Toyota Corolla Repair Manual: 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.
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4 |
Preparation of tools and
measuring gauge |
- Before starting operation, prepare a tool stand, sst, gauge,
oil, shop rag and parts for replacement
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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.
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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.
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(B) jacking up and supporting vehicle
- 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
- Precoated parts are bolts, nuts, etc. That are coated
with a seal lock adhesive at the factory.
- If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
- 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.
- 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.
- Gaskets
(1) when necessary, use a sealer on gaskets to prevent leaks.
- bolts, nuts and screws
(1) carefully observe all the specifications for tightening torques. Always
use a torque wrench.
- 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.
- 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.
- 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.
- 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) |
Hint:
the vehicle is equipped with an srs (supplemental restraint system), such as the
horn button assembly,
the instrument panel passenger airbag assembly, the front seat airbag assembly,
the c ...
Other materials:
Side mudguard sub–assy lh
Replacement
Hint:
use the same procedures for the rh side and lh side.
1. Remove side mudguard sub–assy lh
Using a clip remover, remove the 8 retainers and 9 clips.
using a moulding remover, remove the mudguard.
2. Install side mudguard sub–assy lh
Install the mudguard ...
On–vehicle inspection
1. Inspect cooling system for leaks
Caution:
to avoid the danger of being burned, do not remove the radiator
cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
fill the radiator with coolant and attach a radiator cap tester.
  ...
Terminals of ecu
Oscilloscope wave (*1)
Hint:
terminal: od – gnd
gauge set: 5 v / div, 50 ms / div
condition: during cruise control driving o/d switch on.
...