A/C - Lower Grille mesh Protection Cover

HEATING & AIR CONDITIONING
AC002-06
REVISED

Title:
LOWER GRILLE MESH
PROTECTION COVER

Models:
'05 - '06 Corolla

August 18, 2006

TSB REVISION NOTICE:

^ September 29, 2007: The title has been updated.

Previous versions of this TSB should be discarded.

Introduction
Some customers may experience damage to the A/C condenser if the vehicle is used regularly on road surfaces where debris may contact the condenser. A grille mesh has been made available to reduce the vulnerability of the condenser to road debris.

Applicable Vehicles

^ 2005 - 2006 model year Corolla vehicles produced BEFORE the Production Change Effective VINs shown below.





Production Change Information





Parts Information





Required Tools & Material





Warranty Information

Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

Warranty application is limited to correction of a problem based upon a customer's specific complaint.

Repair Procedure

1. Remove the front spoilers (if equipped).

If the vehicle is NOT equipped with front spoilers, go to step 2.

A. Remove screw "A" from both the passenger and driver's side front spoiler area.

B. Remove screw "B" from both the passenger and driver's side front spoiler area.

C. Remove the two (2) spoiler mounting clamps "C" from the spoiler. Remove the plastic splash shield to gain access to the clamps.

D. Remove the two (2) metal clamps "D."

Be careful NOT to scratch the bumper paint.





E. Depress plastic clamp "E" to release the spoiler assembly from the bumper.





2. Drill two (2) holes in both the passenger and driver's side grille areas as show in the illustration.

To ensure that the bumper does NOT get scratched by the tools, use tape on all exposed paint surfaces near the drilling locations. This is to ensure the paint is protected from the drill and tools.





3. Using 16 plastic zip ties and working from the centermost bottom fastener, fasten the plastic mesh to the backside of the bumper housing/bumper grille at each bumper opening support.

^ Ensure that the plastic zip ties on the top side of the grille are placed as close to the top of the bumper opening support as possible.

^ Ensure that the plastic zip ties on the bottom side of the grille are placed as close to the bottom of the bumper opening support as possible.

^ Ensure that the head of the plastic zip tie fastener is rotated to the rear of the bumper opening away from view.





The plastic mesh should be secured in 16 different locations when complete. The four outermost points of the mesh (marked "X" in the diagram below) will be secured with plastic zip ties to the 4 holes that were drilled into the bumper in step 2. Refer to the following illustration for the locations of these tie points.

NOTE:

^ Ensure that all the plastic zip ties are snug and that the plastic mesh is installed for the best appearance.

^ Do NOT overtighten the plastic zip ties.

4. Reinstall the front spoiler (if equipped) in reverse order of step 1.