Toyota Corolla 2004 REPAIR INSTRUCTION
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
01–5
–INTRODUCTION REPAIR INSTRUCTION
010D8–02
2
1
6
5
4
3
D25016
1 Looks
2 Vehicle protection Set a grill cover, fender cover, seat cover and floor mat before starting the operation.
3 Safe operation
Preparation of tools and
4
measuring gauge
Removal and installation,
5
disassembly and assembly operations
6 Removed parts
Always wear a clean uniform.
Hat and safety shoes must be worn.
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.
Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement.
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.
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 (See page 01–17 ).
2004 COROLLA (RM1037U)
8Author: Date:
01–6
–INTRODUCTION REPAIR INSTRUCTION
(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.
Seal Lock Adhesive
Z11554
(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.
(d) GASKETS
(1) When necessary, use a sealer on gaskets to prevent leaks.
(e) BOLTS, NUTS AND SCREWS
(1) Carefully observe all the specifications for tightening torques. Always use a torque wrench.
Medium Current Fuse and High Current
Fuse Equal Amperage Rating
(f) 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.
Illustration
D27353
BE1367
Symbol Part Name
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
Abbreviation
FUSE
M–FUSE
H–FUSE
V35001
2004 COROLLA (RM1037U)
9Author: Date:
–INTRODUCTION REPAIR INSTRUCTION
(g) 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.
01–7
Shape (Example)
Clip
Removal/Installation
Pliers
Clip Remover
Protective Tape
Screwdriver
2004 COROLLA (RM1037U)
Protective Tape
Scraper
D25786
10Author: Date:
01–8
–INTRODUCTION REPAIR INSTRUCTION
Shape (Example)
Removal/Installation
Removal Installation
Removal Installation
Removal Installation
V35004
2004 COROLLA (RM1037U)
11Author: Date:
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