2009 Toyota Corolla Service & Repair Manual

2004 TOYOTA MOTOR CORPORATION 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: Aug. 2, 2004 01--040802--00 FOREWORD This supplement has been prepared to provide information covering general service repairs for COROLLA which underwent changes in August, 2004. Applicable models: NDE 120 series For the service specifications and repair procedures of the above model other than those listed in the supplement, refer to the following manuals. Manual Name Pub. No. S COROLLA Repair Manual RM925E S COROLLA Repair Manual Supplement (Jan., 2002) RM939E S COROLLA Repair Manual Supplement (Jan., 2003) RM1028E S COROLLA Repair Manual Supplement (May, 2004) RM1106E S 1ND--TV Engine Repair Manual RM1118E S C53, C53A Manual Transaxle Repair Manual RM1117E S COROLLA Electrical Wiring Diagram Supplement (Aug., 2004) EWD626E S COROLLA New Car Featurer Supplement (May, 2004) NCF266E 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 CAUTION This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non--specialized or uncertified technicians perform repair or service only using this manual or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer’s vehicle. In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow the instruction shown below. S Must read this manual thoroughly. It is especially important to have a good understanding of all the contents written in the PRECAUTION of ”INTRODUCTION” section. S The service method written in this manual is very effective to perform repair and service. When performing the operations following the procedures using this manual, be sure to use tools specified and recommended. If using non--specified or recommended tools and service method, be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer’s vehicle before starting the operation. S If part replacement is necessary, must replace the part with the same part number or equivalent part. Do not replace it with inferior quality. S It is important to note that this manual contains various ”Cautions” and ”Notices” that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is important to warn of all the possible hazardous consequences that might result from failure to follow these instructions. BACK TO SUB INDEX TO MODEL INDEX TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

INTRODUCTION PREPARATION SERVICE SPECIFICATIONS DIAGNOSTICS ENGINE CONTROL SYSTEM FUEL EMISSION CONTROL INTAKE ENGINE MECHANICAL EXHAUST COOLING LUBRICATION STARTING & CHARGING DRIVE SHAFT / PROPELLER SHAFT BRAKE MANUAL TRANSMISSION/TRANSAXLE CLUTCH HEATER & AIR CONDITIONER INSTRUMENT PANEL/METER ALPHABETICAL INDEX 1 2 3 5 10 11 12 13 14 15 16 17 19 30 32 41 42 55 71 MAIN INDEX BACK TO FOREWORD & SUB INDEX TO MODEL INDEX TOYOTA COROLLA REPAIR MANUAL SUPP 1129E REPAIR MANUAL SUPPLEMENT 1129E TOYOTA COROLLA

INTRODUCTION HOW TO USE THIS MANUAL 01--1 ............. GENERAL INFORMATION 01--1/2 .................. IDENTIFICATION INFORMATION 01--3 .......... VEHICLE IDENTIFICATION AND SERIAL NUMBERS 01--3 .................. REPAIR INSTRUCTION 01--4 .................. PRECAUTION 01--4/18 ............................. VEHICLE LIFT AND SUPPORT LOCATIONS 01--19/20 .............. HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01--21 ......... GENERAL INFORMATION 01--21 .................. HOW TO PROCEED WITH TROUBLESHOOTING 01--22/31 .................... ELECTRONIC CIRCUIT INSPECTION PROCEDURE 01--32/36 ............... TERMS 01--37 ................................. ABBREVIATIONS USED IN MANUAL 01--37/41 ......... GLOSSARY OF SAE AND TOYOTA TERMS 01--42/44 .. BACK TO MAIN INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

010XJ--02 N17080 Filler Cap Float Reservoir Tank z Grommet Clip Slotted Spring Pin : Specified torque z Non--reusablepart Cylinder Piston Push Rod Washer Snap Ring Boot z 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 COROLLA Supplement (RM1129E) HOW TO USE THIS MANUAL GENERAL INFORMATION 1. GENERAL DESCRIPTION (a) This manual is written in accordance with SAE J2008. (1) Diagnosis (2) Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting (3) Final Inspection (b) This manual explains (1) (see ”Diagnostics” section) and (2). (3) is omitted. (c) The following procedures are omitted from this manual. However, these procedures must be per- formed. (1) Using a jack or lift to perform operations (2) Cleaning a removed part (3) Performing a visual check 2. INDEX (a) An alphabetical INDEX section is provided at the end of the manual 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 procedure. 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) A component illustration is placed under the title where necessary. (b) Non--reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. Example: BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

Illustration: what to do and where Component part No. Explanation text: how to perform task Task heading: what you will be doing Set part No. INSTALL FRONT AXLE HUB BEARING D32545 01--2 -- INTRODUCTION HOW TO USE THIS MANUAL COROLLA Supplement (RM1129E) (c) Torque specifications, grease application areas and non--reusable parts are emphasized 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) Only items with key points are described in the text. What to do and other details are placed in illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. (e) Illustrations of similar vehicle models are sometimes used. In those cases, minor details may be differ- ent from the actual vehicle. (f) 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. It also has information such as specifications and warnings. Example: HINT: This format provides an experienced technician with a FAST TRACK to the necessary information. The task headings are easy to read and the text below the task heading provides detailed information. Important specifications and warnings are always written in bold type. 5. SERVICE SPECIFICATIONS (a) SPECIFICATIONS are presented in bold--faced text throughout the manual. The specifications are also found in the ”Service Specifications” section for quick reference. 6. TERMS DEFINITION CAUTION Possibility of injury to you or other people. NOTICE Possibility of damage to components being repaired. HINT Provides additional information to help you perform repairs. 7. SI UNIT (a) The units used in this manual comply with the SI UNIT (International System of Units) standard. Units from the metric system and the English system are also provided. Example: Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf) BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

2009 Toyota Corolla Service & Repair Manual

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