Toyota Corolla (2004+). Manual - part 2

 

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Toyota Corolla (2004+). Manual - part 2

 

 

01-1
INTRODUCTION
- HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
0103I-08
GENERAL INFORMATION
1.
GENERAL DESCRIPTION
(a)
This manual is made in accordance with SAE J2008.
(b)
Generally, repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting
3. Final Inspection
(c)
This manual explains the 1st process of ”Diagnosis” (found in the ”Diagnostics” section), the 2nd pro-
cess of ”Removing and Installing, Replacing, Disassembling, Installing and Checking, and Adjusting”,
but the 3rd process of ”Final Inspection” is omitted.
(d)
The following essential operations are not written in this manual. However, these operations must be
performed in actual situations.
(1)
Operations with a jack or lift
(2)
Cleaning of a removed part when necessary
(3)
Visual check
2.
INDEX
(a)
An alphabetical INDEX section is provided at the end of the book as a reference to help you find the
item to be repaired.
3.
PREPARATION
(a)
Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repair situation. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4.
REPAIR PROCEDURES
(a)
Component drawing is placed under the title where necessary.
(b)
Non-reusable parts, grease application area, precoated parts and tightening torque are specified in
the component drawings.
Example:
Filler Cap
Float
Clevis Pin
F Gasket
Clip
Reservoir Tank
Boot
F Grommet
Slotted Spring Pin
12 (120, 9)
Clevis
15 (155, 11)
Snap Ring
Washer
Lock Nut
Push Rod
Piston
Cylinder
N·m (kgf·cm, ft·lbf)
: Specified torque
F Non-reusable part
N17080
01-2
INTRODUCTION
- HOW TO USE THIS MANUAL
(c)
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. are described in the illustration.
(d) Installing procedures are performed in the reverse order of the removal and only the important points
are described.
(e) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notices are placed.
(f)
There may be a case where the illustrations of similar models are used. In that case, specific details
may be different from the actual vehicle.
(g) The procedures are presented in a step-by-step format:
(1)
The illustration shows what to do and where to do it.
(2)
The task heading tells what to do.
(3)
The explanation text tells how to perform the task and gives other information such as specifica-
tions and warnings.
Example:
Illustration:
Task heading: what you will be doing
what to do and where
SST
Detailed text: how to perform task
Set part No.
Component part No.
D31132
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary and the text below provides detailed information. Important
specifications and warnings always are written in bold type to stand out from the rest of the text.
5.
SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for quick reference.
6.
TERMS DEFINITION
CAUTION
Indicates the possibility of injury to you or other people.
NOTICE
Indicates the possibility of damage to the components being repaired.
HINT
Provides additional information to help you to perform the repair efficiently.
01-3
INTRODUCTION
-
HOW TO USE THIS MANUAL
7.
SI UNIT
(a) 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 Nm (310 kgfcm, 22 ftlbf)
01-17
INTRODUCTION
- REPAIR INSTRUCTION
010D9-02
VEHICLE LIFT AND SUPPORT LOCATIONS
1.
NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP
(a)
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.
(b)
When removing any parts of heavy weight like the engine and transmission, the center of gravity of
the vehicle moves. Place a balance weight so as to keep it from rolling, or hold the jacking support
location using the mission jack.
2.
NOTICE FOR USING 4 POST LIFT
(a)
Follow the manual instruction for a safety operation.
(b)
Do not damage tires or wheels with a free wheel beam.
(c)
Using a wheel stopper, fix the vehicle.
3.
NOTICE FOR USING JACK AND SAFETY STAND
(a)
Work in a flat place using a wheel stopper at all times.
(b) Use a safety stand with a rubber attachment, as shown
Rubber Attachment
in the illustration.
(c)
Support the specified location with a jack and safety stand
accurately.
(d) When jacking up the front wheels, release the parking
brake and place wheel stoppers only behind the rear
wheels. When jacking up the rear wheels, place wheel
stoppers only in front of the front wheels.
D25082
(e) Do not work or leave the vehicle supported only by a jack.
Be sure to support the vehicle with a safety stand.
(f)
When jacking up only the front wheels or only the rear wheels, place wheel stoppers to both sides of
the wheels that contact ground.
(g)
When jacking down the vehicle with its front wheels jacked up, release the parking brake and place
wheel stoppers only in front of the rear wheels. When jacking down the vehicle with its rear wheels
jacked up, place wheel stoppers only behind the front wheels.
: SUPPORT POSITION, PANTOGRAPH JACK POSITION
: JACK POSITION
D27350
01-18
INTRODUCTION
- REPAIR INSTRUCTION
4.
NOTICE FOR USING SWING ARM TYPE LIFT
(a) Follow the manual instruction of the lift for a safe operation.
(b) Use a cradle with a rubber attachment, as shown in the illustration.
(c)
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.)
(d) 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.
(e) Be sure to lock the swing arm during the operation.
(f)
Lift the vehicle up until the tires float, and shake the vehicle to make sure that the vehicle is stable.
5.
NOTICE FOR USING PLATE TYPE LIFT
(a) Follow the manual instruction of the lift for a safe operation.
(b) Use a plate lift attachment.
(c)
Be sure to set the vehicle to the specified position.
Right and left set position
F Place the vehicle over the center of the lift.
F Align the cushion gum ends of the plate with the attachment lower ends (A and C).
Front and rear set position
F Align the attachment upper end (B) with the rocker flange front side notch.
(d) Lift the vehicle up until the tires float a bit, and shake the vehicle to make sure that the vehicle is stable.
Swing Arm Type Lift
Center of Lift
L
: CENTER OF VEHICLE
Rubber Attachment
GRAVITY (unload condition)
Plate Type Lift
Attachment Dimensions
85 mm (3.35 in.)
70 mm
(2.76 in.)
B
Attachment
100 mm (3.94 in.)
A
C
200 mm (7.87 in.)
D25021
01-5
INTRODUCTION
- REPAIR INSTRUCTION
REPAIR INSTRUCTION
010D8-02
PRECAUTION
1.
BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
2
1
3
6
5
4
D25016
F Always wear a clean uniform.
1
Looks
F Hat and safety shoes must be worn.
2
Vehicle protection
F Set a grill cover, fender cover, seat cover and floor mat before starting the operation.
F In case of working with 2 or more persons, be sure to check safety of one another.
F When working with the engine running, pay attention to the ventilation of the workshop.
F In case of operating on high-temperature parts, rotating, moving and vibrating parts, pay attention not to
3
Safe operation
burn or injure yourself.
F When jacking up the vehicle, be sure to support the specified location with a safety stand.
F When lifting up the vehicle, apply a safety equipment.
Preparation of tools and
4
F Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement.
measuring gauge
F Diagnose with a thorough understanding of the trouble phenomenon and perform effective operations.
Removal and installation,
F Before removing the parts, check the assembly for general condition, deformation and damage.
5
disassembly and assem-
F When the structure is complicated, take a note or put match marks so as not to make mistakes that affect the
bly operations
function of the parts.
F Clean and wash the removed parts if necessary, and assemble them after a thorough check.
F Place the removed parts in the correct order to avoid mixing up or making them dirty.
F As for non-reusable parts such as gasket, O-ring, and self lock nut, change them to new ones following the
6
Removed parts
manual of this instruction.
F Sort out the parts for replacement in a box and show them to the customer.
(b) 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 page 01-17).
01-6
INTRODUCTION
- REPAIR INSTRUCTION
(c)
PRECOATED PARTS
(1)
Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2)
If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3)
When reusing precoated parts, clean off the old
Seal Lock Adhesive
adhesive and dry the part with compressed air.
Z11554
Then apply the specified seal lock adhesive to the
bolt, nut or threads.
NOTICE:
Perform the torque checking with the lower limit value of
the torque tolerance.
(4)
Depending on the seal lock agent to apply, there
may be a case where it is necessary to leave it for
a specified time until it hardens.
(d)
GASKETS
(1)
When necessary, use a sealer on gaskets to prevent leaks.
(e)
BOLTS, NUTS AND SCREWS
(1)
Carefully observe all the specifications for tightening torques. Always use a torque wrench.
(f)
Fuses.
Medium Current Fuse and High Current
Fuse Equal Amperage Rating
(1)
When replacing fuses, be sure that a new fuse has
the correct amperage rating. DO NOT exceed the
rating, or use one with a lower rating.
BE1367
Illustration
Symbol
Part Name
Abbreviation
FUSE
FUSE
MEDIUM CURRENT FUSE
M-FUSE
HIGH CURRENT FUSE
H-FUSE
D27353
V35001
01-7
INTRODUCTION
- REPAIR INSTRUCTION
(g) CLIPS
(1)
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
Pliers
Clip Remover
Protective Tape
Screwdriver
Protective Tape
Scraper
D25786
01-8
INTRODUCTION
- REPAIR INSTRUCTION
Shape (Example)
Removal/Installation
Removal
Installation
Removal
Installation
Removal
Installation
V35004
01-9
INTRODUCTION
- REPAIR INSTRUCTION
(h) REMOVAL AND INSTALLATION OF VACUUM HOSES
(1)
To disconnect vacuum hoses, pull them by holding
the end, not the middle of the hose.
WRONG
CORRECT
D25063
(2)
When disconnecting vacuum hoses, use tags to
identify where they should be reconnected.
(3)
After completing the job, make a double check
whether the vacuum hoses are properly connected.
A 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
D25064
stretched, it may leak air.
(i)
TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
L1
L2
(1)
In case of tightening with a torque wrench which has
an extended length by combining the torque
wrench with SST or extension tool, if you tighten un-
til the reading of the torque wrench reaches the
specified torque value, the actual torque becomes
excessive.
D02612
(2)
In this manual, only the specified torque is de-
scribed. In case of using SST or an extension tool,
calculate the reading of the torque wrench by the
L1
L2
following formula.
(3)
Formula T’=T x L2/(L1 + L2)
T’
Reading of torque wrench Nmkgfcmftlbf
T
Torque Nmkgfcmftlbf
L1
Length of SST or extension tool (cm)
L2
Length of torque wrench (cm)
D01201
01-10
INTRODUCTION
- REPAIR INSTRUCTION
2.
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.
Failure to carry out the service operations in the correct sequence could cause the supplemental restraint
system to unexpectedly deploy during servicing. It may lead to a serious accident.
Furthermore, if a mistake is made in servicing the supplemental restraint system, it is possible that the SRS
will fail to operate when required. Before servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully. Then follow the correct procedure described in
this manual.
(a)
GENERAL NOTICE
(1)
Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diag-
nostic trouble codes become the most important source of information when troubleshooting.
When troubleshooting the supplemental restraint system, always check the diagnostic trouble
codes before disconnecting the battery (See page 05-424).
(2)
Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK”
position and the negative (-) terminal cable is disconnected from the battery.
(The supplemental restraint system is equipped with a back-up power source, so, if work is
started within 90 seconds after disconnecting the negative (-) terminal cable from the battery,
the SRS may deploy.)
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and
audio systems will be cancelled. So, before starting work, make a record of the memorized con-
tents in each memory system. Then, when work is finished, reset the clock and audio systems
as before. To avoid erasing the memory in each memory system, never use a back-up power
supply from another battery.
(3)
Even in case of a minor collision where the SRS does not deploy, the horn button assembly, the
instrument panel passenger airbag assembly, the front seat airbag assembly and the seat belt
pretensioner should be inspected (See pages 60-14, 60-26, 60-32 and 61-9).
(4)
Never use SRS related parts from another vehicle. When replacing parts, replace them with new
parts.
(5)
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
(6)
Never disassemble and repair the airbag sensor assembly, the horn button assembly, the instru-
ment panel passenger airbag assembly, the front seat airbag assembly or the seat belt preten-
sioner.
(7)
If the airbag sensor assembly, the side airbag sensor assembly, the horn button assembly, the
instrument panel passenger airbag assembly, the front seat airbag assembly or the seat belt pre-
tensioner have been dropped, or if there are cracks, dents or other defects in the case, bracket
or connector, replace them with new ones.
(8)
Do not directly expose the airbag sensor assembly, the horn button assembly, the instrument
panel passenger airbag assembly, the front seat airbag assembly or the seat belt pretensioner
to hot air or flames.
(9)
Use a volt/ohmmeter with high impedance (10 kW/V minimum) for troubleshooting of an electrical
circuit.
(10)
Information labels are attached to the SRS components. Follow the manuals on the notices.
(11)
After work on the supplemental restraint system is completed, check the SRS warning light (See
page 05-424).
01-11
INTRODUCTION
- REPAIR INSTRUCTION
(b) 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
Mark
troubles may occur. Refer to page 60-22 on this
manual concerning the correct installation of the
steering wheel.
D25079
(c)
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 top surface facing upward. Placing it with the pad surface facing downward may lead
to a serious accident if the airbag accidentally inflates. Also, do not place the horn button on top
of one another.
(2)
Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which
is very dangerous).
(3)
Grease should not be applied to the horn button assembly, and the pad should not be cleaned
with detergents of any kinds.
(4)
Store the horn button assembly where the ambient temperature remains below 93°C (200°F),
without high humidity and away from electrical noise.
(5)
When using electric welding, first disconnect the airbag connector (4 yellow pins) under the steer-
ing column near the combination switch connector before starting work.
(6)
When disposing of the vehicle or the horn button assembly alone, the airbag should be deployed
using an SST before disposal (See page 60-14).
Perform the operation in a safe place away from electrical noise.
Example:
CORRECT
WRONG
D27357
Example:
Z13950
01-12
INTRODUCTION
- REPAIR INSTRUCTION
(d) INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY
(1)
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.
(2)
Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which
is very dangerous).
(3)
Grease should not be applied to the instrument panel passenger airbag assembly, and the airbag
door should not be cleaned with detergents of any kind.
(4)
Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without
high humidity and away from electrical noise.
(5)
When using electric welding, first disconnect the airbag connector (4 yellow pins) installed on the
assembly before starting work.
(6)
When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using
an SST before disposal (See page 60-26).
Perform the operation in a safe place away from electrical noise.
Example:
CORRECT
WRONG
D27358
Example:
Z13951
(e) FRONT SEAT AIRBAG ASSEMBLY
(1)
Always store a removed or new front seat airbag assembly with the airbag inflation direction fac-
ing upward. Placing the airbag assembly with the airbag inflation direction facing downward
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
is very dangerous).
(3)
Grease should not be applied to the front seat airbag assembly, and the airbag door should not
be cleaned with detergents of any kind.
(4)
Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without
high humidity and away from electrical noise.
(5)
When using electric welding, first disconnect the airbag connector (2 yellow pins) installed on the
assembly before starting work.
01-13
INTRODUCTION
- REPAIR INSTRUCTION
(6)
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
(f)
SEAT BELT PRETENSIONER
(1)
Never measure the resistance of the seat belt pretensioner (This may cause the seat belt preten-
sioner to activate, which is very dangerous).
(2)
Never disassemble the seat belt pretensioner.
(3)
Never install the seat belt pretensioner to another vehicle.
(4)
Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F)
without high humidity and away from electrical noise.
(5)
When using electric welding, first disconnect the connector (2 yellow pins) before starting work.
(6)
When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensioner should
be activated before disposal (See page 61-9). Perform the operation in a safe place away from
electrical noise.
(7)
The seat belt pretensioner is hot after activation, so let it cool down sufficiently before disposal.
Never apply water to cool down the seat belt pretensioner.
(8)
Oil or water should not be put on the front seat outer belt, and the front seat outer belt should
not be cleaned with detergents of any kind.
Example:
D26613
(g) AIRBAG SENSOR ASSEMBLY
(1)
Never reuse the airbag sensor assembly 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, it could cause an undesired ignition of the supple-
mental restraint system.
(3)
Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK”
position and the negative (-) terminal cable is disconnected from the battery, even if only loosen-
ing the set bolts of the airbag sensor assembly.
01-14
INTRODUCTION
- REPAIR INSTRUCTION
(h) WIRE HARNESS AND CONNECTOR
(1)
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.
3.
ELECTRONIC CONTROL
Negative (-)
(a)
REMOVAL AND INSTALLATION OF BATTERY TERMI-
Terminal
NAL
(1)
Before performing electrical work, disconnect the
battery negative (-) terminal cable beforehand so
as to prevent burnt-out damage by short.
(2)
When disconnecting and installing the terminal
cable, turn the ignition switch and lighting switch
D25080
OFF, and loosen the terminal nut completely. Per-
form these operations without twisting or prying the
terminal.
(3)
When the battery terminal is removed, all the me-
mories of the clock, radio, DTCs, etc. will be erased.
So before removing it, check them and note them
down.
(b)
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 destroyed by static electric-
ity).
(2)
To disconnect electronic connectors, pull the con-
nector itself, not the wires.
(3)
Be careful not to drop electronic components, such
WRONG
D01556
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not be reused.
(4)
When cleaning the engine with steam, protect the
electronic components, air filter and emission-re-
lated components from water.
(5)
Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(6)
When checking the continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
4.
REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1)
Work in a place with good air ventilation and without anything flammable such as welder, grinder,
drill, electric motor or stove in the surroundings.
(2)
Never work in a place such as a pit or nearby a pit, as there is a possibility that vaporized fuel
is filled in those places.
(b) REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1)
Prepare a fire extinguisher before starting the operation.
(2)
For prevention of static electricity, install a ground on the fuel changer, vehicle and fuel tank, and
do not spray much water so as to prevent slipping.

 

 

 

 

 

 

 

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