2009 2012 toyota corolla body repair manual sua chua than vo

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This repair manual has been prepared to provide essential formation on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA COROLLA

in-Applicable models: AZE141 series

ZRE142 series This manual consists of body repair methods, exploded dia- grams 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 fend- ers of the TOYOTA model is bolted on and require no welding When repairing, don’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 tions and country of destination Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations.

specifica-For the repair procedures and specifications other than damaged body components of the TOYOTA COROLLA refer to the repair manuals.

collision-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.

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ABOUT THIS MANUAL

Scope of the repair work explanation

S This text explains the welding panel replacement instructions from the vehicle’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.

Views of weld panel replacement instructions

PrecautionAbout this vehicle

BODY PANEL REPLACEMENT

Instructions for replacing the weld panelsfrom the white body condition, from whichbolted parts have been removed, withindividual supply parts

Front side member replacement

Quarter panel replacement

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

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Under Surface of The Rocker Panel

Imaginary Datum Line

Center-to-center straight-line distance

direc-S The height from an 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 tance Therefore, please use the dimensions as a reference.

dis-(d) The line that connects the places listed below is the nary datum line when measuring the height (The dimensions are printed in the text.)

1 The place that was lowered A mm from the under surface of

the rocker panel centered on the front jack up point

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

3 The place that was lowered C mm from the under surface of

the rocker panel centered on the rear jack up point

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Plate LoosenessBody Looseness

Pointer LoosenessPointer

Master Gauge

Pointer

BODY DIMENSIONS DI-2

2 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.

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.

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

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Front cross member side gusset standard holeHood lock support brace installation nutFront fender extension standard holeRadiator upper support installation nutRadiator upper support installation nut

Front apron to cowl side membe upper standard hole

Front fender installation nut

–

ø10 (0.39)M6 (0.24)ø10 (0.39)M6 (0.24)M6 (0.24)ø10 (0.39)M6 (0.24)–

Front fender installation nut

Front suspension support installation hole-inner

Hood hinge installation nut-erar

Cowl top panel center mark

Front side member standard hole

Engin mounting installation nut

Radiator support standard hole

M6 (0.24)ø11 (0.43)M8 (0.31)–ø18 (0.71)ø12 (0.47)M12 (0.47)ø10 (0.39)

A,a C,c L,l

700 783 666 (27.56) (30.83) (26.22)

Height from Imaginary Datum Line

HINT: For symbols, capital letters indicate right side of vehicle,

small letters indicate left side of vehicle (seen from rear)

568 (22.36)

845 (33.27)

937 (36.89)

519 (20.43)

638 (25.12)

592 (23.31)

728 (28.66)

906 (35.67)

728 (28.66)

960 (37.80)

534 (21.02) 908 (35.75) 486 (19.13)

604 (23.78)

269 (10.59)

339 (13.35)

891 (35.08)

501 (19.72)

929 (36.57)

830 (32.68)

1,575 (62.01)

1,023 (40.28)

1,456 (57.32)

1,038 (40.87)

1,010 (39.76)

BODY DIMENSION DRAWINGS

ENGINE COMPARTMENT

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Rocker panel assembly markRoof side rail assembly markCenter body pillar assembly markCenter body pillar assembly markFront door lock striker installation nutRear door hinge installation nutRear door hinge installation nut

Roof panel corner

Hood hinge installation nut-rear

Front door hinge installation nut

Front body pillar assembly mark

Rocker panel assembly mark

ĊM8 (0.31)M8 (0.31)M8 (0.31)ĊĊĊ

1,456 (57.32)

919 (36.18) 1,561 (61.46)

775 (30.51)

1,092 (42.99)

861 (33.90)

813 (32.01) (47.91) 1,217

986 (38.82)

1,016 (40.00)

877 (34.53) 857 (33.74)

1,109 (43.66)

BODY OPENING AREAS (Side View: Front)

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Rocker panel assembly mark

Rear door hinge installation nut

Center body pillar assembly mark

ĊM8 (0.31)M8 (0.31)ĊĊ

ĊĊĊĊM8 (0.31)

1,062 (41.81)

671 (26.42)

981 (38.62) 999 (39.33) (37.28) 947

838 (32.99)

BODY OPENING AREAS (Side View: Rear)

Sedan

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Roof panel corner

Quarter panel standard hole

Quarter panel / upper back panel adjoining portion

Ċ

ĊĊ

Quarter panel standard hole

Rear suspension installation holeCenter body pillar assembly mark

ø13 (0.51)Ċø16 (0.63)Ċ

Quarter panel end housing / Luggage compartment opening

trough adjoining portion

13.5 x 10.5 (0.53 x 0.41)

841 (33.11)

1,240 (48.82)

984 (38.74)

1,035 (40.75)

479 (18.86)

1,386 (54.57)

1,189 (46.81)

862 (33.94)

1,172 (46.14)

922 (36.30)

1,474 (58.03)

1,284 (50.55)

1,144 (45.04)

1,103 (43.43)

1,200 (47.24)

Quarter panel end housing / Body lower back panel adjoining portion

BODY OPENING AREAS (Rear View)

Sedan

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Engine mounting center member installation nut

Front suspension crossmember installation nut

Front floor under reinforcement standard hole

M10 (0.39)ø18 (0.71)M14 (0.55)M14 (0.55)ø18 (0.71)ø10 (0.39)

HINT:

1) For symbols, capital letters indicate right side of vehicle,

2) Point A,a, B,b, I,i on the vehicle are asymmetrical

Symbol Name Hole dia.

G, g

H, h

I, iJ

K, k

L, l

Rear floor side front member standard holeTrailing arm installation hole

Rear floor NO 2 crossmember standard hole

Rear floor centermember NO 4 reinforcement standard hole

Rear floor side rear member standard holeTransport hook installation hole-rear

ø25 (0.98)ø13 (0.51)ø10 (0.39)ø8 (0.31)ø15 (0.59)

1 2 3

100 100 100 (3.94) (3.94) (3.94)

RH

LH

Front

ImaginaryDatum Line

1,263 (49.72)

985

(49.29) 786

(30.94)

1,538 (60.55)

840 (33.07)

1,223 (48.15)

890 (35.04)

1,228 (48.35)

400 (15.75)

1,282 (50.47)

870 (34.25)

1,147 (45.16)

870

455 (17.91)

1,129 (44.45)

1,035 (40.75)

641 (25.24)

730 (28.74)

912 (35.91)

839 (33.03)

966 (38.03)

860 (33.86)

835 (32.87)

641 (25.24) 656

(25.83)

754 (29.68)

874 (34.41)

1,547 (60.91)

D,d 91 (3.58)

E,e 57 (2.24)

F,f 48 (1.89)

G,g 146 (5.75)

H,h 123 (4.84)

I,i 307 (12.09) J 119 (4.69)

K,k 297 (11.69)

L,l 271 (10.67)

19 x 16 (0.75 x 0.63)

UNDER BODY

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Engine mounting center member installation nut

Front suspension support installation hole

Front side member standard holet

Front floor under reinforcement standard hole

M10 (0.39)ø18 (0.71)M14 (0.55)ø11 (0.43)M14 (0.55)ø18 (0.71)ø10 (0.39)

H, h

I, i

J, j

K, kL

Rear floor centermember NO 4 reinforcement standard hole

Rear floor side rear member standard holeTransport hook installation hole-rea

ø25 (0.98)ø13 (0.51)ø10 (0.39)ø15 (0.59)ø8 (0.31)ø15 (0.59)

1 2 3

100 100 100 (3.94) (3.94) (3.94) Wheel base 2,600 (102.36)

RH

LH

Front

ImaginaryDatum Line

2,064

(81.26)

986 (38.82) 1,542

20

(0.79)

1,125 (44.29)

2,064

(81.26)

485 (19.09)

1,539 (60.59)

80

(3.15)

0

445 (17.52)

435 (17.13)

614 (24.17)

238 (9.37)

437 (17.20)

435 (17.13) 626

(24.65)

536 (21.10)

1,038 (40.87)

1,760 (69.29)

435 (17.13)

512 (20.16)

265 (10.43)

67 (2.64)

517 (20.35)

E,e 91 (3.58)

F,f 57 (2.24)

G,g 48 (1.89)

H,h 146 (5.75)

I,i 123 (4.84) J,j 307 (12.09)

K,k 404 (15.91) L 119 (4.69)

M,m 297 (11.69)

N,n 271 (10.67)

19 x 16 (0.75 x 0.63)

HINT:

2) Point A,a, B,b, J,j on the vehicle are asymmetrical

UNDER BODY

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Lower arm installation hole

Front suspension crossmember installation hole

ø15.5 (0.61)ø22 (0.87)

Front

ImaginaryDatum Line

689 (27.13)

912 (35.91)

309 (12.17)

335 (13.19)

660 (25.98) 354 (13.94)

890 (35.04)

639 (25.16)

952 (37.48)

306 (12.05)

B,b 194 (7.64)

A,a 89 (3.50)

C,c 67 (2.64)

D,d 73 (2.87)

FRONT SUSPENSION CROSSMEMBER

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Lower arm installation hole

Front suspension crossmember installation hole

ø15.5 (0.61)ø22 (0.87)

C, c

D, d

ø13 (0.51)ø20 (0.79)

ImaginaryDatum Line

456 (17.95)

177 (6.97) (6.97) 177

445 (17.52)

344 (13.54)

0

D,d 148 (5.83)

B,b 194 (7.64)

A,a 89 (3.50)

C,c 67 (2.64)

D,d 73 (2.87)

Front

Lower arm installation holeFront suspension crossmember installation hole

FRONT SUSPENSION CROSSMEMBER

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Front bumper cover installation bolt

Headlight installation bolt

ĊĊ

HINT:

2) These values are actual measurements made on model Use these reference values

1,542 (60.71)

627 (24.68)

1,517 (59.72)

316 (12.44)

1,537 (60.51)

987 (38.86)

1,482 (58.35)

627 (24.68) 1,375

(54.13) (58.19) 1,478

1,375 (54.13)

339 (13.35)

REFERENCE VALUE

ENGINE COMPARTMENT

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Center member installation bolt

Front suspension crossmember installation bolt

––

912 (35.91)

890 (35.04)

966 (38.03)

870 (34.25)

1,048 (41.26)

726 (28.58)

1,402 (55.20)

978 (38.50)

1,352 (53.23)

HINT:

2) These values are actual measurements made on model Use these reference values

UNDER BODY

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Unit: mm

(Two-Dimensional Distance)

Front suspension support

Front bumper reinforcement

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MEMO

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4 ANTI-RUST TREATMENT AFTER INSTALLATION

(a) BODY SEALER APPLICATION

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.

(c) VEHICLE BODY ANTI-RUST AGENT APPLICATION

PURPOSE:

The purpose is to protect areas from rust which are ficult to paint such as the backside of the box-shaped cross section frame parts.

dif-METHOD:

Apply anti-rust agent through the service holes and/or installation holes of the parts.

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5 HEADLIGHT BRACKET REPAIR

HINT:

S If the installation area of the headlight assembly is damaged, use the supply retainer for low-cost repair.

S Ensure that the headlight assembly is not damaged.

(a) INSTALL UPPER HEADLIGHT PROTECTOR RETAINER

(1) Cut off the part shaded in the illustration and smooth with sandpaper.

NOTICE:

After cutting off the part, place the upper light protector retainer against the bosses and gradually file away the old bracket if it interferes with the installation of the supply bracket.

head-(2) Install the upper headlight protector retainer with the

(2) Install the lower headlight protector retainer with the 2 screws.

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E160572

(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.

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

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INTRODUCTION IN-4

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

S Wireless door lock control system(*4)

S Smart key system (*4)

S Engine start

—

S The deterioration of fuel

S Automatic transmission

assembly (*1)

S Large shift shock

S The deterioration of fuel

Tire pressure warning ECU 1 Register transmitter IDs2 Initialize tire pressure

warning system

S When DTC detection conditions

of “transmitter ID not received”

DTC are met, TPWS indicatorblinks for 1 minute, and then illuminates

S Tire pressure monitoring function

—

Tire pressure warning valve

and transmitter

1 Register transmitter IDs

2 Initialize tire pressurewarning system

1 When DTC detection conditions

of “transmitter ID not received”

DTC are met, TPWS indicatorblinks for 1 minute, and then illuminates

2 Tire pressure monitoring function

of replaced wheel

Even if only one wheel isreplaced, IDs for all 4wheels must be registered

Brake actuator assembly

(Skid control ECU)

Perform yaw rate and acceleration sensor zeropoint calibration

S VSC OFF indicator light blinks

S VSC disabled or malfunctioning

Perform yaw rate and acceleration sensor zeropoint calibration with theignition switch on (enginestopped)

S Yaw rate and

S VSC OFF indicator light blinks

S VSC disabled or malfunctioning

Perform yaw rate and acceleration sensor zeropoint calibration with theignition switch on (enginestopped)

S Power steering ECU (*2)

S Steering column (*2)

Perform rotation angle sensor initialization andtorque sensor zero pointcalibration

S P/S warning light comes on

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Replacement Part Necessary Procedure

Effect/Inoperative Function When Necessary Procedures are not Performed

2 Refer to wireless doorlock control system

“REGISTRATION”

procedures

Steering lock actuator

S Certification ECU (*4)

S Electrical key transmitter

S Wireless door lock control system

S Smart key system

ID code box (*4) 1 ECU code registration2 ECU communication ID

registration

S Wireless door lock control system

S Smart key system

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)

—

S Sliding roof drive gear

(Sliding roof ECU)

S Sliding roof housing

S Sliding roof drive cable

Perform sliding roof drivegear reset

S Automatic open/close function ofroof glass

S Jam protection function

S Operation function after ignitionswitch off

Necessary when removedand installed (Not necessary when the slidingroof drive gear (sliding roofECU) is removed andinstalled together with thesliding roof housing.)

*1: for U341E, U250E Automatic Transaxle

*2: for 2AZ−FE

*3: for 2ZR−FE

*4: w/ Smart Key System

*5: w/o Smart Key System

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(a) VEHICLE PROTECTION

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

(b) SAFETY

(1) Never stand in the path of the chain when using a

pull-er on the body or frame, and be sure to attach a safety cable.

(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.

(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.

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F33015

2 PRECAUTIONS WHEN REPAIRING BODY FRAME PARTS

(INCLUDING CRUSH BOX)

(a) PROHIBITION OF HEAT REPAIR FOR BODY FRAME PARTS

(1) Rustproof high strength steel sheets are used for the body frame Therefore, if these parts are heat re- paired 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 sist rust.

re-(b) WHEN TO REPLACE FRAME PARTS

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 formation angle being sharp.

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Old Spot Locations

New Spot Locations

IN-8

3 PRECAUTIONS FOR CORRECT REPAIR

(a) REMOVAL OF ADJACENT COMPONENTS

(1) When removing adjacent components, apply tive tape to the surrounding body and your tools to prevent damage.

protec-NOTICE:

If the paint film is damaged, make sure to refinish the paint.

(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 tact surfaces.

con-(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.

Thickness of welded portion Diameter of plug hole

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.)

(d) WELDING PRECAUTIONS

(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.

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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

ABS Acrylonitrile Butadiene

Styrene

80(176)

Alcohol is harmless if applied onlyfor short time in small amounts(e.g., quick wiping to removegrease)

Avoid gasoline and organic

or aromatic solvents

AES Acrylonitrile Ethylene Styrene (176)80

ASA Acrylonitrile Styrene

Acrylate

80(176)

EPDM Ethylene Propylene (212)100 Alcohol is harmless Gasoline isharmless if applied only for short

time in small amounts

Most solvents are harmlessbut avoid dipping in gasoline,solvents, etc

PBT Polybutylene Terephthalate (320)160 Alcohol and gasoline are harmless Most solvents are harmless

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

Avoid alkali

PET Polyethylene Terephthalate (167)75 Alcohol and gasoline are harmless Avoid dipping in water.PMMA Polymethyl Methacrylate (176)80 Alcohol is harmless if applied onlyfor short time in small amounts Avoid dipping or immersingin alcohol, gasoline,

solvents, etc

PVC Polyvinylchloride (Vinyl) (176)80

Alcohol and Gasoline are harmless

if applied only for short time in smallamounts (e.g., quick wiping to remove grease)

Avoid dipping or immersing

in alcohol, gasoline, solvents, etc

TPE Thermoplastic Elastomer (176)80

Most solvents are harmlessbut avoid dipping in gasoline, solvents, etc

TPO Thermoplastic Olefine (176)80

Most solvents are harmlessbut avoid dipping in gasoline, solvents,etc.TSOP

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Code Material name

Heat*

resistant temperature limit _C (_F)

Resistance to

TSOP TOYOTA Super Olefine

Polymer

80(176) Alcohol and gasoline are harmless. Most solvents are harmless.

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

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/ Made up of 2 or more kinds of materials

S Resin material differs with model

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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

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Formed material application areas (refer to PC-8)

Laser WeldingAdhesive Application Area

ABOUT THIS VEHICLE

1 STRUCTURAL OUTLINE

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B0710190003

590 MPa High stregth steel

980 MPa Ultra High stregth steel

IN-14

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: JACK POSITION

: VEHICLE CENTER OF GRVITY (unloaded condition)

: SUPPORT POSITION, PANTOGRAPH JACK POSITION

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

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(b) NOTICE FOR USING SWING ARM TYPE LIFT

Tiêu đề	2009 2012 Toyota Corolla Body Repair Manual Sua Chua Than Vo
Thể loại	repair manual

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