Audi A6 1900, Corolla 2010, Corolla 2009 User Manual

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, 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 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 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.

Section Title Contents Examples

INTRODUCTION

BODY PANEL REPLACEMENT

BODY DIMENSIONS Body aligning measurements. Dimension diagrams.

PAINT S COATING

Explanation of general body repair.

Views of weld panel replacement instructions.

Instructions for replacing the weld panels

from the white body condition, from which

bolted parts have been removed, with

individual supply parts.

Scope and type of anti-rust treatment, etc.

together with weld panel replacement.

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

Precaution

About this vehicle

Front side member replacement.

Quarter panel replacement.

Body sealer.

Under coat.

BODY DIMENSIONS

DI-1

Three-dimensional distance

Two-dimensional distance

Vertical distance in center

A mm B mm

Center-to-center straight-line distance

Center-to-center horizontal distance in forward/

rearward direction

Vertical distance in lower surface

Imaginary Datum Line

Under Surface of The Rocker Panel

C mm

Imaginary Datum Line

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 direc-

tion between the centers of two measuring points.

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 dis-

tance. Therefore, please use the dimensions as a reference.

(d) The line that connects the places listed below is the imagi-

nary datum line when measuring the height. (The dimensions are printed in the text.)

SYMBOL Name

1

2

3

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.

DI-2

BODY DIMENSIONS

Body Looseness

Pointer Looseness

Pointer

Wrong

Pointer

Plate Looseness

Master Gauge

Correct

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.

BODY DIMENSIONS DI-3

BODY DIMENSION DRAWINGS

ENGINE COMPARTMENT

(Three-Dimensional Distance)

568

(22.36)

845

(33.27)

937

(36.89)

1,575

(62.01)

592

(23.31)

501

(19.72)

638

(25.12)

728

(28.66)

929

(36.57)

1,023

(40.28)

906

(35.67)

830

(32.68)

960

(37.80)

519

(20.43)

728

(28.66)

(19.13)

(21.02)

486

891

(35.08)

534

908

(35.75)

1,456

(57.32)

604

(23.78)

1,010

(39.76)

1,038

(40.87)

269

(10.59)

339

(13.35)

Height from Imaginary Datum Line

Vehicle Dimensions

A-n B-c C-l C-M C-m

or or or or or I-j J-j M-m

a-N b-C c-L c-m c-M

1,537 1,250 1,392 263 1,457 852 1,561 1,410

(60.51) (49.21) (54.80) (10.35) (57.36) (33.54) (61.46) (55.51)

N-n or or

L-N L-n

l-n l-N

1,517 747 1,290

(59.72) (29.41) (50.79)

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

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

Symbol Name Hole dia.

A, a

B, b

C, c

D

E, e

F

f

G, g

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)

mm (in.)

Symbol Name Hole dia.

H, h

I

J, j

K, k

L, l

M, m

N, n

–

Front cross member side gusset standard hole

Hood lock support brace installation nut

Front fender extension standard hole

Radiator 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)

ø10 (0.39)

M6 (0.24)

–

BODY DIMENSIONSDI-4

BODY OPENING AREAS (Side View: Front)

(Three-Dimensional Distance)

1,092

775

(30.51)

1,109

(43.66)

(42.99)

861

(33.90)

877

(34.53)

857

(33.74)

813

(32.01)

986

(38.82)

1,016

(40.00)

1,217

(47.91)

1,456

(57.32)

919

(36.18)

1,561

(61.46)

Vehicle Dimensions

E-e F-f G-g H-h I-i J-j K-k L-l

1,327 1,417 1,420 1,418 1,159 1,280 1,448 1,563

(52.24) (55.79) (55.91) (55.83) (45.63) (50.39) (57.01) (61.54)

E-f E-h E-i E-k F-j F-k H-i C-L C-N D-L D-M G-I

or or or or or or or or or or or or

e-F e-H e-I e-K f-J f-K h-I c-l c-n d-l d-m g-i

1,519 1,629 1,389 1,632 1,815 1,670 1,617 1,062 1,101 1,069 1,135 1,104

(59.80) (64.13) (54.68) (64.25) (71.46) (65.75) (63.66) (41.81) (43.35) (42.09) (44.68) (43.46)

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

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

Symbol Name Hole dia.

A, a

B, b

C, c

D, d

E, e

F, f

G, g

Roof panel corner

Hood hinge installation nut-rear

Front door hinge installation nut

Front body pillar assembly mark

Rocker panel assembly mark

Ċ

M8 (0.31)

Ċ

mm (in.)

Symbol Name Hole dia.

H, h

K, k

M, m

N, n

Rocker panel assembly mark

Roof side rail assembly mark

I,i

Center body pillar assembly mark

J, j

Center body pillar assembly mark

Front door lock striker installation nut

L, l

Rear door hinge installation nut

Ċ

M8 (0.31)

BODY DIMENSIONS DI-5

BODY OPENING AREAS (Side View: Rear) Sedan

(Three-Dimensional Distance)

999

(39.33)

(38.62)

1,062

(41.81)

671

(26.42)

981

(32.99)

838

947

(37.28)

Vehicle Dimensions

O-o P-p Q-q R-r S-s T-t U-u

1,280 1,450 1,418 1,145 1,226 1,421 1,526

(50.39) (57.09) (55.83) (45.08) (48.27) (55.94) (60.08)

G-q O-q O-s O-t P-s P-t Q-r S-t N-U

or or or or or or or or or

g-Q o-Q o-S o-T p-S p-T q-R s-T n-u

1,702 1,603 1,421 1,588 1,656 1,559 1,619 1,478 1,066

(67.01) (63.11) (55.94) (62.52) (65.20) (61.38) (63.74) (58.19) (41.97)

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

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

Symbol Name Hole dia.

G, g

M, m

N, n

O, o

Rocker panel assembly mark

Rear door hinge installation nut

Center body pillar assembly mark

P, p

Center body pillar assembly mark

Ċ

M8 (0.31)

Ċ

mm (in.)

Symbol Name Hole dia.

Q, q

R, r

S, s

U, u

Rocker panel notch edge

Roof side rail assembly mark

Quarter panel assembly mark

T, t

Quarter panel assembly mark

Rear door lock striker installation nut

Ċ

M8 (0.31)

BODY DIMENSIONSDI-6

BODY OPENING AREAS (Rear View) Sedan

(Three-Dimensional Distance)

1,035

1,240

(48.82)

(40.75)

1,200

(47.24)

Vehicle Dimensions

D-c

or

d-C

1,284

(50.55)

841

(33.11)

1,474

(58.03)

1,284

(50.55)

1,386

(54.57)

(38.74)

(46.14)

984

1,172

1,189

(46.81)

922

(36.30)

1,103

(43.43)

1,144

(45.04)

862

(33.94)

479

(18.86)

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

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

Symbol Name Hole dia.

A, a

B, b

C, c

D, d

Roof panel corner

Quarter panel standard hole

Quarter panel / upper back panel adjoining portion

Quarter panel end housing / Luggage compartment opening trough adjoining portion

Ċ

13.5 x 10.5

(0.53 x 0.41)

Ċ

mm (in.)

Symbol Name Hole dia.

E, e

G, g

H, h

Quarter panel standard hole

Quarter panel end housing/ Body lower back panel adjoining

F, f

portion

Rear suspension installation hole

Center body pillar assembly mark

ø13 (0.51)

Ċ

ø16 (0.63)

Ċ

UNDER BODY

(Three-Dimensional Distance)

840

(33.07)

BODY DIMENSIONS DI-7

RH

LH

Front

985

(38.78)

(30.94)

786

730

(28.74)

1,263

(49.72)

912

(35.91)

839

(33.03)

1,252

(49.29)

890

(35.04)

400

(15.75)

1,538

(60.55)

966

(38.03)

1,547

(60.91)

870

(34.25)

1,223

(48.15)

860

(33.86)

123

100 100 100

(3.94) (3.94) (3.94)

870

(34.25)

455

(17.91)

1,129

(44.45)

1,228

(48.35)

1,035

(40.75)

656

(25.83)

1,282

(50.47)

835

(32.87)

754

(29.68)

641

(25.24)

874

(34.41)

641

(25.24)

1,147

(45.16)

1,035

(40.75)

A,a 149

(5.87)

B,b 320

(12.60)

C,c

232

(9.13)

D,d

91

(3.58)

E,e

123

57

(2.24)

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.

Symbol Name Hole dia.

A, a

B, b

C, c

D, d

E, e

F, f

Engine mounting center member installation nut

Front side member standard hole

Front suspension crossmember installation nut

Front side member standard hole

Front floor under reinforcement standard hole

M10 (0.39)

ø18 (0.71)

M14 (0.55)

ø18 (0.71)

ø10 (0.39)

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)

Imaginary

L,l

271

(10.67)

Datum Line

mm (in.)

Symbol Name Hole dia.

G, g

H, h

K, k

Rear floor side front member standard hole

Trailing arm installation hole

I,i

Rear floor NO. 2 crossmember standard hole

J

Rear floor centermember NO. 4 reinforcement standard hole

Rear floor side rear member standard hole

L, l

Transport hook installation hole-rear

ø25 (0.98)

ø13 (0.51)

ø10 (0.39)

ø8 (0.31)

19 x 16

(0.75 x 0.63)

ø15 (0.59)

UNDER BODY

BODY DIMENSIONSDI-8

(Two-Dimensional Distance)

2,064

RH

LH

(3.15)

Front

2,162

(85.12)

20

(0.79)

80

2,162

(85.12)

(81.26)

500

(19.69)

485

(19.09)

2,064

(81.26)

1,542

(60.71)

456

(17.95)

626

(24.65)

1,539

(60.59)

Wheel base 2,600 (102.36)

1,258

(49.53)

445

(17.52)

435

(17.13)

860

(33.86)

407

435

(17.13)

435

(17.13)

(16.02)

614

(24.17)

512

(20.16)

599

(23.58)

0

123

100 100 100

(3.94) (3.94) (3.94)

(36.22)

238

(9.37)

265

(10.43)

(38.82)

920

(36.22)

986

1,125

(44.29)

(17.20)

536

(21.10)

1,038

(40.87)

437

67

(2.64)

517

(20.35)

1,760

(69.29)

A,a

149

(5.87)

B,b

320

(12.60)

C,c 232

(9.13)

D,d 736

(28.98)

E,e

91

(3.58)

F, f

1

57

(2.24)

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.

Symbol Name Hole dia.

A, a

B, b

C, c

D, d

E, e

G, g

Engine mounting center member installation nut

Front side member standard hole

Front suspension crossmember installation nut

Front suspension support installation hole

Front suspension crossmember installation nut

F, f

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)

2

G,g

(1.89)

3

48

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)

Imaginary

N,n

271

(10.67)

Datum Line

Symbol Name Hole dia.

H, h

K, k

M, m

N, n

Rear floor side front member standard hole

I,i

Trailing arm installation hole

J, j

Rear absorber mounting member standard hole

Rear spring bracket installation hole

L

Rear floor centermember NO. 4 reinforcement standard hole

Rear floor side rear member standard hole

Transport hook installation hole-rea

ø25 (0.98)

ø13 (0.51)

ø10 (0.39)

ø15 (0.59)

ø8 (0.31)

19 x 16

(0.75 x 0.63)

ø15 (0.59)

mm (in.)

BODY DIMENSIONS DI-9

FRONT SUSPENSION CROSSMEMBER

(Three-Dimensional Distance)

Front

309

(12.17)

335

(13.19)

LH

660

(25.98)

354

(13.94)

689

(27.13)

912

(35.91)

890

(35.04)

639

(25.16)

RH

952

(37.48)

306

(12.05)

B,b 194

(7.64)

A,a

89

(3.50)

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

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

Symbol Name Hole dia.

A, a

Lower arm installation hole

B, b

Front suspension crossmember installation hole

ø15.5 (0.61)

ø22 (0.87)

Imaginary Datum Line

C,c

67

(2.64)

Symbol Name Hole dia.

C, c

D, d

Front suspension crossmember standard hole

Front suspension crossmember installation hole

D,d

73

(2.87)

mm (in.)

ø13 (0.51)

ø20 (0.79)

BODY DIMENSIONSDI-10

FRONT SUSPENSION CROSSMEMBER

(Two-Dimensional Distance)

Front

B,b 136

(5.35)

177

(6.97)

RH

344

(13.54)

445

(17.52)

0

A,a 242

(9.53)

D,d

148

(5.83)

LH

456

(17.95)

0

177

(6.97)

B,b 194

(7.64)

A,a

89

(3.50)

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

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

Symbol Name Hole dia.

A, a

B, b

Lower arm installation hole

Front suspension crossmember installation hole

ø15.5 (0.61)

ø22 (0.87)

Imaginary Datum Line

C,c

67

(2.64)

Symbol Name Hole dia.

C, c

D, d

Lower arm installation hole

Front suspension crossmember installation hole

D,d

73

(2.87)

mm (in.)

ø13 (0.51)

ø20 (0.79)

REFERENCE VALUE

ENGINE COMPARTMENT

(Three-Dimensional Distance)

BODY DIMENSIONS

DI-11

316

(12.44)

627

(24.68)

1,482

(58.35)

1,542

(60.71)

987

(38.86)

1,517

(59.72)

1,375

(54.13)

1,537

(60.51)

1,478

(58.19)

1,375

(54.13)

627

(24.68)

339

(13.35)

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.

A, a

Front bumper cover installation bolt

B, b

Headlight installation bolt

Ċ

Symbol Name Hole dia.

D, d

E, e

Front fender installation bolt

mm (in.)

Ċ

UNDER BODY

(Two-Dimensional Distance)

821

(32.32)

BODY DIMENSIONSDI-12

726

(28.58)

1,048

(41.26)

(55.20)

Vehicle Dimensions

A-B A-b A-C A-c A-D A-d

782 759 1,020 1,002 1,382 1,369

(30.79) (29.88) (40.16) (39.45) (54.41) (53.90)

1,402

912

(35.91)

890

(35.04)

966

(38.03)

870

(34.25)

978

(38.50)

1,352

(53.23)

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.

A, a

B, b

Center member installation bolt

Front suspension crossmember installation bolt

–

Symbol Name Hole dia.

C, c

D, d

Front suspension crossmember installation bolt

Front side member installation hole

mm (in.)

–

ø18 (0.71)

UNDER BODY

(Two-Dimensional Distance)

BODY DIMENSIONS DI-13

Front bumper reinforcement

59.8

[RH]

13.10_

Front suspension support

[LH]

59.8

12.3_

0.4

2.3

66.4

102

3_

32.6

32.3

56.7

57.5

6.6

2.3_

2.3

9.4

13.9

Unit: mm

DI-14

MEMO

INTRODUCTION

4. ANTI-RUST TREATMENT AFTER INSTALLATION

Sealer Gun

F33011

(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.

NOTICE: Apply body sealer neatly to parts that require a high quality appearance.

(b) UNDERCORT APPLICATION

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

IN-1

F33012

F33013

(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.

INTRODUCTIONIN-2

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 headlight protector retainer against the bosses and gradually file away the old bracket if it interferes

E163300

with the installation of the supply bracket.

(2) Install the upper headlight protector retainer with the

2 screws.

E163301

E160571

E160570

(b) INSTALL LOWER HEADLIGHT PROTECTOR

RETAINER

(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.

E160573

E160572

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.

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

INTRODUCTIONIN-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.

Effect/Inoperative

Replacement Part Necessary Procedure

Vehicle Identification Number (VIN) registration

ECU commnication ID

ECM

S Automatic transmission

assembly (*1)

S Engine assembly (*1)

Tire pressure warning ECU

Tire pressure warning valve and transmitter

Brake actuator assembly (Skid control ECU)

S Yaw rate and

acceleration sensor

S Front wheel alignment

adjustment

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

Power steering ECU (*3)

Steering column (*3)

registration

Reset memory (*1)

Reset memory

1. Register transmitter IDs

2. Initialize tire pressure warning system

1. Register transmitter IDs

2. Initialize tire pressure warning system

Perform yaw rate and acceleration sensor zero point calibration

1. Clear zero point calibration data

2. Perform yaw rate and acceleration sensor zero point calibration

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

1. Assist map writing

2. Torque sensor zero point calibration

Torque sensor zero point calibration

MIL comes on Using the Techstream.

S Wireless door lock control system

S Smart key system (*4) S Engine start

S Large shift shock S The deterioration of fuel efficien-

S When DTC detection conditions

S Tire pressure monitoring function

1. When DTC detection conditions

2. Tire pressure monitoring function

S VSC OFF indicator light blinks S VSC disabled or malfunctioning

S P / S warning light comes on S EPS control

S P /S warning light comes on S EPS control

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

Function When

Necessary Procedures

are not Performed

(*4)

cy

of “transmitter ID not received” DTC are met, TPWS indicator blinks for 1 minute, and then illuminates

of replaced wheel

Note

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Using the Techstream.

Using the intelligent tester.

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

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

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

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