Repair Instruction: Precaution

1. HINTS ON OPERATIONS
   Fig 1: Identifying Basic Operation Repair Hints

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   Fig 2: Basic Operation Repair Descriptions

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2. 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 VEHICLE LIFT AND SUPPORT LOCATIONS ).
   Fig 3: Applying Seal Lock Adhesive To Bolt

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3. PRECOATED PARTS
   1. Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.
   2. If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.
   3. When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part.
   4. Some seal lock agents harden slowly. You may have to wait for the seal lock agent to harden.
4. GASKETS
   1. When necessary, use a sealer on gaskets to prevent leaks.
5. BOLTS, NUTS AND SCREWS
   1. Carefully follow all the specifications for tightening torques. Always use a torque wrench.
   NOTE: Perform the torque with the lower limit value of the torque tolerance.
6. FUSES
   1. When replacing fuses, be sure that the new fuse has the correct amperage rating. Do Not exceed the rating or use one with a lower rating.
   Fig 4: Identifying Various Fuse

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   Fig 5: Fuse Illustration And Symbol Chart

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7. CLIPS
   1. The removal and installation methods of typical clips used in body parts are shown in the table below.

   HINT:

   If clips are damaged during a procedure, always replace the damaged clip with a new clip.

   Fig 6: Typical Clips Removing And Installing Methods Chart (1 Of 2)

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   Fig 7: Typical Clips Removing And Installing Methods Chart (2 Of 2)

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8. REMOVAL AND INSTALLATION OF VACUUM HOSES
   1. To disconnect vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage.
      Fig 8: Identifying Proper Vacuum Hoses Disconnecting Procedure

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   2. When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
   3. After completing the job, double check that the vacuum hoses are properly connected. The 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.
   Fig 9: Attaching Tags For Identification

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9. TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL
   1. If SST or an extension tool is combined with the torque wrench to extend its length, do not tighten the torque wrench to the specified torque values in this information. The actual torque will be excessive.
   2. Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench.

      Formula: T' = T x L2/(L1 + L2)

Fig 10: Identifying Torque Wrench

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Fig 11: Identifying Torque Wrench With Extension Tool

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HINT:

The COROLLA MATRIX is equipped with a Supplemental Restraint System (SRS) and seat belt pretensioner.

Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury.

Furthermore, if a mistake is made when servicing the SRS, it is possible that the SRS may fail to operate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following carefully.

1. GENERAL NOTICE
   1. As the malfunction symptoms of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery (see DTC CHECK/CLEAR ).
   2. Work must be started at least 90 seconds after the ignition switch is turned OFF and the negative (-) terminal cable is disconnected from the battery.

      (The SRS is equipped with a back-up power source. If work is started within 90 seconds after turning the ignition switch OFF and disconnecting the negative (-) terminal cable from the battery, the SRS may deploy).

      When the negative (-) terminal cable is disconnected from the battery, clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio systems as before.

      CAUTION: Never use a back-up power source (battery or other) to avoid erasing system memory. The back-up power source may inadvertently power the SRS and cause it to deploy.
   3. In minor collisions where the SRS does not deploy, the horn button assembly, instrument panel passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly and seat belt pretensioner should be inspected before further use of the vehicle (see DISPOSAL , DISPOSAL , FRONT SEAT AIRBAG ASSY RH , DISPOSAL and DISPOSAL ).
   4. Never use SRS parts from another vehicle. When replacing parts, use new parts.
   5. Before repairs, remove the airbag sensor if impacts are likely to be applied to the sensor during repairs.
   6. Never disassemble and attempt to repair the airbag sensor assembly, horn button assembly, instrument panel passenger airbag assembly, curtain shield airbag assembly, front seat airbag assembly or seat belt pretensioner.
   7. Replace the center airbag sensor assembly, side airbag sensor assembly, horn button assembly, or the instrument panel passenger airbag assembly, curtain shield airbag assembly or front seat airbag assembly if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present.
   8. Do not directly expose the airbag sensor assembly, horn button assembly, instrument panel passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly or seat belt pretensioner to hot air or flames.
   9. Use a voltmeter/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting electrical circuits.
   10. Information labels are attached to the SRS components. Follow the instructions on the labels.
   11. After work on the SRS is completed, check the SRS warning lamp (see DTC CHECK/CLEAR ).
2. SPIRAL CABLE (in Combination Switch)
   1. The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other problems may occur. Refer to REPLACEMENT for information about correct installation of the steering wheel.
   Fig 12: Locating Spiral Cable Position

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3. HORN BUTTON ASSEMBLY (with Airbag)
   1. When removing the horn button assembly or handling a new horn button, it should be placed with the pad surface facing up. See the illustration below.

      Placing the horn button with the pad surface facing down may lead to a serious accident if the airbag accidently inflates. Also, do not place anything on top of the horn button.

   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
   3. Grease or detergents of any kind should not be applied to the steering wheel pad.
   4. Store the horn button assembly in an area where the ambient temperature is below 93°C (200 °F), the humidity is not high and electrical noise is not nearby.
   5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag or seat belt pretensioner deploying due to currents entering the squib wiring.
   6. When disposing of the vehicle or the horn button assembly by itself, the airbag should be inflated using an SST before disposal (see DISPOSAL ). Activate in a safe place away from electrical noise.
   Fig 13: Identifying Proper Horn Button Assembly Storing Position

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   Fig 14: Precautions For SRS System (1 Of 5)

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4. INSTRUMENT PANEL PASSENGER AIRBAG ASSY
   1. Always place a removed or new instrument panel passenger airbag assembly with the airbag inflation direction facing up.

      Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag inflates.

   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
   3. Grease or detergents of any kind should not be applied to the instrument panel passenger airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and electrical noise is not nearby.
   5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.
   6. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (see DISPOSAL ).

      Activate in a safe place away from electrical noise.

   Fig 15: Identifying Instrument Panel Passenger Airbag Assembly Proper Storing Position

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   Fig 16: Precautions For SRS System (2 Of 5)

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5. CURTAIN SHIELD AIRBAG ASSEMBLY
   1. Always place the removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place.
      NOTE: Plastic bag is not reusable.
      CAUTION: Never disassemble the curtain shield airbag assembly.
   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
   3. Grease or detergents of any kind should not be applied to the curtain shield airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200° F), the humidity is not high and electrical noise is not nearby.
   5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.
   6. When disposing of a vehicle or the curtain shield airbag assembly unit, the airbag should be deployed using SST before disposal (see DISPOSAL ).

      Activate in a safe place away from electrical noise.

   Fig 17: Identifying Curtain Shield Airbag Assembly Proper Storing Position

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   Fig 18: Precautions For SRS System (3 Of 5)

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6. FRONT SEAT AIRBAG ASSEMBLY
   1. Always place a removed or new front seat airbag assembly with the airbag inflation direction facing up.

      Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag deploys.

   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
   3. Grease or detergents of any kind should not be applied to the front airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and electrical noise is not nearby.
   5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.
   6. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (see FRONT SEAT AIRBAG ASSY RH ).

      Activate in a safe place away from electrical noise.

   Fig 19: Precautions For SRS System (4 Of 5)

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7. SEAT BELT PRETENSIONER
   1. Never measure the resistance of the seat belt pretensioner. This may cause the seat belt pretensioner to activate, which could cause serious injury.
   2. Never disassemble the seat belt pretensioner.
   3. Never install the seat belt pretensioner on another vehicle.
   4. Store the seat belt pretensioner in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and electrical noise is not nearby.
   5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.
   6. When disposing of a vehicle or the seat belt pretensioner unit by itself, the seat belt pretensioner should be activated before disposal (see DISPOSAL ). Activate in a safe place away from electrical noise.
   7. As the seat belt pretensioner is hot after being activated, allow some time for it to cool down sufficiently before disposal. Never apply water to try to cool down the seat belt pretensioner.
   8. Grease, detergents, oil or water should not be applied to the front seat outer belt.
   Fig 20: Precautions For SRS System (5 Of 5)

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8. AIRBAG SENSOR ASSEMBLY
   1. Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has deployed.
   2. The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not mounted to the floor, the SRS may activate.
   3. Work must be started at least 90 seconds after the ignition switch is turned OFF and the negative (-) terminal cable is disconnected from the battery, even if only loosening the set bolts of the airbag sensor assembly.
9. WIRE HARNESS AND CONNECTOR
   1. The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it.

Fig 21: Identifying Battery Negative (-) Terminal Cable

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1. REMOVAL AND INSTALLATION OF BATTERY TERMINAL
   1. Before carrying out any work on the vehicle electronics, disconnect the battery negative (-) terminal cable to prevent component and wire damage caused by accidental short circuits.
   2. When disconnecting the terminal cable, turn the ignition switch and head light dimmer switch OFF and loosen the terminal nut completely. Perform these operations without twisting or prying the terminal. Remove the battery cable from the battery post.
   3. Clock settings, radio settings, DTCs and other data are erased when the battery cable is removed. Write down any necessary data before disconnecting the battery cable.
   Fig 22: Precaution For Handling Electronic Parts

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2. HANDLING OF ELECTRONIC PARTS
   1. Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity.
   2. To disconnect electronic connectors, pull the connector itself, not the wires.
   3. Be careful not to drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced.
   4. When cleaning the engine with steam, protect the electronic components, air filter and emissions-related components from water.
   5. Never use an impact wrench to remove or install temperature switches or temperature sensors.
   6. When measuring the resistance of a wire connector, insert the tester probe carefully to prevent terminals from bending.

1. Follow the guidelines below regarding the work area.
   1. Work in a place with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources.
   2. Never work in a pit or near a pit as vaporized fuel will collect in those places.
2. Prepare a fire extinguisher before starting work.
3. To prevent static electricity, install a ground on the fuel changer, vehicle and fuel tank, and do not spray the area with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread and cause a fire hazard.
4. Avoid using electric motors, work lights and other electric equipment that can cause sparks or high temperatures.
5. Avoid using iron hammers as they may create sparks.
6. Dispose of fuel-contaminated separately using a fire resistant container.

1. If any metal particle enters the inlet pass, this may damage the engine.
2. When removing and installing the inlet system parts, cover the openings of the removed parts and engine openings. Use gummed tape or other suitable materials.
3. When installing the inlet system parts, check that no metal particles have entered the engine or the installed part.

Fig 23: Identifying Inlet System Parts

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1. Before removing the hose, check the clamp position so that it can be reinstalled in the same position.
2. Replace deformed or dented clamps with a new one.
3. When reusing a hose, attach the clamp on the clamp track portion of the hose.
4. For a spring type clamp, you may want to spread the tabs slightly after installation by pushing in the direction of the arrow marks as shown in the illustration.

Fig 24: Identifying Clamp Track And Spring Type Clamp

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1. Install the antenna as far away from the ECU and sensors of the vehicle electronic systems as possible.
2. Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details of the ECU and sensors locations, refer to the section on applicable components.
3. Keep the antenna and feeder separate from other wirings as much as possible. This will prevent signals from the communication equipment from affecting vehicle equipment and vice-versa.
4. Check that the antenna and feeder are correctly adjusted.
5. Do not install any high-powered mobile communication system.

Fig 25: View Of Vehicles Equipped With Mobile Communication System

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1. BEFORE BEGINNING TEST
   NOTE: Tester following 2 wheel load setting (2 wheel power absorption type) testers cannot be used: 1) 2 wheel chassis dynamometers, and 2) equipment that has a 2 wheel chassis dynamometer, speedometer tester and brake tester combined.
2. BRAKING FORCE TEST (Vehicle speed: 0.5 km/h (0.3mph))

   When performing measurement with a low-speed type brake tester, observe the following instructions.

   1. Position the wheels to be tested (front or rear) on the tester rollers.
   2. Raise the other wheel with rigid racks or place the wheels on free rollers.
   3. Move the shift lever to N.
   4. Fasten the vehicle with lock chains.
   5. Idle the engine, and perform measurement by driving the tester rollers.
   NOTE:

   • Tester with a function of load measurement cannot be used.
   • High-speed type brake tester cannot be used.
3. SPEEDOMETER TEST OR OTHER TESTS (Using speedometer or chassis dynamometer)

   When performing test, use the method shown below.

   1. Place the front wheels onto the rollers.
   2. Set the rear wheels free with free rollers or safety stands.
   3. Fasten the vehicle with lock chains.
   4. Start the engine, and then measure the vehicle speed by increasing the speed gradually in the "D" range.
   5. After the measurement completion, decrease the vehicle speed with brake gradually, and then stop the vehicle.
   NOTE:

   • Inspection should be performed in the front wheels.
   • Do not start, accelerate or decelerate the vehicle suddenly.
   • Maximum vehicle speed must be below 60 km/h or 37 mph (when using a free roller, it must be below 50 km/h or 31 mph).
   • Driving time for the test should be within 1 minute.

   HINT:

   Only the tests of No.3 and No.4, shown in the Fig 26 below, can have a high-speed test or heavy load test.

   Fig 26: Speedometer And Other Test Chart (Using Speedometer Or Chassis Dynamometer)

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   NOTE:

   • Confirm that the vehicle is securely immobilized.
   • Never operate the clutch or brakes, and never drive the wheels or decelerate suddenly.
   • Be sure to strictly follow the above procedure for the test, because functions of 4WD system might fail, parts of driving system might malfunction, or the vehicle might unexpectedly jump out.
4. ON-VEHICLE WHEEL BALANCING MEASUREMENT

   When doing on-vehicle wheel balancing measurement on a full-time 4WD vehicle, to prevent the wheels from rotating at different speeds in different directions from each other (which could damage the center differential), always be sure to observe the following precautions:

   1. Jack up all the 4 wheels with a 2-post-type lift. All the 4 wheels should be jacked up, clearing the ground completely.
   2. Fasten the vehicle by setting 2 pick-up stands in the bottom of the suspension arm's tip of the front wheels or rear wheels to be measured.
   3. Support the vehicle with safety stands so that the vehicle will not lean in the vehicle's front/rear direction.
   4. Release the parking brake.
   5. Check that no dragging force exists by turning each wheel by hand.
   6. Set the wheel balancers.
   7. Measurement should be performed by using both of the engine drive and wheel balancer roller drive.
   Fig 27: Identifying On-Vehicle Wheel Balancing Procedure

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• Use one of the methods shown below to tow a vehicle.
• When there is trouble with the chassis and drive train, use method 1(flat bed truck).
• Recommended method: No.1, No.2, No.3 Emergency Method: No.4

Fig 28: Identifying Various Vehicle Towing Method (Full-Time 4WD Vehicles)

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• For example, the towing methods shown below are dangerous or damage the vehicle, and therefore do not use them.

Fig 29: Identifying Wrong Towing Of Full-Time 4WD Vehicles

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1. Use only unleaded gasoline.
2. Avoid prolonged idling.

   Avoid running the engine at idle speed for more than 20 minutes.

3. Avoid a spark jump test.
   1. Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
   2. While testing, never race the engine.
4. Avoid a prolonged engine compression measurement.

   Engine compression measurements must be performed as rapidly as possible.

5. Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter.