Page 1 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...
Page 2 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...
Page 3 TOYOTA MOTOR CORPORATION TOYOTA MOTOR CORPORATION 2003 All rights reserved. This book may not be repro- duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing: May 9, 2003 01–030509–00...
Page 4 01–1 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 0103I–08 GENERAL INFORMATION GENERAL DESCRIPTION This manual is made in accordance with SAE J2008. Generally, repair operations can be separated in the following 3 main processes: 1. Diagnosis 2.
Page 5 01–2 INTRODUCTION – HOW TO USE THIS MANUAL Tightening torque, grease application area, and non–reusable parts are described as important points 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.
Page 6 01–3 INTRODUCTION – HOW TO USE THIS MANUAL SI UNIT 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) 2004 COROLLA (RM1037U)
Page 7 01–4 INTRODUCTION – IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION 01031–06 VEHICLE IDENTIFICATION AND SERIAL NUMBERS VEHICLE IDENTIFICATION NUMBER 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 D27356 ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL...
Page 8 01–5 INTRODUCTION – REPAIR INSTRUCTION REPAIR INSTRUCTION 010D8–02 PRECAUTION BASIC REPAIR HINT HINTS ON OPERATIONS D25016 S Always wear a clean uniform. Looks S Hat and safety shoes must be worn. S Set a grill cover, fender cover, seat cover and floor mat before starting the operation. Vehicle protection S In case of working with 2 or more persons, be sure to check safety of one another.
Page 9 01–6 INTRODUCTION – REPAIR INSTRUCTION PRECOATED PARTS Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive.
Page 10 01–7 INTRODUCTION – REPAIR INSTRUCTION CLIPS 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. Shape (Example) Removal/Installation Clip...
Page 11 01–8 INTRODUCTION – REPAIR INSTRUCTION Removal/Installation Shape (Example) Removal Installation Removal Installation Removal Installation V35004 2004 COROLLA (RM1037U) Author : Date :...
Page 12 01–9 INTRODUCTION – REPAIR INSTRUCTION REMOVAL AND INSTALLATION OF VACUUM HOSES To disconnect vacuum hoses, pull them by holding the end, not the middle of the hose. CORRECT WRONG D25063 When disconnecting vacuum hoses, use tags to identify where they should be reconnected. After completing the job, make a double check whether the vacuum hoses are properly connected.
Page 13 01–10 INTRODUCTION – REPAIR INSTRUCTION FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER HINT: The vehicle is equipped with an SRS (Supplemental Restraint System), such as the horn button assembly, the instrument panel passenger airbag assembly, the front seat airbag assembly, the center airbag sensor assembly, the front airbag sensor, the side airbag sensor and the seat belt pretensioner.
Page 14 01–11 INTRODUCTION – REPAIR INSTRUCTION SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other Mark troubles may occur. Refer to page 60–22 on this manual concerning the correct installation of the...
Page 15 01–12 INTRODUCTION – REPAIR INSTRUCTION INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY Always store a removed or new instrument panel passenger airbag assembly with the airbag inflation direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates. Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous).
Page 16 01–13 INTRODUCTION – REPAIR INSTRUCTION When disposing of a vehicle or the side airbag assembly alone, the airbag should be deployed using an SST before disposal (See page 60–32). Perform the operation in a safe place away from electrical noise. Example: D27360 SEAT BELT PRETENSIONER...
Page 17 01–14 INTRODUCTION – REPAIR INSTRUCTION WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the instrument panel wire harness assembly. All the con- nectors in the system are in a standard yellow color. If the SRS wire harness becomes discon- nected or the connector becomes broken due to an accident, etc., repair or replace it.
Page 18 01–15 INTRODUCTION – REPAIR INSTRUCTION Never use any electric equipment like an electric motor or a working light, as they may cause sparks or high temperature. Never use an iron hammer, as it may cause sparks. Dispose of the shop rag separately from any fuel deposit. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS If any metal tip is mixed in the inlet pass, this may give a...
Page 19 01–16 INTRODUCTION – REPAIR INSTRUCTION FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER CAUTION: If large amount of unburned fuel flows into the converter, it may cause overheating and a fire hazard. To prevent this, observe the following precautions. Use only unleaded gasoline. Avoid prolonged idling.
Page 20 01–17 INTRODUCTION – REPAIR INSTRUCTION 010D9–02 VEHICLE LIFT AND SUPPORT LOCATIONS NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP As a rule, the vehicle must be unloaded when jacking up. Never jack up or lift up the vehicle loaded with things of heavy weight. When removing any parts of heavy weight like the engine and transmission, the center of gravity of the vehicle moves.
Page 21 01–18 INTRODUCTION – REPAIR INSTRUCTION NOTICE FOR USING SWING ARM TYPE LIFT Follow the instruction manual of the lift for a safe operation. Use a cradle with a rubber attachment, as shown in the illustration. Set in the vehicle so as to make its center of gravity as close as possible to the center of the lift. (”L” becomes short.) Place the vehicle horizontally by adjusting the height of the cradle, and match the groove of the cradle and the safety stand support location accurately.
Page 22 05–638 7. Power Door Lock Control System 05–670 8. Wireless Door Lock Control System 05–685 9. TOYOTA Vehicle Intrusion Protection System 05–700 10.Cruise Control System 05–742 FOR USING HAND–HELD TESTER Before using the tester, the tester’s operator manual should be read thoroughly.
Page 23 01–20 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01035–10 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Carry out troubleshooting in accordance with the procedures on the following page. Here, only the basic procedures are shown. Details are provided in the Diagnostics Section, showing the most effective methods for each circuit.
Page 24 01–21 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Confirmation test After completing repairs, confirm that the problem has been solved (If the problem does not recur, per- form a confirmation test under the same conditions and in the same environment as when it occurred for the first time).
Page 25 01–22 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CUSTOMER PROBLEM ANALYSIS HINT: In troubleshooting, the problem symptoms must be confirmed accurately, meaning that all preconcep- tions must be set aside in order to make an accurate judgement. To ascertain what the problem symp- toms are, it is extremely important to ask the customer about the problem and conditions when it oc- curred.
Page 26 01–23 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in COROLLA has various functions. The first function is the Diagnostic Trouble Code (DTC) Check, in which a malfunction in the signal circuits to the ECU is stored in code form in the ECU memory.
Page 27 01–24 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DTC check DTC displayed Normal code displayed Troubleshooting of problem indicated by DTC Symptom confirmation No problem symptoms exist Problem symptoms exist If a DTC is displayed in the initial DTC check, it indicates that a trouble may have occurred in a wire harness or connector in that circuit in the past, therefore check the wire harness and connectors (See page 01–30).
Page 28 01–25 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occurs. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer’s vehicle should be simulated.
Page 29 01–26 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Do not apply heat directly to the parts in the ECU. WATER SPRINKLING METHOD: When the malfunc- tion seems to occur on a rainy day or in high–humid- ity. Sprinkle water onto the vehicle and check if the malfunc- tion occurs.
Page 30 01–27 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DIAGNOSTIC TROUBLE CODE CHART The inspection procedures are shown in the table below. This table allows efficient and accurate trouble- shooting using the diagnostic trouble codes displayed in the diagnostic trouble code chart. Proceed with troubleshooting in accordance with the inspection procedures listed in the diagnostic chart corresponding to the diagnostic trouble codes displayed.
Page 31 01–28 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a Normal code is displayed in the diagnostic trouble code chart but the prob- lem is still occurring.
Page 32 01–29 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CIRCUIT INSPECTION How to read and use each page is shown below. D Circuit Description D Inspection Procedures The major role and, operation of the circuit Use the inspection procedures to determine and its component parts are explained.
Page 33 The connector with a lock should be securely con- nected until it makes a ”click” sound. When checking the connector with a Toyota electri- WRONG cal tester, check it from the backside (harness side) of the connector using a mini test lead.
Page 34 01–31 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Checking of the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, check the engaged condition and sliding resistance. Same terminal as a male terminal D25088 REPAIR METHOD OF CONNECTOR TERMINAL If there is on the contact point, clean the contact...
Page 35 01–32 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Check the resistance. Fig. 2 Disconnect connectors A and C and measure the resistance between them. Resistance: 1 Ω or less HINT: Sensor Measure the resistance while lightly shaking the wire harness vertically and horizontally.
Page 36 01–33 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CHECK SHORT CIRCUIT Fig. 5 If the wire harness is ground shorted as shown in Fig. 5, C SHORT locate the section by conducting a resistance check with the body ground in step (b). Z17008 Check the resistance with the body ground.
Page 37 01–34 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CHECK AND REPLACE ECU NOTICE: Start an inspection of the connector from the back- side of the connector on the wire harness side with the connector connected to the ECU. When no measurement condition is specified, per- form the inspection with the engine stopped and also the ignition switch ON.
Page 38 01–35 INTRODUCTION – TERMS TERMS 01037–07 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning Anti–Lock Brake System Alternating Current Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential Air–Fuel Ratio Active Height Control Suspension Automatic Locking Retractor Alternator Amplifier Antenna...
Page 39 01–36 INTRODUCTION – TERMS Abbreviations Meaning DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection Data Link Connector Distributorless Ignition DOHC Double Overhead Camshaft Dash Pot Dead Soak Digital Signal Processor Diagnostic Trouble Code Digital Versatible Disc Electric Brake Force Distribution ECAM Engine Control And Measurement System Electronic Controlled Diesel...
Page 40 01–37 INTRODUCTION – TERMS Abbreviations Meaning High Intensity Discharge (Head Lamp) Hydraulic Power Unit Housing Hard Top Heated Windshield System Idle Air Control Integrated Circuit Indirect Diesel Injection Independent Front Suspension Ignition Integrated Ignition Assembly Intake (Manifold, Valve) Intermittent Instrument Panel Independent Rear Suspension Idle Speed Control Junction Block...
Page 41 Special Service Materials Special Service Tools Standard Cold–Start Fuel Injection Switch System Transaxle TACH Tachometer Throttle Body Electronic Fuel Injection Turbocharger TCCS TOYOTA Computer–Controlled System Timing Control Valve Top Dead Center TEMP. Temperature 2004 COROLLA (RM1037U) Author : Date :...
Page 42 Abbreviations Meaning TEMS TOYOTA Electronic Modulated Suspension Toyota Free–Tronic Total Information System For Vehicle Development Transmission TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharge Three–Way Catalyst TVIP TOYOTA Vehicle Intrusion Protection Underdrive Undersize...
Page 43 – TERMS 010DA–02 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their TOYOTA equivalents. TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )––ABBREVIATIONS...
Page 44 01–41 INTRODUCTION – TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO Idle Air Control Idle Speed Control (ISC) Intake Air Temperature Intake or Inlet Air Temperature Ignition Control Module – Indirect Fuel Injection Indirect Injection (IDL) Inertia Fuel–Shutoff – Idle Speed Control –...
Page 45 01–42 INTRODUCTION – TERMS Transmission Control Module Transmission ECU, ECT ECU Throttle Position Throttle Position Transmission Range – Bimetallic Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three–Way Catalytic (TWC) Three–Way Catalytic Converter Manifold Converter TWC+OC Three–Way + Oxidation Catalytic Converter + CCo Volume Air Flow...
Page 46 PREPARATION 09816–30010 Oil Pressure Switch Socket SFI SYSTEM Diagnosis Check Wire No.2 SFI SYSTEM 09843–18040 SUPPLEMENTAL RESTRAINT SYSTEM Recomended Tools TOYOTA Electrical Tester SFI SYSTEM 09082–00040 SUPPLEMENTAL RESTRAINT SYSTEM ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] COMBINATION METER WIRELESS DOOR LOCK CONTROL SYSTEM (09083–00150)
Page 47 02–2 PREPARATION – ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM 021A2–03 PREPARATION Equipment Ohmmeter Radiator cup tester Torque wrench 2004 COROLLA (RM1037U) Author : Date :...
Page 48 FUEL SYSTEM (09268–41300) Hose FUEL SYSTEM (95336–08070) 09842–30080 Wire ”H” EFI Inspection FUEL SYSTEM Recomended Tools 09082–00040 TOYOTA Electrical Tester FUEL SYSTEM Test Lead Set FUEL SYSTEM (09083–00150) Butyl Tape Set FUEL PUMP ASSY 08850–00065 FUEL TANK ASSY Equipment Service wire harness...
Page 49 02–4 PREPARATION – EMISSION CONTROL EMISSION CONTROL 021BN–01 PREPARATION 09992–00242 Turbocharger Pressure Gauge EMISSION CONTROL SYSTEM Equipment Service Wire Harness Ohmmeter Vacuum gauge 2004 COROLLA (RM1037U) Author : Date :...
Page 50 02–5 PREPARATION – ENGINE MECHANICAL ENGINE MECHANICAL 021CI–02 PREPARATION 09011–38121 12 mm Socket Wrench for 12 CYLINDER BLOCK ASSY(April, 2003) Pointed Head Oil Pan Seal Cutter PARTIAL ENGINE ASSY(April, 2003) 09032–00100 09201–01055 Valve Guide Bushing Remover & CYLINDER HEAD ASSY Replacer 5.5 Valve Guide Bushing Remover &...
Page 51 02–6 PREPARATION – ENGINE MECHANICAL 09228–06501 Oil Filter Wrench PARTIAL ENGINE ASSY(April, 2003) 09268–21010 Fuel Hose Puller CYLINDER HEAD GASKET 09301–00210 Clutch Guide Tool ENGINE REAR OIL SEAL PARTIAL ENGINE ASSY(April, 2003) Boll Joint Puller PARTIAL ENGINE ASSY(April, 2003) 09628–62011 09670–00010 Front Crossmember Guide Tool PARTIAL ENGINE ASSY(April, 2003)
Page 52 02–7 PREPARATION – ENGINE MECHANICAL (09963–01000) Pin 10 CHAIN SUB–ASSY TIMING CHAIN OR BELT COVER OIL SEAL ENGINE REAR OIL SEAL CYLINDER HEAD GASKET PARTIAL ENGINE ASSY(April, 2003) Compression Gauge Attachment ENGINE ASSEMBLY 09992–00500 CYLINDER HEAD GASKET Recomended Tools Pin Punch . CYLINDER HEAD ASSY 09031–00040 09040–00011...
Page 53 02–8 PREPARATION – ENGINE MECHANICAL 08833–00080 Adhesive 1344 CYLINDER BLOCK ASSY(April, 2003) THREE BOND 1344 LOCTITE 242 or equivalent Equipment CO/HC meter Cylinder gauge Dial indicator Feeler gauge Micrometer Piston heater Plastigage Precision straight edge Radiator cap tester Sandpaper(#400) Steel square Straight edge Spring tester Spring tension gauge...
Page 54 02–9 PREPARATION – EXHAUST EXHAUST 021A3–02 PREPARATION Equipment Torque wrench Vernier calipers 2004 COROLLA (RM1037U) Author : Date :...
Page 55 Test Lead Set COOLING FAN SYSTEM (09083–00150) Equipment Heater Radiator cap tester Slide calipers Thermometer Torque wrench Coolant Item Capacity Classification Engine coolant 6.5 liters (6.9 US qts, 5.7 lmp. qts) TOYOTA long life coolant 2004 COROLLA (RM1037U) Author : Date :...
Page 56 02–11 PREPARATION – LUBRICATION LUBRICATION 021A4–03 PREPARATION 09228–06501 Oil Filter Wrench OIL FILTER SUB–ASSY Equipment Feeler gauge Radiator cup tester Torque wrench Lubricant Item Capacity Classification Oil grade API grade SL Energy–Conserving or ILSAC, mul- – ti–grade engine oil Drain and refill w/ oil filter change 3.7 liters (3.9 US qts, 3.3 lmp.
Page 57 02–12 PREPARATION – IGNITION IGNITION 021A5–02 PREPARATION Recomended Tools (09857–00031) Spark Plug Gap Gauge IGNITION SYSTEM Equipment Ohmmeter Spark plug cleaner 2004 COROLLA (RM1037U) Author : Date :...
Page 58 Alternator Pulley Set Nut 22 mm GENERATOR ASSY (09820–06020) Wrench Recomended Tools 09011–12291 Socket Wrench for 29 mm . GENERATOR ASSY 09082–00040 TOYOTA Electrical Tester STARTING SYSTEM STARTER ASSY GENERATOR ASSY STARTING SYSTEM(April, 2003) STARTER ASSY(April, 2003) Test Lead Set STARTING SYSTEM (09083–00150)
Page 59 02–14 PREPARATION – FRONT SUSPENSION FRONT SUSPENSION 021C2–01 PREPARATION 09628–62011 Boll Joint Puller LOWER BALL JOINT ASSY FRONT Front Crossmember Guide Tool FRONT SUSPENSION 09670–00010 SUB–ASSY LOWER NO.1 LH STABILIZER BAR FRONT 09727–30021 Coil Spring Compressor FRONT SHOCK ABSORBER WITH COIL SPRING Front Spring Upper Seat Holder FRONT SHOCK ABSORBER WITH...
Page 60 02–15 PREPARATION – REAR SUSPENSION REAR SUSPENSION 021BV–01 PREPARATION 09710–04101 Base REAR AXLE BEAM ASSY Coil Spring Compressor REAR SHOCK ABSORBER WITH 09727–30021 COIL SPRING 09950–40011 Puller B Set REAR AXLE BEAM ASSY Hanger 200 REAR AXLE BEAM ASSY (09951–04020) Slide Arm REAR AXLE BEAM ASSY (09952–04010)
Page 61 02–16 PREPARATION – REAR SUSPENSION (09951–00630) Replacer 63 REAR AXLE BEAM ASSY Recomended Tools Hexagon Wrench Set REAR SHOCK ABSORBER WITH 09040–00011 COIL SPRING Socket Hexagon Wrench 6 REAR SHOCK ABSORBER WITH (09043–20060) COIL SPRING Equipment Torque wrench Dial indicator with magnetic base Wheel balancer Tire pressure gauge Alignment tester...
Page 62 02–17 PREPARATION – TIRE & WHEEL TIRE&WHEEL 021C4–01 PREPARATION Equipment Tire pressure gauge Dial indicator with magnetic base Wheel balancer 2004 COROLLA (RM1037U) Author : Date :...
Page 63 02–18 PREPARATION – DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT / PROPELLER SHAFT 021BZ–01 PREPARATION 09240–00020 Wire Gauge Set FRONT DRIVE SHAFT Wire Gauge FRONT DRIVE SHAFT (09242–00150) 1.5 mm (0.059 in.) 09520–00031 Rear Axle Shaft Puller FRONT AXLE HUB SUB–ASSY LH Drive Shaft Remover Attachment FRONT DRIVE SHAFT 09520–01010...
Page 64 02–19 PREPARATION – DRIVE SHAFT / PROPELLER SHAFT 09608–32010 Steering Knuckle Oil Seal FRONT AXLE HUB SUB–ASSY LH Replacer Ball Joint Puller REAR AXLE LH HUB BOLT 09628–10011 FRONT AXLE LH HUB BOLT Boll Joint Puller FRONT DRIVE SHAFT 09628–62011 FRONT AXLE HUB SUB–ASSY LH 09930–00010 Drive Shaft Nut Chisel...
Page 65 02–20 PREPARATION – DRIVE SHAFT / PROPELLER SHAFT 09950–60010 Replacer Set FRONT AXLE HUB SUB–ASSY LH Replacer 37 FRONT AXLE HUB SUB–ASSY LH (09951–00370) Replacer 60 FRONT AXLE HUB SUB–ASSY LH (09951–00600) (09951–00640) Replacer 64 FRONT AXLE HUB SUB–ASSY LH Replacer Set No.2 FRONT AXLE HUB SUB–ASSY LH 09950–60020...
Page 66 02–21 PREPARATION – DRIVE SHAFT / PROPELLER SHAFT Equipment Torque wrench Dial indicator with magnetic base Lubricant Item Capacity Front drive shaft Inboard joint grease 135 – 155 g (4.8 – 5.5 oz.) 2004 COROLLA (RM1037U) Author : Date :...
Page 67 02–22 PREPARATION – BRAKE BRAKE 021CC–02 PREPARATION 09023–00100 Union Nut Wrench 10 mm BRAKE FLUID FRONT BRAKE REAR BRAKE BRAKE ACTUATOR ASSY BRAKE BOOSTER ASSY PROPORTIONING VALVE ASSY BRAKE MASTER CYLINDER SUB–ASSY(April, 2003) Crankshaft Pulley Replacer SKID CONTROL SENSOR 09214–76011 Rear Axle Shaft Puller SKID CONTROL SENSOR 09520–00031...
Page 68 02–23 PREPARATION – BRAKE Equipment Ruler Dial indicator Micrometer Torque wrench Brake drum gauge Lubricant Item Capacity Classification Brake fluid – SAE J1703 or FMVSS No. 116 DOT3 2004 COROLLA (RM1037U) Author : Date :...
Page 69 02–24 PREPARATION – PARKING BRAKE PARKING BRAKE 021CD–01 PREPARATION 09718–00010 Shoe Hold Down Spring Driver PARKING BRAKE CABLE ASSY NO.3 Equipment Torque wrench 2004 COROLLA (RM1037U) Author : Date :...
Page 70 021CJ–01 PREPARATION 09023–12700 Union Nut Wrench 17mm AUTOMATIC TRANSAXLE ASSY(ATM) Oil Seal Puller FRONT DIFFERENTIAL 09308–00010 SEAL(ATM) 09350–32014 TOYOTA Automatic Transmission AUTOMATIC TRANSAXLE Tool Set ASSY(ATM) FRONT DIFFERENTIAL SEAL(ATM) TORQUE CONVERTER CLUTCH AND DRIVE PLATE(ATM) (09351–32010) One–way Clutch Test Tool...
Page 71 02–26 PREPARATION – AUTOMATIC TRANSMISSION / TRANS Recomended Tools 09011–12301 Socket Wrench 30 mm AUTOMATIC TRANSAXLE ASSY(ATM) 09042–00010 Torx Socket T30 FLOOR SHIFT PARKING LOCK CABLE ASSY(ATM) Socket Hexagon Wrench 10 FRONT DIFFERENTIAL (09043–20100) SEAL(ATM) Equipment Straight edge Torque converter clutch Vernier calipers Torque converter clutch Dial indicator or dial indicator with magnetic base...
Page 72 INPUT SHAFT ASSY(C59) OUTPUT SHAFT ASSY(C59) (09316–00011) Replacer Pipe MANUAL TRANSAXLE ASSY(C59) Replacer ”A” INPUT SHAFT ASSY(C59) (09316–00021) (09316–00031) Replacer ”B” OUTPUT SHAFT ASSY(C59) 09350–32014 TOYOTA Automatic Transmission MANUAL TRANSAXLE ASSY(C59) Tool Set 2004 COROLLA (RM1037U) Author : Date :...
Page 73 02–28 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE (09351–32120) Overdrive Bearing Replacer MANUAL TRANSAXLE ASSY(C59) Drive Shaft Remover Attachment MANUAL TRANSAXLE ASSY 09520–01010 FRONT DIFFERENTIAL OIL SEAL Differential Side Gear Shaft MANUAL TRANSAXLE ASSY 09520–24010 Puller FRONT DIFFERENTIAL OIL SEAL (09520–32040) Shocker Set MANUAL TRANSAXLE ASSY FRONT DIFFERENTIAL OIL SEAL Differential Oil Seal Replacer...
Page 74 02–29 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE 09636–20010 Upper Ball Joint Dust Cover MANUAL TRANSAXLE ASSY(C59) Replacer INPUT SHAFT ASSY(C59) Front Crossmember Guide Tool MANUAL TRANSAXLE ASSY 09670–00010 Front Suspension Bushing Tool MANUAL TRANSAXLE ASSY(C59) 09710–20011 (09710–06071) Replacer MANUAL TRANSAXLE ASSY(C59) Back–up Light Switch Tool MANUAL TRANSAXLE ASSY(C59) 09817–16011 Drive Shaft Nut Chisel...
Page 75 02–30 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE (09957–04010) Attachment MANUAL TRANSAXLE ASSY(C59) Puller B Set MANUAL TRANSAXLE ASSY(C59) 09950–40011 Hanger 150 MANUAL TRANSAXLE ASSY(C59) (09951–04010) (09951–04020) Hanger 200 MANUAL TRANSAXLE ASSY(C59) Slide Arm MANUAL TRANSAXLE ASSY(C59) (09952–04010) Center Bolt 150 MANUAL TRANSAXLE ASSY(C59) (09953–04020) (09953–04030) Center Bolt 200...
Page 76 02–31 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE (09951–00190) Replacer 19 MANUAL TRANSAXLE ASSY(C59) Replacer 20 MANUAL TRANSAXLE ASSY(C59) (09951–00200) Replacer 22 SHIFT & SELECT LEVER SHAFT (09951–00220) ASSY(C59) (09951–00360) Replacer 36 MANUAL TRANSAXLE ASSY(C59) Replacer 37 MANUAL TRANSAXLE ASSY(C59) (09951–00370) Replacer 42 MANUAL TRANSAXLE ASSY(C59) (09951–00420) (09951–00450)
Page 77 02–32 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE 09950–70010 Handle Set FRONT DIFFERENTIAL OIL SEAL MANUAL TRANSAXLE ASSY(C59) SHIFT & SELECT LEVER SHAFT ASSY(C59) Handle 100 MANUAL TRANSAXLE ASSY(C59) (09951–07100) SHIFT & SELECT LEVER SHAFT ASSY(C59) Handle 150 MANUAL TRANSAXLE ASSY(C59) (09951–07150) (09951–07200) Handle 200 FRONT DIFFERENTIAL OIL SEAL Recomended Tools...
Page 78 02–33 PREPARATION – MANUAL TRANSMISSION/TRANSAXLE Lubricant Item Capacity Classification API GL–4 or GL–5 Manual transaxle oil 1.9 liters (2.0 US qts, 1.7 lmp. qts) SAE 75W–90 (w/ Differential oil) 2004 COROLLA (RM1037U) Author : Date :...
Page 79 CLUTCH MASTER CYLINDER ASSY 09031–00030 09040–00011 Hexagon Wrench Set CLUTCH MASTER CYLINDER ASSY CLUTCH PEDAL SUB–ASSY 09082–00040 TOYOTA Electrical Tester CLUTCH START SWITCH ASSY 09905–00013 Snap Ring Pliers CLUTCH MASTER CYLINDER ASSY Equipment Vernier calipers Dial indicator with magnetic base...
Page 80 02–35 PREPARATION – STEERING COLUMN STEERING COLUMN 021CA–01 PREPARATION 09950–50013 Puller C Set STEERING COLUMN ASSY Hanger 150 STEERING COLUMN ASSY (09951–05010) (09952–05010) Slide Arm STEERING COLUMN ASSY Center Bolt 150 STEERING COLUMN ASSY (09953–05020) Claw No.2 STEERING COLUMN ASSY (09954–05021) Recomended Tools 09042–00010...
Page 81 02–36 PREPARATION – POWER STEERING POWER STEERING 021CB–01 PREPARATION 09023–38200 Union Nut Wrench 12mm RACK & PINION POWER STEERING GEAR ASSY Union Nut Wrench 14mm VANE PUMP ASSY 09023–38400 RACK & PINION POWER STEERING GEAR ASSY 09521–24010 Rear Axle Shaft Puller RACK &...
Page 82 02–37 PREPARATION – POWER STEERING 09631–10030 Oil Seal Remover VANE PUMP ASSY Steering Rack Oil Seal Test Tool RACK & PINION POWER STEERING 09631–12071 GEAR ASSY Packing RACK & PINION POWER STEERING (09633–00010) GEAR ASSY 09631–16020 Steering Rack Cover ”A” RACK &...
Page 83 02–38 PREPARATION – POWER STEERING (09952–05010) Slide Arm RACK & PINION POWER STEERING GEAR ASSY Center Bolt 150 RACK & PINION POWER STEERING (09953–05020) GEAR ASSY Claw No.2 RACK & PINION POWER STEERING (09954–05021) GEAR ASSY 09950–60010 Replacer Set VANE PUMP ASSY RACK &...
Page 84 02–39 PREPARATION – POWER STEERING (09952–06010) Adapter RACK & PINION POWER STEERING GEAR ASSY Handle Set VANE PUMP ASSY 09950–70010 RACK & PINION POWER STEERING GEAR ASSY Handle 100 VANE PUMP ASSY (09951–07100) RACK & PINION POWER STEERING GEAR ASSY (09951–07150) Handle 150 RACK &...
Page 85 02–40 PREPARATION – HEATER & AIR CONDITIONER HEATER & AIR CONDITIONER 021CK–01 PREPARATION 07110–58060 Air Conditioner Service Tool Set REFRIGERANT COOLER COMPRESSOR ASSY W/RECEIVER CONDENSER ASSY AIR CONDITIONER UNIT ASSY Refrigerant Drain Service Valve REFRIGERANT (07117–58060) COOLER COMPRESSOR ASSY W/RECEIVER CONDENSER ASSY AIR CONDITIONER UNIT ASSY (07117–58070) T–Joint...
Page 86 02–41 PREPARATION – HEATER & AIR CONDITIONER 09950–50013 Puller C Set AIR CONDITIONER UNIT ASSY Hanger 150 AIR CONDITIONER UNIT ASSY (09951–05010) Slide Arm AIR CONDITIONER UNIT ASSY (09952–05010) (09953–05020) Center Bolt 150 AIR CONDITIONER UNIT ASSY Claw No.2 AIR CONDITIONER UNIT ASSY (09954–05021) Recomended Tools Hexagon Wrench Set...
Page 87 02–42 PREPARATION – HEATER & AIR CONDITIONER 95416–00140 Gas Leak Detector REFRIGERANT (Halogen Leak Detector) COOLER COMPRESSOR ASSY (DENSO Part No.) W/RECEIVER CONDENSER ASSY AIR CONDITIONER UNIT ASSY Equipment Voltmeter Anmeter Ohmmeter Vinyl tape Hexagon wrench 5 mm (0.20 in.) Hexagon wrench 14 mm (0.55 in.) Vise pliers Gas leak detector...
Page 88 02–43 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 022XY–01 PREPARATION 09082–00700 SRS Airbag Deployment Tool FRONT SEAT AIRBAG ASSY RH INSTRUMENT PANEL PASSENGER AIR BAG ASSY HORN BUTTON ASSY(April, 2003) Airbag Deployment Wire FRONT SEAT AIRBAG ASSY RH 09082–00750 Sub–harness No.3 09082–00780 Airbag Deployment Wire...
Page 89 02–44 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM (09954–05021) Claw No.2 SPIRAL CABLE SUB–ASSY Recomended Tools Torx Socket T30 SPIRAL CABLE SUB–ASSY 09042–00010 Equipment Torque wrench Bolt Length: 35.0 mm (1.387 in.) Pitch: 1.0 mm (0.039 in.) Airbag disposal Diam.: 6.0 mm (0.236 in.) Tire Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.)
Page 90 02–45 PREPARATION – SEAT BELT SEAT BELT 021C3–02 PREPARATION 09082–00700 SRS Airbag Deployment Tool FRONT SEAT BELT Airbag Deployment Wire FRONT SEAT BELT 09082–00770 Sub–harness No.5 Equipment Torque wrench 2004 COROLLA (RM1037U) Author : Date :...
Page 91 02–46 PREPARATION – LIGHTING LIGHTING 021C6–01 PREPARATION Recomended Tools 09070–20010 Moulding Remover BACK UP LAMP ASSY LH Test Lead Set LIGHTING SYSTEM (09083–00150) Equipment Torque wrench 2004 COROLLA (RM1037U) Author : Date :...
Page 92 PREPARATION 09843–18040 Diagnosis Check Wire No.2 WIPER AND WASHER SYSTEM Recomended Tools 09042–00010 Torx Socket T30 WINDSHIELD WIPER MOTOR ASSY TOYOTA Electrical Tester WIPER AND WASHER SYSTEM 09082–00040 Test Lead Set WIPER AND WASHER SYSTEM (09083–00150) Equipment Torque wrench 2004 COROLLA (RM1037U)
Page 93 02–48 PREPARATION – AUDIO & VISUAL SYSTEM AUDIO & VISUAL SYSTEM 021C1–01 PREPARATION 09950–50013 Puller C Set ANTENNA CORD SUB–ASSY Hanger 150 ANTENNA CORD SUB–ASSY (09951–05010) (09952–05010) Slide Arm ANTENNA CORD SUB–ASSY Center Bolt 150 ANTENNA CORD SUB–ASSY (09953–05020) Claw No.2 ANTENNA CORD SUB–ASSY (09954–05021) Recomended Tools...
Page 94 02–49 PREPARATION – AUDIO & VISUAL SYSTEM 09060–60350 Revet Cutter FRONT NO.1 SPEAKER ASSY Moulding Remover ANTENNA CORD SUB–ASSY 09070–20010 AMPLIFIER ANTENNA ASSY Equipment Torque wrench 2004 COROLLA (RM1037U) Author : Date :...
Page 95 02–50 PREPARATION – COMMUNICATION SYSTEM COMMUNICATION SYSTEM 021CO–01 PREPARATION Recomended Tools 09082–00040 TOYOTA Electrical Tester HORN SYSTEM Equipment Battery 2004 COROLLA (RM1037U) Author : Date :...
Page 96 02–51 PREPARATION – WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD/WINDOWGLASS/MIRROR 021CG–01 PREPARATION Recomended Tools 09070–20010 Moulding Remover WINDSHIELD GLASS TOYOTA Electrical Tester WINDOW DEFOGGER SYSTEM 09082–00040 POWER MIRROR CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM Test Lead Set POWER WINDOW CONTROL (09083–00150) SYSTEM Equipment Adhesive Knife...
Page 97 02–52 PREPARATION – INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER 021C0–01 PREPARATION 09950–50013 Puller C Set INSTRUMENT PANEL SUB–ASSY LOWER Hanger 150 INSTRUMENT PANEL SUB–ASSY (09951–05010) LOWER (09952–05010) Slide Arm INSTRUMENT PANEL SUB–ASSY LOWER Center Bolt 150 INSTRUMENT PANEL SUB–ASSY (09953–05020) LOWER Claw No.2 INSTRUMENT PANEL SUB–ASSY (09954–05021) LOWER...
Page 98 02–53 PREPARATION – SEAT SEAT 021BX–01 PREPARATION Equipment Hog ring pliers Hog ring Torque wrench Tape To avoid surface damage 2004 COROLLA (RM1037U) Author : Date :...
Page 99 02–54 PREPARATION – THEFT DETERRENT & DOOR LOCK THEFT DETERRENT & DOOR LOCK 021CN–01 PREPARATION Recomended Tools 09082–00040 TOYOTA Electrical Tester POWER DOOR LOCK CONTROL SYSTEM 2004 COROLLA (RM1037U) Author : Date :...
Page 100 02–55 PREPARATION – SLIDING ROOF/CONVERTIBLE SLIDING ROOF/CONVERTIBLE 021C9–02 PREPARATION Recomended Tools 09041–00020 Torx Driver T25 SLIDING ROOF HOUSING SUB–ASSY TOYOTA Electrical Tester SLIDING ROOF SYSTEM 09082–00040 Equipment Torque wrench 2004 COROLLA (RM1037U) Author : Date :...
Page 101 02–56 PREPARATION – ENGINE HOOD/DOOR ENGINE HOOD/DOOR 022VI–01 PREPARATION 09804–24010 Luggage Compartment Door Torsion LUGGAGE DOOR HINGE TORSION Bar Tool BAR RH Door Hinge Set Bolt Wrench FRONT DOOR 09812–00010 Recomended Tools Torx Socket T30 FRONT DOOR 09042–00010 REAR DOOR Torx Socket T40 FRONT DOOR 09042–00020...
Page 102 02–57 PREPARATION – EXTERIOR/INTERIOR TRIM EXTERIOR/INTERIOR TRIM 021C5–02 PREPARATION Recomended Tools 09070–20010 Moulding Remover FRONT DOOR BELT MOULDING ASSY LH REAR DOOR BELT MOULDING ASSY LH ROOF DRIP SIDE FINISH MOULDING CENTER LH REAR BUMPER ROOF HEADLINING ASSY Equipment Adhesive tape To avoid surface damage.
Page 103 02–58 PREPARATION – VEHICLE CONTROL SYSTEM VEHICLE CONTROL SYSTEM 021CP–01 PREPARATION Recomended Tools 09082–00040 TOYOTA Electrical Tester IGNITION OR STARTER SWITCH ASSY 2004 COROLLA (RM1037U) Author : Date :...
Page 104 02–59 PREPARATION – CRUISE CONTROL CRUISE CONTROL 021BI–01 PREPARATION 09950–50013 Puller C Set SPEED CONTROL MAIN SWITCH ASSY Hanger 150 SPEED CONTROL MAIN SWITCH (09951–05010) ASSY (09952–05010) Slide Arm SPEED CONTROL MAIN SWITCH ASSY Center Bolt 150 SPEED CONTROL MAIN SWITCH (09953–05020) ASSY Claw No.2...
Page 105 03–26 SERVICE SPECIFICATIONS – REAR SUSPENSION REAR SUSPENSION 030PR–01 SERVICE DATA Toe–in (total) 0_16’ " 16’ (0.26_ " 0.26_, 2.6 " 2.5 mm, 0.10 " 0.10 in.) USA, Canada P195/65R15 89S 0_16’ " 16’ (0.26_ " 0.26_, 2.6 " 2.5 mm, 0.10 " 0.10 in.) P185/65R15 86S Rear wheel align- 0°01’...
Page 106 03–27 SERVICE SPECIFICATIONS – REAR SUSPENSION 030PS–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Piston rod set nut Shock absorber x Body Hub nut 1,050 Shock absorber x Rear axle beam Stabilizer bar x Rear axle beam 1,990 Rear axle hub set bolt Parking brake cabke bracket set bolt 48 in.
Page 107 03–28 SERVICE SPECIFICATIONS – TIRE & WHEEL TIRE&WHEEL 030Q2–01 SERVICE DATA Tire runout 3.0 mm (0.118 in.) or less Imbalance after adjustment 8.0 g (0.018 lb) or less 2004 COROLLA (RM1037U) Author : Date :...
Page 108 03–29 SERVICE SPECIFICATIONS – DRIVE SHAFT / PROPELLER SHAFT / AXLE DRIVE SHAFT / PROPELLER SHAFT / AXLE 030PW–01 SERVICE DATA Front axle hub bearing Backlash Maximum: 0.05 mm (0.0020 in.) Front axle hub sub–assy Deviation Maximum: 0.05 mm (0.0020 in.) Rear axle hub &...
Page 109 03–30 SERVICE SPECIFICATIONS – DRIVE SHAFT / PROPELLER SHAFT / AXLE 030PX–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Front wheel set nut 1,050 Rear wheel set nut 1,050 Manual transaxle oil drain plug 39.2 Automatic transaxle fluid drain plug 17.5 Lower ball joint assy front x Suspension arm sub–assy lower No.1 Tie rod end sub–assy x Steering knuckle...
Page 110 03–31 SERVICE SPECIFICATIONS – BRAKE BRAKE 030Q4–01 SERVICE DATA Brake pedal height (from asphalt sheet) 134.9 – 144.9 mm (5.311 – 5.703 in.) 136.0 – 146.0 mm (5.353 – 5.747 in.) Brake Pedal free play 1 – 6 mm (0.04 – 0.24 in.) Stop light switch clearance 0.5 –...
Page 111 03–32 SERVICE SPECIFICATIONS – BRAKE 030Q5–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Bleeder plug 74 in. lbf Brake booster clevis lock nut Brake pedal support sub–assy x Brake pedal sub–assy 36.8 Brake booster x Body 12.7 Brake pedal support sub–assy x Body 23.6 Brake master cylinder x Piston stopper bolt Brake master cylinder x Reservoir...
Page 112 03–33 SERVICE SPECIFICATIONS – PARKING BRAKE PARKING BRAKE 030Q6–01 SERVICE DATA Parking brake lever travel at 196 N (20 kgf, 44.1 lbf): 6 – 9 clicks 2004 COROLLA (RM1037U) Author : Date :...
Page 113 03–34 SERVICE SPECIFICATIONS – PARKING BRAKE 030Q7–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Wheel nut 1,050 Parking brake lock nut 44 in. lbf Parking brake lever sub–assy x body 12.5 Heat insulator No.2 x Body 48 in. lbf Heat insulator No.1 x Body 48 in.
Page 114 03–35 SERVICE SPECIFICATIONS – AUTOMATIC TRANSMISSION / TRANSAXLE AUTOMATIC TRANSMISSION / TRANSAXLE 0305K–06 SERVICE DATA A245E Line pressure (Wheel locked) Engine idling D position 382 – 422 kPa (3.9 – 4.3 kgf/cm , 55 – 61 psi) R position 647 – 760 kPa (6.6 – 7.8 kgf/cm , 94 –...
Page 115 03–36 SERVICE SPECIFICATIONS – AUTOMATIC TRANSMISSION / TRANSAXLE 0305L–06 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Park/neutral position switch x Transaxle Bolt 49 in. lbf 49 in. lbf Control shaft lever x Park/neutral position switch 12.5 Battery carrier x Body Engine hanger x Engine Drain plug x Oil pan 17.5...
Page 116 03–37 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE MANUAL TRANSMISSION / TRANSAXLE 030QD–01 SERVICE DATA MANUAL TRANSAXLE ASSY 5th gear thrust clearance STD: 0.10 – 0.57 mm (0.0039 – 0.0224 in.) MAX: 0.57 mm (0.0224 in.) 5th gear radial clearance KOYO made STD: 0.015 –...
Page 117 03–38 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE 3rd gear radial clearance KOYO made STD: 0.015 – 0.058 mm (0.0006 – 0.0023 in.) MAX: 0.058 mm (0.0023 in.) NSK made STD: 0.015 – 0.056 mm (0.0006 – 0.0022 in.) MAX: 0.056 mm (0.0022 in.) Input shaft run out MAX: 0.015 mm (0.0006 in.)
Page 118 03–39 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE Output shaft front bearing snap ring thickness 1.85 – 1.90 mm (0.728 – 0.0748 in.) 1.90 – 1.95 mm (0.748 – 0.0768 in.) 1.95 – 2.00 mm (0.768 – 0.0787 in.) 2.00 – 2.05 mm (0.787 – 0.0807 in.) 2.05 –...
Page 119 03–40 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE 030QE–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Floor shift transmission control cable assy x Body 44 in. lbf Front floor heat insulator No.1 x Body 49 in. lbf Airbag sensor assy center x Body 17.5 Shift cable grommet retainer No.1 x Body 44 in.
Page 120 03–41 SERVICE SPECIFICATIONS – MANUAL TRANSMISSION / TRANSAXLE Part Tightened kgf cm ft lbf Shift & select lever shaft assy x Manual transmission case 19.6 Lock ball assy No.1 x Manual transmission case 29.4 Selecting bell crank assy x Manual transmission case 24.5 Floor shift control lever housing support bracket x Transaxle case 11.3...
Page 121 03–42 SERVICE SPECIFICATIONS – CLUTCH CLUTCH 030EF–02 SERVICE DATA Pedal height from asphalt sheet 135.8 – 145.8 mm (5.346 – 5.740 in.) Clutch pedal free play 5.0 – 15.0 mm (0.197 – 0591 in.) Clutch pedal push rod play at pedal top 1.0 –...
Page 122 03–43 SERVICE SPECIFICATIONS – CLUTCH 030EG–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Clutch pedal sub–assy x Clutch pedal support 36.8 Clutch pedal support set bolt x Body 19.1 Cylinder push rod clevis lock nut 24.5 Clutch master cylinder assy x Clutch pedal support 11.8 Clutch master cylinder assy x Flexible hose tube 15.2...
Page 123 03–44 SERVICE SPECIFICATIONS – STEERING COLUMN STEERING COLUMN 030Q8–01 SERVICE DATA STEERING SYSTEM Steering wheel freeplay Maximum 30 mm (1.18 in.) 2004 COROLLA (RM1037U) Author : Date :...
Page 124 03–45 SERVICE SPECIFICATIONS – STEERING COLUMN 030Q9–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Sliding yoke x Steering intermediate shaft Sliding yoke x Steering column assy Steering column assy set bolt Steering wheel set nut Steering wheel pad set screw (Torx screw) 78 in.·lbf 2004 COROLLA (RM1037U) Author :...
Page 125 03–46 SERVICE SPECIFICATIONS – POWER STEERING POWER STEERING 030QA–01 SERVICE DATA POWER STEERING FLUID Fluid level rise Maximum 5 mm (0.20 in.) Fluid pressure at idle speed with valve closed 7,300 – 7,800 kPa (75 – 80 kgf/cm , 1,067 – 1,138 psi) STEERING WHEEL Steering effort at idle speed (Reference) 6 N·m (60 kgf·cm, 53 in.·lbf)
Page 126 03–47 SERVICE SPECIFICATIONS – POWER STEERING 030QB–01 TORQUE SPECIFICATION Part tightened kgf cm ft lbf POWER STEERING VANE PUMP Vane pump housing rear x Vane pump housing front Pressure port union Suction port union set bolt Oil pressure switch Vane pump assy x Vane pump bracket rear Vane pump assy set bolt Pressure feed tube assy x Vane pump assy 41 (44)
Page 127 03–48 SERVICE SPECIFICATIONS – HEATER AND AIR CONDITIONING HEATER & AIR CONDITIONER 030QI–01 SERVICE DATA 490 " 30 g (17.28 " 1.06 oz.) Refrigerant charge volume Standard: Magnetic clutch clearance 0.35 – 0.60 mm (0.013 – 0.023 in.) 2004 COROLLA (RM1037U) Author : Date :...
Page 128 03–49 SERVICE SPECIFICATIONS – HEATER AND AIR CONDITIONING 030QJ–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf AIR CONDITIONER UNIT ASSY Air conditioning tube assy x Cooler evaporator sub–assy No. 1 30 in. lbf Air conditioner unit assy x Body 87 in.
Page 129 03–50 SERVICE SPECIFICATIONS – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 030FN–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Horn button assy x Steering wheel assy 78 in. lbf Steering wheel assy x Steering column assy Instrument panel passenger airbag assy x Instrument panel reinforcement Airbag sensor assy center x Body 17.5 Airbag front RH sensor x Body...
Page 130 03–51 SERVICE SPECIFICATIONS – SEAT BELT SEAT BELT 030PY–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf FRONT SEAT BELT Front shoulder belt anchor adjuster assy x Body 41.2 Front seat outer belt assy (Upper part of retractor) x Body 43 in.
Page 131 03–52 SERVICE SPECIFICATIONS – WIPER & WASHER WIPER & WASHER 030PT–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Wind shield wiper motor assy Wiper link assy 66 in. lbf Wiper link assy Body 49 in. lbf FR Wiper arm RH Wiper link 20.5 FR Wiper arm LH...
Page 132 03–53 SERVICE SPECIFICATIONS – AUDIO & VISUAL SYSTEM AUDIO & VISUAL SYSTEM 030PN–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Amplifier antenna assy x Antenna nut 40 in. lbf 2004 COROLLA (RM1037U) Author : Date :...
Page 133 03–54 SERVICE SPECIFICATIONS – INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER 030PZ–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Instrument panel reinforce Body 2004 COROLLA (RM1037U) Author : Date :...
Page 134 03–55 SERVICE SPECIFICATIONS – SEAT SEAT 030PU–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf FRONT SEAT Seat back assembly x Seat adjuster assembly Seat belt inner x Seat adjuster assembly Seat assembly x Body REAR SEAT (SEDAN WITH SEPARATE TYPE) Seat back hinge x Seat back REAR SEAT (SEDAN WITH BENCH TYPE) Seat back assembly x Body...
Page 135 03–56 SERVICE SPECIFICATIONS – SLIDING ROOF/CONVERTIBLE SLIDING ROOF/CONVERTIBLE 030QN–02 SERVICE DATA Sliding roof Difference in level between sliding roof weatherstrip and roof panel 0 + 1.5 mm (0 " 0.059 in.) Except corners of rear side Corner of rear side –1.0 –...
Page 136 03–57 SERVICE SPECIFICATIONS – SLIDING ROOF/CONVERTIBLE 030QO–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Sliding roof glass assembly Drive cable 35 in. lbf Sliding roof housing assembly Body 44 in. lbf Sliding roof housing assembly Sliding roof drive gear 47 in.
Page 137 03–58 SERVICE SPECIFICATIONS – ENGINE HOOD/DOOR ENGINE HOOD/DOOR 030Q3–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf HOOD Hood x Hood hinge Hood lock x Body 71 in. lbf FRONT DOOR Front door check assembly (door panel side bolt) x Front door 49 in.
Page 138 03–59 SERVICE SPECIFICATIONS – EXTERIOR/INTERIOR TRIM EXTERIOR/INTERIOR TRIM 030PV–02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Radiator grille Body 44 in. lbf Front bumper reinfocement Body Rear bumper arm LH Body Rear bumper arm RH Body Rear bumper reinfocement No.1 Rear bumper arm LH Rear bumper reinfocement No.1 Rear bumper arm RH Bumper mounting set bolt No.
Page 139 03–60 SERVICE SPECIFICATIONS – CRUISE CONTROL CRUISE CONTROL 030OV–01 SERVICE DATA Accelerator auto drive cable clearance Standard 2 – 6 mm (0.079 – 0.236 in.) 2004 COROLLA (RM1037U) Author : Date :...
Page 140 03–61 SERVICE SPECIFICATIONS – CRUISE CONTROL 030PO–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Cruise control actuator assy x Cruise control bracket 52 in. lbf 2004 COROLLA (RM1037U) Author : Date :...
Page 141 10–1 ENGINE CONTROL SYSTEM – SFI SYSTEM SFI SYSTEM 1008D–01 ON–VEHICLE INSPECTION INSPECTION THROTTLE BODY IDLE SPEED Open CONTROL VALVE ASSY NOTICE: It is impossible to check the resister value and the op- Close eration of ISC valve by itself, because the ISC valve has an IC circuit inside it, which transforms the duty Valve signal from the ECM to the derive signal.
Page 142 10–2 ENGINE CONTROL SYSTEM – SFI SYSTEM 1008E–02 INSPECTION INTAKE AIR FLOW METER SUB–ASSY Ohmmeter Inspect the intake air flow meter resistance. Using an ohmmeter, measure the resistance be- tween terminals THA and E2. Resistance: At –20_C (–4_F) 13.6 to 18.4 kΩ At 20_C (68_F) 2.21 to 2.69 kΩ...
Page 143 10–3 ENGINE CONTROL SYSTEM – SFI SYSTEM THROTTLE BODY ASSY Throttle Stop Screw Check throttle body. Check that throttle valve shaft is not rickety. Check that each port is not stopped up. Check that throttle valve opens and closes smooth- Check that there is no clearance between the throttle stop screw and throttle lever at the throttle Throttle Lever...
Page 144 10–4 ENGINE CONTROL SYSTEM – SFI SYSTEM E.F.I. ENGINE COOLANT TEMPERATURE SENSOR Resistance inspection. Using an ohmmeter, measure the resistance be- Ohmmeter tween each terminal. Resistance: At 20_C (68_F) 2.32 – 2.59 kΩ At 80_C (176_F) 0.310 – 0.326 kΩ NOTICE: In case of checking the water temperature sensor in the wa- ter, be careful not to allow water to go into the terminals,...
Page 145 10–5 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY THROTTLE BODY ASSY 1008F–01 COMPONENTS 7.0 (71, 62 in.·lbf) Clip Vacuum Hose Cylinder Head Vacuum Hose Cover No. 2 Air Cleaner Hose No. 1 Manifold Stay No. 2 (M/T) 13 (133, 9.6) Water By–pass Hose 30 (306, 22) z Gasket...
Page 146 10–6 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY 1008G–02 Removal & Installation and Disassembly & Reassembly DRAIN COOLANT(See page 16–7) REMOVE CYLINDER HEAD COVER NO.2 Remove 2 nuts, 2clips and the cylinder head cover No. 2. A65077 REMOVE AIR CLEANER CAP SUB–ASSY Disconnect the MAF connector.
Page 147 10–7 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY Disconnect 2 water by–pass hoses. A65189 Remove 5 bolts, 2 nuts, throttle body bracket and throttle body. (Transaxle M/T) A65190 Remove 3bolts, 2nuts and throttle body. (Transaxle A/T) A66636 Remove 2 bolts and accelerator cable bracket. A65192 REMOVE E.F.I.
Page 148 10–8 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY REMOVE THLOTTLE BODY IDLE SPEED CONTROL VALVE ASSY Remove 3 screws and the idle speed control valve assy. Remove the gasket from the throttle body. A65182 INSTALL THLOTTLE BODY IDLE SPEED CONTROL VALVE ASSY Install a new gasket on the throttle body.
Page 149 10–9 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY Install the throttle body with 5 bolts and 2 nuts.(Transaxle M/T) Torque: A 30 N m (306 kgf cm, 22 ft lbf) B 13 N m (133 kgf cm, 9.6 ft lbf) A65190 Install the throttle body with 3 bolts and 2 nuts.(Transaxle A/T)
Page 150 10–10 ENGINE CONTROL SYSTEM – THROTTLE BODY ASSY Connect 3 vacuum hoses, as shown in the illustration. Connect the VSV connector. Connect the intake air flow meter connector. A65177 INSTALL CYLINDER HEAD COVER NO.2 Install the cylinder head cover No. 2 with 2 nuts and 2 clips.
Page 151 10–11 ENGINE CONTROL SYSTEM – ECM (1ZZ–FE) (April, 2003) ECM (1ZZ–FE) (April, 2003) 100HN–02 REPLACEMENT DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE GLOVE COMPARTMENT DOOR ASSY (See Page 71–10) REMOVE ECM Remove the 2 clips using a clip remover. Then, open the cover.
Page 152 10–12 ENGINE CONTROL SYSTEM – ECM (1ZZ–FE) (April, 2003) REMOVE ECM BRACKET NO.2 (DENSO MADE) Remove the 2 screws, then remove the ECM bracket No. A83795 REMOVE ECM BRACKET NO.1 Remove the 2 screws, then remove the ECM bracket No. DENSO Made: DELCO Made: A83796...
Page 153 10–13 ENGINE CONTROL SYSTEM – ECM (1ZZ–FE) (April, 2003) INSTALL ECM COVER Install a new ECM cover to the ECM as shown in the il- lustration. DENSO Made: DELCO Made: 1 to 6.2 mm (0.039 to 0.244 in.) 4.5 mm (0.177 in.) 0 to 2.5 mm (0 to 0.098 in.) 5 mm...
Page 154 11–10 FUEL – FUEL INJECTOR ASSY 110FJ–01 REPLACEMENT WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11–1) REMOVE CYLINDER HEAD COVER NO.2 Remove the 2 nuts, 2 clips and cylinder head cover. A65077 DISCONNECT VENTILATION HOSE Disconnect the ventilation hose from the cylinder head cover.
Page 155 11–11 FUEL – FUEL INJECTOR ASSY DISCONNECT FUEL TUBE SUB–ASSY Using a SST, disconnect the fuel tube. Retainer 09268–21010 (at 4 places) Assemble the SST to the connection as shown. Turn the SST, align the retainers inside the connec- tor with the SST chamfered parts and insert the SST into the connector.
Page 156 11–12 FUEL – FUEL INJECTOR ASSY REMOVE FUEL INJECTOR ASSY Pull out the 4 fuel injectors from the fuel delivery pipe. A65085 INSTALL FUEL INJECTOR ASSY New Insulator Install a new insulator to the each fuel injector. Apply a light coat of spindle oil or gasoline to a new O– ring, and install it to the each fuel injector.
Page 157 11–13 FUEL – FUEL INJECTOR ASSY INSTALL CYLINDER HEAD COVER NO.2 Install the cylinder head cover with the 2 nuts and 2 clips. Torque: 7.0 N m (71 kgf cm, 62 in. lbf) CHECK FUEL LEAK (See page 11–1) 2004 COROLLA (RM1037U) Author : Date :...
Page 158 11–14 FUEL – FUEL PUMP ASSY FUEL PUMP ASSY 110FK–01 COMPONENTS Rear Seat Cushion Assy Rear Floor Service Hole Cover Fuel Tank Main Tube Sub–assy 6.0 (61, 53 in. lbf) Fuel Evaporation Tube Sub–assy No 2 Fuel Tank Vent Tube Set Plate Tube Joint Clip Fuel Pump Assembly z Gasket...
Page 159 11–15 FUEL – FUEL PUMP ASSY Vapor Pressure Sensor Assy Tube Joint Clip Fuel Pump Harness Fuel Suction Plate Sub–assy Fuel Filter Fuel Sender Gauge Assy Fuel Pump Assy z O–ring Fuel Pressure Regulator Assy Fuel Pump Filter z Clip Fuel Pump Cushion Rubber Fuel Suction Support No.
Page 160 11–16 FUEL – FUEL PUMP ASSY 110FL–01 Removal & Installation and Disassembly & Reassembly REMOVE BENCH TYPE REAR SEAT CUSHION ASSY (See page 72–6, 72–8) REMOVE REAR FLOOR SERVICE HOLE COVER Remove the rear service hole cover. Butyl Tape A65023 Disconnect the fuel pump and vapor pressure sensor connector.
Page 161 11–17 FUEL – FUEL PUMP ASSY DISCONNECT FUEL EMISSION TUBE SUB–ASSY NO.1 Pinch the fuel tube connector clip and then pull out the fuel emission tube. NOTICE: Check if there is any dirt like mud around the fuel tube connector before this work and clean dirt away. Be careful of dirt like mud because the fuel tube con- nector has an O–ring to seal the fuel tube connector A65025...
Page 162 11–18 FUEL – FUEL PUMP ASSY REMOVE FUEL SUCTION SUPPORT NO.2 Using a screwdriver, disconnect the 5 snap claws from the claw holes, and remove the fuel suction support. NOTICE: Do not damage the fuel suction support. A65029 REMOVE FUEL PUMP CUSHION RUBBER Remove the fuel pump cushion rubber.
Page 163 11–19 FUEL – FUEL PUMP ASSY REMOVE FUEL PUMP HARNESS Remove the fuel pump harness from the fuel suction plate. A65034 REMOVE FUEL PUMP Pull out the fuel pump from the fuel filter. A65035 REMOVE FUEL PUMP FILTER Using a small screwdriver, pry out the clip. Pull out the fuel pump filter from the fuel pump.
Page 164 11–20 FUEL – FUEL PUMP ASSY INSTALL FUEL PRESSURE REGULATOR O–RING Apply a light coat Apply a light coat of gasoline to a new O–ring, and install of gasoline it to the fuel pressure regulator. A65038 INSTALL FUEL PUMP FILTER Install the fuel pump filter with a new clip.
Page 165 11–21 FUEL – FUEL PUMP ASSY CONNECT FUEL TANK MAIN TUBE SUB–ASSY Connect the fuel tank main tube with the tube joint clip. NOTICE: Check that there is no scratch or foreign objects on the connecting parts. Check that the fuel tube joint is inserted fully and securely. Check that the tube joint clip is on the collar of the fuel tube joint.
Page 166 11–22 FUEL – FUEL TANK ASSY FUEL TANK ASSY 110FD–01 COMPONENTS Rear Seat Cushion Assy Rear Floor Service Hole Cover Fuel Tank Main Tube Sub–assy 6.0 (61, 53 in. lbf) Fuel Evaporation Tube Sub–assy No 2 Fuel Tank Vent Tube Set Plate Tube Joint Clip Fuel Pump Assembly z Gasket...
Page 167 11–23 FUEL – FUEL TANK ASSY Parking Brake Cable Assy No. 2 5.4 (55, 48 in. lbf) 5.4 (55, 48 in. lbf) Parking Brake Cable Assy No. 3 Clip Fuel Tank Protector No. 1 Front Floor Carpet Assy Front z Gasket 5.4 (55, 48 in.
Page 168 11–24 FUEL – FUEL TANK ASSY Fuel Emission Tube Check Valve Protector Sub–assy No. 1 Fuel Tube Vent Hose Valve to Fuel Filler Pipe Hose Fuel Tank Inlet Valve Assy Fuel Tank Main Tube Sub–assy z Gasket z Fuel Tank Cushion No. 1 Fuel Tube Clamp No.
Page 169 11–25 FUEL – FUEL TANK ASSY 110FE–01 Removal & Installation and Disassembly & Reassembly REMOVE BENCH TYPE REAR SEAT CUSHION ASSY (See page 72–6, 72–8) REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11–16) WORK FOR PREVENTING GASOLINE FROM SPILLING OUT Start the engine.
Page 170 11–26 FUEL – FUEL TANK ASSY Disconnect the oxygen sensor connector. Remove the 2 exhaust pipe supports. Remove the 4 bolts, 4 compression springs and exhaust pipe. A65706 REMOVE FUEL TANK PROTECTOR NO.1 Remove the 5 bolts and fuel tank protector. A65049 SEPARATE PARKING BRAKE CABLE ASSY NO.2 Remove the 2 installing bolts of the parking brake cable.
Page 171 11–27 FUEL – FUEL TANK ASSY SEPARATE PARKING BRAKE CABLE ASSY NO.3 Remove the 2 installing bolts of the parking brake cable. A65051 DISCONNECT FUEL TANK MAIN TUBE SUB–ASSY Pinch the fuel tube connector clip, and remove the fuel tube connector clip. Pull out the fuel tank main tube.
Page 172 11–28 FUEL – FUEL TANK ASSY DISCONNECT FUEL TANK VENT HOSE Disconnect the fuel tank bent hose from the charcoal can- Push ister. Pinch Push the connector deep inside. Pinch portion A. Pinch Pull out the connector. A65056 DISCONNECT VALVE TO FUEL FILLER PIPE HOSE Disconnect the valve to fuel filler pipe hose from the fuel tank inlet pipe.
Page 173 11–29 FUEL – FUEL TANK ASSY REMOVE FUEL TANK MAIN TUBE SUB–ASSY Remove the fuel tank main tube from the fuel tube clamp and bracket. A65061 REMOVE FUEL TUBE CLAMP NO.4 Remove the bolt and fuel tank clamp. A65062 REMOVE FUEL TUBE BRACKET Remove the fuel tube bracket from the fuel tank.
Page 174 11–30 FUEL – FUEL TANK ASSY REMOVE FUEL TUBE CLAMP NO.2 Remove the fuel tube clamp from the fuel tank. A65065 REMOVE CHECK VALVE PROTECTOR Using a screwdriver, unlock the claw, and remove the check valve protector by turning it counter clockwise. A65066 REMOVE FUEL TANK INLET VALVE ASSY Clip Remover...
Page 175 11–31 FUEL – FUEL TANK ASSY REMOVE FUEL TANK CUSHION NO.1 Remove the 7 fuel tank cushions from the fuel tank. A65069 INSTALL FUEL TANK CUSHION NO.1 Install the 7 new fuel tank cushions to the fuel tank. A65069 INSTALL CHECK VALVE GASKET Install a new gasket to the fuel tank.
Page 176 11–32 FUEL – FUEL TANK ASSY INSTALL FUEL TANK ASSY Set a mission jack to the fuel tank. Install the fuel tank and 2 fuel tank bands with the 4 bolts. Torque: 39 N m (400 kgf cm, 29 ft lbf) CONNECT FUEL EMISSION TUBE SUB–ASSY NO.1 Push in the fuel tube connector to the pipe until fuel tube connector makes ”click”...
Page 177 11–33 FUEL – FUEL TANK ASSY Install a new gasket on the exhaust pipe (rear side). Install the exhaust pipe with the 4 compression springs and 4 bolts. Tail Pipe Side Torque: 43 N m (440 kgf cm, 32 ft lbf) Install the 2 exhaust pipe supports.
Page 178 12–7 EMISSION CONTROL – EMISSION CONTROL SYSTEM While holding the air inlet port closed, apply vacuum Purge Port (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the EVAP port Air Inlet Port and check that air flows into the purge port. If operation is not as spacified, replace the charcoal canister.
Page 179 12–8 EMISSION CONTROL – EMISSION CONTROL SYSTEM VENTILATION VALVE SUB–ASSY Cylinder Head Side Install clean hose to the PCV valve. Inspect the PCV valve operation. Clean Hose Blow air into the cylinder head side, and check that air passes through easily. CAUTION: Do not suck air through the valve.
Page 180 12–9 EMISSION CONTROL – EMISSION CONTROL SYSTEM Check that air flows from ports E to F. A65914 Apply battery positive voltage across the terminals. Check that air does not flow from ports E to F. If operation is not as specified, replace the VSV. Battery A65915 VACUUM SWITCHING VALVE ASSY NO.1...
Page 181 12–10 EMISSION CONTROL – EMISSION CONTROL SYSTEM Apply battery positive voltage across the terminals. Check that air does not flow from ports A to B. If operation is not as specified, replace the VSV. Battery A65919 2004 COROLLA (RM1037U) Author : Date : 1010...

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