2010 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

010XK--02 D33475 A B D33476 C B E A D -- INTRODUCTION IDENTIFICATION INFORMATION 01--3 COROLLA Supplement (RM1129E) IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION AND SERIAL NUMBERS 1. VEHICLE IDENTIFICATION NUMBER (a) The vehicle identification number is stamped on the vehicle 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: 1CD--FTV, 1ND--TV B:2ZZ--GE, 3ZZ--FE, 4ZZ--FE C: C50, C53, C53A, C64, C150 D: E351, E357 E: A246E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

010XL--02 B84157 1 2 3 4 5 6 01--4 -- INTRODUCTION REPAIR INSTRUCTION COROLLA Supplement (RM1129E) REPAIR INSTRUCTION PRECAUTION 1. BASIC REPAIR HINT (a) HINTS ON OPERATIONS 1 Attire S Always wear a clean uniform. S Hat and safety shoes must be worn. 2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. 3 Safe operation S When working with 2 or more persons, be sure to check safety for one another. S When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. S If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. S When jacking up the vehicle, be sure to support the specified location with a safety stand. S When lifting up the vehicle, use appropriate safety equipment. 4 Preparation of tools and measuring gauge Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement. 5 Removal and installation, disassembly and assembly operations S Diagnose with a thorough understanding of proper procedures and of the reported problem. S Before removing the parts, check the general condition of the assembly and for deformation and damage. S When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed. S Clean and wash the removed parts if necessary and assemble them after a thorough check. 6 Removed parts S Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts. S Fornon--reusable parts such as gaskets, O--rings, and self--locking nuts, replace them with new ones as instructed in this manual. S Retain the removed parts for customer inspection, if requested. BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

Z11554 Seal Lock Adhesive -- INTRODUCTION REPAIR INSTRUCTION 01--5 COROLLA Supplement (RM1129E) (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--19). (c) PRECOATED PARTS (1) Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory. (2) If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive. (3) When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part. (4) Some seal lock agents harden slowly. You may have to wait for the seal lock agent to harden. (d) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks. (e) BOLTS, NUTS AND SCREWS (1) Carefully follow all the specifications for tightening torques. Always use a torque wrench. BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

V35007 D25628 V35008 Illustration Symbol Part Name Abbreviation FUSE MEDIUM CURRENT FUSE HIGH CURRENT FUSE FUSIBLE LINK CIRCUIT BREAKER FUSE M--FUSE H--FUSE FL CB 01--6 -- INTRODUCTION REPAIR INSTRUCTION COROLLA Supplement (RM1129E) (f) FUSES (1) When inspecting a fuse, check that the wire of the fuse is not broken. (2) When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating. BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

D25786 Shape (Example) Removal/Installation Clip Remover Pliers Screwdriver Scraper Protective Tape Clip Protective Tape Remove clips from front or rear using clip remover or pliers. Remove fasteners with a clip remover or screwdriver. Remove clips with a wide scraper to prevent panel damage. -- INTRODUCTION REPAIR INSTRUCTION 01--7 COROLLA Supplement (RM1129E) (g) CLIPS (1) The removal and installation methods of typical clips used for vehicle body parts are shown in the table below. HINT: If clips are damaged during a procedure, always replace the damaged clip with a new clip. BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

2010 Toyota Corolla Service & Repair Manual

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