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Toyota Corolla (2004+). Manual - part 12

03-52

SERVICE SPECIFICATIONS

- WIPER & WASHER

WIPER & WASHER

030PT-01

TORQUE SPECIFICATION

Part Tightened

Nm

kgfcm

ftlbf

Wind shield wiper motor assy  Wiper link assy

7.5

66 in.lbf

Wiper link assy  Body

5.5

49 in.lbf

FR Wiper arm RH  Wiper link

20.5

209

FR Wiper arm LH  Wiper link

20.5

209

17-10

LUBRICATION

- OIL FILTER SUB-ASSY

OIL FILTER SUB-ASSY

1707K-01

REPLACEMENT

CAUTION:

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from

the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains po-

tentially harmful contaminants which may cause skin cancer.

Exercise caution in order to minimize the length and frequency of contact of your skin to used

oil. W ear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use

water-less hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or sol-

vents.

In order to preserve the environment, used oil and used oil filter must be disposed of only at

designated disposal sites.

REMOVE ENGINE UNDER COVER RH

DRAIN ENGINE OIL

(a) Remove the oil pan drain plug and drain the engine oil.

REMOVE OIL FILTER SUB-ASSY

(a) Using SST, remove the oil filter

SST

09228-06501

SST

B00182

INSTALL OIL FILTER SUB-ASSY

(a) Check and clean the oil filter installation surface.

(b) Apply clean engine oil to the gasket of a new oil filter.

(c)

Lightly screw the oil filter into place, and tighten it until the

gasket contacts the seat.

3/4 turn

(d) Using SST, tighten it an additional 3/4 turn.

SST

09228-06501

A65962

INSTALL OIL PAN DRAIN PLUG

(a) Clean and install the oil pan drain plug with a new gasket.

Torque: 37 N m (377 kgf cm, 27 in. lbf)

17-11

LUBRICATION

OIL FILTER SUB-ASSY

ADD ENGINE OIL

Capacity:

Drain and refill w/ Oil filter change 3.7 liters (3.9 US qts, 3.3 lmp. qts)

Drain and refill w/o Oil filter change 3.5 liters (3.7 US qts, 3.1 lmp. qts)

Dry fill 4.2 liters (4.4 US qts, 3.7 lmp. qts)

INSPECT OIL LEAK

17-3

LUBRICATION

- OIL PUMP ASSY

OIL PUMP ASSY

1707L-01

COMPONENTS

Fan and Generator V Belt

54 (551, 40)

25 (255, 18)

37 (377, 27)

Vane Pump Assy

Terminal Cap

No. 1

Generator Assy

9.8 (100, 7)

7.0 (71, 62 in. lbf)

Clip

Cylinder Head Cover No. 2

52 (530, 38)

Engine Mounting Insulator Front LH

52 (530, 38)

Clip

Engine Under Cover RH

N·m (kgf·cm, ft·lbf)

: Specified torque

A64042

17-4

LUBRICATION

- OIL PUMP ASSY

9.0 (92, 80 in. lbf)

Engine Wire

9.0 (92, 80 in. lbf)

Ignition Coil Assy

Ventilation Hose No. 2

9.0 (92, 80 in. lbf)

11 (112, 8)

Seal Washer

11 (112, 8)

Clamp Bracket

11 (112, 8)

Ventilation Hose

Clamp Bracket

Cylinder Head Cover

Sub-assy

Gasket

N·m (kgf·cm, ft·lbf)

: Specified torque

A64043

17-5

LUBRICATION

- OIL PUMP ASSY

Transverse Engine

Engine Mounting Bracket

47 (479, 35)

29 (296, 21)

Chain Tensioner Assy No. 1

9.0 (92, 80 in. lbf)

Timing Chain or

V-ribbed Belt

Belt Cover Sub-assy

Tensioner Assy

13 (133, 10) (M6)

19 (194, 14) (M8)

13 (133, 10)

69 (704, 51)

Crankshaft Pulley

138 (1,047, 102)

F Oil Seal

9.0 (92, 80 in. lbf1) (L=20)

9.0 (92, 80 in. lbf)

11 (112, 8) (L=35)

Crank Position Sensor

F O-ring

Water Pump Assy

Chain Vibration Damper No. 1

Chain Sub-assy

Chain Tensioner Slipper

9.5 (97, 84 in. lbf)

Oil Pump Assy

F Gasket

19 (194, 14)

F Gasket

9.0 (92, 80 in. lbf)

37 (377, 27 )

Crankshaft timing

Oil Pan Drain Plug

Crankshaft Position Sensor

Plate No. 1

Sprocket

N·m (kgf·cm, ft·lbf)

: Specified torque

9.0 (92, 80 in. lbf)

F Non-reusable part

A65220

17-6

LUBRICATION

- OIL PUMP ASSY

Oil Pump Relief Valve Plug

37 (375, 27)

Oil Pump Body Cover

10 (105, 8.0)

Oil Pump Relief Valve Spring

Oil Pump Relief Valve

Drive Rotor

Driven Rotor

Oil Pump Body

N·m (kgf·cm, ft·lbf)

: Specified torque

A65213

17-8

LUBRICATION

- OIL PUMP ASSY

1707N-01

OVERHAUL

REMOVE OIL PUMP RELIEF VALVE

(a) Remove the oil pump relief valve plug, oil pump relief

(1)

valve spring and oil pump relief valve.

(1)

Oil pump relief valve plug

(2)

Oil pump relief valve spring

(2)

(3)

Oil pump relief valve

(3)

A64849

INSPECT OIL PUMP ASSY

(a) Remove 3 screws and oil pump cover.

A64847

(b) Inspect the oil pump relief valve.

(1)

Coat the valve with engine oil and check that it falls

smoothly into the valve hole by it own weight.

(c)

Inspect the oil pump rotor sub-assembly.

(1)

Coat the oil pump gear set with engine oil and place

them into the oil pump body. Check that the rotors

revolves smoothly.

A32175

(d) Inspect rotor tip clearance.

(1)

Using a feeler gauge, measure the clearance be-

tween the drive and driven rotor tips.

Standard tip clearance:

0.040 - 0.160 mm (0.0016 - 0.0063 in.)

A32176

17-9

LUBRICATION

- OIL PUMP ASSY

(e) Inspect body clearance.

(1)

Using a feeler gauge, measure the clearance be-

tween the driven rotor and body.

Standard body clearance:

0.260 - 0.325 mm (0.0102 - 0.0128 in.)

A32177

(f)

Inspect rotor side clearance.

(1)

Using a feeler gauge and precision straight edge,

measure the clearance between the rotors and pre-

cision straight edge.

Standard side clearance:

0.025 - 0.071 mm (0.0010 - 0.0028 in.)

A32178

(g) Install oil pump rotor sub-assembly.

Mark

(1)

Coat the oil pump gear set with engine oil and place

it into pump body with the marks facing the pump

body cover side.

A62990

(h) Install the oil pump cover with 3 screws.

Torque: 10 N m (105 kgf cm, 8.0 ft lbf)

A64847

INSTALL OIL PUMP RELIEF VALVE

(a) Install the oil pump relief valve plug, oil pump relief valve

(1)

spring and oil pump relief valve.

Torque: 37 N m (375 kgf cm, 27 ft lbf)

(1)

Oil pump relief valve plug

(2)

Oil pump relief valve spring

(3)

Oil pump relief valve

(3)

A64849

17-7

LUBRICATION

- OIL PUMP ASSY

1707M-02

REPLACEMENT

DRAIN ENGINE OIL

(a) Remove the oil pan drain plug and drain the engine oil.

REMOVAL & INSTALLATION CHAIN SUB-ASSY(See page

14-82)

REMOVE CHAIN VIBRATION DAMPER NO.1

(a) Remove 2 bolts and chain vibration damper No. 1.

REMOVE OIL PUMP ASSY

(a) Remove the 5 bolts.

(b) Remove the oil pump assy and gasket.

B08737

INSTALL OIL PUMP ASSY

(a) Place a new gasket on the cylinder block.

(b) Engage the spline teeth of the oil pump drive rotor with the

large teeth of the crankshaft, and side the oil pump.

(c)

Install the oil pump with the 5 bolts.

Torque: 9.0 N m (92 kgf cm, 80 in. lbf)

A30890

INSTALL CHAIN VIBRATION DAMPER NO.1

(a) Install the chain vibration damper No. 1 with 2 bolts.

Torque: 9.0 N m (92 kgf cm, 8.0 in. lbf)

INSTALL OIL PAN DRAIN PLUG

(a) Clean and install the oil pan drain plug with a new gasket.

Torque: 37 N m (377 kgf cm, 27 ft lbf)

ADD ENGINE OIL

Capacity:

Drain and refill w/ Oil filter change 3.7 liters (3.9 US qts, 3.3 lmp. qts)

Drain and refill w/o Oil filter change 3.5 liters (3.7 US qts, 3.1 lmp. qts)

Dry fill 4.2 liters (4.4 US qts, 3.7 lmp. qts)

ADD COOLANT(Seepage 16-7)

10. INSPECT OIL LEAK

11. INSPECT CHECK ENGINE COOLANT LEAK(See page 16-1)

17-1

LUBRICATION

- LUBRICATION SYSTEM (April, 2003)

LUBRICATION SYSTEM (April, 2003)

1707J-03

ON-VEHICLE INSPECTION

CHECK ENGINE OIL LEVEL

(a) After warming up the engine and then 5 minutes after the engine stops, oil level should be between

the ”L” and ”F” marks on the oil level gage.

If low, check for leakage and add oil up to the ”F” mark.

NOTICE:

Do not fill with engine oil above the ”F” mark.

CHECK ENGINE OIL QUALITY

(a) Check the oil for deterioration, entry of water, discoloring

Recommended Viscosity (SAE)

or thinning.

If the quality is visibly poor, replace the oil.

5W-30

Oil grade:

Use API grade SL ”Energy-Conserving”, or ILSAC

FC -29 -18

-7

multigrade engine oil.

FF -20

100

SAE 5W-30 is the best choice for good fuel economy,

A66623

and good starting in cold weather.

If SAE 5W-30 is not available, SAE 10W-30 may be

used.

However, it should be replaced with SAE 5W-30 at the

next oil replacement.

INSPECT OIL PRESSURE

(a) Disconnect the oil pressure switch connector.

(b) Using a 24 mm deep socket wrench, remove the oil pres-

sure switch.

Oil Pressure

Switch

A63370

(c)

Install the oil pressure gauge.

Oil Pressure Gauge

(d) Warm up the engine.

(e) Inspect the oil pressure.

Oil pressure:

At idle

29 kPa (0.3 kgf/cm2, 4.2 psi) or more

At 3,000 rpm

294 to 539 kPa (3.0 to 5.5 kgf/cm2, 43 to 78 psi)

A63373

17-2

LUBRICATION

- LUBRICATION SYSTEM (April, 2003)

(f)

Apply adhesive to 2 or 3 threads of the oil pressure switch.

Adhesive

Adhesive:

Part No. 08833-00080, THREE BOND 1344,

LOCTITE 242 or equivalent

(g) Using a 24 mm deep socket wrench, install the oil pres-

sure switch.

Torque: 15 N m (153 kgf cm, 11 ft lbf)

(h) Connect the oil pressure switch connector.

A50082

(i)

Check for the engine oil leaks.

18-2

IGNITION

- IGNITION SYSTEM

1804C-01

INSPECTION

SPARK PLUG

NOTICE:

Never use a wire brush for cleaning.

Never attempt to adjust the electrode gap on used

spark plug.

Spark plug should be replaced every 192,000 km

(120,000 miles).

(a) Clean the spark plugs.

Air pressure: Below 588 kPa (6.0 kg/cm

2, 85 psi)

Duration: 20 seconds or less

A50033

(b) Check the spark plug for thread damage and insulator

damage.

HINT:

If abnormal, replace the spark plug.

Recommended spark plug:

SK16R11 (DENSO made)

IFR5A11 (NGK made)

B01301

(c)

Check the spark plug electrode gap.

Electrode gap: 1.1 mm (0.043 in.)

Electrode Gap

B02101

CRANK POSITION SENSOR NO.1

(a) Using an ohmmeter, measure the resistance between terminals.

RESISTANCE:

At cold

835 - 1,400 W

At hot

1,060 - 1,645 W

NOTICE:

”Cold” and ”Hot” on the table express the temperature of the coils themselves. ”Cold” is from -10

(14_F) to 50 _C (122_F) and ”Hot” is from 50

_C (122_F) to 100 _C (212_F).

HINT:

If the resistance is not as specified, replace the crank position sensor No. 1.

18-3

IGNITION

- IGNITION SYSTEM

CRANK POSITION SENSOR

(a) Using an ohmmeter, measure the resistance between terminals.

RESISTANCE:

At cold

1,630 - 2,740

At hot

2,065 - 3,225 W

NOTICE:

”Cold” and ”Hot” on the table express the temperature of the coils themselves. ”Cold” is from -10

(14_F) to 50 _C (122_F) and ”Hot” is from 50

_C (122_F) to 100 _C (212_F).

HINT:

If the resistance is not as specified, replace the crank position sensor.

IGNITION RELAY

(a) Continuity inspection.

(1)

Using an ohmmeter, check that continuity exists be-

tween each terminal.

Specified condition:

Between terminal 1 and 2 Continuity

Between terminal 3 and 5 No continuity

(2)

Using an ohmmeter, check that continuity exists be-

E12471

tween terminals 3 and 5 when the battery voltage is

applied across terminals 1 and 2.

18-1

IGNITION

- IGNITION SYSTEM

IGNITION SYSTEM

1804B-01

ON-VEHICLE INSPECTION

NOTICE:

”Cold” and ”Hot” in these sentences express the temperature of the coils themselves. ”Cold” is from

-10_C (14_F) to 50 _C (122_F) and ”Hot” is from 50

_C (122_F) to 100 _C (212_F).

INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST

(a) Confirm DTC.

NOTICE:

If DTC is indicated, carry out troubleshooting in accordance with the procedure on the following DTC.

(b) Check that the spark occurs.

(1)

Remove the ignition coils (with igniter).

(2)

Using a 16 mm (0.63 in) plug wrench, remove the spark plugs.

(3)

Install the spark plugs to each ignition coils (with igniter), and connect the ignition coil connectors.

(4)

Disconnect the 4 injector connectors.

(5)

Ground the spark plugs.

(6)

Check if spark occurs while engine is being cranked.

NOTICE:

Be sure to ground the spark plug, when checking.

Replace the ignition coil when it is given an impact.

Do not crank the engine for more than 2 seconds.

HINT:

If the spark does not occur, do the test as follow.

(c)

Using a 16 mm (0.63 in.) plug wrench, install the spark plugs.

Torque: 25 N m (255 kgf cm, 18 ft lbf)

(d) Install the ignition coil with igniter.

Torque: 9.0 N m (92 kgf cm, 80 in. lbf)

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