Toyota Corolla (2004+). Manual - part 95
14-145
ENGINE MECHANICAL
- CYLINDER HEAD ASSY
26. INSTALL W/HEAD TAPER SCREW PLUG NO.2
(a) Using a socket hexagon wrench 10, install the taper
screw plug with a new gasket.
Torque: 44 N m (449 kgf cm, 33 ft lbf)
A62890
14-1
ENGINE MECHANICAL
- ENGINE ASSEMBLY
ENGINE ASSEMBLY
140OC-03
INSPECTION
1.
INSPECT COOLANT (See page 16-1)
2.
INSPECT ENGINE OIL (See page 17-1)
3.
INSPECT BATTERY (See page 19-13)
4.
INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSY
5.
INSPECT SPARK PLUG (See page 18-2)
6.
INSPECT FAN AND GENERATOR V BELT
HINT:
You don’t need to check the belt deflection because auto tensioner is adopted.
7.
INSPECT IGNITION TIMING
(a) Warm up engine.
(b) When using hand-held tester or OBDII scan tool.
(1)
Connect the hand-held tester or OBDII scan tool to
the DLC3.
HINT:
Please refer to the hand-held tester or OBDII scan tool opera-
tor’s manual for further details.
(c)
When not using hand-held tester or OBDII scan tool.
TC
(1)
Using SST, connect terminal 13 (TC) and 4 (CG) of
the DLC3.
SST
09843-18040
NOTICE:
F
Be sure not to connect incorrectly. It causes breakage
of the engine.
F
Turn OFF all electrical systems.
CG
A62199
F
Operate the inspection when the cooling fan motor is
turned OFF
(2)
Remove the 2 nuts, 2 clips and cylinder head cover.
(3)
Pull out the wire harness as shown in the illustration.
(4)
Connect the clip of the timing light to the engine.
NOTICE:
F
Use a timing light which can detect the first signal.
F
After checking, be sure to tape the wire harness.
A64072
(5)
Inspect ignition timing at idle.
Ignition timing: 8 - 12
_BTDC
NOTICE:
When checking the ignition timing, the transmission is at
neutral position.
HINT:
After engine rpm is kept at 1,000 - 1,300 rpm for 5 seconds,
check that it returns idle speed.
14-2
ENGINE MECHANICAL
- ENGINE ASSEMBLY
(6)
Disconnect the terminal 13 (TC) and 4 (CG) of the
DLC3.
(7)
Inspect ignition timing at idle.
Ignition timing: 10 - 18
_BTDC
(8)
Confirm that ignition timing moves to advanced
angle side when the engine rpm is increased.
(9)
Remove the timing light.
(10) Install cylinder head cover No.2 with the 2 nuts and
2 clips.
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
8.
INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand-held tester or OBDII scan tool.
(1)
Connect the hand-held tester or OBDII scan tool to the DLC3.
HINT:
Please refer to the hand - held tester or OBDII scan tool operator’s manual for further details.
(c)
Check the idle speed.
Idle speed: 650 - 750 rpm
NOTICE:
F
Check idle speed with cooling fan OFF.
F
Switch off all accessories and air conditioning.
9.
INSPECT COMPRESSION
(a) Warm up and stop engine.
(b) Remove ignition coil.
(c)
Remove spark plugs.
(d) Inspect cylinder compression pressure.
SST
09992-00500
(1)
Insert a compression gauge into the spark plug
hole.
A01037
(2)
Fully open the throttle.
(3)
While cranking the engine, measure the compres-
sion pressure.
Compression pressure
1,300 kPa (13.3 kgf cm 2, 189 psi)
Minimum pressure: 1,000 kPa (10.2 kgf
cm 2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf cm 2, 15 psi)
NOTICE:
F
Always use a fully charged battery to obtain engine
speed of 250 rpm or more.
F
Check other cylinder’s compression pressure in the
same way.
F
This measurement must be done in as short a time as
possible.
14-3
ENGINE MECHANICAL
-
ENGINE ASSEMBLY
(4)
If the cylinder compression in one more cylinders is
low, pour a small amount of engine oil into the cylin-
der through the spark plug hole and repeat steps (1)
through (3) for cylinders with low compression.
HINT:
F
If adding oil helps the compression, it is likely that the pis-
ton rings and/or cylinder bore are worn or damaged.
F
If pressure stays low, a valve may be sticking or seating
is improper, or there may be leakage past the gasket.
10. INSPECT CO/HC
(a) Start the engine.
(b) Race engine at 2,500 rpm for approx. 180 seconds.
(c)
Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into tailpipe during idling.
(d) Immediately check CO/HC concentration at idle and/or 2,500 rpm.
HINT:
F
Complete the measuring within 3 minutes.
F
When doing the 2 mode (idle and 2,500 rpm) test, these measuring orders are prescribed by the appli-
cable local regulations.
(e) If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.
(1)
Check heated oxygen sensor operation. (See page 12-6)
(2)
See the table below for possible causes, and then inspect and correct the applicable causes if
necessary.
CO
HC
Problems
Causes
3. Faulty ignitions:
F Incorrect timing
F Fouled, shorted or improperly gapped plugs
Normal
High
Rough idle
4. Incorrect valve clearance
5. Leaky intake and exhaust valves
6. Leaky cylinders
1. Vacuum leaks:
F PCV hoses
F Intake manifold
Rough idle
Low
High
F Throttle body
(Fluctuating HC reading)
F ISC valve
F Brake booster line
2. Lean mixture causing misfire
1. Restricted air filter
2. Plugged PCV valve
3. Faulty EFI systems:
F Faulty pressure regulator
Rough idle
High
High
F Defective water temperature sensor
(Black smoke form exhaust)
F DEFECTIVE Air-flow meter
F Faulty ECM
F Faulty injectors
F Faulty throttle position sensor
14-130
ENGINE MECHANICAL
- ENGINE REAR OIL SEAL
ENGINE REAR OIL SEAL
140ON-01
REPLACEMENT
1.
REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page
41-17)
2.
REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page
40-9)
3.
REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42-18)
(a) Remove the 6 bolts and clutch cover.
4.
REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42-18)
5.
REMOVE FLYWHEEL SUB-ASSY (M/T TRANSAXLE)
(a) Fix the crankshaft with SST, then remove the 8 bolts and
flywheel.
SST
09960-10010 (09962-01000, 09963-01000)
SST
A62838
6.
REMOVE DRIVE PLATE & RING GEAR SUB-ASSY
(A/T TRANSAXLE)
(a) Fix the crankshaft with SST, then remove the 8 bolts and
drive plate & ring gear.
SST
09960-10010 (09962-01000, 09963-01000)
SST
A62838
7.
REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
Cut Position
(b) Using a screwdriver with taping its tip, pry out the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If there is, mend it with a sandpaper (#400).
A62202
8.
INSTALL ENGINE REAR OIL SEAL
SST
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST, tap in the oil seal until its surface is flush with
the rear oil seal retainer edge.
SST
09223-15020, 09950-70010 (09951-07100)
NOTICE:
A62203
Wipe off extra grease on the crankshaft.
14-131
ENGINE MECHANICAL
- ENGINE REAR OIL SEAL
9.
INSTALL FLYWHEEL SUB-ASSY (M/T TRANSAXLE)
(a) Fix the crankshaft with SST.
SST
09960-10010 (09962-01000, 09963-01000)
SST
A62838
(b) Clean the bolt and bolt hole.
(c)
Apply adhesive to the bolts.
Adhesive:
1
Part No. 09330-00070, THREE BOND or equivalent.
7
(d) Install and uniformly tighten the 8 bolts, in several passes,
5
4
in the sequence shown.
3
Torque: 49 N m (500 kgf cm, 36 ft lbf)
6
8
2
A62205
(e) Mark the bolts with paint.
(f)
Retighten the bolts by an additional 90F.
90 F
(g) Check that the point marked bolts are moved at 90F
angle.
A62206
10. INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See page
42-18)
SST
09301-00210
11. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page
42-18)
12. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY
(A/T TRANSAXLE)
(a) Fix the crankshaft with SST.
SST
09960-10010 (09962-01000, 09963-01000)
SST
A62838
14-132
ENGINE MECHANICAL
- ENGINE REAR OIL SEAL
(b) Clean the bolt and bolt hole.
(c)
Apply adhesive to the bolts.
Adhesive:
1
7
Part No. 09330-00070, THREE BOND or equivalent.
5
(d) Install and uniformly tighten the 8 bolts, in several passes,
4
in the sequence shown.
3
(e) Fix the crankshaft with SST.
6
8
Torque: 88 N m (897 kgf cm, 65 ft lbf)
2
A62204
13. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page
41-17)
14. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page
40-9)
14-4
ENGINE MECHANICAL
- FAN AND GENERATOR V BELT
FAN AND GENERATOR V BELT
140OD-01
REPLACEMENT
1.
REMOVE ENGINE UNDER COVER RH
2.
REMOVE FAN AND GENERATOR V BELT
(a) Turn the V-ribbed belt tensioner slowly clockwise and
loosen it. Then, remove the fan and generator V belt and
put back the V-ribbed belt tensioner little by little and fix
it quietly.
A60622
14-16
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
PARTIAL ENGINE ASSY (April, 2003)
140OF-03
COMPONENTS
7.0 (71, 62 in. lbf)
x2
x2
Cylinder Head Cover No. 2
Clip
19 (194, 14)
w/ Air Conditioning:
Radiator Support Upper
19 (194, 14)
w/ Air Conditioning:
Radiator Support Upper
Radiator Hose Inlet
w/ Air Conditioning:
Radiator Assy
Radiator Hose Outlet
Clip
A/T:
Oil Cooler Outlet Tube No. 1
A/T:
Oil Cooler Inlet Tube No. 1
Engine Under Cover RH
Clip
Engine Under Cover LH
N·m (kgf·cm, ft·lbf)
: Specified torque
A64035
14-17
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
w/ Cruise Control:
Cruise Control Actuator Assy
Heater Inlet Water Hose
Heater Outlet Water Hose
6.0 (61, 53 in. lbf)
Fuel Tube Sub-assy
Union to Connector Tube Hose
Accelerator Control
EFI Fuel Pipe Clamp
Cable Assy
3.5 (36, 31 in. lbf)
5.0 (51, 44 in. lbf)
Battery Clamp
Air Cleaner Cap
Sub-assy
Sub-assy
Battery
Air Cleaner Filter
Element Sub-assy
7.0 (71, 62 in. lbf)
Battery Tray
13 (133, 10)
Battery Carrier
Air Cleaner Case
Sub-assy
N·m (kgf·cm, ft·lbf)
: Specified torque
A64036
14-18
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
Fan and Generator V Belt
A/T:
Clip
Floor Shift Cable
Transmission Control Shift
12 (122, 9)
w/ Air Conditioning:
Compressor and Magnetic Clutch
29 (296, 21)
5.0 (51, 44 in. lbf)
7.8 (80, 69 in. lbf)
Return Tube Sub-assy
25 (255, 18)
25 (255, 18)
12 (122, 9)
Clip
M/T:
Clip
Clutch Release Cylinder Assy
Plate Washer
M/T:
Floor Shift Cable Transmission
Control Select
M/T:
Floor Shift Cable Transmission
Control Shift
N·m (kgf·cm, ft·lbf)
: Specified torque
A64037
14-19
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
Grove Compartment Door Assy
Cowl Side Trim Board RH
Front Door Scuff Plate RH
Clip
Steering Intermediate Shaft
35 (360, 26)
Clip
Column Hole Cover Silencer Sheet
Front Stabilizer Link Assy LH
74 (755, 55)
_ Cotter Pin
Front Drive Shaft Assy LH
49 (500, 36)
Tie Rod End
Sub-assy LH
Front Suspension Arm
_
216 (2,203, 160)
Sub-assy Lower No. 1 LH
Front Axle Hub LH Nut
89 (908, 66)
89 (908, 66)
_ Gasket
Compression
Exhaust Pipe Assy Front
Spring
43 (440, 32)
_ Gasket
Floor Panel
30 (306, 22)
Brace Front
Compression Spring
43 (440, 32)
N·m (kgf·cm, ft·lbf)
: Specified torque
_ Non-reusable part
A64038
14-20
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
52 (530, 38)
Engine Mounting
Insulator RH
Engine Assembly with Transaxle
52 (530, 38)
80 (816, 59)
157 (1,601, 116)
39 (398, 29)
113 (1,152, 83)
TMMC, NUMMI Made:
65 (663, 48)
52 (530, 38)
TAKAOKA, TAL Made:
87 (887, 64)
37 (377, 27)
Front Suspension
Crossmember
Vane Pump Assy
w/ Center Member
N·m (kgf·cm, ft·lbf)
: Specified torque
A64039
14-21
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
M/T:
Flywheel Sub-assy
M/T:
47 (479, 35)
Clutch Disk Assy
M/T:
Clutch Cover Assy
64 (653, 47)
Starter Assy
See page 14-27
9.8 (100, 7)
1st 49 (500, 36)
37 (377, 27)
2nd Turn 90 F
37 (377, 27)
19 (194, 14)
A/T:
Drive Plate & Ring Gear Sub-assy
M/T:
Manual Transaxle Assy
64 (653, 47)
Drive Plate
88 (897, 65)
Spacer FR
27 (275, 20)
Drive Plate
Spacer RR
Automatic Transaxle Assy
N·m (kgf·cm, ft·lbf)
: Specified torque
A66030
14-22
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
9.0 (92, 80 in. lbf)
19 (194, 14)
Fuel Delivery Pipe Sub-assy
No. 1 Spacer
Water By-pass Pipe No. 1
9.0 (92, 80 in. lbf)
Camshaft
Ignition Coil Assy
Position Sensor
9.0 (92, 80 in. lbf)
29 (296, 21)
9.0 (92, 80 in. lbf)
_ Gasket
Knock Sensor
69 (704, 51)
20 (204, 15)
V-ribbed Belt
Engine Oil Pressure Switch Assy
Tensioner Assy
15 (153, 11)
Thermostat
25 (250, 18)
_ Gasket
Generator Assy
Water Inlet
11 (112, 8)
Crankshaft Position Sensor
_ Gasket
9.0 (92, 80 in. lbf)
54 (550, 40)
13 (133, 10)
Intake Manifold
Clamp Bracket
Oil Level
Gage Guide
Oil Level Gage
N·m (kgf·cm, ft·lbf)
: Specified torque
_ O-ring
Sub-assy
30 (306, 22)
_ Non-reusable part
A84913