Toyota Corolla (E120) 2002–2008 Repair Manual / Introduction / Repair instruction / Precaution / Basic repair hint

Toyota Corolla (E120): Basic repair hint

(A) hints on operations

1	Looks	Always wear a clean uniform. Hat and safety shoes must be worn.
2	Vehicle protection	Set a grill cover, fender cover, seat cover and floor mat before starting the operation.
3	Safe operation	In case of working with 2 or more persons, be sure to check safety of one another. When working with the engine running, pay attention to the ventilation of the workshop. In case of operating on high–temperature parts, rotating, moving and vibrating parts, pay attention not to burn or injure yourself. When jacking up the vehicle, be sure to support the specified location with a safety stand. When lifting up the vehicle, apply a safety equipment.
4	Preparation of tools and measuring gauge	Before starting operation, prepare a tool stand, sst, gauge, oil, shop rag and parts for replacement
5	Removal and installation, disassembly and assembly operations	Diagnose with a thorough understanding of the trouble phenomenon and perform effective operations. Before removing the parts, check the assembly for general condition, deformation and damage. When the structure is complicated, take a note or put match marks so as not to make mistakes that affect the function of the parts. Clean and wash the removed parts if necessary, and assemble them after a thorough check.
6	Removed parts	Place the removed parts in the correct order to avoid mixing up or making them dirty. As for non–reusable parts such as gasket, o–ring, and self lock nut, change them to new ones following the instruction of this manual. Sort out the parts for replacement in a box and show them to the customer.

(B) jacking up and supporting vehicle

1. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations

(C) precoated parts

1. Precoated parts are bolts, nuts, etc. That are coated with a seal lock adhesive at the factory.
2.  If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive.
3.  When reusing precoated parts, clean off the old adhesive and dry the part with compressed air.

   Then apply the specified seal lock adhesive to the bolt, nut or threads.

Notice

: perform the torque checking with the lower limit value of the torque tolerance.

4. Depending on the seal lock agent to apply, there may be a case where it is necessary to leave it for a specified time until it hardens.

4. Gaskets
   (1) when necessary, use a sealer on gaskets to prevent leaks.
5.  bolts, nuts and screws (1) carefully observe all the specifications for tightening torques. Always use a torque wrench.
6.  fuses.

   (1) When replacing fuses, be sure that a new fuse has the correct amperage rating. Do not exceed the rating, or use one with a lower rating.

7. Clips
   (1) the removal and installation methods of typical clips used in body parts are shown in the table below.

Hint

: if the clip is damaged during the a procedure, always replace it with a new clip.

8. Removal and installation of vacuum hoses (1) to disconnect vacuum hoses, pull them by holding the end, not the middle of the hose.

(2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected.

(3) After completing the job, make a double check whether the vacuum hoses are properly connected.

A label under the hood shows the proper layout.

(4) When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step–down adapter for adjustment. Once the hose has been stretched, it may leak air.

9. Torque when using torque wrench with extension tool (1) in case of tightening with a torque wrench which has an extended length by combining the torque wrench with sst or extension tool, if you tighten until the reading of the torque wrench reaches the specified torque value, the actual torque becomes excessive.

   (2) In this manual, only the specified torque is described.

   In case of using sst or an extension tool, calculate the reading of the torque wrench by the following formula.

   (3) Formula t’=t x l2/(l1 + l2)

T’	Reading of torque wrench {nvm (kgf·cm, ftvlbf)}
T	Torque {nvm (kgf·cm, ftvlbf)}
L1	Length of sst or extension tool (cm)
L2	Length of torque wrench (cm)