
Acceptable x 1.5 x 3 x 5 x 10
Criteria Consultation(18) 1.5 < x < 3 3<x<5 5<x 10 < x
Not acceptable 3 x 5 x --- ---
Mating joints
Sag As per Table 31 As per Table 32 As per Table 33 As per Table 34
Warp
Note (18): If the amount of deformation is somewhere between the acceptable and unacceptable
limits, determine whether the deformation is detrimental to the appearance or not through
Remark: “x” represents the amount of gap, difference in level, sag, or warp.
Table 31 Mating Joints Where Gap or Difference in Level Is Noticeable by Passengers (Reference)
Mating joints between products
Roof side pillar garnish
Deck side trim
Opening trim
Tonneau cover
Opening trim
Luggage-compartment trim rear
cover
Package tray trim Roof side pillar garnish
Rear bumper spoiler
Rear mudguard
Rear bumper cover Rear fender flare
Rear combination-lamp assembly
Body
Rear fender flare Body
Table 32 Mating Joints Where Gap or Difference in Level Is Not Noticeable by Passengers (Reference)
Body
Luggage-compartment front trim cover Body
Rear bumper cover Rear wheelhousing liner
Rear mudguard Rear fender flare
Body
Rear fender flare
Body
Mar. 2021
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Table 33 Movable Product’s Mating Joints Where Gap or Difference in Level Is Noticeable by Passengers
(Reference)
Deck board Deck side trim
Deck mat
Rear floor board
Rear floor mat
Luggage-compartment trim floor board
Luggage-compartment trim floor mat
Table 34 Surfaces Whose Sag or Warp Is Noticeable by Passengers (Reference)

Sag or warp
Product Location
Luggage-compartment trim floor board
Luggage-compartment trim floor mat
Deck board
Designed surface
Deck mat
Rear floor board
Rear floor mat
Applicable Standards
TSF0300G Cut and white body standard pattern
TSH1504G Test method for flexibility of paint film
TSL0601G Criteria for test for quality of color change by aging
TSM0500G Flammability test method for interior materials
TSM0501G Standard test methods for plastic molding materials
TSM0502G General test method regarding material properties for plastic
interior/exterior design parts
TSM0503G Fogging test method for non-metallic materials
TSM0505G Smell quality of non-metallic materials
TSM0508G Volatile component measurement method using sampling bag
TSM0512G Part volatile component measurement method using large sampling bag
TSM1500G Rubber materials
TSM5505G Ethylene-vinyl acetate copolymer resin molding material
TSM5518G Polyethylene resin molding material
TSM5601G Composite reinforced polypropylene molding materials
TSM5608G High performance polypropylene resin molding material
TSM5708G Elastomer modified polypropylene resin molding materials for exterior parts
TSM6506G Sheet molding compound materials
TSM6508G Bulk molding compound materials
TSZ6005G Indication method of material marking for plastic parts and rubber parts
ISO 105-A02 Textiles -- Tests for colour fastness -- Part A02: Grey scale for assessing
change in colour
JIS L 0804 Grey scale for assessing change in colour
Mar. 2021
28 / 28


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TOYOTA ENGINEERING STANDARD

This standard has been revised as a result of the following changes:

Prepared and Written by: Design Quality Innovation Dept.

Copyright TOYOTA MOTOR CORPORATION

HP PELZER PIMSA AUTOMOTIVE A.S.

HP PELZER PIMSA AUTOMOTIVE A.S.

TOYOTA ENGINEERING STANDARD TSF0902G

Fig. 1 Rear Body (Nonmetal Products in the Target Zone)

HP PELZER PIMSA AUTOMOTIVE A.S.

TOYOTA ENGINEERING STANDARD TSF0902G

Table 1 Target Products (Reference)

HP PELZER PIMSA AUTOMOTIVE A.S.

TOYOTA ENGINEERING STANDARD TSF0902G

Table 2 Regional Criteria

Table 3 Applicable Region ( : Applicable)

Cambodia Armenia --- ---

East Timor Azerbaijan ---

Indonesia Bahrain ---

Laos Cyprus ---

ASEAN Malaysia Georgia ---

Singapore GCC/ Jordan ---

Vietnam Lebanon ---

Bangladesh Oman ---

Bhutan --- Qatar ---

Pakistan --- Yemen ---

Sri Lanka Taiwan

HP PELZER PIMSA AUTOMOTIVE A.S.

TOYOTA ENGINEERING STANDARD TSF0902G

2. Shape, Design, and Material Marking

HP PELZER PIMSA AUTOMOTIVE A.S.

TOYOTA ENGINEERING STANDARD TSF0902G

Table 5 Test Items for Rear Mudguard

HP PELZER PIMSA AUTOMOTIVE A.S.

TOYOTA ENGINEERING STANDARD TSF0902G

Table 6 Test Items for Rear Fender Flare

HP PELZER PIMSA AUTOMOTIVE A.S.

TOYOTA ENGINEERING STANDARD TSF0902G

Table 7 Quality Requirements

HP PELZER PIMSA AUTOMOTIVE A.S.

TOYOTA ENGINEERING STANDARD TSF0902G

All target interior products

HP PELZER PIMSA AUTOMOTIVE A.S.

TOYOTA ENGINEERING STANDARD TSF0902G

Table 8 Quality Requirements of Deck Side Trim and Quarter Trim

Heat resistance (method B) Deck side trim: No remarkable abnormalities(3) in

Heat aging No abnormalities, such as surface lift and peeling, shall

HP PELZER PIMSA AUTOMOTIVE A.S.

TOYOTA ENGINEERING STANDARD TSF0902G

5. General Test Conditions

5.2 Test Samples

5.3 Conditioning of Test Samples

5.4 Quantities of Test Samples

HP PELZER PIMSA AUTOMOTIVE A.S.

TOYOTA ENGINEERING STANDARD TSF0902G

6.1 Assembly Tests

Table 10 Products to Be Combined in an Assembly (Reference)

HP PELZER PIMSA AUTOMOTIVE A.S.

TOYOTA ENGINEERING STANDARD TSF0902G

6.1.1 Test Preparation

(2) Measuring dimensions

6.1.2 Heat Resistance Test

HP PELZER PIMSA AUTOMOTIVE A.S.