Решил выложить всё что скопилось с разных источников, за почти 2 года эксплуатации своего авто, думаю будет полезно. Скажу заранее спасибо, если найдёте тут свои труды 
Всё на Яндекс.Диске
На русском:
Manual_Corolla_E12_Rus
Самое обычное руководство пользователя на русском, иногда полезно, чтобы не лазить в бардачок, PDF 2 части. yadi.sk/d/BOZDqBl-ntK9m
Corolla руководство по ремонту
Хорошая справка по ремонту и диагностике, судя по картинкам внутри — для дорестайла.
Внимание! Запускать по ярлычку «Запустить.bat» yadi.sk/d/BPQQr38FntK85
3zz-fe по русски
Очень годный мануал не только по 3zz, но и по подкапотке в целом, взят откуда-то с драйва.
yadi.sk/d/afrUWRKdntK69
На Английском:
2004 Corolla USA
Полное руководство по ремонту американской короллы, включая схемы эл. цепей
yadi.sk/d/d8pGQ_XVntKf6
SIL
Схема электрики, pdf
yadi.sk/d/rTox__85ntKmw
Toyota Corolla models USA 2003 — 2008
Скан книги на английском, от весьма известного американского издателя книг по ремонту и обслуживанию (американская королла). yadi.sk/d/yBTIUaWUntL6n
Ссылки на каталоги з/ч
Удобно для поиска part-num. запчастей
www.japancats.ru/Toyota/
aes24.ru/?page=originalcats спасибо ssmitti
Если у кого-то есть что-то ещё — обязательно пишите, соберём всю коллекцию в одном месте!
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Manuals and User Guides for Toyota Corolla 2004. We have 5 Toyota Corolla 2004 manuals available for free PDF download: Repair Manual Supplement, Owner’s Manual, Operating Manual, Manual, Specifications
Руководство на английском языке по техническому обслуживанию и ремонту автомобиля Toyota Corolla 1980-1987 годов выпуска.
- Автор: —
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- Страниц: 339
- Формат: PDF
- Размер: 489 Mb
Руководство на английском языке по техническому обслуживанию и ремонту автомобиля Toyota Corolla 1984-1992 годов выпуска.
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Руководство на английском языке по техническому обслуживанию и ремонту автомобиля Toyota Corolla 2003-2008 годов выпуска.
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- Год издания: —
- Страниц: 244
- Формат: PDF
- Размер: 105,1 Mb
Руководство на английском языке по техническому обслуживанию и ремонту автомобиля Toyota Corolla 1997-2002 годов выпуска с бензиновыми двигателями.
- Автор: —
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- Размер: 33,9 Mb
Сборник руководств на английском языке по техническому обслуживанию и ремонту автомобиля Toyota Corolla 2004 года выпуска.
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- Издательство: Toyota Motor Corporation
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- Размер: 29,6 Mb
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Мультимедийное руководство по эксплуатации и ремонту автомобиля Toyota Corolla 1992-1998 годов выпуска.
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Руководство по эксплуатации и техническому обслуживанию автомобиля Toyota Corolla 2001-2006 годов выпуска.
- Автор: —
- Издательство: Toyota Motor Corporation
- Год издания: 2006
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Руководство по эксплуатации и техническому обслуживанию автомобиля Toyota Corolla с 2007 года выпуска.
- Автор: —
- Издательство: Toyota Motor Corporation
- Год издания: 2006
- Страниц: 400
- Формат: PDF
- Размер: 33,6 Mb
Мультимедийное руководство по техническому обслуживанию и ремонту автомобиля Toyota Corolla с 2002 года выпуска.
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Руководство по техническому обслуживанию и ремонту автомобиля Toyota Corolla 2001-2006 годов выпуска с бензиновыми двигателями объемом 1,4/1,6/1,8 л.
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Руководство по эксплуатации и ремонту автомобилей Toyota Auris и Toyota Corolla с 2007 года выпуска с бензиновыми и дизельными двигателями.
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Руководство по эксплуатации и ремонту автомобиля Toyota Corolla с 2013 года выпуска с бензиновыми и дизельными двигателями.
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Руководство по эксплуатации, техническому обслуживанию и ремонту автомобиля Toyota Corolla 1983-1992 годов выпуска с бензиновыми и дизельными двигателями.
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Contents
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Table of Contents
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Troubleshooting
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INTRODUCTION
INTAKE
EXHAUST
STARTING & CHARGING
FRONT SUSPENTION
REAR SUSPENTION
TIRE & WHEEL
HEATER & AIR CONDITIONER
1
2
3
5
10
11
12
13
14
15
16
17
18
19
26
27
28
30
32
33
40
41
42
50
51
55
60
Related Manuals for Toyota Corolla 2004
Summary of Contents for Toyota Corolla 2004
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Page 1
INTRODUCTION PREPARATION SERVICE SPECIFICATIONS DIAGNOSTICS ENGINE CONTROL SYSTEM FUEL EMISSION CONTROL INTAKE ENGINE MECHANICAL EXHAUST COOLING LUBRICATION IGNITION STARTING & CHARGING FRONT SUSPENTION REAR SUSPENTION TIRE & WHEEL DRIVE SHAFT / PROPELLER SHAFT BRAKE PARKING BRAKE AUTOMATIC TRANSMISSION / TRANS MANUAL TRANSMISSION/TRANSAXLE CLUTCH STEERING COLUMN… -
Page 2
SEAT BELT LIGHTING WIPER & WASHER AUDIO & VISUAL SYSTEM WIRING COMMUNICATION SYSTEM WINDSHIELD/WINDOWGLASS/MIRROR INSTRUMENT PANEL/METER SEAT THEFT DETTERENT & DOOR LOCK SLIDING ROOF/CONVERTIBLE ENGINE HOOD/DOOR EXTERIOR/INTERIOR TRIM VEHICLE CONTROL SYSTEM CRUISE CONTROL MAINTENANCE ALPHABETICAL INDEX… -
Page 3
TOYOTA MOTOR CORPORATION TOYOTA MOTOR CORPORATION 2003 All rights reserved. This book may not be repro- duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing: May 9, 2003 01–030509–00… -
Page 4
01–1 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 0103I–08 GENERAL INFORMATION GENERAL DESCRIPTION This manual is made in accordance with SAE J2008. Generally, repair operations can be separated in the following 3 main processes: 1. Diagnosis 2. -
Page 5
01–2 INTRODUCTION – HOW TO USE THIS MANUAL Tightening torque, grease application area, and non–reusable parts are described as important points in the procedures. NOTICE: There are cases where such information can only be explained by using an illustration. In these cases, all the information such as torque, oil, etc. -
Page 6
01–3 INTRODUCTION – HOW TO USE THIS MANUAL SI UNIT The units given in this manual are primarily expressed according to the SI UNIT (International System of Units), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N m (310 kgf cm, 22 ft lbf) 2004 COROLLA (RM1037U) -
Page 7
01–4 INTRODUCTION – IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION 01031–06 VEHICLE IDENTIFICATION AND SERIAL NUMBERS VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the ve- hicle identification number plate and certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label D27356 ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL… -
Page 8
01–5 INTRODUCTION – REPAIR INSTRUCTION REPAIR INSTRUCTION 010D8–02 PRECAUTION BASIC REPAIR HINT HINTS ON OPERATIONS D25016 S Always wear a clean uniform. Looks S Hat and safety shoes must be worn. S Set a grill cover, fender cover, seat cover and floor mat before starting the operation. Vehicle protection S In case of working with 2 or more persons, be sure to check safety of one another. -
Page 9
01–6 INTRODUCTION – REPAIR INSTRUCTION PRECOATED PARTS Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. -
Page 10
01–7 INTRODUCTION – REPAIR INSTRUCTION CLIPS 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. Shape (Example) Removal/Installation Clip… -
Page 11
01–8 INTRODUCTION – REPAIR INSTRUCTION Removal/Installation Shape (Example) Removal Installation Removal Installation Removal Installation V35004 2004 COROLLA (RM1037U) Author : Date :… -
Page 12
01–9 INTRODUCTION – REPAIR INSTRUCTION REMOVAL AND INSTALLATION OF VACUUM HOSES To disconnect vacuum hoses, pull them by holding the end, not the middle of the hose. CORRECT WRONG D25063 When disconnecting vacuum hoses, use tags to identify where they should be reconnected. After completing the job, make a double check whether the vacuum hoses are properly connected. -
Page 13
01–10 INTRODUCTION – REPAIR INSTRUCTION FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER HINT: The vehicle is equipped with an SRS (Supplemental Restraint System), such as the horn button assembly, the instrument panel passenger airbag assembly, the front seat airbag assembly, the center airbag sensor assembly, the front airbag sensor, the side airbag sensor and the seat belt pretensioner. -
Page 14
01–11 INTRODUCTION – REPAIR INSTRUCTION SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other Mark troubles may occur. Refer to page 60–22 on this manual concerning the correct installation of the… -
Page 15
01–12 INTRODUCTION – REPAIR INSTRUCTION INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY Always store a removed or new instrument panel passenger airbag assembly with the airbag inflation direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates. Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous). -
Page 16
01–13 INTRODUCTION – REPAIR INSTRUCTION When disposing of a vehicle or the side airbag assembly alone, the airbag should be deployed using an SST before disposal (See page 60–32). Perform the operation in a safe place away from electrical noise. Example: D27360 SEAT BELT PRETENSIONER… -
Page 17
01–14 INTRODUCTION – REPAIR INSTRUCTION WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the instrument panel wire harness assembly. All the con- nectors in the system are in a standard yellow color. If the SRS wire harness becomes discon- nected or the connector becomes broken due to an accident, etc., repair or replace it. -
Page 18
01–15 INTRODUCTION – REPAIR INSTRUCTION Never use any electric equipment like an electric motor or a working light, as they may cause sparks or high temperature. Never use an iron hammer, as it may cause sparks. Dispose of the shop rag separately from any fuel deposit. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS If any metal tip is mixed in the inlet pass, this may give a… -
Page 19
01–16 INTRODUCTION – REPAIR INSTRUCTION FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER CAUTION: If large amount of unburned fuel flows into the converter, it may cause overheating and a fire hazard. To prevent this, observe the following precautions. Use only unleaded gasoline. Avoid prolonged idling. -
Page 20
01–17 INTRODUCTION – REPAIR INSTRUCTION 010D9–02 VEHICLE LIFT AND SUPPORT LOCATIONS NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP As a rule, the vehicle must be unloaded when jacking up. Never jack up or lift up the vehicle loaded with things of heavy weight. When removing any parts of heavy weight like the engine and transmission, the center of gravity of the vehicle moves. -
Page 21
01–18 INTRODUCTION – REPAIR INSTRUCTION NOTICE FOR USING SWING ARM TYPE LIFT Follow the instruction manual of the lift for a safe operation. Use a cradle with a rubber attachment, as shown in the illustration. Set in the vehicle so as to make its center of gravity as close as possible to the center of the lift. (”L” becomes short.) Place the vehicle horizontally by adjusting the height of the cradle, and match the groove of the cradle and the safety stand support location accurately. -
Page 22
05–638 7. Power Door Lock Control System 05–670 8. Wireless Door Lock Control System 05–685 9. TOYOTA Vehicle Intrusion Protection System 05–700 10.Cruise Control System 05–742 FOR USING HAND–HELD TESTER Before using the tester, the tester’s operator manual should be read thoroughly. -
Page 23
01–20 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01035–10 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Carry out troubleshooting in accordance with the procedures on the following page. Here, only the basic procedures are shown. Details are provided in the Diagnostics Section, showing the most effective methods for each circuit. -
Page 24
01–21 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Confirmation test After completing repairs, confirm that the problem has been solved (If the problem does not recur, per- form a confirmation test under the same conditions and in the same environment as when it occurred for the first time). -
Page 25
01–22 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CUSTOMER PROBLEM ANALYSIS HINT: In troubleshooting, the problem symptoms must be confirmed accurately, meaning that all preconcep- tions must be set aside in order to make an accurate judgement. To ascertain what the problem symp- toms are, it is extremely important to ask the customer about the problem and conditions when it oc- curred. -
Page 26
01–23 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in COROLLA has various functions. The first function is the Diagnostic Trouble Code (DTC) Check, in which a malfunction in the signal circuits to the ECU is stored in code form in the ECU memory. -
Page 27
01–24 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DTC check DTC displayed Normal code displayed Troubleshooting of problem indicated by DTC Symptom confirmation No problem symptoms exist Problem symptoms exist If a DTC is displayed in the initial DTC check, it indicates that a trouble may have occurred in a wire harness or connector in that circuit in the past, therefore check the wire harness and connectors (See page 01–30). -
Page 28
01–25 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occurs. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer’s vehicle should be simulated. -
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01–26 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Do not apply heat directly to the parts in the ECU. WATER SPRINKLING METHOD: When the malfunc- tion seems to occur on a rainy day or in high–humid- ity. Sprinkle water onto the vehicle and check if the malfunc- tion occurs. -
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01–27 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DIAGNOSTIC TROUBLE CODE CHART The inspection procedures are shown in the table below. This table allows efficient and accurate trouble- shooting using the diagnostic trouble codes displayed in the diagnostic trouble code chart. Proceed with troubleshooting in accordance with the inspection procedures listed in the diagnostic chart corresponding to the diagnostic trouble codes displayed. -
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01–28 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a Normal code is displayed in the diagnostic trouble code chart but the prob- lem is still occurring. -
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01–29 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CIRCUIT INSPECTION How to read and use each page is shown below. D Circuit Description D Inspection Procedures The major role and, operation of the circuit Use the inspection procedures to determine and its component parts are explained. -
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The connector with a lock should be securely con- nected until it makes a ”click” sound. When checking the connector with a Toyota electri- WRONG cal tester, check it from the backside (harness side) of the connector using a mini test lead. -
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01–31 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Checking of the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, check the engaged condition and sliding resistance. Same terminal as a male terminal D25088 REPAIR METHOD OF CONNECTOR TERMINAL If there is on the contact point, clean the contact… -
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01–32 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Check the resistance. Fig. 2 Disconnect connectors A and C and measure the resistance between them. Resistance: 1 Ω or less HINT: Sensor Measure the resistance while lightly shaking the wire harness vertically and horizontally. -
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01–33 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CHECK SHORT CIRCUIT Fig. 5 If the wire harness is ground shorted as shown in Fig. 5, C SHORT locate the section by conducting a resistance check with the body ground in step (b). Z17008 Check the resistance with the body ground. -
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01–34 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CHECK AND REPLACE ECU NOTICE: Start an inspection of the connector from the back- side of the connector on the wire harness side with the connector connected to the ECU. When no measurement condition is specified, per- form the inspection with the engine stopped and also the ignition switch ON. -
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01–35 INTRODUCTION – TERMS TERMS 01037–07 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning Anti–Lock Brake System Alternating Current Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential Air–Fuel Ratio Active Height Control Suspension Automatic Locking Retractor Alternator Amplifier Antenna… -
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01–36 INTRODUCTION – TERMS Abbreviations Meaning DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection Data Link Connector Distributorless Ignition DOHC Double Overhead Camshaft Dash Pot Dead Soak Digital Signal Processor Diagnostic Trouble Code Digital Versatible Disc Electric Brake Force Distribution ECAM Engine Control And Measurement System Electronic Controlled Diesel… -
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01–37 INTRODUCTION – TERMS Abbreviations Meaning High Intensity Discharge (Head Lamp) Hydraulic Power Unit Housing Hard Top Heated Windshield System Idle Air Control Integrated Circuit Indirect Diesel Injection Independent Front Suspension Ignition Integrated Ignition Assembly Intake (Manifold, Valve) Intermittent Instrument Panel Independent Rear Suspension Idle Speed Control Junction Block… -
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Special Service Materials Special Service Tools Standard Cold–Start Fuel Injection Switch System Transaxle TACH Tachometer Throttle Body Electronic Fuel Injection Turbocharger TCCS TOYOTA Computer–Controlled System Timing Control Valve Top Dead Center TEMP. Temperature 2004 COROLLA (RM1037U) Author : Date :… -
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Abbreviations Meaning TEMS TOYOTA Electronic Modulated Suspension Toyota Free–Tronic Total Information System For Vehicle Development Transmission TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharge Three–Way Catalyst TVIP TOYOTA Vehicle Intrusion Protection Underdrive Undersize… -
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– TERMS 010DA–02 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their TOYOTA equivalents. TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )––ABBREVIATIONS… -
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01–41 INTRODUCTION – TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO Idle Air Control Idle Speed Control (ISC) Intake Air Temperature Intake or Inlet Air Temperature Ignition Control Module – Indirect Fuel Injection Indirect Injection (IDL) Inertia Fuel–Shutoff – Idle Speed Control –… -
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01–42 INTRODUCTION – TERMS Transmission Control Module Transmission ECU, ECT ECU Throttle Position Throttle Position Transmission Range – Bimetallic Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three–Way Catalytic (TWC) Three–Way Catalytic Converter Manifold Converter TWC+OC Three–Way + Oxidation Catalytic Converter + CCo Volume Air Flow… -
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PREPARATION 09816–30010 Oil Pressure Switch Socket SFI SYSTEM Diagnosis Check Wire No.2 SFI SYSTEM 09843–18040 SUPPLEMENTAL RESTRAINT SYSTEM Recomended Tools TOYOTA Electrical Tester SFI SYSTEM 09082–00040 SUPPLEMENTAL RESTRAINT SYSTEM ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] COMBINATION METER WIRELESS DOOR LOCK CONTROL SYSTEM (09083–00150) -
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02–2 PREPARATION – ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM 021A2–03 PREPARATION Equipment Ohmmeter Radiator cup tester Torque wrench 2004 COROLLA (RM1037U) Author : Date :… -
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FUEL SYSTEM (09268–41300) Hose FUEL SYSTEM (95336–08070) 09842–30080 Wire ”H” EFI Inspection FUEL SYSTEM Recomended Tools 09082–00040 TOYOTA Electrical Tester FUEL SYSTEM Test Lead Set FUEL SYSTEM (09083–00150) Butyl Tape Set FUEL PUMP ASSY 08850–00065 FUEL TANK ASSY Equipment Service wire harness… -
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02–4 PREPARATION – EMISSION CONTROL EMISSION CONTROL 021BN–01 PREPARATION 09992–00242 Turbocharger Pressure Gauge EMISSION CONTROL SYSTEM Equipment Service Wire Harness Ohmmeter Vacuum gauge 2004 COROLLA (RM1037U) Author : Date :… -
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02–5 PREPARATION – ENGINE MECHANICAL ENGINE MECHANICAL 021CI–02 PREPARATION 09011–38121 12 mm Socket Wrench for 12 CYLINDER BLOCK ASSY(April, 2003) Pointed Head Oil Pan Seal Cutter PARTIAL ENGINE ASSY(April, 2003) 09032–00100 09201–01055 Valve Guide Bushing Remover & CYLINDER HEAD ASSY Replacer 5.5 Valve Guide Bushing Remover &… -
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02–6 PREPARATION – ENGINE MECHANICAL 09228–06501 Oil Filter Wrench PARTIAL ENGINE ASSY(April, 2003) 09268–21010 Fuel Hose Puller CYLINDER HEAD GASKET 09301–00210 Clutch Guide Tool ENGINE REAR OIL SEAL PARTIAL ENGINE ASSY(April, 2003) Boll Joint Puller PARTIAL ENGINE ASSY(April, 2003) 09628–62011 09670–00010 Front Crossmember Guide Tool PARTIAL ENGINE ASSY(April, 2003) -
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02–7 PREPARATION – ENGINE MECHANICAL (09963–01000) Pin 10 CHAIN SUB–ASSY TIMING CHAIN OR BELT COVER OIL SEAL ENGINE REAR OIL SEAL CYLINDER HEAD GASKET PARTIAL ENGINE ASSY(April, 2003) Compression Gauge Attachment ENGINE ASSEMBLY 09992–00500 CYLINDER HEAD GASKET Recomended Tools Pin Punch . CYLINDER HEAD ASSY 09031–00040 09040–00011… -
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02–8 PREPARATION – ENGINE MECHANICAL 08833–00080 Adhesive 1344 CYLINDER BLOCK ASSY(April, 2003) THREE BOND 1344 LOCTITE 242 or equivalent Equipment CO/HC meter Cylinder gauge Dial indicator Feeler gauge Micrometer Piston heater Plastigage Precision straight edge Radiator cap tester Sandpaper(#400) Steel square Straight edge Spring tester Spring tension gauge… -
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02–9 PREPARATION – EXHAUST EXHAUST 021A3–02 PREPARATION Equipment Torque wrench Vernier calipers 2004 COROLLA (RM1037U) Author : Date :… -
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Test Lead Set COOLING FAN SYSTEM (09083–00150) Equipment Heater Radiator cap tester Slide calipers Thermometer Torque wrench Coolant Item Capacity Classification Engine coolant 6.5 liters (6.9 US qts, 5.7 lmp. qts) TOYOTA long life coolant 2004 COROLLA (RM1037U) Author : Date :… -
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02–11 PREPARATION – LUBRICATION LUBRICATION 021A4–03 PREPARATION 09228–06501 Oil Filter Wrench OIL FILTER SUB–ASSY Equipment Feeler gauge Radiator cup tester Torque wrench Lubricant Item Capacity Classification Oil grade API grade SL Energy–Conserving or ILSAC, mul- – ti–grade engine oil Drain and refill w/ oil filter change 3.7 liters (3.9 US qts, 3.3 lmp. -
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02–12 PREPARATION – IGNITION IGNITION 021A5–02 PREPARATION Recomended Tools (09857–00031) Spark Plug Gap Gauge IGNITION SYSTEM Equipment Ohmmeter Spark plug cleaner 2004 COROLLA (RM1037U) Author : Date :… -
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Alternator Pulley Set Nut 22 mm GENERATOR ASSY (09820–06020) Wrench Recomended Tools 09011–12291 Socket Wrench for 29 mm . GENERATOR ASSY 09082–00040 TOYOTA Electrical Tester STARTING SYSTEM STARTER ASSY GENERATOR ASSY STARTING SYSTEM(April, 2003) STARTER ASSY(April, 2003) Test Lead Set STARTING SYSTEM (09083–00150) -
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02–14 PREPARATION – FRONT SUSPENSION FRONT SUSPENSION 021C2–01 PREPARATION 09628–62011 Boll Joint Puller LOWER BALL JOINT ASSY FRONT Front Crossmember Guide Tool FRONT SUSPENSION 09670–00010 SUB–ASSY LOWER NO.1 LH STABILIZER BAR FRONT 09727–30021 Coil Spring Compressor FRONT SHOCK ABSORBER WITH COIL SPRING Front Spring Upper Seat Holder FRONT SHOCK ABSORBER WITH… -
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02–15 PREPARATION – REAR SUSPENSION REAR SUSPENSION 021BV–01 PREPARATION 09710–04101 Base REAR AXLE BEAM ASSY Coil Spring Compressor REAR SHOCK ABSORBER WITH 09727–30021 COIL SPRING 09950–40011 Puller B Set REAR AXLE BEAM ASSY Hanger 200 REAR AXLE BEAM ASSY (09951–04020) Slide Arm REAR AXLE BEAM ASSY (09952–04010) -
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02–16 PREPARATION – REAR SUSPENSION (09951–00630) Replacer 63 REAR AXLE BEAM ASSY Recomended Tools Hexagon Wrench Set REAR SHOCK ABSORBER WITH 09040–00011 COIL SPRING Socket Hexagon Wrench 6 REAR SHOCK ABSORBER WITH (09043–20060) COIL SPRING Equipment Torque wrench Dial indicator with magnetic base Wheel balancer Tire pressure gauge Alignment tester… -
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02–17 PREPARATION – TIRE & WHEEL TIRE&WHEEL 021C4–01 PREPARATION Equipment Tire pressure gauge Dial indicator with magnetic base Wheel balancer 2004 COROLLA (RM1037U) Author : Date :… -
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02–18 PREPARATION – DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT / PROPELLER SHAFT 021BZ–01 PREPARATION 09240–00020 Wire Gauge Set FRONT DRIVE SHAFT Wire Gauge FRONT DRIVE SHAFT (09242–00150) 1.5 mm (0.059 in.) 09520–00031 Rear Axle Shaft Puller FRONT AXLE HUB SUB–ASSY LH Drive Shaft Remover Attachment FRONT DRIVE SHAFT 09520–01010… -
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02–19 PREPARATION – DRIVE SHAFT / PROPELLER SHAFT 09608–32010 Steering Knuckle Oil Seal FRONT AXLE HUB SUB–ASSY LH Replacer Ball Joint Puller REAR AXLE LH HUB BOLT 09628–10011 FRONT AXLE LH HUB BOLT Boll Joint Puller FRONT DRIVE SHAFT 09628–62011 FRONT AXLE HUB SUB–ASSY LH 09930–00010 Drive Shaft Nut Chisel… -
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02–20 PREPARATION – DRIVE SHAFT / PROPELLER SHAFT 09950–60010 Replacer Set FRONT AXLE HUB SUB–ASSY LH Replacer 37 FRONT AXLE HUB SUB–ASSY LH (09951–00370) Replacer 60 FRONT AXLE HUB SUB–ASSY LH (09951–00600) (09951–00640) Replacer 64 FRONT AXLE HUB SUB–ASSY LH Replacer Set No.2 FRONT AXLE HUB SUB–ASSY LH 09950–60020… -
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02–21 PREPARATION – DRIVE SHAFT / PROPELLER SHAFT Equipment Torque wrench Dial indicator with magnetic base Lubricant Item Capacity Front drive shaft Inboard joint grease 135 – 155 g (4.8 – 5.5 oz.) 2004 COROLLA (RM1037U) Author : Date :… -
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02–22 PREPARATION – BRAKE BRAKE 021CC–02 PREPARATION 09023–00100 Union Nut Wrench 10 mm BRAKE FLUID FRONT BRAKE REAR BRAKE BRAKE ACTUATOR ASSY BRAKE BOOSTER ASSY PROPORTIONING VALVE ASSY BRAKE MASTER CYLINDER SUB–ASSY(April, 2003) Crankshaft Pulley Replacer SKID CONTROL SENSOR 09214–76011 Rear Axle Shaft Puller SKID CONTROL SENSOR 09520–00031… -
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02–23 PREPARATION – BRAKE Equipment Ruler Dial indicator Micrometer Torque wrench Brake drum gauge Lubricant Item Capacity Classification Brake fluid – SAE J1703 or FMVSS No. 116 DOT3 2004 COROLLA (RM1037U) Author : Date :… -
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02–24 PREPARATION – PARKING BRAKE PARKING BRAKE 021CD–01 PREPARATION 09718–00010 Shoe Hold Down Spring Driver PARKING BRAKE CABLE ASSY NO.3 Equipment Torque wrench 2004 COROLLA (RM1037U) Author : Date :… -
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021CJ–01 PREPARATION 09023–12700 Union Nut Wrench 17mm AUTOMATIC TRANSAXLE ASSY(ATM) Oil Seal Puller FRONT DIFFERENTIAL 09308–00010 SEAL(ATM) 09350–32014 TOYOTA Automatic Transmission AUTOMATIC TRANSAXLE Tool Set ASSY(ATM) FRONT DIFFERENTIAL SEAL(ATM) TORQUE CONVERTER CLUTCH AND DRIVE PLATE(ATM) (09351–32010) One–way Clutch Test Tool… -
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02–26 PREPARATION – AUTOMATIC TRANSMISSION / TRANS Recomended Tools 09011–12301 Socket Wrench 30 mm AUTOMATIC TRANSAXLE ASSY(ATM) 09042–00010 Torx Socket T30 FLOOR SHIFT PARKING LOCK CABLE ASSY(ATM) Socket Hexagon Wrench 10 FRONT DIFFERENTIAL (09043–20100) SEAL(ATM) Equipment Straight edge Torque converter clutch Vernier calipers Torque converter clutch Dial indicator or dial indicator with magnetic base… -
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INPUT SHAFT ASSY(C59) OUTPUT SHAFT ASSY(C59) (09316–00011) Replacer Pipe MANUAL TRANSAXLE ASSY(C59) Replacer ”A” INPUT SHAFT ASSY(C59) (09316–00021) (09316–00031) Replacer ”B” OUTPUT SHAFT ASSY(C59) 09350–32014 TOYOTA Automatic Transmission MANUAL TRANSAXLE ASSY(C59) Tool Set 2004 COROLLA (RM1037U) Author : Date :… -
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02–28 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE (09351–32120) Overdrive Bearing Replacer MANUAL TRANSAXLE ASSY(C59) Drive Shaft Remover Attachment MANUAL TRANSAXLE ASSY 09520–01010 FRONT DIFFERENTIAL OIL SEAL Differential Side Gear Shaft MANUAL TRANSAXLE ASSY 09520–24010 Puller FRONT DIFFERENTIAL OIL SEAL (09520–32040) Shocker Set MANUAL TRANSAXLE ASSY FRONT DIFFERENTIAL OIL SEAL Differential Oil Seal Replacer… -
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02–29 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE 09636–20010 Upper Ball Joint Dust Cover MANUAL TRANSAXLE ASSY(C59) Replacer INPUT SHAFT ASSY(C59) Front Crossmember Guide Tool MANUAL TRANSAXLE ASSY 09670–00010 Front Suspension Bushing Tool MANUAL TRANSAXLE ASSY(C59) 09710–20011 (09710–06071) Replacer MANUAL TRANSAXLE ASSY(C59) Back–up Light Switch Tool MANUAL TRANSAXLE ASSY(C59) 09817–16011 Drive Shaft Nut Chisel… -
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02–30 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE (09957–04010) Attachment MANUAL TRANSAXLE ASSY(C59) Puller B Set MANUAL TRANSAXLE ASSY(C59) 09950–40011 Hanger 150 MANUAL TRANSAXLE ASSY(C59) (09951–04010) (09951–04020) Hanger 200 MANUAL TRANSAXLE ASSY(C59) Slide Arm MANUAL TRANSAXLE ASSY(C59) (09952–04010) Center Bolt 150 MANUAL TRANSAXLE ASSY(C59) (09953–04020) (09953–04030) Center Bolt 200… -
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02–31 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE (09951–00190) Replacer 19 MANUAL TRANSAXLE ASSY(C59) Replacer 20 MANUAL TRANSAXLE ASSY(C59) (09951–00200) Replacer 22 SHIFT & SELECT LEVER SHAFT (09951–00220) ASSY(C59) (09951–00360) Replacer 36 MANUAL TRANSAXLE ASSY(C59) Replacer 37 MANUAL TRANSAXLE ASSY(C59) (09951–00370) Replacer 42 MANUAL TRANSAXLE ASSY(C59) (09951–00420) (09951–00450) -
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02–32 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE 09950–70010 Handle Set FRONT DIFFERENTIAL OIL SEAL MANUAL TRANSAXLE ASSY(C59) SHIFT & SELECT LEVER SHAFT ASSY(C59) Handle 100 MANUAL TRANSAXLE ASSY(C59) (09951–07100) SHIFT & SELECT LEVER SHAFT ASSY(C59) Handle 150 MANUAL TRANSAXLE ASSY(C59) (09951–07150) (09951–07200) Handle 200 FRONT DIFFERENTIAL OIL SEAL Recomended Tools… -
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02–33 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE Lubricant Item Capacity Classification API GL–4 or GL–5 Manual transaxle oil 1.9 liters (2.0 US qts, 1.7 lmp. qts) SAE 75W–90 (w/ Differential oil) 2004 COROLLA (RM1037U) Author : Date :… -
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CLUTCH MASTER CYLINDER ASSY 09031–00030 09040–00011 Hexagon Wrench Set CLUTCH MASTER CYLINDER ASSY CLUTCH PEDAL SUB–ASSY 09082–00040 TOYOTA Electrical Tester CLUTCH START SWITCH ASSY 09905–00013 Snap Ring Pliers CLUTCH MASTER CYLINDER ASSY Equipment Vernier calipers Dial indicator with magnetic base… -
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02–35 PREPARATION – STEERING COLUMN STEERING COLUMN 021CA–01 PREPARATION 09950–50013 Puller C Set STEERING COLUMN ASSY Hanger 150 STEERING COLUMN ASSY (09951–05010) (09952–05010) Slide Arm STEERING COLUMN ASSY Center Bolt 150 STEERING COLUMN ASSY (09953–05020) Claw No.2 STEERING COLUMN ASSY (09954–05021) Recomended Tools 09042–00010… -
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02–36 PREPARATION – POWER STEERING POWER STEERING 021CB–01 PREPARATION 09023–38200 Union Nut Wrench 12mm RACK & PINION POWER STEERING GEAR ASSY Union Nut Wrench 14mm VANE PUMP ASSY 09023–38400 RACK & PINION POWER STEERING GEAR ASSY 09521–24010 Rear Axle Shaft Puller RACK &… -
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02–37 PREPARATION – POWER STEERING 09631–10030 Oil Seal Remover VANE PUMP ASSY Steering Rack Oil Seal Test Tool RACK & PINION POWER STEERING 09631–12071 GEAR ASSY Packing RACK & PINION POWER STEERING (09633–00010) GEAR ASSY 09631–16020 Steering Rack Cover ”A” RACK &… -
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02–38 PREPARATION – POWER STEERING (09952–05010) Slide Arm RACK & PINION POWER STEERING GEAR ASSY Center Bolt 150 RACK & PINION POWER STEERING (09953–05020) GEAR ASSY Claw No.2 RACK & PINION POWER STEERING (09954–05021) GEAR ASSY 09950–60010 Replacer Set VANE PUMP ASSY RACK &… -
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02–39 PREPARATION – POWER STEERING (09952–06010) Adapter RACK & PINION POWER STEERING GEAR ASSY Handle Set VANE PUMP ASSY 09950–70010 RACK & PINION POWER STEERING GEAR ASSY Handle 100 VANE PUMP ASSY (09951–07100) RACK & PINION POWER STEERING GEAR ASSY (09951–07150) Handle 150 RACK &… -
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02–40 PREPARATION – HEATER & AIR CONDITIONER HEATER & AIR CONDITIONER 021CK–01 PREPARATION 07110–58060 Air Conditioner Service Tool Set REFRIGERANT COOLER COMPRESSOR ASSY W/RECEIVER CONDENSER ASSY AIR CONDITIONER UNIT ASSY Refrigerant Drain Service Valve REFRIGERANT (07117–58060) COOLER COMPRESSOR ASSY W/RECEIVER CONDENSER ASSY AIR CONDITIONER UNIT ASSY (07117–58070) T–Joint… -
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02–41 PREPARATION – HEATER & AIR CONDITIONER 09950–50013 Puller C Set AIR CONDITIONER UNIT ASSY Hanger 150 AIR CONDITIONER UNIT ASSY (09951–05010) Slide Arm AIR CONDITIONER UNIT ASSY (09952–05010) (09953–05020) Center Bolt 150 AIR CONDITIONER UNIT ASSY Claw No.2 AIR CONDITIONER UNIT ASSY (09954–05021) Recomended Tools Hexagon Wrench Set… -
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02–42 PREPARATION – HEATER & AIR CONDITIONER 95416–00140 Gas Leak Detector REFRIGERANT (Halogen Leak Detector) COOLER COMPRESSOR ASSY (DENSO Part No.) W/RECEIVER CONDENSER ASSY AIR CONDITIONER UNIT ASSY Equipment Voltmeter Anmeter Ohmmeter Vinyl tape Hexagon wrench 5 mm (0.20 in.) Hexagon wrench 14 mm (0.55 in.) Vise pliers Gas leak detector… -
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02–43 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 022XY–01 PREPARATION 09082–00700 SRS Airbag Deployment Tool FRONT SEAT AIRBAG ASSY RH INSTRUMENT PANEL PASSENGER AIR BAG ASSY HORN BUTTON ASSY(April, 2003) Airbag Deployment Wire FRONT SEAT AIRBAG ASSY RH 09082–00750 Sub–harness No.3 09082–00780 Airbag Deployment Wire… -
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02–44 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM (09954–05021) Claw No.2 SPIRAL CABLE SUB–ASSY Recomended Tools Torx Socket T30 SPIRAL CABLE SUB–ASSY 09042–00010 Equipment Torque wrench Bolt Length: 35.0 mm (1.387 in.) Pitch: 1.0 mm (0.039 in.) Airbag disposal Diam.: 6.0 mm (0.236 in.) Tire Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.) -
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02–45 PREPARATION – SEAT BELT SEAT BELT 021C3–02 PREPARATION 09082–00700 SRS Airbag Deployment Tool FRONT SEAT BELT Airbag Deployment Wire FRONT SEAT BELT 09082–00770 Sub–harness No.5 Equipment Torque wrench 2004 COROLLA (RM1037U) Author : Date :… -
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02–46 PREPARATION – LIGHTING LIGHTING 021C6–01 PREPARATION Recomended Tools 09070–20010 Moulding Remover BACK UP LAMP ASSY LH Test Lead Set LIGHTING SYSTEM (09083–00150) Equipment Torque wrench 2004 COROLLA (RM1037U) Author : Date :… -
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PREPARATION 09843–18040 Diagnosis Check Wire No.2 WIPER AND WASHER SYSTEM Recomended Tools 09042–00010 Torx Socket T30 WINDSHIELD WIPER MOTOR ASSY TOYOTA Electrical Tester WIPER AND WASHER SYSTEM 09082–00040 Test Lead Set WIPER AND WASHER SYSTEM (09083–00150) Equipment Torque wrench 2004 COROLLA (RM1037U) -
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02–48 PREPARATION – AUDIO & VISUAL SYSTEM AUDIO & VISUAL SYSTEM 021C1–01 PREPARATION 09950–50013 Puller C Set ANTENNA CORD SUB–ASSY Hanger 150 ANTENNA CORD SUB–ASSY (09951–05010) (09952–05010) Slide Arm ANTENNA CORD SUB–ASSY Center Bolt 150 ANTENNA CORD SUB–ASSY (09953–05020) Claw No.2 ANTENNA CORD SUB–ASSY (09954–05021) Recomended Tools… -
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02–49 PREPARATION – AUDIO & VISUAL SYSTEM 09060–60350 Revet Cutter FRONT NO.1 SPEAKER ASSY Moulding Remover ANTENNA CORD SUB–ASSY 09070–20010 AMPLIFIER ANTENNA ASSY Equipment Torque wrench 2004 COROLLA (RM1037U) Author : Date :… -
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02–50 PREPARATION – COMMUNICATION SYSTEM COMMUNICATION SYSTEM 021CO–01 PREPARATION Recomended Tools 09082–00040 TOYOTA Electrical Tester HORN SYSTEM Equipment Battery 2004 COROLLA (RM1037U) Author : Date :… -
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02–51 PREPARATION – WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD/WINDOWGLASS/MIRROR 021CG–01 PREPARATION Recomended Tools 09070–20010 Moulding Remover WINDSHIELD GLASS TOYOTA Electrical Tester WINDOW DEFOGGER SYSTEM 09082–00040 POWER MIRROR CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM Test Lead Set POWER WINDOW CONTROL (09083–00150) SYSTEM Equipment Adhesive Knife… -
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02–52 PREPARATION – INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER 021C0–01 PREPARATION 09950–50013 Puller C Set INSTRUMENT PANEL SUB–ASSY LOWER Hanger 150 INSTRUMENT PANEL SUB–ASSY (09951–05010) LOWER (09952–05010) Slide Arm INSTRUMENT PANEL SUB–ASSY LOWER Center Bolt 150 INSTRUMENT PANEL SUB–ASSY (09953–05020) LOWER Claw No.2 INSTRUMENT PANEL SUB–ASSY (09954–05021) LOWER… -
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02–53 PREPARATION – SEAT SEAT 021BX–01 PREPARATION Equipment Hog ring pliers Hog ring Torque wrench Tape To avoid surface damage 2004 COROLLA (RM1037U) Author : Date :… -
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02–54 PREPARATION – THEFT DETERRENT & DOOR LOCK THEFT DETERRENT & DOOR LOCK 021CN–01 PREPARATION Recomended Tools 09082–00040 TOYOTA Electrical Tester POWER DOOR LOCK CONTROL SYSTEM 2004 COROLLA (RM1037U) Author : Date :… -
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02–55 PREPARATION – SLIDING ROOF/CONVERTIBLE SLIDING ROOF/CONVERTIBLE 021C9–02 PREPARATION Recomended Tools 09041–00020 Torx Driver T25 SLIDING ROOF HOUSING SUB–ASSY TOYOTA Electrical Tester SLIDING ROOF SYSTEM 09082–00040 Equipment Torque wrench 2004 COROLLA (RM1037U) Author : Date :… -
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02–56 PREPARATION – ENGINE HOOD/DOOR ENGINE HOOD/DOOR 022VI–01 PREPARATION 09804–24010 Luggage Compartment Door Torsion LUGGAGE DOOR HINGE TORSION Bar Tool BAR RH Door Hinge Set Bolt Wrench FRONT DOOR 09812–00010 Recomended Tools Torx Socket T30 FRONT DOOR 09042–00010 REAR DOOR Torx Socket T40 FRONT DOOR 09042–00020… -
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02–57 PREPARATION – EXTERIOR/INTERIOR TRIM EXTERIOR/INTERIOR TRIM 021C5–02 PREPARATION Recomended Tools 09070–20010 Moulding Remover FRONT DOOR BELT MOULDING ASSY LH REAR DOOR BELT MOULDING ASSY LH ROOF DRIP SIDE FINISH MOULDING CENTER LH REAR BUMPER ROOF HEADLINING ASSY Equipment Adhesive tape To avoid surface damage. -
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02–58 PREPARATION – VEHICLE CONTROL SYSTEM VEHICLE CONTROL SYSTEM 021CP–01 PREPARATION Recomended Tools 09082–00040 TOYOTA Electrical Tester IGNITION OR STARTER SWITCH ASSY 2004 COROLLA (RM1037U) Author : Date :… -
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02–59 PREPARATION – CRUISE CONTROL CRUISE CONTROL 021BI–01 PREPARATION 09950–50013 Puller C Set SPEED CONTROL MAIN SWITCH ASSY Hanger 150 SPEED CONTROL MAIN SWITCH (09951–05010) ASSY (09952–05010) Slide Arm SPEED CONTROL MAIN SWITCH ASSY Center Bolt 150 SPEED CONTROL MAIN SWITCH (09953–05020) ASSY Claw No.2… -
Page 105
03–26 SERVICE SPECIFICATIONS – REAR SUSPENSION REAR SUSPENSION 030PR–01 SERVICE DATA Toe–in (total) 0_16’ » 16’ (0.26_ » 0.26_, 2.6 » 2.5 mm, 0.10 » 0.10 in.) USA, Canada P195/65R15 89S 0_16’ » 16’ (0.26_ » 0.26_, 2.6 » 2.5 mm, 0.10 » 0.10 in.) P185/65R15 86S Rear wheel align- 0°01’… -
Page 106
03–27 SERVICE SPECIFICATIONS – REAR SUSPENSION 030PS–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Piston rod set nut Shock absorber x Body Hub nut 1,050 Shock absorber x Rear axle beam Stabilizer bar x Rear axle beam 1,990 Rear axle hub set bolt Parking brake cabke bracket set bolt 48 in. -
Page 107
03–28 SERVICE SPECIFICATIONS – TIRE & WHEEL TIRE&WHEEL 030Q2–01 SERVICE DATA Tire runout 3.0 mm (0.118 in.) or less Imbalance after adjustment 8.0 g (0.018 lb) or less 2004 COROLLA (RM1037U) Author : Date :… -
Page 108
03–29 SERVICE SPECIFICATIONS – DRIVE SHAFT / PROPELLER SHAFT / AXLE DRIVE SHAFT / PROPELLER SHAFT / AXLE 030PW–01 SERVICE DATA Front axle hub bearing Backlash Maximum: 0.05 mm (0.0020 in.) Front axle hub sub–assy Deviation Maximum: 0.05 mm (0.0020 in.) Rear axle hub &… -
Page 109
03–30 SERVICE SPECIFICATIONS – DRIVE SHAFT / PROPELLER SHAFT / AXLE 030PX–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Front wheel set nut 1,050 Rear wheel set nut 1,050 Manual transaxle oil drain plug 39.2 Automatic transaxle fluid drain plug 17.5 Lower ball joint assy front x Suspension arm sub–assy lower No.1 Tie rod end sub–assy x Steering knuckle… -
Page 110
03–31 SERVICE SPECIFICATIONS – BRAKE BRAKE 030Q4–01 SERVICE DATA Brake pedal height (from asphalt sheet) 134.9 – 144.9 mm (5.311 – 5.703 in.) 136.0 – 146.0 mm (5.353 – 5.747 in.) Brake Pedal free play 1 – 6 mm (0.04 – 0.24 in.) Stop light switch clearance 0.5 –… -
Page 111
03–32 SERVICE SPECIFICATIONS – BRAKE 030Q5–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Bleeder plug 74 in. lbf Brake booster clevis lock nut Brake pedal support sub–assy x Brake pedal sub–assy 36.8 Brake booster x Body 12.7 Brake pedal support sub–assy x Body 23.6 Brake master cylinder x Piston stopper bolt Brake master cylinder x Reservoir… -
Page 112
03–33 SERVICE SPECIFICATIONS – PARKING BRAKE PARKING BRAKE 030Q6–01 SERVICE DATA Parking brake lever travel at 196 N (20 kgf, 44.1 lbf): 6 – 9 clicks 2004 COROLLA (RM1037U) Author : Date :… -
Page 113
03–34 SERVICE SPECIFICATIONS – PARKING BRAKE 030Q7–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Wheel nut 1,050 Parking brake lock nut 44 in. lbf Parking brake lever sub–assy x body 12.5 Heat insulator No.2 x Body 48 in. lbf Heat insulator No.1 x Body 48 in. -
Page 114
03–35 SERVICE SPECIFICATIONS – AUTOMATIC TRANSMISSION / TRANSAXLE AUTOMATIC TRANSMISSION / TRANSAXLE 0305K–06 SERVICE DATA A245E Line pressure (Wheel locked) Engine idling D position 382 – 422 kPa (3.9 – 4.3 kgf/cm , 55 – 61 psi) R position 647 – 760 kPa (6.6 – 7.8 kgf/cm , 94 –… -
Page 115
03–36 SERVICE SPECIFICATIONS – AUTOMATIC TRANSMISSION / TRANSAXLE 0305L–06 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Park/neutral position switch x Transaxle Bolt 49 in. lbf 49 in. lbf Control shaft lever x Park/neutral position switch 12.5 Battery carrier x Body Engine hanger x Engine Drain plug x Oil pan 17.5… -
Page 116
03–37 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE MANUAL TRANSMISSION / TRANSAXLE 030QD–01 SERVICE DATA MANUAL TRANSAXLE ASSY 5th gear thrust clearance STD: 0.10 – 0.57 mm (0.0039 – 0.0224 in.) MAX: 0.57 mm (0.0224 in.) 5th gear radial clearance KOYO made STD: 0.015 –… -
Page 117
03–38 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE 3rd gear radial clearance KOYO made STD: 0.015 – 0.058 mm (0.0006 – 0.0023 in.) MAX: 0.058 mm (0.0023 in.) NSK made STD: 0.015 – 0.056 mm (0.0006 – 0.0022 in.) MAX: 0.056 mm (0.0022 in.) Input shaft run out MAX: 0.015 mm (0.0006 in.) -
Page 118
03–39 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE Output shaft front bearing snap ring thickness 1.85 – 1.90 mm (0.728 – 0.0748 in.) 1.90 – 1.95 mm (0.748 – 0.0768 in.) 1.95 – 2.00 mm (0.768 – 0.0787 in.) 2.00 – 2.05 mm (0.787 – 0.0807 in.) 2.05 –… -
Page 119
03–40 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE 030QE–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Floor shift transmission control cable assy x Body 44 in. lbf Front floor heat insulator No.1 x Body 49 in. lbf Airbag sensor assy center x Body 17.5 Shift cable grommet retainer No.1 x Body 44 in. -
Page 120
03–41 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE Part Tightened kgf cm ft lbf Shift & select lever shaft assy x Manual transmission case 19.6 Lock ball assy No.1 x Manual transmission case 29.4 Selecting bell crank assy x Manual transmission case 24.5 Floor shift control lever housing support bracket x Transaxle case 11.3… -
Page 121
03–42 SERVICE SPECIFICATIONS – CLUTCH CLUTCH 030EF–02 SERVICE DATA Pedal height from asphalt sheet 135.8 – 145.8 mm (5.346 – 5.740 in.) Clutch pedal free play 5.0 – 15.0 mm (0.197 – 0591 in.) Clutch pedal push rod play at pedal top 1.0 –… -
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03–43 SERVICE SPECIFICATIONS – CLUTCH 030EG–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Clutch pedal sub–assy x Clutch pedal support 36.8 Clutch pedal support set bolt x Body 19.1 Cylinder push rod clevis lock nut 24.5 Clutch master cylinder assy x Clutch pedal support 11.8 Clutch master cylinder assy x Flexible hose tube 15.2… -
Page 123
03–44 SERVICE SPECIFICATIONS – STEERING COLUMN STEERING COLUMN 030Q8–01 SERVICE DATA STEERING SYSTEM Steering wheel freeplay Maximum 30 mm (1.18 in.) 2004 COROLLA (RM1037U) Author : Date :… -
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03–45 SERVICE SPECIFICATIONS – STEERING COLUMN 030Q9–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Sliding yoke x Steering intermediate shaft Sliding yoke x Steering column assy Steering column assy set bolt Steering wheel set nut Steering wheel pad set screw (Torx screw) 78 in.·lbf 2004 COROLLA (RM1037U) Author :… -
Page 125
03–46 SERVICE SPECIFICATIONS – POWER STEERING POWER STEERING 030QA–01 SERVICE DATA POWER STEERING FLUID Fluid level rise Maximum 5 mm (0.20 in.) Fluid pressure at idle speed with valve closed 7,300 – 7,800 kPa (75 – 80 kgf/cm , 1,067 – 1,138 psi) STEERING WHEEL Steering effort at idle speed (Reference) 6 N·m (60 kgf·cm, 53 in.·lbf) -
Page 126
03–47 SERVICE SPECIFICATIONS – POWER STEERING 030QB–01 TORQUE SPECIFICATION Part tightened kgf cm ft lbf POWER STEERING VANE PUMP Vane pump housing rear x Vane pump housing front Pressure port union Suction port union set bolt Oil pressure switch Vane pump assy x Vane pump bracket rear Vane pump assy set bolt Pressure feed tube assy x Vane pump assy 41 (44) -
Page 127
03–48 SERVICE SPECIFICATIONS – HEATER AND AIR CONDITIONING HEATER & AIR CONDITIONER 030QI–01 SERVICE DATA 490 » 30 g (17.28 » 1.06 oz.) Refrigerant charge volume Standard: Magnetic clutch clearance 0.35 – 0.60 mm (0.013 – 0.023 in.) 2004 COROLLA (RM1037U) Author : Date :… -
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03–49 SERVICE SPECIFICATIONS – HEATER AND AIR CONDITIONING 030QJ–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf AIR CONDITIONER UNIT ASSY Air conditioning tube assy x Cooler evaporator sub–assy No. 1 30 in. lbf Air conditioner unit assy x Body 87 in. -
Page 129
03–50 SERVICE SPECIFICATIONS – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 030FN–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Horn button assy x Steering wheel assy 78 in. lbf Steering wheel assy x Steering column assy Instrument panel passenger airbag assy x Instrument panel reinforcement Airbag sensor assy center x Body 17.5 Airbag front RH sensor x Body… -
Page 130
03–51 SERVICE SPECIFICATIONS – SEAT BELT SEAT BELT 030PY–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf FRONT SEAT BELT Front shoulder belt anchor adjuster assy x Body 41.2 Front seat outer belt assy (Upper part of retractor) x Body 43 in. -
Page 131
03–52 SERVICE SPECIFICATIONS – WIPER & WASHER WIPER & WASHER 030PT–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Wind shield wiper motor assy Wiper link assy 66 in. lbf Wiper link assy Body 49 in. lbf FR Wiper arm RH Wiper link 20.5 FR Wiper arm LH… -
Page 132
03–53 SERVICE SPECIFICATIONS – AUDIO & VISUAL SYSTEM AUDIO & VISUAL SYSTEM 030PN–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Amplifier antenna assy x Antenna nut 40 in. lbf 2004 COROLLA (RM1037U) Author : Date :… -
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03–54 SERVICE SPECIFICATIONS – INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER 030PZ–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Instrument panel reinforce Body 2004 COROLLA (RM1037U) Author : Date :… -
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03–55 SERVICE SPECIFICATIONS – SEAT SEAT 030PU–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf FRONT SEAT Seat back assembly x Seat adjuster assembly Seat belt inner x Seat adjuster assembly Seat assembly x Body REAR SEAT (SEDAN WITH SEPARATE TYPE) Seat back hinge x Seat back REAR SEAT (SEDAN WITH BENCH TYPE) Seat back assembly x Body… -
Page 135
03–56 SERVICE SPECIFICATIONS – SLIDING ROOF/CONVERTIBLE SLIDING ROOF/CONVERTIBLE 030QN–02 SERVICE DATA Sliding roof Difference in level between sliding roof weatherstrip and roof panel 0 + 1.5 mm (0 » 0.059 in.) Except corners of rear side Corner of rear side –1.0 –… -
Page 136
03–57 SERVICE SPECIFICATIONS – SLIDING ROOF/CONVERTIBLE 030QO–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Sliding roof glass assembly Drive cable 35 in. lbf Sliding roof housing assembly Body 44 in. lbf Sliding roof housing assembly Sliding roof drive gear 47 in. -
Page 137
03–58 SERVICE SPECIFICATIONS – ENGINE HOOD/DOOR ENGINE HOOD/DOOR 030Q3–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf HOOD Hood x Hood hinge Hood lock x Body 71 in. lbf FRONT DOOR Front door check assembly (door panel side bolt) x Front door 49 in. -
Page 138
03–59 SERVICE SPECIFICATIONS – EXTERIOR/INTERIOR TRIM EXTERIOR/INTERIOR TRIM 030PV–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Radiator grille Body 44 in. lbf Front bumper reinfocement Body Rear bumper arm LH Body Rear bumper arm RH Body Rear bumper reinfocement No.1 Rear bumper arm LH Rear bumper reinfocement No.1 Rear bumper arm RH Bumper mounting set bolt No. -
Page 139
03–60 SERVICE SPECIFICATIONS – CRUISE CONTROL CRUISE CONTROL 030OV–01 SERVICE DATA Accelerator auto drive cable clearance Standard 2 – 6 mm (0.079 – 0.236 in.) 2004 COROLLA (RM1037U) Author : Date :… -
Page 140
03–61 SERVICE SPECIFICATIONS – CRUISE CONTROL 030PO–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Cruise control actuator assy x Cruise control bracket 52 in. lbf 2004 COROLLA (RM1037U) Author : Date :… -
Page 141
10–1 ENGINE CONTROL SYSTEM – SFI SYSTEM SFI SYSTEM 1008D–01 ON–VEHICLE INSPECTION INSPECTION THROTTLE BODY IDLE SPEED Open CONTROL VALVE ASSY NOTICE: It is impossible to check the resister value and the op- Close eration of ISC valve by itself, because the ISC valve has an IC circuit inside it, which transforms the duty Valve signal from the ECM to the derive signal. -
Page 142
10–2 ENGINE CONTROL SYSTEM – SFI SYSTEM 1008E–02 INSPECTION INTAKE AIR FLOW METER SUB–ASSY Ohmmeter Inspect the intake air flow meter resistance. Using an ohmmeter, measure the resistance be- tween terminals THA and E2. Resistance: At –20_C (–4_F) 13.6 to 18.4 kΩ At 20_C (68_F) 2.21 to 2.69 kΩ… -
Page 143
10–3 ENGINE CONTROL SYSTEM – SFI SYSTEM THROTTLE BODY ASSY Throttle Stop Screw Check throttle body. Check that throttle valve shaft is not rickety. Check that each port is not stopped up. Check that throttle valve opens and closes smooth- Check that there is no clearance between the throttle stop screw and throttle lever at the throttle Throttle Lever… -
Page 144
10–4 ENGINE CONTROL SYSTEM – SFI SYSTEM E.F.I. ENGINE COOLANT TEMPERATURE SENSOR Resistance inspection. Using an ohmmeter, measure the resistance be- Ohmmeter tween each terminal. Resistance: At 20_C (68_F) 2.32 – 2.59 kΩ At 80_C (176_F) 0.310 – 0.326 kΩ NOTICE: In case of checking the water temperature sensor in the wa- ter, be careful not to allow water to go into the terminals,… -
Page 145
10–5 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY THROTTLE BODY ASSY 1008F–01 COMPONENTS 7.0 (71, 62 in.·lbf) Clip Vacuum Hose Cylinder Head Vacuum Hose Cover No. 2 Air Cleaner Hose No. 1 Manifold Stay No. 2 (M/T) 13 (133, 9.6) Water By–pass Hose 30 (306, 22) z Gasket… -
Page 146
10–6 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY 1008G–02 Removal & Installation and Disassembly & Reassembly DRAIN COOLANT(See page 16–7) REMOVE CYLINDER HEAD COVER NO.2 Remove 2 nuts, 2clips and the cylinder head cover No. 2. A65077 REMOVE AIR CLEANER CAP SUB–ASSY Disconnect the MAF connector. -
Page 147
10–7 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY Disconnect 2 water by–pass hoses. A65189 Remove 5 bolts, 2 nuts, throttle body bracket and throttle body. (Transaxle M/T) A65190 Remove 3bolts, 2nuts and throttle body. (Transaxle A/T) A66636 Remove 2 bolts and accelerator cable bracket. A65192 REMOVE E.F.I. -
Page 148
10–8 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY REMOVE THLOTTLE BODY IDLE SPEED CONTROL VALVE ASSY Remove 3 screws and the idle speed control valve assy. Remove the gasket from the throttle body. A65182 INSTALL THLOTTLE BODY IDLE SPEED CONTROL VALVE ASSY Install a new gasket on the throttle body. -
Page 149
10–9 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY Install the throttle body with 5 bolts and 2 nuts.(Transaxle M/T) Torque: A 30 N m (306 kgf cm, 22 ft lbf) B 13 N m (133 kgf cm, 9.6 ft lbf) A65190 Install the throttle body with 3 bolts and 2 nuts.(Transaxle A/T) -
Page 150
10–10 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY Connect 3 vacuum hoses, as shown in the illustration. Connect the VSV connector. Connect the intake air flow meter connector. A65177 INSTALL CYLINDER HEAD COVER NO.2 Install the cylinder head cover No. 2 with 2 nuts and 2 clips. -
Page 151
10–11 ENGINE CONTROL SYSTEM – ECM (1ZZ–FE) (April, 2003) ECM (1ZZ–FE) (April, 2003) 100HN–02 REPLACEMENT DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE GLOVE COMPARTMENT DOOR ASSY (See Page 71–10) REMOVE ECM Remove the 2 clips using a clip remover. Then, open the cover. -
Page 152
10–12 ENGINE CONTROL SYSTEM – ECM (1ZZ–FE) (April, 2003) REMOVE ECM BRACKET NO.2 (DENSO MADE) Remove the 2 screws, then remove the ECM bracket No. A83795 REMOVE ECM BRACKET NO.1 Remove the 2 screws, then remove the ECM bracket No. DENSO Made: DELCO Made: A83796… -
Page 153
10–13 ENGINE CONTROL SYSTEM – ECM (1ZZ–FE) (April, 2003) INSTALL ECM COVER Install a new ECM cover to the ECM as shown in the il- lustration. DENSO Made: DELCO Made: 1 to 6.2 mm (0.039 to 0.244 in.) 4.5 mm (0.177 in.) 0 to 2.5 mm (0 to 0.098 in.) 5 mm… -
Page 154
11–10 FUEL – FUEL INJECTOR ASSY 110FJ–01 REPLACEMENT WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11–1) REMOVE CYLINDER HEAD COVER NO.2 Remove the 2 nuts, 2 clips and cylinder head cover. A65077 DISCONNECT VENTILATION HOSE Disconnect the ventilation hose from the cylinder head cover. -
Page 155
11–11 FUEL – FUEL INJECTOR ASSY DISCONNECT FUEL TUBE SUB–ASSY Using a SST, disconnect the fuel tube. Retainer 09268–21010 (at 4 places) Assemble the SST to the connection as shown. Turn the SST, align the retainers inside the connec- tor with the SST chamfered parts and insert the SST into the connector. -
Page 156
11–12 FUEL – FUEL INJECTOR ASSY REMOVE FUEL INJECTOR ASSY Pull out the 4 fuel injectors from the fuel delivery pipe. A65085 INSTALL FUEL INJECTOR ASSY New Insulator Install a new insulator to the each fuel injector. Apply a light coat of spindle oil or gasoline to a new O– ring, and install it to the each fuel injector. -
Page 157
11–13 FUEL – FUEL INJECTOR ASSY INSTALL CYLINDER HEAD COVER NO.2 Install the cylinder head cover with the 2 nuts and 2 clips. Torque: 7.0 N m (71 kgf cm, 62 in. lbf) CHECK FUEL LEAK (See page 11–1) 2004 COROLLA (RM1037U) Author : Date :… -
Page 158
11–14 FUEL – FUEL PUMP ASSY FUEL PUMP ASSY 110FK–01 COMPONENTS Rear Seat Cushion Assy Rear Floor Service Hole Cover Fuel Tank Main Tube Sub–assy 6.0 (61, 53 in. lbf) Fuel Evaporation Tube Sub–assy No 2 Fuel Tank Vent Tube Set Plate Tube Joint Clip Fuel Pump Assembly z Gasket… -
Page 159
11–15 FUEL – FUEL PUMP ASSY Vapor Pressure Sensor Assy Tube Joint Clip Fuel Pump Harness Fuel Suction Plate Sub–assy Fuel Filter Fuel Sender Gauge Assy Fuel Pump Assy z O–ring Fuel Pressure Regulator Assy Fuel Pump Filter z Clip Fuel Pump Cushion Rubber Fuel Suction Support No. -
Page 160
11–16 FUEL – FUEL PUMP ASSY 110FL–01 Removal & Installation and Disassembly & Reassembly REMOVE BENCH TYPE REAR SEAT CUSHION ASSY (See page 72–6, 72–8) REMOVE REAR FLOOR SERVICE HOLE COVER Remove the rear service hole cover. Butyl Tape A65023 Disconnect the fuel pump and vapor pressure sensor connector. -
Page 161
11–17 FUEL – FUEL PUMP ASSY DISCONNECT FUEL EMISSION TUBE SUB–ASSY NO.1 Pinch the fuel tube connector clip and then pull out the fuel emission tube. NOTICE: Check if there is any dirt like mud around the fuel tube connector before this work and clean dirt away. Be careful of dirt like mud because the fuel tube con- nector has an O–ring to seal the fuel tube connector A65025… -
Page 162
11–18 FUEL – FUEL PUMP ASSY REMOVE FUEL SUCTION SUPPORT NO.2 Using a screwdriver, disconnect the 5 snap claws from the claw holes, and remove the fuel suction support. NOTICE: Do not damage the fuel suction support. A65029 REMOVE FUEL PUMP CUSHION RUBBER Remove the fuel pump cushion rubber. -
Page 163
11–19 FUEL – FUEL PUMP ASSY REMOVE FUEL PUMP HARNESS Remove the fuel pump harness from the fuel suction plate. A65034 REMOVE FUEL PUMP Pull out the fuel pump from the fuel filter. A65035 REMOVE FUEL PUMP FILTER Using a small screwdriver, pry out the clip. Pull out the fuel pump filter from the fuel pump. -
Page 164
11–20 FUEL – FUEL PUMP ASSY INSTALL FUEL PRESSURE REGULATOR O–RING Apply a light coat Apply a light coat of gasoline to a new O–ring, and install of gasoline it to the fuel pressure regulator. A65038 INSTALL FUEL PUMP FILTER Install the fuel pump filter with a new clip. -
Page 165
11–21 FUEL – FUEL PUMP ASSY CONNECT FUEL TANK MAIN TUBE SUB–ASSY Connect the fuel tank main tube with the tube joint clip. NOTICE: Check that there is no scratch or foreign objects on the connecting parts. Check that the fuel tube joint is inserted fully and securely. Check that the tube joint clip is on the collar of the fuel tube joint. -
Page 166
11–22 FUEL – FUEL TANK ASSY FUEL TANK ASSY 110FD–01 COMPONENTS Rear Seat Cushion Assy Rear Floor Service Hole Cover Fuel Tank Main Tube Sub–assy 6.0 (61, 53 in. lbf) Fuel Evaporation Tube Sub–assy No 2 Fuel Tank Vent Tube Set Plate Tube Joint Clip Fuel Pump Assembly z Gasket… -
Page 167
11–23 FUEL – FUEL TANK ASSY Parking Brake Cable Assy No. 2 5.4 (55, 48 in. lbf) 5.4 (55, 48 in. lbf) Parking Brake Cable Assy No. 3 Clip Fuel Tank Protector No. 1 Front Floor Carpet Assy Front z Gasket 5.4 (55, 48 in. -
Page 168
11–24 FUEL – FUEL TANK ASSY Fuel Emission Tube Check Valve Protector Sub–assy No. 1 Fuel Tube Vent Hose Valve to Fuel Filler Pipe Hose Fuel Tank Inlet Valve Assy Fuel Tank Main Tube Sub–assy z Gasket z Fuel Tank Cushion No. 1 Fuel Tube Clamp No. -
Page 169
11–25 FUEL – FUEL TANK ASSY 110FE–01 Removal & Installation and Disassembly & Reassembly REMOVE BENCH TYPE REAR SEAT CUSHION ASSY (See page 72–6, 72–8) REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11–16) WORK FOR PREVENTING GASOLINE FROM SPILLING OUT Start the engine. -
Page 170
11–26 FUEL – FUEL TANK ASSY Disconnect the oxygen sensor connector. Remove the 2 exhaust pipe supports. Remove the 4 bolts, 4 compression springs and exhaust pipe. A65706 REMOVE FUEL TANK PROTECTOR NO.1 Remove the 5 bolts and fuel tank protector. A65049 SEPARATE PARKING BRAKE CABLE ASSY NO.2 Remove the 2 installing bolts of the parking brake cable. -
Page 171
11–27 FUEL – FUEL TANK ASSY SEPARATE PARKING BRAKE CABLE ASSY NO.3 Remove the 2 installing bolts of the parking brake cable. A65051 DISCONNECT FUEL TANK MAIN TUBE SUB–ASSY Pinch the fuel tube connector clip, and remove the fuel tube connector clip. Pull out the fuel tank main tube. -
Page 172
11–28 FUEL – FUEL TANK ASSY DISCONNECT FUEL TANK VENT HOSE Disconnect the fuel tank bent hose from the charcoal can- Push ister. Pinch Push the connector deep inside. Pinch portion A. Pinch Pull out the connector. A65056 DISCONNECT VALVE TO FUEL FILLER PIPE HOSE Disconnect the valve to fuel filler pipe hose from the fuel tank inlet pipe. -
Page 173
11–29 FUEL – FUEL TANK ASSY REMOVE FUEL TANK MAIN TUBE SUB–ASSY Remove the fuel tank main tube from the fuel tube clamp and bracket. A65061 REMOVE FUEL TUBE CLAMP NO.4 Remove the bolt and fuel tank clamp. A65062 REMOVE FUEL TUBE BRACKET Remove the fuel tube bracket from the fuel tank. -
Page 174
11–30 FUEL – FUEL TANK ASSY REMOVE FUEL TUBE CLAMP NO.2 Remove the fuel tube clamp from the fuel tank. A65065 REMOVE CHECK VALVE PROTECTOR Using a screwdriver, unlock the claw, and remove the check valve protector by turning it counter clockwise. A65066 REMOVE FUEL TANK INLET VALVE ASSY Clip Remover… -
Page 175
11–31 FUEL – FUEL TANK ASSY REMOVE FUEL TANK CUSHION NO.1 Remove the 7 fuel tank cushions from the fuel tank. A65069 INSTALL FUEL TANK CUSHION NO.1 Install the 7 new fuel tank cushions to the fuel tank. A65069 INSTALL CHECK VALVE GASKET Install a new gasket to the fuel tank. -
Page 176
11–32 FUEL – FUEL TANK ASSY INSTALL FUEL TANK ASSY Set a mission jack to the fuel tank. Install the fuel tank and 2 fuel tank bands with the 4 bolts. Torque: 39 N m (400 kgf cm, 29 ft lbf) CONNECT FUEL EMISSION TUBE SUB–ASSY NO.1 Push in the fuel tube connector to the pipe until fuel tube connector makes ”click”… -
Page 177
11–33 FUEL – FUEL TANK ASSY Install a new gasket on the exhaust pipe (rear side). Install the exhaust pipe with the 4 compression springs and 4 bolts. Tail Pipe Side Torque: 43 N m (440 kgf cm, 32 ft lbf) Install the 2 exhaust pipe supports. -
Page 178
12–7 EMISSION CONTROL – EMISSION CONTROL SYSTEM While holding the air inlet port closed, apply vacuum Purge Port (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the EVAP port Air Inlet Port and check that air flows into the purge port. If operation is not as spacified, replace the charcoal canister. -
Page 179
12–8 EMISSION CONTROL – EMISSION CONTROL SYSTEM VENTILATION VALVE SUB–ASSY Cylinder Head Side Install clean hose to the PCV valve. Inspect the PCV valve operation. Clean Hose Blow air into the cylinder head side, and check that air passes through easily. CAUTION: Do not suck air through the valve. -
Page 180
12–9 EMISSION CONTROL – EMISSION CONTROL SYSTEM Check that air flows from ports E to F. A65914 Apply battery positive voltage across the terminals. Check that air does not flow from ports E to F. If operation is not as specified, replace the VSV. Battery A65915 VACUUM SWITCHING VALVE ASSY NO.1… -
Page 181
12–10 EMISSION CONTROL – EMISSION CONTROL SYSTEM Apply battery positive voltage across the terminals. Check that air does not flow from ports A to B. If operation is not as specified, replace the VSV. Battery A65919 2004 COROLLA (RM1037U) Author : Date : 1010…
’04 Corolla_U (L/O 0306)
1
2004 COROLLA from Oct. ’03 Prod. (OM12859U)
OPERATION OF INSTRUMENTS AND
CONTROLS
Overview of instruments and controls
Instrument panel overview 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument cluster overview 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicator symbols on the instrument panel 6. . . . . . . . . . . . . . . . . . . . . . .
SECTION 1− 1
Рычаг переключения передач Рис. 3.69. Рычаг переключения передач Рычаг переключения передач состоит из следующих
Проверка уровня масла в механической коробке передач Остановите автомобиль на ровной площадке. Отверните пробку
Рис. 3.89. Детали рычага переключения передач Отсоединение тросов механизма выбора и переключения передач в
Рис. 2.218. Компоненты головки блока цилиндров Снятие конической резьбовой пробки № 2 Рис. 2.219.
Общие сведения Рис. 3.63. Привод сцепления Привод сцепления состоит из следующих узлов: электродвигатель, датчик
Слейте масло. Снимите передние колеса. Снимите передний левый приводной вал в сборе. Снимите передний
Внимание! Не разбирайте наружный шарнир Разборка Слейте рабочую жидкость из автоматической коробки передач (автоматическая
Рис. 3.54. Коробки передач устанавливаемые на автомобили Corolla Verso На новые модели Corolla Verso
Рис. 3.59. Блок-схема системы мультимодальной коробки передач В целом, устройство и принцип действия мультимодальной
Трехконусный механизм синхронизации (1-я и 2-я передачи) Рис. 3.56. Трехконусный механизм синхронизации (1-я и
This manual covers the operation and repair of a Toyota Corolla manufactured from 2001 to 2006. The book describes the repair of cars with petrol and diesel engines with a volume of 1.4 / 1.6 /
2.0D liters.
Your Toyota Corolla car
Manual
Regular Maintenance — Gasoline Engines
Regular Maintenance — Diesel Engines
Repair Procedures Without Removing the Engine from the Engine Compartment — Gasoline Engines
Repair Procedures Without Removing the Engine from the Engine Compartment — Diesel Engines
Removing the Engine from the Engine Compartment and Overhaul Procedures
Cooling system, heater and air conditioning system
Power supply and exhaust system — petrol engines
Power supply and exhaust system — diesel engines
Emissions Control Systems — Gasoline Engines
Emissions Control Systems — Diesel Engines
Starting and recharging systems
Ignition system — gasoline engines
Clutch
Manual Transmission
Automatic transmission
Drive shafts
Brake system
Steering and suspension
Body structure and components
Electrical equipment and electrical systems
Toyota Corolla 2001-2007 INTRODUCTION Download
Toyota Corolla 2001-2007 PREPARATION Download
Toyota Corolla 2001-2007 SERVICE SPECIFICATIONS Download
Toyota Corolla 2001-2007 DIAGNOSTICS-ABS Download
Toyota Corolla 2001-2007 DIAGNOSTICS-AUTOMATIC TRANSMISSION Download
Toyota Corolla 2001-2007 DIAGNOSTICS-AUDIO SYSTEM Download
Toyota Corolla 2001-2007 DIAGNOSTICS-COMBINATION METER Download
Toyota Corolla 2001-2007 DIAGNOSTICS – CRUISE CONTROL SYSTEM Download
Toyota Corolla 2001-2007 DIAGNOSTICS – POWER DOOR LOCK CONTROL SYSTEM Download
Toyota Corolla 2001-2007 DIAGNOSTICS-SFI SYSTEM Download
Toyota Corolla 2001-2007 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM Download
Toyota Corolla 2001-2007 DIAGNOSTICS-TOYOTA VEHICLE INTRUSION PROTECTION Download
Toyota Corolla 2001-2007 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM Download
Toyota Corolla 2001-2007 ENGINE CONTROL SYSTEM Download
Toyota Corolla 2001-2007 FUEL Download
Toyota Corolla 2001-2007 EMISSION CONTROL Download
Toyota Corolla 2001-2007 ENGINE MECHANICAL Download
Toyota Corolla 2001-2007 EXHAUST Download
Toyota Corolla 2001-2007 COOLING Download
Toyota Corolla 2001-2007 LUBRICATION Download
Toyota Corolla 2001-2007 IGNITION Download
Toyota Corolla 2001-2007 STARTING & CHARGING Download
Toyota Corolla 2001-2007 FRONT SUSPENTION Download
Toyota Corolla 2001-2007 REAR SUSPENTION Download
Toyota Corolla 2001-2007 TIRE & WHEEL Download
Toyota Corolla 2001-2007 DRIVE SHAFT . PROPELLER SHAFT Download
Toyota Corolla 2001-2007 BRAKE Download
Toyota Corolla 2001-2007 PARKING BRAKE Download
Toyota Corolla 2001-2007 AUTOMATIC TRANSMISSION .TRANS Download
Toyota Corolla 2001-2007 MANUAL TRANSMISSION.TRANSAXLE Download
Toyota Corolla 2001-2007 CLUTCH Download
Toyota Corolla 2001-2007 STEERING COLUMN Download
Toyota Corolla 2001-2007 POWER STEERING Download
Toyota Corolla 2001-2007 HEATER & AIR CONDITIONER Download
Toyota Corolla 2001-2007 SUPPLEMENTAL RESTRAINT SYSTEM Download
Toyota Corolla 2001-2007 SEAT BELT Download
Toyota Corolla 2001-2007 LIGHTING Download
Toyota Corolla 2001-2007 WIPER & WASHER Download
Toyota Corolla 2001-2007 AUDIO & VISUAL SYSTEM Download
Toyota Corolla 2001-2007 WIRING Download
Toyota Corolla 2001-2007 COMMUNICATION SYSTEM Download
Toyota Corolla 2001-2007 WINDSHIELD.WINDOWGLASS.MIRROR Download
Toyota Corolla 2001-2007 INSTRUMENT PANEL.METER Download
Toyota Corolla 2001-2007 SEAT Download
Toyota Corolla 2001-2007 THEFT DETTERENT & DOOR LOCK Download
Toyota Corolla 2001-2007 SLIDING ROOF.CONVERTIBLE Download
Toyota Corolla 2001-2007 ENGINE HOOD. DOOR Download
Toyota Corolla 2001-2007 EXTERIOR/INTERIOR TRIM Download
Toyota Corolla 2001-2007 VEHICLE CONTROL SYSTEM Download
Toyota Corolla 2001-2007 CRUISE CONTROL Download
Toyota Corolla 2001-2007 MAINTENANCE Download
2005 SYSTEM WIRING DIAGRAMS Toyota — Corolla CE 1ZZ Fe Download
2007 SYSTEM WIRING DIAGRAMS Toyota — Corolla S Download
Руководство по эксплуатации и ремонту Toyota Corolla Verso 3
В этом разделе вы найдете пошаговые инструкции с иллюстрациями по ремонту и техническому обслуживанию японских компактных минивэнов «Toyota Corolla Verso 3» (третье поколение, код AR10), которые производились с 2004 года по 2009 год. Данное руководство содержит в себе информацию по ремонту бензиновых двигателей объемом 1.6 литра (3ZZ-FE) и 1.8 литра (ZZ-FE), а также дизельных моторов объемом 2.0 литра (1CD-FTV). Помимо этого вы найдете информацию по ремонту и обслуживанию других узлов автомобиля, таких как трансмиссия, ходовая часть, электрооборудование и элементов кузова.
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