2010 Toyota Corolla Service Repair Manual.pdf

service repair manual instant download

1. FOREWORD
This repair manual has been prepared to provide essential in-
formation 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 dia-
grams and illustrations of the body components and other in-
formation 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 specifica-
tions 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 collision-
damaged 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.

2. ABOUT THIS MANUAL
Scope of the repair work explanation
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
This manual has been divided as shown below.
Section Title
Contents Examples
INTRODUCTION
Explanation of general body repair.
Views of weld panel replacement instructions.
Precaution About this vehicle
BODY PANEL REPLACEMENT
Instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts. Front side member replacement. Quarter panel replacement.
BODY DIMENSIONS Body aligning measurements. Dimension diagrams.
PAINT COATING
Scope and type of anti-rust treatment, etc. together with weld panel replacement. Body sealer. Under coat.
Contents omitted in this manual
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

3. Three-dimensional
distance
Two-dimensional
distance
Center-to-center horizontal
distance in forward /
rearward direction
Vertical distance
in center
Vertical distance
in lower surface
Imaginary Datum Line
Under Surface of
The Rocker Panel
Imaginary Datum Line
A mm B mm C mm
Center-to-center
straight-line
distance
BODY DIMENSIONS DI-1
GENERAL INFORMATION
1. BASIC DIMENSIONS
(a) There are two types of dimensions in the diagram.
(1) (Three-dimensional distance)
Straight-line distance between the centers of two
measuring points.
(2) (Two-dimensional distance)
Horizontal distance in forward/rearward direc-
tion between the centers of two measuring
points.
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 refer-
ence.
(d) The line that connects the places listed below is the imagi-
nary datum line when measuring the height. (The dimen-
sions are printed in the text.)
SYMBOL
Name
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 of the 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.

4. Plate Looseness
Body Looseness
Pointer Looseness
Pointer
Master Gauge
Wrong Correct
Pointer
BODY DIMENSIONSDI-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 track-
ing 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.

5. Front cross member side gusset standard hole
Hood lock support brace installation nut
Front fender extension standard hole
Radiator upper support installation nut
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)
M6 (0.24)
ø10 (0.39)
M6 (0.24)
–
(Three-Dimensional Distance)
Symbol Name Hole dia.
mm (in.)
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
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).
L-N L-n
N-n or or
l-n l-N
1,517 747 1,290
(59.72) (29.41) (50.79)
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)
Symbol Name Hole dia.
H, h
I
J, j
K, k
L, l
M, m
N, n
–
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 DIMENSIONS
DI-3
BODY DIMENSION DRAWINGS
ENGINE COMPARTMENT

6. Rocker panel assembly mark
Roof side rail assembly mark
Center body pillar assembly mark
Center body pillar assembly mark
Front door lock striker installation nut
Rear door hinge installation nut
Rear door hinge installation nut
(Three-Dimensional Distance)
Symbol Name Hole dia.
mm (in.)
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 door hinge installation nut
Front body pillar assembly mark
Front body pillar assembly mark
Rocker panel assembly mark

M8 (0.31)
M8 (0.31)
M8 (0.31)



HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (seen from rear).
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)
Symbol Name Hole dia.
H, h
I,i
J, j
K, k
L, l
M, m
N, n




M8 (0.31)
M8 (0.31)
M8 (0.31)
1,456
(57.32)
919
(36.18)
1,561
(61.46)
775
(30.51)
1,092
(42.99)
861
(33.90)
813
(32.01)
1,217
(47.91)
986
(38.82)
1,016
(40.00)
877
(34.53)
857
(33.74)
1,109
(43.66)
BODY DIMENSIONS
DI-4
BODY OPENING AREAS (Side View: Front)

7. (Three-Dimensional Distance)
Symbol Name Hole dia.
mm (in.)
G, g
M, m
N, n
O, o
P, p
Rocker panel assembly mark
Rear door hinge installation nut
Rear door hinge installation nut
Center body pillar assembly mark
Center body pillar assembly mark

M8 (0.31)
M8 (0.31)


HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (seen from rear).
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)
Symbol Name Hole dia.
Q, q
R, r
S, s
T, t
U, u
Rocker panel notch edge
Roof side rail assembly mark
Quarter panel assembly mark
Quarter panel assembly mark
Rear door lock striker installation nut




M8 (0.31)
1,062
(41.81)
671
(26.42)
981
(38.62)
999
(39.33)
947
(37.28)
838
(32.99)
BODY DIMENSIONS
DI-5
BODY OPENING AREAS (Side View: Rear)
Sedan

8. (Three-Dimensional Distance)
Symbol Name Hole dia.
mm (in.)
A, a
B, b
C, c
D, d
Roof panel corner
Quarter panel standard hole
Quarter panel / upper back panel adjoining portion



HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (seen from rear).
Vehicle Dimensions
D-c
or
d-C
1,284
(50.55)
Symbol Name Hole dia.
E, e
F, f
G, g
H, h
Quarter panel standard hole
Rear suspension installation hole
Center body pillar assembly mark
ø13 (0.51)

ø16 (0.63)

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 DIMENSIONS
DI-6
BODY OPENING AREAS (Rear View)
Sedan

9. (Three-Dimensional Distance)
Symbol Name Hole dia.
mm (in.)
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 suspension crossmember installation nut
Front side member standard hole
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,
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.
G, g
H, h
I,i
J
K, k
L, l
Rear floor side front member standard hole
Trailing arm installation hole
Rear floor NO. 2 crossmember standard hole
Rear floor centermember NO. 4 reinforcement standard hole
Rear floor side rear member standard hole
Transport hook installation hole-rear
ø25 (0.98)
ø13 (0.51)
ø10 (0.39)
ø8 (0.31)
ø15 (0.59)
123
100 100 100
(3.94) (3.94) (3.94)
RH
LH
Front
Imaginary
Datum Line
123
1,263
(49.72)
985
(38.78) 1,252
(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
(34.25)
1,035
(40.75)
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)
A,a
149
(5.87)
B,b
320
(12.60)
C,c
232
(9.13)
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)
BODY DIMENSIONS
DI-7
UNDER BODY

10. (Two-Dimensional Distance)
Symbol Name Hole dia.
mm (in.)
A, a
B, b
C, c
D, d
E, e
F, f
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
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)
Symbol Name Hole dia.
H, h
I,i
J, j
K, k
L
M, m
N, n
Rear floor side front member standard hole
Trailing arm installation hole
Rear absorber mounting member standard hole
Rear spring bracket installation hole
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)
ø15 (0.59)
123
100 100 100
(3.94) (3.94) (3.94)
Wheel base 2,600 (102.36)
RH
LH
Front
Imaginary
Datum Line
0
1 32
2,162
(85.12)
407
(16.02)
2,064
(81.26)
986
(38.82)
1,542
(60.71)
920
(36.22)
1,258
(49.53)
20
(0.79)
1,125
(44.29)
500
(19.69)
2,162
(85.12)
456
(17.95)
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)
860
(33.86)
599
(23.58)
920
(36.22)
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
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:
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.
BODY DIMENSIONS
DI-8
UNDER BODY

11. (Three-Dimensional Distance)
Symbol Name Hole dia.
mm (in.)
A, a
B, b
Lower arm installation hole
Front suspension crossmember installation hole
ø15.5 (0.61)
ø22 (0.87)
HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (seen from rear).
Symbol Name Hole dia.
C, c
D, d
Front suspension crossmember standard hole
Front suspension crossmember installation hole
ø13 (0.51)
ø20 (0.79)
Front
LH RH
Imaginary
Datum 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)
BODY DIMENSIONS
DI-9
FRONT SUSPENSION CROSSMEMBER

12. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING

NOTE:
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click on the link above,
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13. (Two-Dimensional Distance)
Symbol Name Hole dia.
mm (in.)
A, a
B, b
Lower arm installation hole
Front suspension crossmember installation hole
ø15.5 (0.61)
ø22 (0.87)
HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (seen from rear).
Symbol Name Hole dia.
C, c
D, d
ø13 (0.51)
ø20 (0.79)
LH RH
Imaginary
Datum Line
456
(17.95)
177
(6.97)
177
(6.97)
445
(17.52)
344
(13.54)
B,b
136
(5.35)
0
A,a
242
(9.53)
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 hole
Front suspension crossmember installation hole
BODY DIMENSIONS
DI-10
FRONT SUSPENSION CROSSMEMBER

14. (Three-Dimensional Distance)
Symbol Name Hole dia.
mm (in.)
A, a
B, b
Front bumper cover installation bolt
Headlight installation bolt


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.
D, d
E, e
Front fender installation bolt
Front fender installation bolt


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)
1,478
(58.19)
1,375
(54.13)
339
(13.35)
BODY DIMENSIONS
DI-11
REFERENCE VALUE
ENGINE COMPARTMENT

15. (Two-Dimensional Distance)
Symbol Name Hole dia.
mm (in.)
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
–
ø18 (0.71)
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)
821
(32.32)
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:
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.
BODY DIMENSIONS
DI-12
UNDER BODY