Toyota Corolla (2004+). Manual - part 98

 

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Toyota Corolla (2004+). Manual - part 98

 

 

14-71
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(h) Remove the camshaft while holding the chain.
A32125
(i)
Tie the chain with a string as shown in the illustration.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
(j)
Remove the valve lifters.
A65711
(k)
Using a micrometer, measure the thickness of the re-
moved valve lifters.
(l)
Calculate the thickness of a new lifter so that the valve
clearance comes within the specified value.
A
Thickness of new lifter
B
Thickness of used lifter
C
Measured valve clearance
Valve clearance:
A01082
Intake A = B + (C - 0.20 mm (0.0079 in.))
Exhaust A = B + (C - 0.30 mm (0.0118 in.))
Example (Intake):
Measure intake valve clearance = 0.40 mm (0.0158 in.)
0.40 mm (0.0158 in.) - 0.20 mm (0.0079 in.) = 0.20 mm (0.0079 in.)
(Measured - Specification = Excess clearance)
Used lifter measurement = 5.250 mm (0.2067 in.)
0.20 mm (0.0079 in.) + 5.250 mm (0.2067 in.) = 5.450 mm (0.2146 in.)
(Excess clearance + Used lifter = Ideal new lifter)
Closest new lifter = 5.460 mm (0.2150 in.)
Select No. 46 lifter
HINT:
F
Select a new lifter with a thickness as close as possible
to the calculated values.
F
Lifter are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm
(0.2260 in.).
F
Refer to new lifter thickness table on the next 2 pages.
Valve Lifter Selection Chart (Intake)
New lifter thickness
mm (in.)
Lifter
Lifter
Lifter
Thickness
Thickness
Thickness
No.
No.
No.
06
5.060
(0.1992)
30
5.300
(0.2087)
54
5.540
(0.2181)
08
5.080
(0.2000)
32
5.320
(0.2094)
56
5.560
(0.2189)
10
5.100
(0.2008)
34
5.340
(0.2102)
58
5.580
(0.2197)
12
5.120
(0.2016)
36
5.360
(0.2110)
60
5.600
(0.2205)
14
5.140
(0.2024)
38
5.380
(0.2118)
62
5.620
(0.2213)
16
5.160
(0.2031)
40
5.400
(0.2126)
64
5.640
(0.2220)
18
5.180
(0.2039)
42
5.420
(0.2134)
66
5.660
(0.2228)
20
5.200
(0.2047)
44
5.440
(0.2142)
68
5.680
(0.2236)
22
5.220
(0.2055)
46
5.460
(0.2150)
70
5.700
(0.2244)
Intake valve clearance (Cold):
0.15 to 0.25 mm (0.006 to 0.010 in.)
24
5.240
(0.2063)
48
5.480
(0.2157)
72
5.720
(0.2252)
EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and
26
5.260
(0.2071)
50
5.500
(0.2165)
74
5.740
(0.2260)
the measured clearance is 0.400 mm (0.0157 in.).
28
5.280
(0.2079)
52
5.520
(0.2173)
Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter.
Valve Lifter Selection Chart (Exhaust)
New lifter thickness
mm (in.)
Lifter
Lifter
Lifter
Thickness
Thickness
Thickness
No.
No.
No.
06
5.060
(0.1992)
30
5.300
(0.2087)
54
5.540
(0.2181)
08
5.080
(0.2000)
32
5.320
(0.2094)
56
5.560
(0.2189)
10
5.100
(0.2008)
34
5.340
(0.2102)
58
5.580
(0.2197)
12
5.120
(0.2016)
36
5.360
(0.2110)
60
5.600
(0.2205)
14
5.140
(0.2024)
38
5.380
(0.2118)
62
5.620
(0.2213)
16
5.160
(0.2031)
40
5.400
(0.2126)
64
5.640
(0.2220)
18
5.180
(0.2039)
42
5.420
(0.2134)
66
5.660
(0.2228)
20
5.200
(0.2047)
44
5.440
(0.2142)
68
5.680
(0.2236)
22
5.220
(0.2055)
46
5.460
(0.2150)
70
5.700
(0.2244)
Exhaust valve clearance (Cold):
0.25 to 0.35 mm (0.010 to 0.014 in.)
24
5.240
(0.2063)
48
5.480
(0.2157)
72
5.720
(0.2252)
EXAMPLE: The 5.340 mm (0.2102 in.) lifter is installed, and
26
5.260
(0.2071)
50
5.500
(0.2165)
74
5.740
(0.2260)
the measured clearance is 0.440 mm (0.0173 in.).
Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter.
28
5.280
(0.2079)
52
5.520
(0.2173)
14-74
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(m) As shown in the illustration, install the chain on the cam-
Painted Mark
shaft timing gear with the painted mark aligned with the
timing mark on the camshaft timing gear.
Timing Mark
A62195
(n) Examine the front marks and numbers, then tighten the
4
1
2
3
bolts in the order shown in the illustration.
Torque: 13 Nm (133 kgfcm, 10 ftlbf)
A62196
Painted Mark
(o) Put the camshaft No. 2 on the cylinder head with the
painted mark of the chain aligned with the timing mark on
the camshaft timing gear.
Timing Mark
A62197
(p) Raise the camshaft, then tighten the set bolt temporarily.
A32124
(q) Examine the front marks and numbers, then tighten the
bolts in the order shown in the illustration.
7
Torque:
23 Nm (235 kgfcm, 17 ftlbf) for bearing cap No. 1
13 Nm (133 kgfcm, 10 ftlbf) for bearing cap No. 3
6
5
3
1
2
4
A62198
14-75
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(r)
Fix the camshaft with a spanner and so on, then tighten
Fix
the camshaft timing gear set bolt.
Torque: 54 Nm (551 kgfcm, 40 ftlbf)
Tighten
NOTICE:
Be careful not to damage the valve lifter.
A65685
(s)
Check the painted marks on the chain and camshaft tim-
Painted Mark
ing gears. Then, check that the crankshaft pulley groove
and the timing mark of the timing chain cover are aligned
as shown in the illustration.
Groove
A65684
(t)
Install the chain tensioner.
(1)
Check the O-ring is clean, and set the hook as
O-ring
shown in the illustration.
Raise
(2)
Apply a light coat of engine oil to the O-ring.
Push
Hook
Pin
A65678
(3)
Install the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgfcm, 80 inlbf)
NOTICE:
F
Be careful not twist the O-ring.
F
When installing the tensioner, set the hook again if
the hook releases the plunger.
A64863
14-76
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(4)
Turn the crankshaft counterclockwise, then discon-
nect the plunger knock pin from the hook.
Disconnect
Turn
Hook
Pin
A65679
(5)
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
72. INSTALL CYLINDER HEAD COVER GASKET
(a) Install the gasket to the cylinder head cover.
A64857
73. INSTALL CYLINDER HEAD COVER SUB-ASSY
Seal Packing
(a) Remove any old packing (FIPG) material.
(b) Apply the seal packing to the 2 locations as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
F
Remove any oil from the contact surface.
F
Install the cylinder head cover within 3 minutes after
A62182
applying the seal packing.
F
Do not put into engine oil 2 hours of installation.
14-77
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(c)
Install the cylinder head cover with the 9 bolts, 2 seal
A
A
A
washers and 2 nuts.
Torque:
A
11 Nm (112 kgfcm, 8 ftlbf) for bolt A and nut A
B
B
9.0 Nm (92 kgfcm, 80 inlbf) for bolt B
A
A
A
A
A
A65687
74. INSTALL SPARK PLUG
(a) Using a spark plug wrench, install the spark plugs.
Torque: 25 Nm (255 kgfcm, 18 ftlbf)
A64855
75. INSTALL VENTILATION VALVE SUB-ASSY
(a) Install the ventilation valve to the cylinder head cover.
Torque: 30 Nm (306 kgfcm, 22 ftlbf)
A64854
76. INSTALL OIL FILLER CAP GASKET
(a) Install the gasket to the oil filler cap.
A65590
14-78
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
77. INSTALL OIL FILLER CAP SUB-ASSY
(a) Install the oil filler cap to the cylinder head cover.
A64852
14-27
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
141GS-01
REPLACEMENT
1.
WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11-1)
2.
REMOVE FRONT WHEELS
3.
REMOVE ENGINE UNDER COVER RH
4.
REMOVE ENGINE UNDER COVER LH
5.
DRAIN COOLANT (See page 16-7)
6.
REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts, 2 clips and cylinder head cover.
A65077
7.
DISCONNECT RADIATOR HOSE INLET
(a) Disconnect the radiator hose inlet from the radiator.
8.
DISCONNECT RADIATOR HOSE OUTLET
(a) Disconnect the radiator hose outlet from the radiator.
9.
DISCONNECT OIL COOLER INLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler inlet tube from the radiator.
10. DISCONNECT OIL COOLER OUTLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler outlet tube from the radiator.
11. REMOVE RADIATOR SUPPORT UPPER (W/ AIR CONDITIONING)
(a) Remove the 2 bolts and 2 radiator support upper.
12. REMOVE RADIATOR ASSY (W/ AIR CONDITIONING)
(a) Disconnect the connector and harness clamp, and remove the radiator.
13. REMOVE BATTERY
14. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts and battery carrier.
15. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
(a) Disconnect the mass air flow sensor connector.
(b) Disconnect the VSV connector.
C80159
14-28
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(c)
Disconnect the 3 vacuum hoses, as shown in the illustra-
tion.
(d) Loosen the air cleaner hose clamp and disconnect the air
cleaner hose.
(e) Remove the air cleaner cap.
(f)
Remove the air cleaner filter element.
A65177
(g) Disconnect the wire harness clamp, connector and hose.
(h) Remove the 3 bolts and air cleaner case.
A66032
16. REMOVE EFI FUEL PIPE CLAMP (See page 11-10)
17. DISCONNECT FUEL TUBE SUB-ASSY (See page 11-10)
18. SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a) Loosen the nut, then remove the accelerator control cable.
19. SEPARATE CRUISE CONTROL ACTUATOR ASSY (W/
CRUISE CONTROL)
(a) Disconnect the actuator connector.
(b) Remove the 2 bolts, then separate the actuator from the
body.
A65807
20. DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a) Disconnect the union to connector tube hose from the brake booster.
21. DISCONNECT HEATER INLET WATER HOSE
(a) Disconnect the heater inlet water hose from the air condi-
tioner tube.
A65832
14-29
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
22. DISCONNECT HEATER OUTLET WATER HOSE
(a) Disconnect the heater outlet water hose from the air con-
ditioner tube.
A65833
23. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE)
(See page 41-17)
24. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE)
(See page 41-17)
25. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE)
(See page 40-9)
26. SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See page
41-17)
27. REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71-10)
28. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the ECM and junction
block.
(b) Pull out the engine wire.
(c)
Remove the engine room relay block cover.
(d) Disconnect the engine wire from the engine room relay
block.
A66034
29. REMOVE FAN AND GENERATOR V BELT
(a) Slowly turn the V-ribbed belt tensioner clockwise, then
remove the V belt.
A60622
30. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(See page 55-34)
HINT:
Hang up the hoses instead of detaching.
14-30
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
31. SEPARATE RETURN TUBE SUB-ASSY
(a) Separate the vane pump oil reservoir from the oil reser-
voir bracket.
(b) Remove the 2 bolts installing the return tube.
A65809
32.
REMOVE FRONT DOOR SCUFF PLATE RH (See page 76-21)
33.
REMOVE COWL SIDE TRIM BOARD RH (See page 71-10)
34.
REMOVE COLUMN HOLE COVER SILENCER SHEET
(a)
Remove the 2 clips and column hole cover silencer sheet.
35.
SEPARATE STEERING INTERMEDIATE SHAFT (See page 51-18)
36.
REMOVE FLOOR PANEL BRACE FRONT
(a)
Remove the 2 nuts and floor panel brace front.
37.
REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2)
38.
REMOVE FRONT AXLE HUB LH NUT (See page 30-6)
SST
09930-00010
39.
REMOVE FRONT AXLE HUB RH NUT (See page 30-6)
SST
09930-00010
40.
SEPARATE TIE ROD END SUB-ASSY LH (See page 30-6)
SST
09628-62011
41.
SEPARATE TIE ROD END SUB-ASSY RH (See page 30-6)
SST
09628-62011
42.
SEPARATE FRONT STABILIZER LINK ASSY LH (See page
51-18)
43.
SEPARATE FRONT STABILIZER LINK ASSY RH (See page
51-18)
44.
SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See page
30-6)
45.
SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH (See page
30-6)
46.
SEPARATE FRONT AXLE ASSY LH (See page 30-6)
47.
SEPARATE FRONT AXLE ASSY RH (See page 30-6)
48. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.
(b) Remove the 4 bolts, 2 nuts and engine mounting insula-
tor.
A64005
14-31
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(c)
Remove the through bolt and nut, then detach the engine
mounting insulator from the vehicle.
A55685
(d) Remove the 6 bolts, as shown in the illustration.
(e) Carefully, remove the engine with transaxle from the ve-
hicle.
A50289
(f)
Install the 2 engine hangers with the 2 bolts.
Front Side:
Rear Side:
Part No.:
12281-15040 for No. 1 engine hanger
12281-22021 for No. 2 engine hanger
91512-B1016 for bolt
Torque: 38 Nm (387 kgfcm, 28 ftlbf)
HINT:
Be sure to install the engine hanger (12281-22021) to the front
A62830
side of the engine and the engine hanger (12281-15040) to the
rear side.
(g) Using the chain block and engine sling device, hang the
engine assembly.
49. SEPARATE VANE PUMP ASSY (See page 51-8)
NOTICE:
Do not disconnect the hose.
50. REMOVE FRONT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Remove the through bolt and nut, then detach the engine
mounting insulator FR from the engine mounting bracket.
A62711
14-32
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(b) Remove the through bolt, then detach the engine mount-
ing insulator RR from the suspension crossmember.
(c)
Separate the engine and transaxle assembly from the
suspension crossmember and engine mounting member.
A61180
51. REMOVE STARTER ASSY (See page 19-4)
52. REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page
41-17)
53. REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page
40-9)
54. REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See page 42-18)
55. REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See page 42-18)
56. 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
57. 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
58. REMOVE GENERATOR ASSY (See page 19-16)
59. REMOVE IGNITION COIL ASSY
(a) Disconnect the 4 ignition coil connectors.
A64021
14-33
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(b) Remove the bolt and nut installing the engine wire.
A64022
(c)
Remove the 4 bolts and 4 ignition coils.
A64023
60. REMOVE FUEL DELIVERY PIPE SUB-ASSY (See page 11-10)
61. REMOVE INTAKE MANIFOLD
(a) Disconnect the 2 water hoses from the throttle body.
(b) Disconnect the 2 vacuum hoses from the intake manifold.
(c)
Remove the 4 bolts, 2 nut, 2 wire brackets, intake man-
ifold and throttle body assembly.
(d) Remove the gasket from the intake manifold and throttle
body assembly.
A14660
62. REMOVE OIL LEVEL GAGE SUB-ASSY
(a) Remove the oil level gage from the oil level gage guide.
63. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the bolt and oil level gage guide.
A64026

 

 

 

 

 

 

 

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