Toyota Corolla 2004 Manuel utilisateur

INTRODUCTION

PREPARATION

SERVICE SPECIFICATIONS

DIAGNOSTICS

ENGINE CONTROL SYSTEM

FUEL

EMISSION CONTROL

INTAKE

ENGINE MECHANICAL

EXHAUST

COOLING

LUBRICATION

IGNITION

STARTING & CHARGING

FRONT SUSPENTION

REAR SUSPENTION

TIRE & WHEEL

DRIVE SHAFT / PROPELLER SHAFT

BRAKE

PARKING BRAKE

AUTOMATIC TRANSMISSION / TRANS

MANUAL TRANSMISSION/TRANSAXLE

CLUTCH

STEERING COLUMN

POWER STEERING

HEATER & AIR CONDITIONER

SUPPLEMENTAL RESTRAINT SYSTEM

SEAT BELT

LIGHTING

WIPER & WASHER

AUDIO & VISUAL SYSTEM

WIRING

COMMUNICATION SYSTEM

WINDSHIELD/WINDOWGLASS/MIRROR

INSTRUMENT PANEL/METER

SEAT

THEFT DETTERENT & DOOR LOCK

SLIDING ROOF/CONVERTIBLE

ENGINE HOOD/DOOR

EXTERIOR/INTERIOR TRIM

VEHICLE CONTROL SYSTEM

CRUISE CONTROL

MAINTENANCE

ALPHABETICAL INDEX

2003 TOYOTA MOTOR CORPORATION

duced or copied, in whole or in part, without the

written permission of Toyota Motor Corporation.

First Printing: May 9, 2003 01–030509–00

FOREWORD

This manual (Volume 2) contains engine, chassis and body and electrical service procedures for the 2004

COROLLA.

Applicable models: ZZE130 series

For preparation, specifications and diagnostics procedures, refer to VOLUME 1 (Pub. No. RM1037U1).

The manual is divided into 39 sections with a thumb index for each section at the edge of the pages.

Please note that the publications below have also been prepared as relevant service manuals for the compo-

nents and systems in this vehicles.

ManualName Pub.No.

A245E, A246E Automatic Transaxle Repair Manual RM941U

2004 COROLLA Electrical Wiring Diagram EWD533U

All information in this manual is based on the latest product information at the time of publication. However,

specifications and procedures are subject to change without notice.

TOYOTA MOTOR CORPORATION

0103I–08

N17080

Filler Cap

Float

Reservoir Tank

Grommet

Clip

Slotted Spring Pin

: Specified torque

Non–reusable part

Cylinder

Piston Push Rod

Washer

Snap Ring

Boot

Gasket

Lock Nut

Clevis Pin

Clevis

N·m (kgf·cm, ft·lbf)

12 (120, 9)

15 (155, 11)

–INTRODUCTION HOW TO USE THIS MANUAL 01–1

4Author: Date:

2004 COROLLA (RM1037U)

HOW TO USE THIS MANUAL

GENERAL INFORMATION

1. GENERAL DESCRIPTION

(a) This manual is made in accordance with SAE J2008.

(b) Generally, repair operations can be separated in the following 3 main processes:

1. Diagnosis

2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting

3. Final Inspection

cess of ”Removing and Installing, Replacing, Disassembling, Installing and Checking, and Adjusting”,

but the 3rd process of ”Final Inspection” is omitted.

(d) The following essential operations are not written in this manual. However, these operations must be

performed in actual situations.

(1) Operations with a jack or lift

(2) Cleaning of a removed part when necessary

(3) Visual check

2. INDEX

(a) An alphabetical INDEX section is provided at the end of the book as a reference to help you find the

item to be repaired.

3. PREPARATION

(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending

on the repair situation. Be sure to use SST and SSM when they are required and follow the working

procedure properly. A list of SST and SSM is in the Preparation section of this manual.

4. REPAIR PROCEDURES

(a) Component drawing is placed under the title where necessary.

(b) Non–reusable parts, grease application area, precoated parts and tightening torque are specified in

the component drawings.

Example:

Illustration:

what to do and where

Component part No.

Detailed text: how to perform task

Task heading: what you will be doing

Set part No.

D31132

SST

01–2 –INTRODUCTION HOW TO USE THIS MANUAL

5Author: Date:

2004 COROLLA (RM1037U)

in the procedures.

NOTICE:

There are cases where such information can only be explained by using an illustration. In these

cases, all the information such as torque, oil, etc. are described in the illustration.

(d) Installing procedures are performed in the reverse order of the removal and only the important points

are described.

(e) Only items with points are described in the procedure, and the operational portion and content are

placed using an illustration. In the explanations, details of the operational method, standard value and

notices are placed.

(f) There may be a case where the illustrations of similar models are used. In that case, specific details

may be different from the actual vehicle.

(g) The procedures are presented in a step–by–step format:

(1) The illustration shows what to do and where to do it.

(2) The task heading tells what to do.

(3) The explanation text tells how to perform the task and gives other information such as specifica-

tions and warnings.

Example:

HINT:

This format provides an experienced technician with a FAST TRACK to the necessary information. The task

heading can be read at a glance when necessary and the text below provides detailed information. Important

specifications and warnings always are written in bold type to stand out from the rest of the text.

5. SERVICE SPECIFICATIONS

(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-

dure to look up your specifications. The specifications are also found in the Service Specifications sec-

tion for quick reference.

6. TERMS DEFINITION

CAUTION Indicatesthe possibility of injury to you or other people.

NOTICE Indicates the possibility of damage to the components being repaired.

HINT Provides additional information to help you to perform the repair efficiently.

–INTRODUCTION HOW TO USE THIS MANUAL 01–3

6Author: Date:

2004 COROLLA (RM1037U)

7. SI UNIT

(a) The units given in this manual are primarily expressed according to the SI UNIT (International System

of Units), and alternately expressed in the metric system and in the English System.

Example:

Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf)

01031–06

D27356

D27359

01–4 –INTRODUCTION IDENTIFICATION INFORMATION

7Author: Date:

2004 COROLLA (RM1037U)

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION AND SERIAL NUMBERS

1. VEHICLE IDENTIFICATION NUMBER

(a) The vehicle identification number is stamped on the ve-

hicle identification number plate and certification label, as

shown in the illustration.

A: Vehicle Identification Number Plate

B: Certification Label

2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL

NUMBER

(a) The engine serial number is stamped on the cylinder

block of the engine, and the transaxle serial number is

stamped on the housing, as shown in the illustration.

A: 1ZZ–FE

B: C59

C: A245E

010D8–02

D25016

–INTRODUCTION REPAIR INSTRUCTION 01–5

8Author: Date:

2004 COROLLA (RM1037U)

REPAIR INSTRUCTION

PRECAUTION

1. BASIC REPAIR HINT

(a) HINTS ON OPERATIONS

1 Looks Always wear a clean uniform.

Hat and safety shoes must be worn.

2Vehicle protection Set a grill cover, fender cover, seat cover and floor mat before starting the operation.

3Safe operation

In case of working with 2 or more persons, be sure to check safety of one another.

When working with the engine running, pay attention to the ventilation of the workshop.

In case of operating on high–temperature parts, rotating, moving and vibrating parts, pay attention not to

burn or injure yourself.

When jacking up the vehicle, be sure to support the specified location with a safety stand.

When lifting up the vehicle, apply a safety equipment.

4Preparation of tools and

measuring gauge Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement.

5Removal and installation,

disassembly and assem-

bly operations

Diagnose with a thorough understanding of the trouble phenomenon and perform effective operations.

Before removing the parts, check the assembly for general condition, deformation and damage.

When the structure is complicated, take a note or put match marks so as not to make mistakes that affect the

function of the parts.

Clean and wash the removed parts if necessary, and assemble them after a thorough check.

6Removed parts

Place the removed parts in the correct order to avoid mixing up or making them dirty.

As for non–reusable parts such as gasket, O–ring, and self lock nut, change them to new ones following the

instruction of this manual.

Sort out the parts for replacement in a box and show them to the customer.

(b) JACKING UP AND SUPPORTING VEHICLE

(1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the

vehicle at the proper locations (See page 01–17).

Z11554

Seal Lock Adhesive

BE1367

Medium Current Fuse and High Current

Fuse Equal Amperage Rating

D27353

V35001

Illustration Symbol Part Name Abbreviation

FUSE

MEDIUM CURRENT FUSE

HIGH CURRENT FUSE

FUSE

M–FUSE

H–FUSE

01–6 –INTRODUCTION REPAIR INSTRUCTION

9Author: Date:

2004 COROLLA (RM1037U)

(1) Precoated parts are bolts, nuts, etc. that are coated

with a seal lock adhesive at the factory.

(2) If a precoated part is retightened, loosened or

caused to move in any way, it must be recoated with

the specified adhesive.

(3) When reusing precoated parts, clean off the old

adhesive and dry the part with compressed air.

Then apply the specified seal lock adhesive to the

bolt, nut or threads.

NOTICE:

Perform the torque checking with the lower limit value of

the torque tolerance.

(4) Depending on the seal lock agent to apply, there

may be a case where it is necessary to leave it for

a specified time until it hardens.

(d) GASKETS

(1) When necessary, use a sealer on gaskets to prevent leaks.

(e) BOLTS, NUTS AND SCREWS

(1) Carefully observe all the specifications for tightening torques. Always use a torque wrench.

(f) Fuses.

(1) When replacing fuses, be sure that a new fuse has

the correct amperage rating. DO NOT exceed the

rating, or use one with a lower rating.

D25786

Shape (Example) Removal/Installation

Clip Remover

Pliers

Screwdriver

Scraper

Protective Tape

Clip

Protective Tape

–INTRODUCTION REPAIR INSTRUCTION 01–7

10Author: Date:

2004 COROLLA (RM1037U)

(g) CLIPS

(1) The removal and installation methods of typical clips used in body parts are shown in the table

below.

HINT:

If the clip is damaged during the a procedure, always replace it with a new clip.

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