Toyota Corolla (2004+). Manual - part 99
14-34
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
64. REMOVE WATER BY-PASS PIPE NO.1
(a) Remove the 2 bolts, 2 nuts, water by-pass pipe and gas-
ket.
A64027
65. REMOVE WATER INLET
(a) Remove the 2 nuts and water inlet.
A64028
66. REMOVE THERMOSTAT
67. REMOVE ENGINE OIL PRESSURE SWITCH ASSY (See page 17-1)
68. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and camshaft position sensor.
B00084
69. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts and crankshaft position sensor.
B00086
14-35
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
70. REMOVE KNOCK SENSOR
(a) Remove the nut and knock sensor.
A64029
71. REMOVE V-RIBBED BELT TENSIONER ASSY
(a) Remove the bolts, nut and V-ribbed belt tensioner.
A64059
72. REMOVE MANIFOLD STAY
(a) Remove the 3 bolts and manifold stay.
A64030
73. REMOVE EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Remove the 4 bolts and exhaust manifold heat insulator.
A64031
74. REMOVE EXHAUST MANIFOLD
(a) Remove the 5 nuts, exhaust manifold and gasket.
A64032
14-36
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
75. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
(a) Using SST, remove the engine coolant temperature sen-
sor.
SST
09817-33190
A64033
76. REMOVE RADIO SETTING CONDENSER
(a) Remove the bolt and condenser.
A64034
77. REMOVE WATER BY-PASS HOSE NO.2
78. REMOVE RADIATOR HOSE INLET
79. REMOVE HEATER INLET WATER HOSE
80. REPLACE PARTIAL ENGINE ASSY
81. INSTALL RADIO SETTING CONDENSER
(a) Install the condenser with the bolt.
Torque: 10 N m (102 kgf cm, 7 ft lbf)
A64034
82. INSTALL ENGINE COOLANT TEMPERATURE
SENSOR
(a) Install a new gasket to the engine coolant temperature
sensor.
(b) Using SST, install the engine coolant temperature sensor.
SST
09817-33190
Torque: 20 N m (204 kgf cm, 15 ft lbf)
A64033
14-37
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
83. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 5
nuts.
Torque: 37 N m (377 kgf cm, 27 ft lbf)
A64032
84. INSTALL EXHAUST MANIFOLD HEAT INSULATOR
NO.1
(a) Install the exhaust manifold heat insulator with the 4 bolts.
Torque: 18 N m (184 kgf cm, 13 ft lbf)
A64031
85. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque: 49 N m (500 kgf cm, 36 ft lbf)
A64030
86. INSTALL V-RIBBED BELT TENSIONER ASSY
(a) Install the V-ribbed belt tensioner with the bolt and nut.
Torque:
29 Nm (296 kgf cm, 21 ft lbf) for nut
69 Nm (704 kgf cm, 51 ft lbf) for bolt
A64059
87. INSTALL KNOCK SENSOR
(a) Install the knock sensor with the nut.
Torque: 20 N m (204 kgf cm, 15 ft lbf)
A64029
14-38
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
88. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
B00086
89. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the camshaft position sensor with the bolt.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
B00084
90. INSTALL ENGINE OIL PRESSURE SWITCH ASSY (See page 17-1)
91. INSTALL THERMOSTAT (See page 16-11)
92. INSTALL WATER INLET
(a) Install the water inlet with the 2 nuts.
Torque: 11 N m (112 kgf cm, 8 ft lbf)
A64028
93. INSTALL WATER BY-PASS PIPE NO.1
(a) Install a new gasket and water by-pass with the 2 nuts
and 2 bolts.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
A64027
14-39
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
94. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of a new O-ring, then install it to the oil
level gage guide.
(b) Install the oil level gage guide with the bolt.
Torque: 13 N m (133 kgf cm, 10 ft lbf)
A64026
95. INSTALL INTAKE MANIFOLD
(a) Install a new gasket to the intake manifold.
(b) Install the intake manifold and throttle body assembly with
the 2 brackets, 4 bolts and 2 nuts. Uniformly tighten the
bolts and nuts in several passes.
Torque: 30 N m (306 kgf cm, 22 ft lbf)
(c)
Connect the 2 vacuum hoses to the intake manifold.
(d) Connect the 2 water hoses to the throttle body.
A14660
96. INSTALL FUEL DELIVERY PIPE SUB-ASSY(See page
11-10)
97. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
A64023
(b) Install the engine wire with the bolt and nut.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
A64022
98. INSTALL GENERATOR ASSY (See page 19-16)
14-40
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
99. 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.
90F
(g) Check that the point marked bolts are moved by 90F
angle.
A62206
100. 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
(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
Torque: 88 N m (897 kgf cm, 65 ft lbf)
6
8
2
A62204
14-41
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
101. INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See page
42-18)
SST
09301-00210
102. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See page
42-18)
SST
09301-00210
103. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See page
41-17)
104. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See page
40-9)
105. INSTALL STARTER ASSY (See page 19-4)
106. INSTALL FRONT SU SPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Attach the engine and transaxle assembly to the suspen-
sion crossmember and engine mounting member.
(b) Install the bolt holding the rear engine mounting bracket
to the mounting insulator.
TMMC, NUMMI made:
Torque: 65 N m (663 kgf cm, 48 ft lbf)
A61180
TAKAOKA, TAL made:
Torque: 87 N m (887 kgf cm, 64 ft lbf)
(c)
Install the bolt holding the front engine mounting bracket
to the mounting insulator.
Torque: 52 N m (530 kgf cm, 38 ft lbf)
A62711
107. INSTALL VANE PUMP ASSY (See page 51-8)
108. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine with transaxle on the engine lifter.
(b) Install the engine with transaxle to the vehicle.
(c)
Temporarily, install the suspension crossmember and 6
bolts.
(d) Install the engine mounting insulator LH.
Torque: 80 N m (816 kgf cm, 59 ft lbf)
(e) Install the engine mounting insulator RH.
A50289
Torque: 52 N m (530 kgf cm, 38 ft lbf)
14-42
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
(f)
Insert SST to the positioning holes on the right handle
crossmember and on the right-handle of the vehicle.
SST
09670-00010
(g)
Temporarily tighten the bolt A first, then bolt B.
B
SST
A
A62831
(h)
Insert SST to the positioning holes on the left handle
crossmember and on the left-handle of the vehicle.
SST
09670-00010
(i)
Temporarily tighten the bolt A first, then bolt B.
(j)
Insert SST to the positioning holes on the right-handle
B
crossmember and right-handle of the vehicle, then tight-
SST
en the bolts with the specified torque.
(k)
Insert SST to the positioning holes on the right-handle
A
A62832
crossmember and left-handle of the vehicle, then tighten
the bolts with the specified torque.
SST
09670-00010
Torque:
157 Nm (1,601 kgf cm, 116 ft lbf) for bolt A
113 Nm (1,152 kgf cm, 83 ft lbf) for bolt B
(l)
Tighten the 2 bolts, as shown in the illustration.
Torque: 39 N m (398 kgf cm, 29 ft lbf)
NOTICE:
After installing the crossmember, check that the position-
ing holes on the crossmember and vehicle are aligned with
each other.
A50337
109. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See page
30-6)
110. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH (See page
30-6)
111. INSTALL FRONT STABILIZER LINK ASSY LH (See page
51-18)
112. INSTALL FRONT STABILIZER LINK ASSY RH (See page
51-18)
113. INSTALL TIE ROD END SUB-ASSY LH (See page 30-6)
114. INSTALL TIE ROD END SUB-ASSY RH (See page 30-6)
115. INSTALL FRONT AXLE HUB LH NUT (See page
30-6)
116. INSTALL FRONT AXLE HUB RH NUT (See page 30-6)
117. INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2)
118. INSTALL FLOOR PANEL BRACE FRONT
(a) Install the front floor panel brace with the 2 nuts.
Torque: 30 N m (306 kgf cm, 22 ft lbf)
119. INSTALL STEERING INTERMEDIATE SHAFT (See page 51-18)
14-43
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
120. INSTALL RETURN TUBE SUB-ASSY
A
(a) Install the return tube with 2 bolts.
Torque:
5.0 Nm (51 kgf cm, 44 in. lbf) for bolt A
7.8 Nm (80 kgf cm, 69 in. lbf) for bolt B
B
A65809
121. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(See page 55-34)
122. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See page
41-17)
123. INSTALL CRUISE CONTROL ACTUATOR ASSY (W/
CRUISE CONTROL)
(a) Install the actuator with the 2 bolts.
Torque: 6.0 N m (61 kgf cm, 53 in. lbf)
(b) Connect the actuator connector.
A65807
124. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
(a) Install the air cleaner case with the 3 bolts.
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
(b) Connect the wire harness clamp, connector and hose.
(c)
Install the air cleaner filter element.
(d) Install the air cleaner cap.
(e) Connect the air cleaner hose.
A66032
(f)
Connect the 3 vacuum hoses, as shown in the illustration.
(g) Connect the VSV connector.
(h) Connect the intake air flow meter connector.
A65177
14-44
ENGINE MECHANICAL
- PARTIAL ENGINE ASSY (April, 2003)
125. INSTALL BATTERY CARRIER
(a) Install the battery carrier with the 4 bolts.
Torque: 13 N m (133 kgf cm, 10 ft lbf)
C80159
126. INSTALL BATTERY
Torque:
5.0 Nm (51 kgf cm, 44 in. lbf) for bolt
3.5 Nm (36 kgf cm, 31 in. lbf) for nut
127. INSTALL RADIATOR SUPPORT UPPER (W/ AIR CONDITIONING)
(a) Install the 2 radiator support uppers with the 2 bolts.
Torque: 19 N m (194 kgf cm, 14 ft lbf)
128. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
A65077
129. INSTALL FRONT WHEELS
Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
130. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
131. ADD ENGINE OIL
132. ADD COOLANT (See page 16-7)
133. CHECK FOR ENGINE OIL LEAKS
134. CHECK FOR ENGINE COOLANT LEAKS (See page 16-7)
135. CHECK FUEL LEAK
136. CHECK FOR EXHAUST GAS LEAKS
137. INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14-1)
SST
09843-18040
138. INSPECT CO/HC (See page 14-1)
139. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26-5)
140. CHECK ABS SPEED SENSOR SIGNAL (W/ ABS)
14-128
ENGINE MECHANICAL
- TIMING CHAIN OR BELT COVER OIL SEAL
TIMING GEAR COVER OIL SEAL
140OM-01
REPLACEMENT
1.
REMOVE ENGINE UNDER COVER RH
2.
REMOVE FRONT WHEEL RH
3.
REMOVE FAN AND GENERATOR V BELT
(a) Turn the V-ribbed belt tensioner slowly clockwise and
loosen it. Then, remove the fan and generator belt V and
put back the V-ribbed belt tensioner little by little and fix
it quietly.
A60622
4.
REMOVE ENGINE MOUNTING INSULATOR
SUB-ASSY RH
(a) Remove the the PS oil pump reservoir and put it aside.
(b) Place a wooden block between the jack and engine, and
set the jack. Then, remove the 4 bolts, the 2 nuts and en-
gine mounting insulator RH.
A01045
A64005
5.
REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the crankshaft pulley bolt.
SST
09960-10010 (09962-01000, 09963-01000)
(b) Remove the crankshaft pulley from the crankshaft.
SST
A62837
14-129
ENGINE MECHANICAL
- TIMING CHAIN OR BELT COVER OIL SEAL
6.
REMOVE TIMING GEAR COVER 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).
Pry
A62183
7.
INSTALL TIMING GEAR COVER OIL SEAL
(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 timing chain cover edge.
SST
09223-22010
NOTICE:
A62184
Wipe off extra grease on the crankshaft.
8.
INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the 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
9.
INSTALL ENGINE MOUNTING INSULATOR
SUB-ASSY RH
(a) Install the engine mounting insulator RH with the 4 bolts
and 2 nuts.
Torque: 52 N m (530 kgf cm, 38 ft lbf)
A64005
10. INSTALL FRONT WHEEL RH
Torque: 103 N m (1050 kgf cm, 76 ft lbf)
11. CHECK ENGINE OIL LEAK
14-5
ENGINE MECHANICAL
- VALVE CLEARANCE
VALVE CLEARANCE
140OE-01
ADJUSTMENT
1.
REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts, 2 clips and cylinder head cover.
A65077
2.
DISCONNECT ENGINE WIRE
(a) Remove the 5 clamps from the 5 clamp brackets.
(b) Disconnect the 4 ignition coil connectors.
A64021
(c)
Remove the bolt and nut installing the engine wire.
A64022
3.
REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils.
A64023
14-6
ENGINE MECHANICAL
- VALVE CLEARANCE
4.
DISCONNECT VENTILATION HOSE
(a) Disconnect the ventilation hose from the cylinder head
cover.
A65078
5.
DISCONNECT VENTILATION HOSE NO.2
(a) Disconnect the ventilation hose from the cylinder head
cover.
A64058
6.
REMOVE CYLINDER HEAD COVER SUB-ASSY
(a) Remove the 9 bolts, 2 seal washers, 2 nuts, 3 clamp
brackets and cylinder head cover.
A64856
7.
REMOVE ENGINE UNDER COVER RH