Toyota Yaris: Handling precautions on related components - Introduction - Toyota Yaris XP90 2005–2010 Collision Repair ManualToyota Yaris: Handling precautions on related components

1. BRAKE SYSTEM

The brake system is one of the most important safety components. Always follow the directions and notes given in the brake (32) section of the repair manual for the relevant model when handling brake system parts.

NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC system.

2. DRIVE TRAIN AND CHASSIS

The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections listed in the table below, perform alignments to ensure correct mounting angles and dimensions. Body repair must be particularly accurate to ensure correct alignment.

HINT: Correct procedures and special tools are required for alignment. Always follow the directions given in the repair manual for the relevant model during alignment and section DI of this section.

Component to be aligned Section of repair manual for relevant model
Front Wheels Front Suspension (26) section
Rear Wheels Rear Suspension (27) section

3. COMPONENTS ADJACENT TO THE BODY PANELS

Various types of component parts are mounted directly on or adjacently to the body panels. Strictly observe the following precautions to prevent damaging these components and the body panels during handling.

Before repairing the body panels, remove their components or apply protective covers over the components.

Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool tip or blade to prevent damaging the components and the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body to ensure no damage to painted areas.

HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.

4. ECU (ELECTRONIC CONTROL UNIT)

Many ECUs are mounted in this vehicle.

Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (−) terminal cable from the battery.

When the negative (−) terminal cable is disconnected from the battery, memory of the clock and audio systems will be canceled. So before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before.

When the vehicle has tilt and telescopic steering, power seats and outside rear view mirrors, which are all equipped with a memory function, it is not possible to make a record of the memory contents.

So when the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80 C (176 F).

NOTICE: If it is possible the ambient temperature may reach 80 C (176 F) or more, remove the ECUs from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.

    Proper and efficient work procedures
    1. REMOVAL (a) PRE-REMOVAL MEASURING. (1) Before removal or cutting operations, take measurements in accordance with the dimensions diagram. Always use a puller to straighten a damaged body or f ...

    Precautions for repairing body structure panels
    1. HEAT REPAIR FOR BODY STRUCTURE PANELS Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a collision. Panels that have high streng ...

    See also:

    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 YARIS. Applica ...

    Body dimension drawings
    ENGINE COMPARTMENT Hatchback ENGINE COMPARTMENT Sedan BODY OPENING AREAS (Side View) Hatchback 3 Door BODY OPENING AREAS (Side View: Front) Hatchback 5 Door BODY OPENING AREAS (Side View: ...

    Rear door outer panel (CUT): Hatchback 5 Door
    REPLACEMENT REMOVAL INSTALLATION Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspe ...