Toyota Corolla (2004+). Manual - part 97
14-56
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
36. INSPECT CHAIN SUB-ASSY
(a) Using a spring tension gauge and vernier caliper, pull the
timing chain with 140 N (14.3 kgf, 31.5 lb) and measure
the length of it.
Maximum chain elongation: 122.6 mm (4.827 in.)
Measuring Area
If the chain elongation is greater than maximum, replace the
chain.
HINT:
0
1
2
3
4
5
16
A62819
Make the same measurements pulling at 3 or more places se-
lected at random.
37. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
(a) Wrap the chain around the camshaft timing gear.
(b) Using a vernier caliper, measure the camshaft timing gear
diameter with the chain.
Minimum gear diameter (w/ chain): 97.3 mm (3.831 in.)
NOTICE:
The vernier caliper must contact the chain rollers for mea-
suring.
A30206
If the gear diameter is less than minimum, replace the chain and
camshaft timing gear.
38. INSPECT CRANKSHAFT TIMING GEAR OR
SPROCKET
(a) Wrap the chain around the crankshaft timing gear.
(b) Using a vernier caliper, measure the crankshaft timing
gear diameter with the chain.
Minimum gear diameter (w/ chain): 51.6 mm (2.032 in.)
NOTICE:
The vernier caliper must contact the chain rollers for mea-
EM2378
suring.
If the gear diameter is less than minimum, replace the chain and
crankshaft timing gear.
39. INSPECT CHAIN TENSIONER SLIPPER
(a) Using a vernier caliper, measure the chain tensioner slip-
per wears.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the chain tension-
er slipper.
A32118
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
40. INSPECT CHAIN VIBRATION DAMPER NO.1
(a) Using a vernier caliper, measure the vibration damper
wears.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the chain vibration
damper.
A32119
41. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier caliper, measure the length of cylinder
Overall Length
head bolts from the seat to the end.
Standard bolt length:
146.8 to 148.2 mm (5.780 to 5.835 in.)
Maximum bolt length: 148.5 mm (5.846 in.)
If the bolt length is greater than maximum, replace the cylinder
head set bolt.
A62820
42. INSPECT CAMSHAFT
(a) Inspect the camshaft for runout.
(1)
Place the camshaft on V-blocks.
(2)
Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.03 mm (0.0012 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
EM1628
(b) Inspect the cam lobes.
(1)
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
44.333 to 44.433 mm (1.7454 to 1.7493 in.) for intake
43.761 to 43.861 mm (1.7229 to 1.7268 in.) for exhaust
Minimum cam lobe height:
44.18 mm (1.7394 in.) for intake
43.61 mm (1.7169 in.) for exhaust
EM2011
If the cam lobe height is less than minimum, replace the cam-
shaft.
(c)
Inspect the camshaft journals.
(1)
Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
34.449 to 34.465 mm (1.3563 to 1.3569 in.)
Others journal diameter:
22.949 to 22.965 mm (0.9035 to 0.9041 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
EM2538
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
43. INSTALL OIL STRAINER FLANGE GASKET
(a) Install a new gasket to the bearing cap.
A64884
44. INSTALL OIL STRAINER SUB-ASSY
(a) Install the oil strainer with the 2 nuts and bolt.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
A64883
45. INSTALL OIL PAN SUB-ASSY
Seal Packing
(a) Remove any old packing material from the contact sur-
face and thread holes.
(b) Apply the seal packing in the shape of the bead (Diameter
3.5 mm to 4.5 mm (0.138 to 0.177 in.)) consequently as
A
A
shown in the illustration.
B
B
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
F
Remove any oil from the contact surface.
F
Install the oil pan within 3 minutes after applying the
seal packing.
6 mm (0.236 in.)
4 mm (0.157 in.)
F
Do not put into engine oil within 2 hours of installa-
tion.
A-A
B-B
A65664
(c)
Install the oil pan with the 14 bolts and 2 nuts.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
A64881
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
46. INSTALL OIL PAN DRAIN PLUG
(a) Place a new gasket on the oil pan drain plug, and install
it.
Torque: 37 N m (377 kgf cm, 27 ft lbf)
A64880
47. INSTALL ENGINE REAR OIL SEAL
SST
(a) Apply a light coat of multi-purpose 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 oil seal retainer edge.
SST
09223-15020, 09950-70010 (09951-07100)
A65665
NOTICE:
Wipe off extra grease on the crankshaft.
48. INSTALL OIL FILTER UNION
(a) Using a socket hexagon wrench 12, install the oil filter
union.
Torque: 30 N m (306 kgf cm, 22 ft lbf)
A64878
49. INSTALL OIL FILTER SUB-ASSY
(a) Check and clean the oil filter installation surface.
SST
(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.
(d) Using SST, tighten it an additional 3/4 turn.
SST
09228-06501
A65661
50. INSTALL CYLINDER HEAD GASKET
Lot No.
(a) Place a new cylinder head gasket on the cylinder block
surface with the Lot No. stamp upward.
NOTICE:
F
Pay attention to the installation direction.
F
Place the cylinder head gently in order not to damage
the gasket with the bottom part of the head.
A65666
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
51. INSTALL CYLINDER HEAD SUB-ASSY
(a) Place the cylinder head on the cylinder block.
(b) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
A64915
(c)
Using a bi-hexagon wrench 10, install and uniformly tight-
8
4
2
5
9
en the 10 cylinder head bolts with the plate washers, in
several passes, in the sequence shown.
Torque: 49 N m (500 kgf cm, 36 ft lbf)
10
6
1
3
7
A62816
(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts 90_ in the numerical or-
90_
der shown.
(f)
Check that the point marked bolts are moved by 90_
Engine
angle.
Front
Paint Mark
A65660
52. INSTALL CAMSHAFT TIMING GEAR ASSY
Straight Pin
(a) Put the camshaft timing gear assembly and camshaft to-
gether with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc-
tion (as shown in the illustration) with pushing it lightly
against the camshaft. Push further at the position where
the pin gets into the groove.
CAUTION:
Key Groove
A62824
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right angle).
(c)
Check that there is no clearance between the gear’s
fringe and camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 N m (551 kgf cm 40 ft lbf)
(e) Check that the camshaft timing gear assembly can move
to the retard angle side (the right angle), and is locked at
the most retarded position.
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
53. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
(a) Grip the camshaft with a vise, then install the camshaft
timing gear with the bolt.
Torque: 54 N m (551 kgf cm 40 ft lbf)
NOTICE:
Be careful not to damage the camshaft.
A64874
54. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil on the camshaft journals.
(b) Place the 2 camshafts on the cylinder head with the No.
1 cam lobes facing as shown the illustration.
A64916
(c)
Examine the front marks and numbers, then tighten the
bolts in the order shown in the illustration.
9
6
2
4
8
Torque:
23 Nm (235 kgf cm, 17 ft lbf) for bearing cap No. 1
13 Nm (133 kgf cm, 10 ft lbf) for bearing cap No. 3
5
1
3
7
A65667
55. INSTALL OIL CONTROL VALVE FILTER
(a) Check that no foreign substance on the mesh part of the
oil control valve filter.
Mesh
(b) Install a new gasket and the oil control valve filter on the
bolt, then install it.
Torque: 30 N m (306 kgf cm, 22 ft lbf)
A64873
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
56. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Apply a light coat of engine oil to a new O-ring, then install
it to the camshaft timing oil control valve.
(b) Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
NOTICE:
Be careful not twist the O-ring.
A64872
57. INSTALL OIL PUMP GASKET
(a) Install a new gasket to the cylinder block.
A64871
58. INSTALL OIL PUMP ASSY
(a) Engage the spline teeth of the oil pump drive rotor with the
large teeth of the crankshaft, and side the oil pump into
place.
A64893
(b) Install the oil pump with the 5 bolts.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
A64870
59. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
A64869
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
60. INSTALL CHAIN SUB-ASSY
(a) Set the No. 1 cylinder to the TDC/compression.
Point Mark
(1)
Turn the hexagonal wrench head portion of the
camshafts, then align the point marks of the cam-
shaft timing gears.
A65668
(2)
Using a crankshaft pulley bolt, turn the crankshaft
Point Mark
to align the timing gear key with the point mark lo-
cated on the oil pump.
Timing Gear Key
A65669
(b) Install the chain on the crankshaft timing gear with the yel-
low color mark link aligned with the timing mark on the
crankshaft timing gear.
Mark Link
Timing Mark
A65670
(c)
Using SST, install the crankshaft timing gear.
SST
09223-22010
SST
A65671
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(d) Install the chain on the camshaft timing gears with the yel-
low color mark links aligned with the timing marks on the
Mark Link
camshaft timing gears.
Timing Mark
A65672
61. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N m (189 kgf cm, 14 ft lbf)
A64866
62. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the crankshaft position sensor plate with the ”F”
mark facing forward.
A64867
63. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
SST
(a) Apply a light coat of multi-purpose grease to a new oil
seal lip.
(b) Place the timing chain cover on wooden blocks.
(c)
Using SST, tap in the oil seal until its surface is flush with
Wooden Block
the timing chain cover edge.
SST
09223-22010
NOTICE:
A65673
Keep the lip free off foreign materials.
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
64. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY
(a) Remove any old packing material from the contact sur-
B
face.
(b) Using a torx socket wrench E5, install the 3 stud bolts.
Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
A
A
15
12
38.5
29
12
9
A
B
(mm)
A65674
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(c)
Apply a continuous bead (3.5 to 4.5 mm (0.138 to 0.177
Engine Side:
in.) diameter) of seal packing as shown in the illustration.
Seal packing:
Water pump part: Part No. 08826-00100 or equivalent
Other part: Part No. 08826-00080 or equivalent
NOTICE:
F
Remove any oil from the contact surface.
F
Install the oil pan within 3 minutes after applying the
Seal Packing
A65675
seal packing.
F
Do not put into engine oil within 2 hours of installa-
tion.
Timing Chain Cover Side:
3 (0.118)
3 (0.118)
B
B
A
4.5
(0.177)
6 (0.236)
A
12 (0.472)
7 (0.276)
3 (0.118)
Width 4 (0.157)
A-A
B-B
C
C-C
Part No. 08826-00100 or equivalent
Part No. 08826-00080 or equivalent
(mm (in.))
C
A65676
(d) Install the timing chain cover with the 12 bolts and nut.
Torque:
A
A
13 Nm (133 kgf cm, 10 ft lbf) for bolt A and nut A
19 Nm (189 kgf cm, 14 ft lbf) for bolt B
A
A
A
B
B
B
A
A A
A
A65677
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
65. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check the O-ring is clean, and set the hook as shown in
O-ring
the illustration.
Raise
(b) Apply a light coat of engine oil to the O-ring.
Push
Hook
Pin
A65678
(c)
Install the chain tensioner with the 2 nuts.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
NOTICE:
F
Be careful not twist the O-ring.
F
When installing the chain tensioner, set the hook
again if the hook releases the plunger.
A64863
66. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the crank-
shaft pulley, then slide on the crankshaft pulley.
(b) Using SST, install the crankshaft pulley bolt.
SST
09960-10010 (09962-01000, 09963-01000)
Torque: 138 N m (1,407 kgf cm, 102 ft lbf)
SST
A62837
(c)
Turn the crankshaft counterclockwise, then disconnect
the plunger knock pin from the hook.
Disconnect
Turn
Hook
Pin
A65679
(d) Turn the crankshaft clockwise, then check that the slipper
is pushed by the plunger.
HINT:
If the plunger does not spring out, press the slipper into the
Plunger
chain tensioner with a screwdriver so that the hook is released
from the knock pin and that the plunger springs out.
Turn
Push
A65680
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
67. INSTALL WATER PUMP O-RING
(a) Install a new O-ring to the timing chain cover.
A64860
68. INSTALL WATER PUMP ASSY
B
(a) Install the water pump with the 6 bolts.
Torque:
9.0 Nm (92 kgf cm, 80 in lbf) for bolt A
11 Nm (112 kgf cm, 8 ft lbf) for bolt B
B
A
B
A
B
A65681
69. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the transverse engine engine mounting bracket
with the 3 bolts.
Torque: 47 N m (479 kgf cm, 35 ft lbf)
A64858
70. INSPECT VALVE CLEARANCE
Timing Mark
Timing Mark
(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
A65710
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(b) Check only the valves indicated.
No. 1 Cylinder TDC/Compression:
(1)
Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2)
Record the out-of specification valve clearance
measurements. They will be used later to determine
the required replacement valve lifters.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
A65682
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
(c)
Turn the crankshaft 1 revolution (360_) and set No. 4 the
No. 4 Cylinder TDC/Compression:
cylinder to the TDC/compression.
(d) Check only the valves indicated.
(1)
Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2)
Record the out-of specification valve clearance
measurements. They will be used later to determine
the required replacement valve lifters.
A65683
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 in.) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 in.) for exhaust
71. ADJUST VALVE CLEARANCE
Painted Mark
NOTICE:
Be sure not to revolve the crankshaft without the chain ten-
sioner.
(a) Set the No. 1 cylinder to the TDC/compression.
(b) Place the painted marks on the chain and camshaft timing
gears.
Groove
A65684
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ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(c)
Remove the 2 nuts and chain tensioner.
A64863
(d) Fix the camshaft with a spanner and so on, then loosen
Fix
the camshaft timing gear set bolt.
NOTICE:
Loosen
Be careful not to damage the valve lifter.
A65685
2
4
5
3
1
(e) Loosen the bearing cap bolts on the No. 2 camshaft in the
order as shown in the illustration in several passes, then
remove the bearing caps.
A62188
(f)
Remove the camshaft timing gear as shown in the illustra-
tion.
A32124
(g) Loosen the bearing cap bolts on camshaft in the order as
shown in the illustration in several passes, then remove
the bearing caps.
2
4
3
1
A62189