Toyota Corolla (2004+). Manual - part 10
03-58
SERVICE SPECIFICATIONS
-
ENGINE HOOD/DOOR
ENGINE HOOD/DOOR
030Q3-02
TORQUE SPECIFICATION
Part Tightened
Nm
kgfcm
ftlbf
HOOD
Hood x Hood hinge
13
133
10
Hood lock x Body
7.0
82
71 in.lbf
FRONT DOOR
Front door check assembly (door panel side bolt) x Front door
5.5
56
49 in.lbf
Front door frame sub-assy rear lower x Front door
6.2
63
55 in.lbf
Front door glass sub-assy x Front door window regulator sub-assy
8.0
82
71 in.lbf
Front door hinge x Body
26
265
19
Front door hinge x Door panel
26
265
19
Front door lock assy x Front door
5.0
51
44 in.lbf
Front door lock striker x Body
23
235
17
Front door outside handle frame sub-assy x Front door
4.0
41
35 in.lbf
Front door outside handle cover installation bolt (torx)
4.0
41
35 in.lbf
Front door window regulator sub-assy x Front door
8.0
82
71 in.lbf
Outer rear view mirror assy x Front door
8.0
82
71 in.lbf
Power window regulator motor assy x Front door window regulator
5.4
55
48 in.lbf
REAR DOOR
Rear door check assembly (door panel side bolt) x Rear door
5.5
56
49 in.lbf
Rear door hinge x Body
26
265
19
Rear door hinge x Door panel
26
265
19
Rear door lock assy x Rear door
5.0
51
44 in.lbf
Rear door lock striker x Body
23
235
17
Rear door outside handle frame sub-assy x Rear door
4.0
41
35 in.lbf
Rear door outside handle cover installation bolt (torx)
4.0
41
35 in.lbf
Rear door window regulator sub-assy x Rear door
8.0
82
71 in.lbf
Rear door window division bar x Door panel
Bolt A
6.2
63
55 in.lbf
Power window regulator motor assy x Rear door window regulator
5.4
55
48 in.lbf
LUGGAGE COMPARTMENT DOOR
Luggage compartment door hinge x Luggage compartment door
7.0
71
62 in.lbf
Luggage compartment door lock assy x Luggage compartment door
5.5
56
49 in.lbf
Rear door lock striker x Body
5.5
56
49 in.lbf
03-20
SERVICE SPECIFICATIONS
- IGNITION
IGNITION
030P2-01
SERVICE DATA
Spark plug
Recommended spark plug
DENSO made
SK16R11
NGK made
IFR5A11
Electrode gap
Standard
1.1mm (0.043 in.)
Crank position sensor No. 1
Resistance
at cold
835-1,400W
at hot
1,060-1,645W
Crank position sensor
Resistance
at cold
1,630-2,740W
at hot
2,065-3,225W
Ignition relay
Specified condition
Between terminals 1 and 2
Continuity
Between terminals 3 and 5
No continuity
03-21
SERVICE SPECIFICATIONS
- IGNITION
030P3-01
TORQUE SPECIFICATION
Part Tightened
Nm
kgfcm
ftlbf
Spark plug x Cylinder head cover
25
225
18
Ignition coil x Cylinder head cover
9.0
92
80 in.lbf
03-54
SERVICE SPECIFICATIONS
- INSTRUMENT PANEL/METER
INSTRUMENT PANEL/METER
030PZ-01
TORQUE SPECIFICATION
Part Tightened
Nm
kgfcm
ftlbf
Instrument panel reinforce Body
20
204
15
03-18
SERVICE SPECIFICATIONS
- LUBRICATION
LUBRICATION
030P4-02
SERVICE DATA
Oil pressure
at idle speed
29 kPa (0.3 kgfcm2, 4.2 psi) or more
at 3,000 rpm
294 to 539 kPa (3.0 to 5.5 kgfcm2, 43 to 78 psi)
Oil pump assy
Tip clearance
0.040 to 0.160 mm (0.0016 to 0.0063 in.)
Body clearance
0.260 to 0.325 mm (0.0102 to 0.0128 in.)
Side clearance
0.025 to 0.071 mm (0.0010 to 0.0028 in.)
03-19
SERVICE SPECIFICATIONS
- LUBRICATION
030P5-02
TORQUE SPECIFICATION
Part Tightened
Nm
kgfcm
ftlbf
Oil pressure switch x Crankshaft bearing cap sub-assy
15
153
11
Oil pump assy x Cylinder block sub-assy
9.0
92
80 in.lbf
Chain vibration damper No. 1 x Cylinder head sub-assy
9.0
92
80 in.lbf
Chain vibration damper No. 1 x Cylinder block sub-assy
9.0
92
80 in.lbf
Oil pan drain plug x Oil pan sub-assy
37
377
27
Oil pump cover x Oil pump body
10
105
8
Oil pump relief valve plug x Oil pump body
37
375
27
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 - 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.)
Synchronizer ring No.3 back and 5th gear spline end clearance
Min:
0.75 mm (0.0295 in.)
5th gear inner diameter
STD:
29.915 - 29.931mm (1.1778 - 1.1783 in.)
MAX:
29.931mm (1.1783 in.)
Reverse idler gear sub-assy inner diameter
STD:
18.040 - 18.058 mm (0.7102 - 0.7109 in.)
MAX:
18.058 mm (0.7109 in.)
Reverse idler gear shaft outer diameter
STD:
17.966 - 17.984 mm (0.7073 - 0.7080 in.)
Min:
17.966 mm (0.7073 in.)
Front transaxle case oil seal drive in depth
15.6 - 16.0 mm (0.6142 - 0.6299 in.)
Input shaft front bearing drive in depth
0 - 0.3 mm (0 - 0.012 in.)
Front differential case shim thickness
AA:
2.10 mm (0.0827 in.)
BB:
2.15 mm (0.0846 in.)
CC:
2.20 mm (0.0866 in.)
DD:
2.25 mm (0.0886 in.)
EE:
2.30 mm (0.0906 in.)
FF:
2.35 mm (0.0925 in.)
GG:
2.40 mm (0.0945 in.)
HH:
2.45 mm (0.0965 in.)
JJ:
2.50 mm (0.0984 in.)
KK:
2.55 mm (0.1004 in.)
LL:
2.60 mm (0.1024 in.)
MM;
2.65 mm (0.1043 in.)
NN:
2.70 mm (0.1063 in.)
PP:
2.75 mm (0.1083 in.)
QQ:
2.80 mm (0.1102 in.)
RR:
2.85 mm (0.1122 in.)
SS:
2.90 mm (0.1142 in.)
TT:
2.95 mm (0.1161 in.)
UU:
3.00 mm (0.1181 in.)
Transmission case oil seal drive in depth
9.9
0.3 mm (0.390
0.012 in.)
Transaxle case oil seal drive in depth
1.9
0.3 mm (0.075
0.012 in.)
Reverse restrict pin slotted pin drive in depth
15.5
16.5 mm (0.6102
0.6496 in.)
Transmission clutch hub No.3 snap ring thickness
A:
2.25 mm (0.0886 in.)
B:
2.31 mm (0.0909 in.)
C:
2.37 mm (0.0933 in.)
D:
2.43 mm (0.0957 in.)
E:
2.49 mm (0.0980 in.)
F:
2.55 mm (0.1004 in.)
G:
2.61 mm (0.1028 in.)
INPUT SHAFT ASSY
4th gear thrust clearance
STD:
0.10 - 0.55 mm (0.0039 - 0.0217 in.)
MAX:
0.55 mm (0.0217 in.)
3rd gear thrust clearance
STD:
0.10 - 0.35 mm (0.0039 - 0.0138 in.)
MAX:
0.35 mm (0.0138 in.)
4th 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.)
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.)
Input shaft outer diameter
STD: A
24.885 - 24.900 mm (0.9797 - 0.9803 in.)
B
28.985 - 29.000 mm (1.1411 - 1.1417 in.)
C
30.985 - 31.000 mm (1.2198 - 1.2204 in.)
D
24.985 - 25.000 mm (0.9836 - 0.9842 in.)
Min: A
24.885 mm (0.9797 in.)
B
28.985 mm (1.1411 in.)
C
30.985 mm (1.2198 in.)
D
24.985 mm (0.9836 in.)
4th gear inside diameter
STD:
34.015 - 34.031 mm (1.3391 - 1.3398 in.)
MAX:
34.031 mm (1.3398 in.)
3rd gear inside diameter
STD:
36.015 - 36.031 mm (1.4179 - 1.4185 in.)
MAX:
36.031 mm (1.4185 in.)
3rd gear synchronizer ring back and 3rd gear spline end clearance
Min:
0.65 mm (0.0256 in.)
4th gear synchronizer ring back and 3rd gear spline end clearance
Min:
0.75 mm (0.0295 in.)
Gear shift fork No.2 claw and glove of the transmission hub sleeve No.2
0.15 - 0.35 mm (0.0059 - 0.0137 in.)
clearance
Transmission clutch hub No.2 snap ring thickness
Mark: 0
2.30 mm (0.0906 in.)
1
2.36 mm (0.0929 in.)
2
2.42 mm (0.0953 in.)
3
2.48 mm (0.0976 in.)
4
2.54 mm (0.1000 in.)
5
2.60 mm (0.1024 in.)
Input shaft rear radial ball bearing snap ring
Mark: 0
2.29 mm (0.0901 in.)
1
2.35 mm (0.0925 in.)
2
2.41 mm (0.0948 in.)
3
2.47 mm (0.0972 in.)
4
2.53 mm (0.0996 in.)
5
2.59 mm (0.1019 in.)
OUTPUT SHAFT ASSY
1st gear thrust clearance
STD:
0.10 - 0.40 mm (0.0039 - 0.0157 in.)
2nd gear thrust clearance
STD:
0.10 - 0.45 mm (0.0039 - 0.0177 in.)
1st gear radial clearance
KOYO made:
0.015 - 0.058 mm (0.0006 - 0.0023 in.)
NSK made:
0.015 - 0.056 mm (0.0006 - 0.0022 in.)
1st gear radial clearance
KOYO made:
0.015 - 0.058 mm (0.0006 - 0.0023 in.)
NSK made:
0.015 - 0.056 mm (0.0006 - 0.0022 in.)
Output shaft maximum run out
0.015 mm (0.0006 in.)
Output shaft outer diameter
Part: A
31.985 mm (1.2592 in.)
B
37.985 mm (1.4955 in.)
C
32.985 mm (1.2986 in.)
2nd gear inside diameter
New:
38.015 - 38.031 mm (1.4967 - 1.4973 in.)
MAX:
38.031 mm (1.4973 in.)
1st gear inside diameter
New:
44.015 - 44.031 mm (1.7329 - 1.7335 in.)
MAX:
44.031 mm (1.7335 in.)
1st gear thrust washer thickness
New:
5.975 - 6.025 mm (0.2352 - 0.2372 in.)
Min:
5.975 mm (0.2352 in.)
Synchronizer ring set No.2 back and 2nd gear spline end clearance
0.7 - 1.3 mm (0.0276 - 0.0512 in.)
Synchronizer ring set No.1 back and 2nd gear spline end clearance
0.75 - 1.65 mm (0.0295 - 0.065 in.)
Reverse gear groove and reverse gear shift fork claw clearance
0.15 - 0.35 mm (0.0059 - 0.0138 in.)
03-39
SERVICE SPECIFICATIONS
-
MANUAL TRANSMISSION / TRANSAXLE
Output shaft front bearing snap ring thickness
7
1.85 - 1.90 mm (0.728 - 0.0748 in.)
8
1.90 - 1.95 mm (0.748 - 0.0768 in.)
1
1.95 - 2.00 mm (0.768 - 0.0787 in.)
2
2.00 - 2.05 mm (0.787 - 0.0807 in.)
3
2.05 - 2.10 mm (0.807 - 0.0827 in.)
4
2.10 - 2.15 mm (0.827 - 0.0846 in.)
5
2.15 - 2.20 mm (0.846 - 0.0866 in.)
6
2.20 - 2.25 mm (0.866 - 0.0886 in.)
Transmission clutch hub No.1 snap ring thickness
A
2.50 mm (0.0984 in.)
B
2.56 mm (0.1008 in.)
C
2.62 mm (0.1031 in.)
D
2.68 mm (0.1055 in.)
E
2.74 mm (0.1079 in.)
F
2.80 mm (0.1102 in.)
DIFFERENTIAL CASE ASSY
Front differential side gear backlash
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Front differential pinion thrust washer thickness
0.92 mm (0.0362 in.)
Front differential pinion shaft No.1 outer diameter
16.982 mm (0.6686 in.)
Front differential side gear thrust washer
0.95 mm (0.0374 in.)
1.00 mm (0.0394 in.)
1.05 mm (0.0413 in.)
1.10 mm (0.0433 in.)
1.15 mm (0.0453 in.)
1.20 mm (0.0472 in.)
SHIFT & SELECT LEVER SHAFT ASSY
Control shaft cover oil seal drive in depth
0.7
0.5 mm (0.0276
0.0197 in.)
Select inner lever slotted pin drive in depth
3.0 - 4.0 mm (0.1181 - 0.1575 in.)
Shift lever inner No.1 slotted pin drive in depth
0
0.5 mm (0
0.0197 in.)
Shift lever inner No.2 slotted pin drive in depth
0
0.5 mm (0
0.0197 in.)
03-40
SERVICE SPECIFICATIONS
- MANUAL TRANSMISSION / TRANSAXLE
030QE-01
TORQUE SPECIFICATION
Part Tightened
Nm
kgfcm
ftlbf
Floor shift transmission control cable assy x Body
5.0
51
44 in.lbf
Front floor heat insulator No.1 x Body
5.5
56
49 in.lbf
Airbag sensor assy center x Body
17.5
178
13
Shift cable grommet retainer No.1 x Body
5.0
51
44 in.lbf
Clamp x Body
5.0
51
44 in.lbf
Floor shift shift lever assy x Body
12
120
9
Filler and drain plugs
39.2
400
29
Engine hanger set bolt
38
387
28
Engine mounting bracket RR x Transaxle
64
653
47
Engine mounting bracket RR x Engine mounting insulator RR
87
888
64
Engine mounting bracket FR x Transaxle
64
653
47
Engine mounting bracket FR x Engine mounting insulator FR
52
530
38
Manual transaxle assy x Engine
Bolt A:
64
650
47
Bolt B:
47
480
35
Bolt C:
23
230
17
Transverse engine engine mounting bracket LH x Transaxle
52
530
38
Engine mounting bracket LH x Engine mounting insulator LH
Bolt A:
52
530
38
Nut B:
80
816
59
Starter assy x Manual transaxle assy
37
378
27
Starter wire set nut
9.8
100
87 in.lbf
Clutch release cylinder assy x Transaxle
Bolt A:
25
250
19
Bolt B:
12
120
9
Bolt C:
5.0
21
44 in.lbf
Manual transaxle assy x Wire harness clmap
Bolt A:
25.5
260
19
Bolt B:
12.8
131
9
Manual transaxle assy x Ground cable
13
133
10
Battery carrier x Body
13
133
10
Battery clamp sub-assy x Body
Bolt:
5.0
51
44 in.lbf
Nut:
3.5
36
31 in.lbf
Air cleaner assy x Body
7.0
71
62 in.lbf
Cylinder head cover No.2 x Engine
7.0
71
62 in.lbf
Hood set bolt
13
133
10
Bearing lock plate x transaxle case
11.3
115
8
Oil receiver pipe No.1 x Manual transmission case
17.2
175
13
Oil receiver pipe No.2 x Manual transmission case
17.2
175
13
Reverse restrict pin plug x Manual transmission case
12.7
130
9
Manual transaxle case receiver x Transaxle case
11.3
115
8
Gear shift fork No.1 x Gear shift fork shaft No.1
15.7
160
12
Gear shift head No.1 x Gear shift fork shaft No.2
15.7
160
12
Gear shift fork No.2 x Gear shift fork shaft No.2
15.7
160
12
Reverse shift arm bracket assy x Transaxle case
17.2
175
13
Trasaxle case x Manual transmission case
29.4
300
22
Manual transmission case x Transaxle case
29.4
300
22
Reverse idler gear shaft bolt x Manual transmission case
29.4
300
22
Lock ball assy No.1 x Manual transaxle assy
39.2
400
29
Shift detent ball plug Manual transmission case
24.5
250
18
Shift detent ball plug x Transaxle case
24.5
250
18
Bearing retainer rear x Manual transmission case
27.4
279
20
Gear shift fork No.3 x Gear shift fork shaft No.3
15.7
160
12
Manual transmission output shaft rear set nut x Output shaft
117.6
1,200
87
Manual transmission case cover sub-assy x Manual transmission case
18.1
185
14
03-41
SERVICE SPECIFICATIONS
-
MANUAL TRANSMISSION / TRANSAXLE
Part Tightened
Nm
kgfcm
ftlbf
Shift & select lever shaft assy x Manual transmission case
19.6
200
14
Lock ball assy No.1 x Manual transmission case
29.4
300
22
Selecting bell crank assy x Manual transmission case
24.5
250
18
Floor shift control lever housing support bracket x Transaxle case
11.3
115
8
Back up lamp switch assy x Manual transmission case
40.2
410
30
Speedometer driver hole cover sub-assy x Manual transaxle assy
11.3
115
8
Speedometer sensor x Manual transaxle assy
11.3
115
8
Release fork support x Transaxle case
36.8
375
25
Drain plug sub-assy x Manual transmission case
39.2
400
29
Manual transmission filler plug x Manual transmission case
39.2
400
29
Front differential case x Front differential ring gear
77.4
789
57
Selecting bell crank x Selecting bell crank No.2
11.8
120
9
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
03-34
SERVICE SPECIFICATIONS
- PARKING BRAKE
030Q7-01
TORQUE SPECIFICATION
Part Tightened
Nm
kgfcm
ftlbf
Wheel nut
103
1,050
76
Parking brake lock nut
5.0
55
44 in.lbf
Parking brake lever sub-assy x body
12.5
130
9
Heat insulator No.2 x Body
5.5
55
48 in.lbf
Heat insulator No.1 x Body
5.5
55
48 in.lbf
Fuel tank protector No.1 x Body
5.5
55
48 in.lbf
Exhaust pipe installation bolt
43
440
32
Front floor panel brace
29.6
302
21
Parking brake cable assy No.3 x Body
5.4
55
48 in.lbf
Parking brake cable assy No.3 x Backing plate
7.8
80
69 in.lbf
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/cm2, 1,067 - 1,138 psi)
STEERING WHEEL
Steering effort at idle speed
(Reference)
6 N·m (60 kgf·cm, 53 in.·lbf)
POWER STEERING VANE PUMP
Vane pump rotating torque
0.27 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less
Vane pump shaft and vane pump housing oil clearance
STD
0.021 - 0.043 mm (0.0008 - 0.0017 in.)
Maximum
0.07 mm (0.0028 in.)
Vane plate height
Minimum
7.6 mm (0.299 in.)
Vane plate thickness
Minimum
1.405 mm (0.0553 in.)
Vane plate length
Minimum
11.993 mm (0.4722 in.)
Clearance between the rotor groove and plate
Maximum
0.03 mm (0.0012 in.)
Spring free length
Minimum
36.9 mm (1.453 in.)
POWER STEERING GEAR
Steering rack runout
Maximum
0.1 mm (0.004 in.)
Total preload (Tie rod rotating torque)
(Turning)
0.49 - 3.43 N·m (5.0 - 35 kgf·cm, 4.34 - 30.38 in.·lbf)
Total preload (Control valve rotating torque)
(Turning)
1.0 - 1.8 N·m (10 - 18 kgf·cm, 8.6 - 15.7 in.·lbf)
03-47
SERVICE SPECIFICATIONS
-
POWER STEERING
030QB-01
TORQUE SPECIFICATION
Part tightened
Nm
kgfcm
ftlbf
POWER STEERING VANE PUMP
Vane pump housing rear x Vane pump housing front
22
220
16
Pressure port union
69
700
51
Suction port union set bolt
12
122
9
Oil pressure switch
21
210
15
Vane pump assy x Vane pump bracket rear
37
380
27
Vane pump assy set bolt
37
380
27
Pressure feed tube assy x Vane pump assy
41 (44)
420 (450)
30 (33)
Pressure feed tube assy clamp set bolt
7.8
80
69 in.lbf
POWER STEERING GEAR
Engine hanger set bolt
38
390
28
Control valve housing set bolt
18
185
13
Self-locking nut
25
250
18
Rack housing cap
59
600
43
Rack guide spring cap lock nut
43 (59)
440 (600)
32 (43)
Power steering rack x Rack end
62 (83)
630 (850)
46 (61)
Tie rod assy lock nut
74
750
54
Turn pressure tube union nut
12 (13)
120 (130)
9 (9)
Rack & pinion power steering gear assy set bolt and nut
58
590
43
Pressure feed and return tubes x Control valve housing
23 (25)
235 (255)
17 (18)
Pressure feed tube clamp set bolt
7.8
80
69 in.lbf
Stabilizer link assy set nut
74
755
55
Tie rod assy set nut
49
500
36
Intermediate shaft sub-assy x Control valve shaft
35
360
26
Front suspension crossmember sub-assy x Frame
Bolt A
157
1,600
116
Bolt B
157
1,600
116
Center member x Frame
39
400
29
Center member x Engine mounting insulator FR
52
530
38
Crossmember x Engine mounting insulator RR
52
530
38
Front suspension arm sub-assy lower No.1 x Lower ball joint
89
910
66
Hub nut
103
1,050
76
(
): For use without SST