2009 toyota corolla service repair manual by 1639701yu

FOREWORD This repair manual has been prepared to provide essential information on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA COROLLA Applicable models: AZE141 series ZRE142 series This manual consists of body repair methods, exploded diagrams and illustrations of the body components and other information relating to body panel replacement such as handling precautions, etc. However, it should be noted that the front fenders of the TOYOTA model is bolted on and require no welding. When repairing, donâ&#x20AC;&#x2122;t cut and join areas that are not shown in this manual. Only work on the specified contents to maintain body strength. Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations. For the repair procedures and specifications other than collisiondamaged body components of the TOYOTA COROLLA refer to the repair manuals. If you require the above manuals, please contact your TOYOTA Dealer. All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without prior notice.

ABOUT THIS MANUAL Scope of the repair work explanation S This text explains the welding panel replacement instructions from the vehicleâ&#x20AC;&#x2122;s white body condition. We have abbreviated the explanations of the removal and reinstallation of the equipment parts up to the white body condition and of the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel. Section categories S This manual has been divided as shown below. Section Title

Contents

Examples

INTRODUCTION

Explanation of general body repair. Views of weld panel replacement instructions.

Precaution About this vehicle

BODY PANEL REPLACEMENT

Instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts.

Front side member replacement. Quarter panel replacement.

BODY DIMENSIONS

Body aligning measurements.

Dimension diagrams.

PAINT S COATING

Scope and type of anti-rust treatment, etc. together with weld panel replacement.

Body sealer. Under coat.

Contents omitted in this manual S Make sure to perform the following essential procedures, although they are omitted in this manual. (1) Clean and wash removed parts, if necessary. (2) Visual inspection

BODY DIMENSIONS Three-dimensional distance

Two-dimensional distance

Center-to-center straight-line distance

Center-to-center horizontal distance in forward / rearward direction

Vertical distance in center

DI-1

GENERAL INFORMATION 1.

BASIC DIMENSIONS

(a) There are two types of dimensions in the diagram. (1) (Three-dimensional distance) S Straight-line distance between the centers of two measuring points.

(2) (Two-dimensional distance) S Horizontal distance in forward/rearward direction between the centers of two measuring points. S The height from an imaginary datum line.

Vertical distance in lower surface Imaginary Datum Line

(b) In cases in which only one dimension is given, left and right are symmetrical. (c) The dimensions in the following drawing indicate actual distance. Therefore, please use the dimensions as a reference. (d) The line that connects the places listed below is the imaginary datum line when measuring the height. (The dimensions are printed in the text.) Under Surface of The Rocker Panel

A mm

B mm

C mm Imaginary Datum Line

SYMBOL

Name

The place that was lowered A mm from the under surface of the rocker panel centered on the front jack up point.

The place that was lowered B mm from the under surface of the rocker panel centered between 1 and 3.

The place that was lowered C mm from the under surface of the rocker panel centered on the rear jack up point.

BODY DIMENSIONS

DI-2 Plate Looseness Body Looseness

Pointer Looseness Pointer

MEASURING

(a) Basically, all measurements are to be done with a tracking gauge. For portions where it is not possible to use a tracking gauge, a tape measure should be used. (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers.

Master Gauge

HINT: 1) The height of the left and right pointers must be equal. 2) Always calibrate the tracking gauge before measuring or after adjusting the pointer height. 3) Take care not to drop the tracking gauge or otherwise shock it. 4) Confirm that the pointers are securely in the holes.

Correct

Wrong

Pointer

(c)

When using a tape measure, avoid twists and bends in the tape.

BODY DIMENSIONS

DI-3

BODY DIMENSION DRAWINGS ENGINE COMPARTMENT (Three-Dimensional Distance) 568 (22.36)

1,023 (40.28)

1,575 (62.01) 937 (36.89)

1,456 (57.32)

519 (20.43)

891 (35.08) 906 (35.67)

638 (25.12)

1,038 (40.87)

592 (23.31)

1,010 (39.76)

830 (32.68)

728 (28.66)

929 (36.57)

534 (21.02) 908 (35.75)

960 (37.80)

501 (19.72)

339 (13.35)

604 (23.78)

728 (28.66) 845 (33.27)

269 (10.59)

486 (19.13)

Height from Imaginary Datum Line

Vehicle Dimensions A-n or a-N

B-c or b-C

C-l or c-L

C-M or c-m

C-m or c-M

I-j

J-j

M-m

1,537 (60.51)

1,250 (49.21)

1,392 (54.80)

263 (10.35)

1,457 (57.36)

852 (33.54)

1,561 (61.46)

1,410 (55.51)

N-n

L-N or l-n

L-n or l-N

1,517 (59.72)

747 (29.41)

1,290 (50.79)

A,a

C,c

L,l

700 (27.56)

783 (30.83)

666 (26.22)

HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). Symbol

Name

mm (in.)

Hole dia.

Symbol

A, a

Front fender installation nut

M6 (0.24)

H, h

B, b

Front suspension support installation hole-inner

ø11 (0.43)

C, c

Hood hinge installation nut-erar

M8 (0.31) –

Cowl top panel center mark

Name

Hole dia.

Front cross member side gusset standard hole

ø10 (0.39)

Hood lock support brace installation nut

M6 (0.24)

J, j

Front fender extension standard hole

ø10 (0.39)

K, k

Radiator upper support installation nut

M6 (0.24)

E, e

Front side member standard hole

ø18 (0.71)

L, l

Radiator upper support installation nut

M6 (0.24)

Front side member standard hole

ø12 (0.47)

M, m

Front apron to cowl side membe upper standard hole

ø10 (0.39)

Engin mounting installation nut

M12 (0.47)

N, n

Front fender installation nut

M6 (0.24)

G, g

Radiator support standard hole

ø10 (0.39)

–

DI-4

BODY DIMENSIONS

BODY OPENING AREAS (Side View: Front) (Three-Dimensional Distance)

1,092 (42.99)

919 (36.18) 1,561 (61.46)

813 (32.01) 1,456 (57.32)

775 (30.51) 1,109 (43.66)

861 (33.90)

1,217 (47.91) 986 (38.82)

877 (34.53) 857 (33.74)

1,016 (40.00)

Vehicle Dimensions E-e

F-f

G-g

H-h

I-i

J-j

K-k

L-l

1,327 (52.24)

1,417 (55.79)

1,420 (55.91)

1,418 (55.83)

1,159 (45.63)

1,280 (50.39)

1,448 (57.01)

1,563 (61.54)

E-f or e-F

E-h or e-H

E-i or e-I

E-k or e-K

F-j or f-J

F-k or f-K

H-i or h-I

C-L or c-l

C-N or c-n

D-L or d-l

D-M or d-m

G-I or g-i

1,519 (59.80)

1,629 (64.13)

1,389 (54.68)

1,632 (64.25)

1,815 (71.46)

1,670 (65.75)

1,617 (63.66)

1,062 (41.81)

1,101 (43.35)

1,069 (42.09)

1,135 (44.68)

1,104 (43.46)

HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). Symbol

Name

A, a

Roof panel corner

mm (in.)

Hole dia.

Symbol

H, h

Rocker panel assembly mark

Name

Hole dia. Ċ

B, b

Hood hinge installation nut-rear

M8 (0.31)

I, i

Roof side rail assembly mark

C, c

Front door hinge installation nut

M8 (0.31)

J, j

Center body pillar assembly mark

D, d

Front door hinge installation nut

M8 (0.31)

K, k

Center body pillar assembly mark

E, e

Front body pillar assembly mark

L, l

Front door lock striker installation nut

M8 (0.31)

F, f

Front body pillar assembly mark

M, m

Rear door hinge installation nut

M8 (0.31)

G, g

Rocker panel assembly mark

N, n

Rear door hinge installation nut

M8 (0.31)

BODY DIMENSIONS

DI-5

BODY OPENING AREAS (Side View: Rear) Sedan (Three-Dimensional Distance)

671 (26.42) 981 (38.62) 999 (39.33)

947 (37.28)

838 (32.99) 1,062 (41.81)

Vehicle Dimensions O-o

P-p

Q-q

R-r

S-s

T-t

U-u

1,280 (50.39)

1,450 (57.09)

1,418 (55.83)

1,145 (45.08)

1,226 (48.27)

1,421 (55.94)

1,526 (60.08)

G-q or g-Q

O-q or o-Q

O-s or o-S

O-t or o-T

P-s or p-S

P-t or p-T

Q-r or q-R

S-t or s-T

N-U or n-u

1,702 (67.01)

1,603 (63.11)

1,421 (55.94)

1,588 (62.52)

1,656 (65.20)

1,559 (61.38)

1,619 (63.74)

1,478 (58.19)

1,066 (41.97)

HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). Symbol

Name

mm (in.)

Hole dia.

Symbol

Q, q

Rocker panel notch edge

Rear door hinge installation nut

M8 (0.31)

R, r

Roof side rail assembly mark

Rear door hinge installation nut

M8 (0.31)

S, s

Quarter panel assembly mark

T, t

Quarter panel assembly mark

U, u

Rear door lock striker installation nut

G, g

Rocker panel assembly mark

M, m N, n O, o

Center body pillar assembly mark

P, p

Center body pillar assembly mark

Name

Hole dia.

Ċ M8 (0.31)

DI-6

BODY DIMENSIONS

BODY OPENING AREAS (Rear View) Sedan (Three-Dimensional Distance)

1,035 (40.75)

1,200 (47.24)

1,240 (48.82) 841 (33.11)

1,386 (54.57)

1,189 (46.81)

1,172 (46.14)

1,144 (45.04) 479 (18.86)

984 (38.74) 1,474 (58.03)

1,103 (43.43)

1,284 (50.55)

862 (33.94)

922 (36.30)

Vehicle Dimensions D-c or d-C 1,284 (50.55)

HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). Symbol

Name

A, a

Roof panel corner

B, b

Quarter panel standard hole

C, c D, d

mm (in.)

Hole dia.

Symbol

Name

Hole dia.

E, e

Quarter panel standard hole

13.5 x 10.5 (0.53 x 0.41)

F, f

Quarter panel end housing / Body lower back panel adjoining portion

Quarter panel / upper back panel adjoining portion

G, g

Rear suspension installation hole

ø16 (0.63)

Quarter panel end housing / Luggage compartment opening trough adjoining portion

H, h

Center body pillar assembly mark

ø13 (0.51) Ċ

BODY DIMENSIONS

DI-7

UNDER BODY (Three-Dimensional Distance) 840 (33.07) 455 (17.91)

400 (15.75)

985 (38.78) 786 (30.94) 1,263 (49.72) 730 (28.74)

1,252 (49.29)

1,538 (60.55)

890 (35.04)

912 (35.91)

1,228 (48.35)

870 (34.25)

1,223 (48.15)

1,282 (50.47)

870 (34.25)

966 (38.03)

1,129 (44.45)

1,547 (60.91)

860 (33.86)

Front

C,c D,d 232 91 (9.13) (3.58)

641 (25.24)

874 (34.41)

1,035 (40.75)

1,147 (45.16)

1,035 (40.75)

835 (32.87)

641 (25.24)

839 (33.03)

A,a B,b 149 320 (5.87) (12.60)

754 (29.68) 656 (25.83)

100 (3.94)

E,e 57 (2.24)

F,f 48 (1.89)

H,h I,i 123 307 (4.84) (12.09)

3 G,g 146 (5.75)

L,l 271 (10.67)

K,k 297 (11.69)

J 119 (4.69)

Imaginary Datum Line

HINT: 1) For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). 2) Point A,a, B,b, I,i on the vehicle are asymmetrical.

mm (in.)

Symbol

Name

Hole dia.

Symbol

Name

Hole dia.

A, a

Engine mounting center member installation nut

M10 (0.39)

G, g

Rear floor side front member standard hole

ø25 (0.98)

B, b

Front side member standard hole

ø18 (0.71)

H, h

Trailing arm installation hole

ø13 (0.51)

C, c

Front suspension crossmember installation nut

M14 (0.55)

I, i

Rear floor NO. 2 crossmember standard hole

ø10 (0.39)

D, d

Front suspension crossmember installation nut

M14 (0.55)

E, e

Front side member standard hole

ø18 (0.71)

F, f

Front floor under reinforcement standard hole

ø10 (0.39)

Rear floor centermember NO. 4 reinforcement standard hole

ø8 (0.31)

K, k

Rear floor side rear member standard hole

19 x 16 (0.75 x 0.63)

L, l

Transport hook installation hole-rear

ø15 (0.59)

DI-8

BODY DIMENSIONS

UNDER BODY (Two-Dimensional Distance) 2,064 (81.26) 2,162 (85.12)

1,542 (60.71)

1,258 (49.53)

986 (38.82) 920 1,125 (36.22) (44.29)

407 (16.02)

238 (9.37)

20 (0.79)

80 (3.15)

500 (19.69)

456 (17.95)

614 435 (24.17) (17.13)

445 (17.52)

435 (17.13)

626 (24.65)

485 (19.09)

435 (17.13)

437 (17.20) 536 (21.10)

512 (20.16)

67 (2.64)

517 (20.35)

265 (10.43)

2,162 (85.12)

860 (33.86)

1,539 (60.59)

2,064 (81.26)

Wheel base

2,600 (102.36)

Front

A,a B,b 149 320 (5.87) (12.60)

C,c 232 (9.13)

E,e 91 (3.58)

F,f 57 (2.24)

599 (23.58)

100 (3.94)

G,g 48 (1.89)

D,d 736 (28.98)

I,i 123 (4.84) H,h 146 (5.75)

920 (36.22) 1,038 (40.87)

1,760 (69.29)

K,k M,m 404 297 (15.91) (11.69) J,j 307 (12.09)

L 119 (4.69)

HINT: 1) For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). 2) Point A,a, B,b, J,j on the vehicle are asymmetrical.

N,n 271 (10.67)

Imaginary Datum Line

mm (in.)

Symbol

Name

Hole dia.

Symbol

A, a

Engine mounting center member installation nut

M10 (0.39)

H, h

Name

Hole dia.

Rear floor side front member standard hole

ø25 (0.98)

B, b

Front side member standard hole

ø18 (0.71)

I, i

Trailing arm installation hole

ø13 (0.51)

C, c

Front suspension crossmember installation nut

M14 (0.55)

J, j

Rear absorber mounting member standard hole

ø10 (0.39)

D, d

Front suspension support installation hole

ø11 (0.43)

K, k

Rear spring bracket installation hole

ø15 (0.59)

E, e

Front suspension crossmember installation nut

M14 (0.55)

F, f

Front side member standard holet

ø18 (0.71)

G, g

Front floor under reinforcement standard hole

ø10 (0.39)

Rear floor centermember NO. 4 reinforcement standard hole

ø8 (0.31)

M, m

Rear floor side rear member standard hole

19 x 16 (0.75 x 0.63)

N, n

Transport hook installation hole-rea

ø15 (0.59)

BODY DIMENSIONS

DI-9

FRONT SUSPENSION CROSSMEMBER (Three-Dimensional Distance)

Front

689 (27.13) 912 (35.91) 335 (13.19)

660 (25.98)

309 (12.17)

952 (37.48)

354 (13.94)

639 (25.16)

306 (12.05)

890 (35.04)

Imaginary Datum Line B,b 194 (7.64)

A,a 89 (3.50)

C,c 67 (2.64)

D,d 73 (2.87)

HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). Symbol

Name

A, a

Lower arm installation hole

B, b

Front suspension crossmember installation hole

mm (in.)

Hole dia.

Symbol

Name

Hole dia.

ø15.5 (0.61)

C, c

Front suspension crossmember standard hole

ø13 (0.51)

ø22 (0.87)

D, d

Front suspension crossmember installation hole

ø20 (0.79)

DI-10

BODY DIMENSIONS

FRONT SUSPENSION CROSSMEMBER (Two-Dimensional Distance)

Front

A,a 242 (9.53)

344 (13.54) B,b 136 (5.35)

456 (17.95)

177 (6.97)

445 (17.52)

D,d 148 (5.83)

Imaginary Datum Line B,b 194 (7.64)

A,a 89 (3.50)

C,c 67 (2.64)

D,d 73 (2.87)

HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). Symbol

Name

A, a

Lower arm installation hole

B, b

Front suspension crossmember installation hole

mm (in.)

Hole dia.

Symbol

Name

Hole dia.

ø15.5 (0.61) ø22 (0.87)

C, c

Lower arm installation hole

ø13 (0.51)

D, d

Front suspension crossmember installation hole

ø20 (0.79)

BODY DIMENSIONS

DI-11

REFERENCE VALUE ENGINE COMPARTMENT (Three-Dimensional Distance)

627 (24.68)

1,542 (60.71)

1,517 (59.72)

1,537 (60.51)

1,482 (58.35)

316 (12.44)

1,375 (54.13) 339 627 (13.35) (24.68) 987 (38.86)

1,375 (54.13)

1,478 (58.19)

HINT: 1) For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). 2) These values are actual measurements made on model. Use these reference values. Symbol

Name

Hole dia.

Symbol

mm (in.) Name

Hole dia.

A, a

Front bumper cover installation bolt

D, d

Front fender installation bolt

B, b

Headlight installation bolt

E, e

Front fender installation bolt

DI-12

BODY DIMENSIONS

UNDER BODY

(Two-Dimensional Distance)

726 (28.58)

821 (32.32)

912 (35.91) 978 (38.50) 1,048 (41.26) 890 (35.04) 966 (38.03)

1,402 (55.20)

1,352 (53.23)

870 (34.25)

Vehicle Dimensions A-B

A-b

A-C

A-c

A-D

A-d

782 (30.79)

759 (29.88)

1,020 (40.16)

1,002 (39.45)

1,382 (54.41)

1,369 (53.90)

Name

Hole dia.

Symbol

mm (in.) Name

A, a

Center member installation bolt

–

C, c

Front suspension crossmember installation bolt

B, b

Front suspension crossmember installation bolt

–

D, d

Front side member installation hole

Hole dia. – ø18 (0.71)

BODY DIMENSIONS

DI-13

UNDER BODY (Two-Dimensional Distance)

Front bumper reinforcement [RH] 59.8

59.8

[LH]

12.3_

13.10_

Front suspension support

2.3

32.3

66.4

56.7

0.4

2.3_

57.5

32.6

102

13.9

6.6

2.3

9.4

Unit: mm

DI-14

MEMO

INTRODUCTION

IN-1

4. ANTI-RUST TREATMENT AFTER INSTALLATION

(a) BODY SEALER APPLICATION

Sealer Gun

PURPOSE: For water-proofing and anti-rust measures, always apply the body sealer to the body panel seams and hems of the doors, hood, etc. NOTICE: Apply body sealer neatly to parts that require a high quality appearance. F33011

(b) UNDERCORT APPLICATION PURPOSE: To prevent corrosion and protect the body from gravel, always apply a sufficient undercoating to the areas indicated.

F33012

(c) VEHICLE BODY ANTI-RUST AGENT APPLICATION PURPOSE: The purpose is to protect areas from rust which are difficult to paint such as the backside of the box-shaped cross section frame parts. METHOD: Apply anti-rust agent through the service holes and/or installation holes of the parts. F33013

IN-2

INTRODUCTION

5. HEADLIGHT BRACKET REPAIR HINT: S S

If the installation area of the headlight assembly is damaged, use the supply retainer for low-cost repair. Ensure that the headlight assembly is not damaged.

(a) INSTALL UPPER HEADLIGHT PROTECTOR RETAINER

E163300

(1) Cut off the part shaded in the illustration and smooth with sandpaper. NOTICE: After cutting off the part, place the upper headlight protector retainer against the bosses and gradually file away the old bracket if it interferes with the installation of the supply bracket. (2) Install the upper headlight protector retainer with the 2 screws.

E163301

(b) INSTALL LOWER HEADLIGHT PROTECTOR RETAINER

E160571

(1) Cut off the part shaded in the illustration and smooth with sandpaper. NOTICE: After cutting off the part, place the lower headlight protector retainer against the bosses and gradually file away the old bracket if it interferes with the installation of the supply bracket. (2) Install the lower headlight protector retainer with the 2 screws.

E160570

INTRODUCTION

IN-3

(c) INSTALL LOWER HEADLIGHT BRACKET (1) Cut off the part shaded in the illustration and smooth with sandpaper. NOTICE: After cutting off the part, place the lower headlight bracket against the bosses and gradually file away the old bracket if it interferes with the installation of the supply bracket. E160573

(2) Install the lower headlight bracket with the 2 screws.

E160572

IN-4

INTRODUCTION

6. PROCEDURES NECESSARY WHEN ECU OR OTHER PARTS ARE REPLACED (a) THE WORK LIST

(1) Each inspection procedure refers to the TOYOTA Repair Manual. Replacement Part

Necessary Procedure

Effect/Inoperative Function When Necessary Procedures are not Performed

Note

Vehicle Identification Number (VIN) registration

MIL comes on

ECU commnication ID registration

S Wireless door lock control system (*4) S Smart key system (*4) S Engine start

Reset memory (*1)

S Large shift shock S The deterioration of fuel efficiency

Using the Techstream.

Reset memory

S Large shift shock S The deterioration of fuel efficiency

Using the intelligent tester.

1. Register transmitter IDs 2. Initialize tire pressure warning system

S When DTC detection conditions of “transmitter ID not received” DTC are met, TPWS indicator blinks for 1 minute, and then illuminates S Tire pressure monitoring function

—

Tire pressure warning valve and transmitter

1. Register transmitter IDs 2. Initialize tire pressure warning system

1. When DTC detection conditions of “transmitter ID not received” DTC are met, TPWS indicator blinks for 1 minute, and then illuminates 2. Tire pressure monitoring function of replaced wheel

Even if only one wheel is replaced, IDs for all 4 wheels must be registered.

Brake actuator assembly (Skid control ECU)

Perform yaw rate and acceleration sensor zero point calibration

S VSC OFF indicator light blinks S VSC disabled or malfunctioning

Perform yaw rate and acceleration sensor zero point calibration with the ignition switch on (engine stopped).

S Yaw rate and acceleration sensor S Front wheel alignment adjustment

1. Clear zero point calibration data 2. Perform yaw rate and acceleration sensor zero point calibration

S VSC OFF indicator light blinks S VSC disabled or malfunctioning

Perform yaw rate and acceleration sensor zero point calibration with the ignition switch on (engine stopped).

S Power steering ECU (*2) S Steering column (*2)

Perform rotation angle sensor initialization and torque sensor zero point calibration.

S P /S warning light comes on S EPS control

DTC (C1515 /C1525) will be stored when the power steering ECU is replaced.

Power steering ECU (*3)

1. Assist map writing 2. Torque sensor zero point calibration

S P /S warning light comes on S EPS control

DTC (C1515 /C1525) will be stored when the power steering ECU is replaced.

Steering column (*3)

Torque sensor zero point calibration

Steering effort is different between turning steering wheel to left and right

ECM

S Automatic transmission assembly (*1) S Engine assembly (*1)

Tire pressure warning ECU

Using the Techstream.

—

INTRODUCTION

Replacement Part

Necessary Procedure

Effect/Inoperative Function When Necessary Procedures are not Performed

IN-5

Note

S Door control transmitter (*5) S Door control receiver (*5)

1. Perform identification code registration (key code) 2. Refer to wireless door lock control system “REGISTRATION” procedures

wireless door lock control system

—

Steering lock actuator (Steering lock ECU) (*4)

ECU code registration

Engine start

—

S Certification ECU (*4) S Electrical key transmitter (*4)

Key ID registration

S Wireless door lock control system S Smart key system S Engine start

—

ID code box (*4)

1. ECU code registration 2. ECU communication ID registration

S Wireless door lock control system S Smart key system S Engine start

—

S Perform zero point calibration S Registration ECU data

S Occupant classification system S Passenger airbag ON /OFF indicator S Airbag system (Front passenger side) S Seat belt warning system (Front passenger side)

—

Perform sliding roof drive gear reset.

S Automatic open/close function of roof glass S Jam protection function S Operation function after ignition switch off

Occupant classification ECU

S Sliding roof drive gear (Sliding roof ECU) S Sliding roof housing S Sliding roof drive cable

*1: *2: *3: *4: *5:

for U341E, U250E Automatic Transaxle for 2AZ−FE for 2ZR−FE w/ Smart Key System w/o Smart Key System

Necessary when removed and installed (Not necessary when the sliding roof drive gear (sliding roof ECU) is removed and installed together with the sliding roof housing.)

INTRODUCTION

IN-5

PRECAUTION 1. WORK PRECAUTIONS Glass Cover

(a) VEHICLE PROTECTION (1) When welding, cover glass, seats, carpets, etc. with heat resistant fireploof covers to protect them.

Seat Cover F33000

(b) SAFETY (1) Never stand in the path of the chain when using a puller on the body or frame, and be sure to attach a safety cable.

WRONG

F33001

(2) If it is necessary to use a frame in the area of the fuel tank, first remove the tank and plug the fuel line.

WRONG

F33002

(c) SAFETY WORK CLOTHES (1) In addition to the usual mechanic’s wear, cap and safety shoes, the appropriate gloves, head protector, welder’s glasses, ear plugs, face protector, dust mask, etc. should be worn as the situation demands.

F33003

Code

Name

Dust mask

Face protector

Safety glasses

Safety shoes

Welder’s glasses

Ear plugs

Head protector

Welder’s gloves

IN-6

INTRODUCTION

2. PRECAUTIONS WHEN REPAIRING BODY FRAME PARTS (INCLUDING CRUSH BOX)

(a) PROHIBITION OF HEAT REPAIR FOR BODY FRAME PARTS

F33014

(1) Rustproof high strength steel sheets are used for the body frame. Therefore, if these parts are heat repaired using an acetylene torch or equivalent, the crystalline structure changes, causing the strength of the steel sheets to decrease. Also, the zinc corting which is used to protect the body from rust will be damaged. This causes the surface of the steel sheets to become oxidized, which reduces their ability to resist rust.

(b) WHEN TO REPLACE FRAME PARTS

F33015

NOTICE: Replace frame parts that have kinks. HINT: What is kink? A deformatision bon a steel sheet that cannot be returned to its original shape by pulling or hammering due to the deformation angle being sharp.

INTRODUCTION

IN-7

(c) REPAIR OF DOOR SIDE IMPACT BEAM IS PROHIBITED (1) The impact beam is desined so that it performs at 100% in its original shape. However, if the impact beam is repaired, its performance may not be the same as before the accident. PARTS EHICH ARE PROHIBITED TO BE REPAIRED: Door side impact beam F33016

F33017

(d) REPAIR OF BUMPER REINFORCEMENT IS PROHIBITED (1) The bumper reinforcement is designed so that it parforms at 100% in uts original shape. However, if the impact beam is repaired, its performance may not be the same as before the accident. PARTS EHICH ARE PROHIBITED TO BE REPAIRED: Bumper reinforcement F30442

IN-8

INTRODUCTION

3. PRECAUTIONS FOR CORRECT REPAIR

(a) REMOVAL OF ADJACENT COMPONENTS (1) When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage. NOTICE: If the paint film is damaged, make sure to refinish the paint.

F33007

(b) ANTI-RUST TREATMENT BEFORE WELDING (1) Apply welding primer to the contact surfaces of the welding areas to protect them from rust. NOTICE: Do not apply welding primer outside of the contact surfaces.

F33008

(c) MAKING HOLES FOR PLUG WELDING (1) For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding.

Puncher F33009

Thickness of welded portion

Diameter of plug hole

Under 10 mm (0.04 in.)

Over 5 mm (0.20 in.)

1.0 to 1.6 mm (0.04 to 0.06 in.)

Over 6.5 mm (0.26 in.)

1.7 to 2.3 mm (0.07 to 0.09 in.)

Over 8 mm (0.31 in.)

Over 2.4 mm (0.09 in.)

Over 10 mm (0.39 in.)

(d) WELDING PRECAUTIONS

Old Spot Locations

(1) The number of welding spots should be as follows. Spot weld: 1.3 X No. of manufacturer’s spots Plug weld: More than No. of manufacturer’s plugs (2) Spot weld locations Avoid welding over previously welded areas. New Spot Locations F33010

INTRODUCTION

IN-9

8. PRECAUTIONS FOR RESIN PARTS (a) PLASTIC PROPERTIES CHART

(1) When repairing, some parts may be deformed by the heat. Therefore, confirm the properties of the platic parts, and remove parts beforehand as necessary. Code

Material name

Heat* resistant temperature limit _C (_F)

Resistance to alcohol or gasoline

Notes

ABS

Acrylonitrile Butadiene Styrene

80 (176)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid gasoline and organic or aromatic solvents.

AES

Acrylonitrile Ethylene Styrene

80 (176)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid gasoline and organic or aromatic solvents.

ASA

Acrylonitrile Styrene Acrylate

80 (176)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid gasoline and organic or aromatic solvents.

EPDM

Ethylene Propylene

100 (212)

Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts.

Most solvents are harmless but avoid dipping in gasoline,solvents, etc.

Polyamide (Nylon)

80 (176)

Alcohol and gasoline are harmless.

Avoid battery acid.

PBT

Polybutylene Terephthalate

160 (320)

Alcohol and gasoline are harmless.

Most solvents are harmless.

Polycarbonate

120 (248)

Alcohol is harmless.

Avoid gasoline brake fluid, wax, wax removers and organic solvents. Avoid alkali.

Polyethylene

80 (176)

Alcohol and gasoline are harmless.

Most solvents are harmless.

PET

Polyethylene Terephthalate

75 (167)

Alcohol and gasoline are harmless.

Avoid dipping in water.

PMMA

Polymethyl Methacrylate

80 (176)

Alcohol is harmless if applied only for short time in small amounts

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

Polypropylene

80 (176)

Alcohol and gasoline are harmless.

Most solvents are harmless.

PVC

Polyvinylchloride (Vinyl)

80 (176)

Alcohol and Gasoline are harmless. if applied only for short time in small amounts. (e.g., quick wiping to remove grease).

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

TPE

Thermoplastic Elastomer

80 (176)

Alcohol and Gasoline are harmless. if applied only for short time in small amounts. (e.g., quick wiping to remove grease).

Most solvents are harmless but avoid dipping in gasoline, solvents, etc.

TPO

Thermoplastic Olefine

80 (176)

Alcohol and Gasoline are harmless. if applied only for short time in small amounts. (e.g., quick wiping to remove grease).

Most solvents are harmless but avoid dipping in gasoline, solvents, etc.TSOP

INTRODUCTION

IN-10

Code

TSOP

Material name

TOYOTA Super Olefine Polymer

Heat* resistant temperature limit _C (_F)

Resistance to alcohol or gasoline

Notes

80 (176)

Alcohol and gasoline are harmless.

Most solvents are harmless.

* Temperatures higher than those listed here may result in material deformation during repair.

INTRODUCTION

IN-11

Cowl Top Ventilator Louver (PE / PP / TSOP) Headlight (PC / PP)

Front Wiper Blade (PBT / PE) Front Piller Cover (AES)

Antenna (ABSSASA / PC)

Door Outside Handle (PC / PBT)

Emblem (AES / ABS)

Radiator Grille (TSOP) Front Bumper Cover (TSOP)

Front Spoiler Cover (PP)

Body Rocker Panel Moulding (TSOPSPP) Outer Rear View Mirror (ASA / PBT / ABSSPA / PE / PET / PBT)

Foglight (ASA / PBT)

/ Made up of 2 or more kinds of materials. S Resin material differs with model. B0709140118B

INTRODUCTION

IN-12

Roof Drip Side Finish Moulding (TPE)

Rear Combination Light (ASA / PMMA)

Door Belt Moulding (EPDM / PP)

Luggage Compartment Door Outside Garnish (ABS) Emblem (ABS)

Emblem (ABS) Licence Plate Light (PA / PC)

Rear Spoiler (ABS)

Rear Bumper Cover (TSOP)

Reflex Refrector (ABS / PMMA)

High Mount Stop Light (ABS / PMMA)

Rear Under Spoiler (TSOP) / Made up of 2 or more kinds of materials. S Resin material differs with model. B0709140120

INTRODUCTION

IN-13

ABOUT THIS VEHICLE

1. STRUCTURAL OUTLINE

Laser Welding Adhesive Application Area

. . . Formed material application areas (refer to PC-8)

B0706260033

IN-14

INTRODUCTION

. . . 980 MPa Ultra High stregth steel . . . 590 MPa High stregth steel . . . 440 MPa High stregth steel . . . 370 MPa High stregth steel . . . 340 MPa High stregth steel

B0710190003

INTRODUCTION

IN-15

2. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE (a) NOTICE FOR USING JACK AND SAFETY STAND

Front of vehicle

Remove the jack attachment from the the spare tire cover in the trunk, then, align the concave portion with the rear jack position and jack up the vehicle. NOTICE: Set the jack attachment with the arrow facing towards the front of the vehicle.

: JACK POSITION : SUPPORT POSITION, PANTOGRAPH JACK POSITION : VEHICLE CENTER OF GRVITY (unloaded condition)

B0709140118A

IN-16

INTRODUCTION

(b) NOTICE FOR USING SWING ARM TYPE LIFT

Center of Lift Rubber Attachment

: VEHICLE CENTER OF GRAVITY (unloaded condition)

B0701260007

INTRODUCTION

IN-17

Attachment

Attachment Dimensions 85 mm (3.35 in.)

70 mm (2.76 in.) 100 mm (3.94 in.)

200 mm (7.87 in.)

Right and left set position

S Place the vehicle over the center of the lift.

Front and rear set position

S Align the cushion ends of the plate with the attachment lower ends (A and C). S Align the attachment upper end (B) with the rocker flange front side notch.

B0701260008

IN-18

INTRODUCTION

3. DAMAGE DIAGNOSIS

Confirmation Point

Collision Direction

Collision Force Absorption Direction

Head-on Collision: Front Body Pillar Upper Reinforcement

Rocker Panel Reinforcement

Front Bumper Reinforcement Side Collision:

Front Side Member

Roof Reinforcement

Floor Cross Member

Center Pillar Reinforcement

B0706260035

INTRODUCTION

IN-19

4. COMPONENTS (a) Front bumper

FRONT BUMPER SIDE SUPPORT RH

FRONT BUMPER ENERGY ABSORBER

FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY 36 (367,27) RADIATOR GRILLE PROTECTOR

FRONT BUMPER SIDE SUPPORT LH

FRONT BUMPER ASSEMBLY

CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B0710120001B

INTRODUCTION

IN-20

(b) Side Mudguard

SIDE MUDGUARD

for Sport Package:

ROCKER PANEL REAR MOULDING RETAINER ROCKER PANEL FRONT MOULDING RETAINER

NO. 2 MOULDING TAPE

NO. 1 MOULDING TAPE

SIDE MUDGUARD

Non-reusable part

B192955E01

INTRODUCTION

IN-21

REAR BUMPER SIDE SUPPORT RH NO. 2 REAR BUMPER SIDE SUPPORT RH REAR BUMPER ARM LH

REAR BUMPER SIDE SUPPORT LH 36 (367, 27)

REAR BUMPER ARM RH

36 (367, 27)

REAR UPPER BUMPER RETAINER RH NO. 1 REAR BUMPER REINFORCEMENT REAR BUMPER ENERGY ABSORBER

NO. 2 REAR BUMPER SIDE SUPPORT LH 36 (367, 27)

REAR UPPER BUMPER RETAINER LH

REAR BUMPER ASSMBLY w / Rear Fender Mudguard:

REAR QUARTER PANEL MUDGUARD LH

REAR QUARTER PANEL MUDGUARD RH

CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B0710120002

INTRODUCTION

IN-22

(d) Door

FRONT DOOR INNER GLASS WEATHERSTRIP

FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

w / o Power Window: FRONT ARMREST UPPER BASE PANEL

FRONT DOOR INSIDE HANDLE BEZEL

FRONT DOOR REGULATOR INSIDE HANDLE PLATE

SNAP RING FRONT DOOR TRIM BOARD SUB-ASSEMBLY

FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY

w / Power Window:

FRONT ARMREST UPPER BASE PANEL

B0707100004A

INTRODUCTION

IN-23

REAR DOOR INNER GLASS WEATHERSTRIP

REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

REAR DOOR INSIDE HANDLE BEZEL

REAR DOOR TRIM BOARD SUB-ASSEMBLY

w / Power Window:

w / o Power Window: REAR DOOR ARMREST UPPER BASE PANEL

PLATE

REAR DOOR ARMREST UPPER BASE PANEL

SNAP RING REAR DOOR WINDOW REGULATOR HANDLE ASSEMBLY

B0707100005A

IN-24

INTRODUCTION

w / Rear Spoiler:

REAR SPOILER ASSEMBLY

LIGGAGE COMPARTMENT DOOR COVER

B0707100006

INTRODUCTION

IN-25

(e) Cowl Top Ventilator Louver

FRONT WIPER ARM HEAD CAP 26 (265, 19) 26 (265, 19)

FRONT WIPER ARM AND BLADE ASEMBLY RH

FRONT WIPER ARM AND BLADE ASEMBLY LH

HOOD TO COWL TOP SEAL

CENTER NO. 1 COWL TOP VENTILATOR LOUVER

COWL TOP VENTILATOR LOUVER LH

5.5 (56, 49 in.*lbf)

WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B0707100007

INTRODUCTION

IN-26

(f) Instrument panel

COMBINATION METER ASSEMBLY

INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY

CENTER INSTRUMENT PANEL REGISTER ASSEMBLY INSTRUMENT PANEL FINISH PANEL END RH INSTRUMENT PANEL FINISH PANEL END LH

STEERING PAD

w / Navigation System:

STEERING WHEEL ASSEMBLY

50 (510, 37) CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY LOWER NO.2 STEERING WHEEL COVER 8.8 (90, 78 in..ibf) LOWER NO.3 STEERING WHEEL COVER NAVIGATION RECEIVER WITH BRACKET w / o Navigation System: TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY UPPER STEERING COLUMN COVER

RADIO RECEIVER WITH BRACKET

LOWER STEERING COLUMN COVER

CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft..lbf) : Specified torque B0710150022

INTRODUCTION

IN-27

w / Curtain Shield Airbag: w / Curtain Shield Airbag:

FRONT PILLAR GARNISH CLIP

FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH

SIDE INSTRUMENT PANEL RH

20 (204, 15) SIDE INSTRUMENT PANEL LH

UPPER INSTRUMENT PANEL SUB-ASSEMBLY

NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY

NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY

LOWER INSTRUMENT PANEL FINISH PANEL LH LOWER INSTRUMENT PANEL FINISH PANEL RH

NO. 1 INSTRUMENT PANEL BOX DOOR SUB-ASSEMBLY

LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY GLOVE COMPARTMENT DOOR ASSEMBLY CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. Non-reusable part N.m (kgf.cm, ft..lbf) : Specified torque B0710150023

INTRODUCTION

IN-28

for Automatic Transaxle:

for Manual Transaxle:

SHIFT LEVER KNOB SUB-ASSEMBLY

SHIFT LEVER KNOB SUB-ASSEMBLY INSTRUMENT PANEL BOX ASSEMBLY

CENTER NO. 1 INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY

FRONT NO. 2 CONSOLE BOX INSERT

FRONT NO. 1 CONSOLE BOX INSERT for Automatic Transaxle:

CONSOLE BOX ASSEMBLY

CONSOLE BOX CARPET

UPPER CONSOLE PANEL SUB-ASSEMBLY

for Manual Transaxle:

CONSOLE BOX ASSEMBLY

B0710150026

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