Toyota Corolla (2004+). Manual - part 96
14-23
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
Clamp Bracket
9.0 (92, 80 in. lbf)
Water By-pass Hose No. 2
Radiator Hose Inlet
20 (204, 15)
Engine Coolant
_ Gasket
Temperature Sensor
10 (102, 7)
Radio Setting Condenser
Heater Inlet Water Hose
37 (377, 27)
_ Gasket
18 (184, 13)
Exhaust Manifold
Manifold Stay
49 (500, 36)
Exhaust Manifold Heat Insulator No. 1
N·m (kgf·cm, ft·lbf)
: Specified torque
_ Non-reusable part
A64041
14-24
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
Oil Filler Cap Sub-assy
Gasket
9.0 (92, 80 in. lbf)
11 (112, 8)
Seal Washer
30 (306, 22)
Ventilation Valve Sub-assy
11 (112, 8)
11 (112, 8)
Cylinder Head Cover
Sub-assy
Gasket
Spark Plug
25 (255, 18)
Transverse Engine
Engine Mounting Bracket
47 (479, 35)
Crankshaft Pulley
138 (1,407, 102)
11 (112, 8)
9.0 (92, 80 in. lbf)
_ O-ring
Water Pump Assy
N·m (kgf·cm, ft·lbf)
: Specified torque
_ Non-reusable part
A64054
14-25
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
13 (133, 10)
23 (235, 17)
Camshaft Bearing Cap
No. 3
Camshaft Bearing Cap No. 1
Camshaft No. 2
Camshaft Timing Gear or Sprocket
Camshaft
54 (551, 40)
54 (551, 40)
Camshaft Timing Gear Assy
Chain Sub-assy
Chain Tensioner
Slipper
19 (189, 14)
Crankshaft Timing Gear
Chain Vibration Damper No. 1
9.0 (92, 80 in. lbf)
Crankshaft Position Sensor
Plate No. 1
9.0 (92, 80 in. lbf)
Chain Tensioner Assy No. 1
13 (133, 10)
19 (189, 14)
Timing Chain or Belt
_ Oil Seal
Cover Sub-assy
N·m (kgf·cm, ft·lbf)
: Specified torque
_ Non-reusable part
A62769
14-26
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
See page 14-45
1st 49 (500, 36)
2nd Turn 90 F
Plate Washer
Cylinder Head Sub-assy
_ O-ring
Oil Control Valve Filter
_ Gasket
Camshaft Timing
Oil Control Valve Assy
30 (306, 22)
9.0 (92, 80 in. lbf)
_ Gasket
Cylinder Block Sub-assy
_ Oil Seal
_ Gasket
Oil Pump Assy
30 (306, 22)
9.0 (92, 80 in. lbf)
Oil Filter Union
_ Gasket
Oil Filter Sub-assy
Oil Strainer Sub-assy
9.0 (92, 80 in. lbf)
9.0 (92, 80 in. lbf)
Oil Pan Sub-assy
_ Gasket
37 (377, 27)
Oil Pan Drain Plug
9.0 (92, 80 in. lbf)
N·m (kgf·cm, ft·lbf)
: Specified torque
_ Non-reusable part
A64055
14-45
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
141GT-01
OVERHAUL
1.
REMOVE OIL FILLER CAP SUB-ASSY
(a) Remove the oil filler cap from the cylinder head cover.
A64852
2.
REMOVE OIL FILLER CAP GASKET
(a) Using a screwdriver, remove the gasket from the oil filler
cap.
A65656
3.
REMOVE VENTILATION VALVE SUB-ASSY
(a) Remove the ventilation valve from the cylinder head cov-
er.
A64854
4.
REMOVE SPARK PLUG
(a) Using a spark plug wrench, remove the spark plugs.
A64855
14-46
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
5.
REMOVE CYLINDER HEAD COVER SUB-ASSY
(a) Remove the 9 bolts, 2 seal washers, 2 nuts and cylinder
head cover.
A64856
6.
REMOVE CYLINDER HEAD COVER GASKET
(a) Remove the gasket from the cylinder head cover.
A64857
7.
REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and transverse engine engine mount-
ing bracket.
A64858
8.
REMOVE WATER PUMP ASSY
(a) Remove the 6 bolts and water pump.
A64859
9.
REMOVE WATER PUMP O-RING
(a) Remove an O-ring from the timing chain cover.
A64860
14-47
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
Timing Mark
Timing Mark
10. REMOVE CRANKSHAFT PULLEY
1
2
3 4
5
6
7
8
(a) Set the No. 1 cylinder to the TDC/compression.
(1)
Turn the crankshaft pulley, and align its groove with
timing mark ”0” of the timing chain cover.
(2)
Check that the point marks of the camshaft timing
gears are in straight line on the timing chain cover
surface as shown in the illustration.
HINT:
Point Mark
If not, turn the crankshaft 1 revolution (360_) and align the
Timing Chain
marks as above.
Cover Surface
Groove
A65657
(b) Using SST, remove the crankshaft pulley bolt.
SST
09960-10010 (09962-01000, 09963-01000)
(c)
Remove the crankshaft pulley from the crankshaft.
SST
A62837
11. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts and chain tensioner.
A64863
14-48
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
12. REMOVE TIMING CHAIN OR BELT COVER
SUB-ASSY
(a) Remove the 11 bolts and nut.
(b) Remove the timing chain cover by prying the portions be-
tween the timing chain cover and cylinder head and cylin-
der block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder head and cylinder block.
A66913
(c)
Using a torx socket wrench E5, remove the 3 stud bolts.
A64914
13. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
(a) Place the timing chain cover on wooden blocks.
(b) Using a screwdriver, remove the oil seal.
Wooden Block
A65658
14. REMOVE CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Remove the crankshaft position sensor plate from the
crankshaft.
A64867
14-49
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
15. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and chain tensioner slipper.
A64866
16. REMOVE CHAIN SUB-ASSY
(a) Using the 2 screwdrivers, pry out the chain with the crank-
shaft timing gear as shown in the illustration.
NOTICE:
F
Put shop rag to protect the engine.
F
In case of revolving the camshafts with the chain off
the gears, turn the crankshaft 1/4 revolution for
valves not to touch the pistons.
A65659
17. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the 2 bolts and chain vibration damper.
A64869
18. REMOVE OIL PUMP ASSY
(a) Remove the 5 bolts and oil pump.
A64870
19. REMOVE OIL PUMP GASKET
(a) Remove the gasket from the cylinder block.
A64871
14-50
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
20. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Remove the bolt and camshaft timing oil control valve.
A64872
21. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the bolt with gasket and oil control valve filter.
(b) Remove the gasket and oil control valve filter from the
bolt.
A64873
3
6
8
4
1
22. REMOVE CAMSHAFT
(a) Using several steps, uniformly loosen and remove the 19
bolts in the sequence shown, then remove the 9 bearing
caps.
(b) Remove the 2 camshafts from the cylinder head.
7
9
5
2
A62814
23. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
(a) Grip the camshaft with a vice, and remove the bolt and
camshaft timing gear.
NOTICE:
Be careful not to damage the camshaft.
A64874
14-51
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
24. INSPECT CAMSHAFT TIMING GEAR ASSY
Retard Side
(a) Check the lock of camshaft timing gear.
Path
(1)
Clamp the camshaft in a vise, and confirm the cam-
shaft timing gear is locked.
NOTICE:
Advance
Be careful not to damage the camshaft.
Side Path
(b) Release the lock pin.
(1)
Cover the 4 oil paths of the cam journal with vinyl
tape as shown in the illustration.
HINT:
Two advance side paths are provided in the groove of the cam-
Open
Close
shaft. Plug one of the path with a rubber piece.
(2)
Break through the tapes of the advance side path
and retard side path on the opposite side of the
Open
Close
groove.
Vinyl Tape
Rubber
A62190
(3)
Put air pressure into two broken paths (the advance
Retard
Advanced
side path and retard side path) with about 150 kPa
Side Path
Side Path
{1.5 kgfcm2}.
CAUTION:
Cover the paths with shop rag to avoid oil splashing.
A62191
(4)
Confirm if the camshaft timing gear assembly re-
Retard
Advanced
volves to the timing advance direction when weak-
Side Path
Side Path
ening the air pressure of the timing retard path.
HINT:
The lock pin is released, and camshaft timing gear revolves to
the advance direction.
Decompress
(5)
When the camshaft timing gear comes to the most
Hold Pressure
advanced position, take out the air pressure of the
A62192
timing retard side path, then take out that of the tim-
ing advance side path.
CAUTION:
The camshaft timing assembly gear occasionally shifts to
the retard side abruptly, if the air compression of the ad-
vanced side path is released before the retard side path. It
often causes the breakage of the lock pin.
14-52
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(c)
Check smooth revolution.
(1)
Revolve the camshaft timing gear assembly within
the movable range except for the most retarded
position several times, and check that it revolves
smoothly.
CAUTION:
Be sure to perform this check by hand, instead of air pres-
sure.
(d) Check the lock in the most retarded position.
(1)
Confirm that the camshaft timing gear assembly is
locked at the most retarded position.
25. REMOVE CAMSHAFT TIMING GEAR ASSY
Retard Side
(a) Clamp the camshaft in a vise, and confirm that the gear
Path
is locked.
CAUTION:
Be careful not to damage the camshaft.
Advance
(b) Cover the 4 oil paths of the cam journal with vinyl tape as
Side Path
shown in the illustration.
HINT:
Two advance side paths are provided in the groove of the cam-
shaft. Plug one of the path with a rubber piece.
(c)
Break through the tapes of the advance side path and re-
Open
Close
tard side path on the opposite side of the groove.
Open
Close
Vinyl Tape
Rubber
A62190
(d) Put air pressure into two broken paths (the advance side
Retard
Advanced
path and retard side path) with about 150 kPa {1.5 kgf/
Side Path
Side Path
cm2}.
CAUTION:
Cover the paths with shop rag to avoid oil splashing.
A62191
14-53
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(e) Confirm if the camshaft timing gear assembly revolves to
Retard
Advanced
the timing advance direction when weakening the air
Side Path
Side Path
pressure of the timing retard path.
HINT:
The lock pin is released, and camshaft timing gear revolves to
the advance direction.
Decompress
(f)
When the camshaft timing gear comes to the most ad-
Hold Pressure
vanced position, take out the air pressure of the timing re-
A62192
tard side path, then take out that of timing advance side
path.
CAUTION:
Camshaft timing gear assembly occasionally shifts to the
retard side abruptly, if the air compression of the advanced
side path is released before the retard side path. It often
causes the breakage of the lock pin.
(g) Remove the fringe bolt and camshaft timing gear.
NOTICE:
F
Be sure not to remove the other 4 bolts.
Fringe Bolt
F
In case of reusing the camshaft timing gear, release
the straight pin locking first, then install the gear.
A62193
26. REMOVE CYLINDER HEAD SUB-ASSY
3
7
9
6
2
(a) Using a bi-hexagon wrench 10, uniformly loosen and re-
move the 10 cylinder head bolts, in several passes, in the
sequence shown, then remove the 10 cylinder head bolts
and 10 plate washers.
NOTICE:
F
Be careful not to drop plate washers into the cylinder
head.
1
5
10
8
4
A62816
F
Head warpage or cracking could result from remov-
ing bolts in an incorrect order.
(b) Remove the cylinder head from the cylinder block.
A64915
14-54
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
27. REMOVE CYLINDER HEAD GASKET
(a) Remove the cylinder head gasket from the cylinder block.
A64876
28. REMOVE OIL FILTER SUB-ASSY
(a) Using SST, remove the oil filter.
SST
SST
09228-06501
A65661
29. REMOVE OIL FILTER UNION
(a) Using a socket hexagon wrench 12, remove the oil filter
union.
A64878
30. REMOVE ENGINE REAR OIL SEAL
Cut Position
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with the tip wrapped in tape, pry out
the oil seal.
NOTICE:
After the removal, check if the crankshaft is not damaged.
If damaged, smooth it with a 400-grid sandpaper.
A65662
31. REMOVE OIL PAN DRAIN PLUG
(a) Remove the oil pan drain plug and gasket from the oil pan.
A64880
14-55
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
32. REMOVE OIL PAN SUB-ASSY
(a) Remove the 14 bolts and 2 nuts.
A64881
(b) Insert the blade of SST between the bearing cap and oil
SST
pan, then cut off the applied sealer and remove the oil
pan.
SST
09032-00100
NOTICE:
Be careful not to damage the oil pan contact surface of the
bearing cap and oil pan.
A65663
33. REMOVE OIL STRAINER SUB-ASSY
(a) Remove the bolt, 2 nuts and oil strainer.
A64883
34. REMOVE OIL STRAINER FLANGE GASKET
(a) Remove the gasket from the bearing cap.
A64884
35. INSPECT CHAIN TENSIONER ASSY NO.1
(a) Check that the plunger moves smoothly when the ratchet
Raise
pawl is raised with your finger.
Move
(b) Release the ratchet pawl and check that the plunger is
Lock
locked in place by the ratchet pawl and does not move
when pushed with your finger.
A62818