Toyota 2003 COROLLA Repair Manual Supplement Download Page 649

Page: 649 / 923

G36384

14--16

ENGINE MECHANICAL

VALVE CLEARANCE (1ND--TV)

COROLLA Supplement (RM1129E)

11.

INSTALL RADIATOR SUPPORT OPENING COVER

(a)

Install the radiator support opening cover with the 4 clips.

12. INSTALL ENGINE UNDER COVER RH (TMC MADE)

(See page 13--17)

13. INSTALL ENGINE UNDER COVER RH (EXCEPT TMC MADE)

(See page 13--17)

14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque: 5.4 N

⋅

m (55 kgf

⋅

cm, 48 in.

⋅

lbf)

BACK TO CHAPTER INDEX

TO MODEL INDEX

To Alphabetical Index
To Sub Index

TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

Summary of Contents for 2003 COROLLA

Page 1: ...epair or service only using this manu al 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...

Page 2: ...CATION 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 ...

Page 3: ...T 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 ABBREVIATIONS USED IN MANUAL 01 37 41 GLOSSARY OF SAE AND TOYOTA TERMS 01 42 44 BACK TO MAIN INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 112...

Page 4: ...res 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 u...

Page 5: ...o 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 spec ificati...

Page 6: ...fication 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 ...

Page 7: ...ore starting operation prepare a tool stand SST gauge oil and parts for replacement 5 Removal and installation disassembly and assem bly 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 n...

Page 8: ...oosened or moved in any way it must be recoated with the spe cified 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...

Page 9: ...ION 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 ...

Page 10: ... 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...

Page 11: ... Remover Remove rivet by pushing the center pin through and prying out the rivet shell Remove rivet by unscrewing the center pin and prying out the rivet shell Remove rivet by prying out the pin and then prying out the rivet shell 01 8 INTRODUCTION REPAIR INSTRUCTION COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP...

Page 12: ...r force the hose onto a connector that is too large If a hose has been stretched it may leak air Use a step down adapter if necessary i TORQUE WHEN USING TORQUE WRENCH WITH EX TENSION TOOL 1 Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench Formula T T x L2 L1 L2 T Reading of torque wrench N m kgf cm ft lbf T T...

Page 13: ...tem memory The backup power source may inadvertently power the SRS and cause it to deploy 3 In minor collisions where the SRS does not deploy the horn button assembly see Pub No RM925E page 60 14 front passenger airbag assembly see Pub No RM925E page 60 27 front seat airbag assembly see Pub No RM925E page 60 32 curtain shield airbag assembly see Pub No RM1028E page 60 24 and seat belt pretensioner...

Page 14: ...Also do not place anything on top of the horn button 2 Never measure the resistance of the airbag squib This may cause the airbag to inflate which could cause serious injury 3 Grease or detergents of any kind should not be applied to the steering wheel pad 4 Store the horn button in an area where the ambient temperature is below 93 C 200 F the hu midity is not high and electrical noise is not near...

Page 15: ...elding anywhere on the vehicle disconnect the airbag ECU connectors 4 pins These connectors contain shorting springs This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring 6 When disposing of a vehicle or the airbag assembly unit by itself the airbag should be deployed using SST before disposal see Pub No RM925E page 60 27 Activate in a safe place aw...

Page 16: ...nflation direction facing up Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag deploys 2 Never measure the resistance of the airbag squib This may cause the airbag to inflate which could cause serious injury 3 Grease or detergents of any kind should not be applied to the airbag assembly 4 Store the airbag assembly in an area wh...

Page 17: ... nearby 5 When using electric welding anywhere on the vehicle disconnect the airbag ECU connectors 2 pins These connectors contain shorting springs This feature reduces the possibility of the seat belt pretensioner deploying due to currents entering the squib wiring 6 When disposing of a vehicle or the seat belt pretensioner unit by itself the seat belt pretensioner should be activated before disp...

Page 18: ...ble from the negative battery terminal to pre vent component and wire damage caused by acci dental short circuits 2 When disconnecting the terminal cable turn the ignition switch and headlamp dimmer switch OFF and loosen the terminal nut completely Perform these operations without twisting or prying the ter minal Remove the battery cable from the battery terminal 3 Clock settings radio settings au...

Page 19: ...y using a fire resistant container 5 REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS a If any metal particles enter inlet pass this may damage the engine b When removing and installing inlet system parts cover the openings of the removed parts and engine openings Use gummed tape or other suitable materials c When installing inlet system parts check that no metal particles have entered the engine o...

Page 20: ...C OFF switch to turn off the TRC system 2 Check that the TRC OFF indicator illuminates HINT The SLIP indicator should always operate right after the engine is restarted 3 Begin testing 4 Press the TRC cut TRC OFF switch to turn on the TRC system and check that the TRC OFF indicator turns off HINT The SLIP indicator lamp blinks when the TRC system is operat ing 5 Be sure to follow the instructions ...

Page 21: ...create a fire hazard To prevent this perform the following precautions a Use only unleaded gasoline b Avoid prolonged idling Avoid idling the engine for more than 20 minutes c Avoid a spark jump test 1 Perform a spark jump test only when absolutely necessary Perform this test as rapidly as pos sible 2 While testing never race the engine d Avoid a prolonged engine compression measurement Engine com...

Page 22: ...cks to secure the vehicle 3 NOTICE FOR USING JACK AND SAFETY STAND a Work on a level surface using wheel chocks at all times b Use a rigid rack with a rubber attachment as shown in the illustration c Apply the jack and rigid rack to the specified location on the vehicle d When jacking up the front wheels release the parking brake and place wheel chocks only behind the rear wheels When jacking up t...

Page 23: ...ack support location f Be sure to lock the swing arms before lifting and during work if equipped with arm locks g Use the lift to lift the vehicle up off the ground Stand at a safe distance and shake the vehicle to check its stability 5 NOTICE FOR USING PLATE TYPE LIFT a Follow the safety procedures outlined in its instruction manual b Use plate lift attachments rubber lifting blocks on top of the...

Page 24: ...Page 1 ECD System 1ND TV 05 1 2 Multi mode Manual Transmission System 05 172 3 Combination Meter 05 370 4 Engine Immobilizer System 05 378 FOR USING INTELLIGENT TESTER II S Before using the intelligent tester ll the tester operator s manual should be read thoroughly S If the tester cannot communicate with the ECU controlled systems when you have connected the cable of the tester to the DLC3 with t...

Page 25: ...FREEZE FRAME DATA CHECK a Measure the battery positive voltage Standard 11 to 14 V Engine stopped b Visually check the wire harness connectors and fuses for open and short circuits c Warm up the engine to the normal operating temperature d Confirm the problem symptoms and conditions and check for DTCs Result Result Proceed to DTC is output A DTC is not output B B Go to step 5 A 4 DTC CHART a Recon...

Page 26: ...ATION TEST a After completing repairs confirm that the malfunction no longer exists If the malfunction does not reoc cur perform a confirmation test under the same conditions and in the same environment as when it occurred the first time NEXT END BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 27: ...on 01 24 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS COROLLA Supplement RM1129E CUSTOMER PROBLEM ANALYSIS HINT S In troubleshooting confirm that the problem symptoms have been accurately identified Preconcep tions should be discarded in order to give an accurate judgement To clearly understand what the prob lem symptoms are it is extremely important to ask the customer about the proble...

Page 28: ...lem indicated by the DTC is 1 still occurring or 2 occurred in the past but has since returned to normal In addition the DTC should be compared to the problem symptom to see if they are related For this reason DTCs should be checked before and after confirmation of symptoms i e whether or not problem symptoms exist to determine current system conditions as shown in the flowchart below Never skip t...

Page 29: ... was displayed in the initial DTC check the problem may have occurred in a wire harness or connec tor in that circuit in the past Check the wire harness and connectors see page 01 32 B SYSTEM NORMAL A TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit the DTC displayed first is either for a past problem or a secondary problem BACK TO...

Page 30: ... well as the problem area or parts must be con firmed First narrow down the possible problem circuits according to the symptoms Then connect the tester and carry out the symptom simulation test judging whether the circuit being tested is defective or normal Also confirm the problem symptoms at the same time Refer to the problem symptoms table for each system to narrow down the possible causes 1 VI...

Page 31: ... the front of the radia tor S Never apply water directly ontothe electronic compo nents HINT If the vehicle has or had a water leakage problem the leakage may have damaged the ECU or connections Look for evidence of corrosion or short circuits Proceed with caution during water tests 4 HIGH ELECTRICAL LOAD METHOD When a malfunc tion seems to occur when electrical load is exces sive a Turn on the he...

Page 32: ... sensor assembly D Wire harness B0105 53 05 136 ON D Airbag sensor assembly D Wire harness B0106 54 Open in P squib circuit D Airbag sensor assembly D Wire harness D Short in P squib circuit to Ground ON ON B0100 13 05 119 Short in P squib circuit D Front passenger airbag assembly squib D Airbag sensor assembly D Wire harness D Front passenger airbag assembly squib D Front passenger airbag assembl...

Page 33: ...5 1277 Problem Symptom Page Indicates the page where the flowchart for each circuit is located Circuit Inspection Inspection Order Indicates the circuit which needs to be checkedfor each problem symptom Check in the order indicated by the numbers Circuit or Part Name Indicates the circuit or part which needs to be checked Inspect the Fuse and Relay before confirming the suspected area in the chart...

Page 34: ...color of the stripe D Inspection Procedures Use the inspection procedures to determine if the circuit is normal or abnormal If it is ab normal use it to determine whether the prob lem is located in the sensors actuators wire harness or ECU D Indicates the condition of the connector of the ECU during the check D Connections of tester are indicated by or after terminal name Connector being checked i...

Page 35: ...that there are no deformed damaged loose or missing terminals 4 When connecting a connector press firmly until you hear the lock close with a click sound 5 If checking a connector with a TOYOTA electrical tester check the connector from the backside har ness side using a mini test lead NOTICE S As a waterproof connector cannot be checked from the backside check by connecting a sub harness S Do not...

Page 36: ... use a silver plated fe male terminal 3 Damaged deformed or corroded terminals should be replaced If the terminal will not lock into the housing the housing may have to be replaced e HANDLING OF WIRE HARNESS 1 If removing a wire harness check the wiring and clamping before proceeding so that it can be re stored in the same way 2 Never twist pull or slacken the wire harness more than necessary 3 Th...

Page 37: ...n Connector A terminal 1 Connector B1 terminal 1 Below 1 Ω Connector B2 terminal 1 Connector C terminal 1 10 kΩ or higher If your results match the examples above an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C c Check the voltage 1 In a circuit in which voltage is applied to the ECU connector terminal an open circuit can be checked by conducting a voltage c...

Page 38: ... C 2 Disconnect connector B and measure the resis tance Standard Fig 7 Tester Connection Specified Condition Connector A terminal 1 Body ground 10 kΩ or higher Connector B2 terminal 1 Body ground Below 1 Ω If your results match the examples above a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C 4 CHECK AND REPLACE ECU NOTICE S The connector should not be disc...

Page 39: ...en the ECU ground terminal and body ground Standard Below 1 Ω 2 Disconnect the ECU connector Check the ground terminals on the ECU side and wire harness side for evidence of bending corrosion or foreign materi al Lastly check the contact pressure of the female terminals BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 40: ...tic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension B Battery Voltage BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B L Bi Level B S Bore Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve CB Circuit Breaker CCo Catalytic Converter For Oxidation CCV Canister Closed Valve CD Compac...

Page 41: ...D Electro Deposited Coating EDU Electronic Driving Unit EDIC Electric Diesel Injection Control EFI Electronic Fuel Injection E G Engine EGR Exhaust Gas Recirculation EGR VM EGR Vacuum Modulator ELR Emergency Locking Retractor EMPS Electric Motor Power Steering ENG Engine ESA Electronic Spark Advance ETCS i Electronic Throttle Control System intelligent EVAP Evaporative Emission Control EVP Evapora...

Page 42: ...Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left Hand LHD Left Hand Drive L H W Length Height Width LLC Long Life Coolant LNG Liquified Natural Gas LO Low LPG Liquified Petroleum Gas LSD Limited Slip Differential LSP PV Load Sensing Proportioning And Bypass Valve LSPV Load Sensing Proportioning Valve MAP Manifold Absolute Pressure MAX Maximum MIC Microphone MIL Malfunction Indi...

Page 43: ... RFS Rigid Front Suspension RH Right Hand RHD Right Hand Drive RLY Relay ROM Read Only Memory RR Rear RRS Rigid Front Suspension RWD Rear Wheel Drive SDN Sedan SEN Sensor SICS Starting Injection Control System SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD ...

Page 44: ...WC Three Way Catalyst U D Underdrive U S Undersize VCV Vacuum Control Valve VENT Ventilator VIM Vehicle Interface Module VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Skid Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve VVT i Variable Valve Timing intelligent W With WGN Wagon W H Wire Harness W O Without 1ST First 2ND Second 2WD Two Wheel Drive Vehicle ...

Page 45: ...c Trouble Code Diagnostic Trouble Code DTM Diagnostic Test Mode ECL Engine Coolant Level ECM Engine Control Module Engine ECU Electronic Control Unit ECT Engine Coolant Temperature Coolant Temperature Water Temperature THW EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory EEPROM Erasable Programmable Read Only Memory EPROM EFE Early Fuel...

Page 46: ...tion Catalytic Converter Oxidation Catalyst Convert OC CCo OL Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction AS PCM Powertrain Control Module PNP Park Neutral Position PROM Programmable Read Only Memory PSP Power Steering Pressure PTOX Periodic Trap Oxidizer Diesel Particulate Filter DPF Diesel Particulate Trap DPT RAM Random Access Memory Random Access Memory RAM RM Relay Mod...

Page 47: ...c TWC Manifold Converter CCRO TWC OC Three Way Oxidation Catalytic Converter CCR CCo VAF Volume Airflow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU OC Warm Up Oxidation Catalytic Converter WU TWC Warm Up Three Way Catalytic Converter 3GR Third Gear 4GR Fourth Gear BACK TO CHAPTER INDEX TO MODEL INDEX To...

Page 48: ... 02 12 13 BRAKE 02 14 PREPARATION 02 14 MANUAL TRANSMISSION TRANSAXLE 02 15 PREPARATION 02 15 16 CLUTCH 02 17 PREPARATION 02 17 HEATER AIR CONDITIONER 02 18 PREPARATION 02 18 19 REFER TO FOLLOWING REPAIR MANUALS Manual Name Pub No COROLLA Repair Manual RM925E COROLLA Repair Manual Supplement RM939E COROLLA Repair Manual Supplement RM1028E COROLLA Repair Manual Supplement RM1106E NOTE The above pag...

Page 49: ...ket Wrench ENGINE COOLANT TEMPERATURE SENSOR 1ND TV Recommended Tools 09082 00040 TOYOTA Electrical Tester ECD SYSTEM 1ND TV 09083 00150 Test Lead Set ECD SYSTEM 1ND TV Equipment Ohmmeter Service wire Torque wrench Voltmeter BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 50: ...Tool FUEL TANK ASSY 1ND TV HATCH BACK 09808 01410 Holder FUEL TANK ASSY 1ND TV HATCH BACK 09808 01420 Claw FUEL TANK ASSY 1ND TV HATCH BACK 09808 01430 Bolt FUEL TANK ASSY 1ND TV HATCH BACK Recommended Tools 09082 00040 TOYOTA Electrical Tester FUEL SYSTEM 1ND TV 09130 00150 Water Pump Pliers FUEL FILTER ASSY 1ND TV Equipment Ohmmeter Radiator cap tester Torque wrench BACK TO CHAPTER INDEX TO MODE...

Page 51: ...upplement RM1129E EMISSION CONTROL PREPARATION Equipment Intelligent tester II Ohmmeter Service wire harness Torque wrench Radiator cap testor BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 52: ...Recommended Tools 09082 00040 TOYOTA Electrical Tester TURBOCHARGER SYSTEM 1ND TV 09083 00140 Base Lead TURBOCHARGER SYSTEM 1ND TV Equipment Plastic faced hammer Service wire Torque wrench Vacuum pump Vernier calipers Voltmeter Wooden block BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 53: ... ASSY 1ND TV 09817 33190 Sensor Socket Wrench PARTIAL ENGINE ASSY 1ND TV 09843 18040 Diagnosis Check Wire No 2 ENGINE 1ND TV 09950 70010 Handle Set ENGINE REAR OIL SEAL 1ND TV 09951 07100 Handle 100 ENGINE REAR OIL SEAL 1ND TV 09960 10010 Variable Pin Wrench Set CHAIN SUB ASSY 1ND TV OIL PUMP SEAL 1ND TV ENGINE REAR OIL SEAL 1ND TV CYLINDER HEAD GASKET 1ND TV PARTIAL ENGINE ASSY 1ND TV 09962 01000...

Page 54: ...90 04020 Engine Sling Device PARTIAL ENGINE ASSY 1ND TV SSM 08826 00080 Seal Packing Black or equivalent FIPG CHAIN SUB ASSY 1ND TV CAMSHAFT 1ND TV VALVE CLEARANCE 1ND TV CYLINDER HEAD GASKET 1ND TV 08826 00100 Seal Packing 1282B THREE BOND 1282B or equivalent FIPG CHAIN SUB ASSY 1ND TV CYLINDER HEAD GASKET 1ND TV 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent CAMSHAFT 1ND TV ENGINE REAR ...

Page 55: ...plement RM1129E Dial indicator with magnetic base Tire pressure gauge Alignment tester Toe in gauge Sandpaper 400 Chain block Angle gauge BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 56: ... COROLLA Supplement RM1129E EXHAUST PREPARATION Equipment Plastic faced hammer Torque wrench Vernier calipers Wooden block BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 57: ...ctrical Tester COOLING FAN SYSTEM 1ND TV 09083 00150 Test Lead Set COOLING FAN SYSTEM 1ND TV Equipment Belt tension gauge Ohmmeter Radiator cap tester Torque wrench Vernier calipers Coolant Item Capacity Classification Engine coolant w heater w o heater 5 5 liters 5 8 US qts 4 8 lmp qts 5 3 liters 5 6 US qts 4 7 lmp qts TOYOTA SUPER LONG LIFE Antifreeze Cool ant or equivalent BACK TO CHAPTER INDEX...

Page 58: ...09963 01000 Pin 10 OIL PUMP ASSY 1ND TV SSM 08826 00080 Seal Packing Black or equivalent FIPG OIL PUMP ASSY 1ND TV 08826 00100 Seal Packing 1282B THREE BOND 1282B or equivalent FIPG OIL PUMP ASSY 1ND TV Equipment Belt tension gauge Radiator cap tester Torque wrench Lubricant Item Capacity Classification Oil grade Use ACEA B1 API grade CF 4 CF or G DLD 1 You may also use API CE or CD Drain and refi...

Page 59: ...0040 TOYOTA Electrical Tester PRE HEATING SYSTEM 1ND TV STARTING SYSTEM 1ND TV 09083 00150 Test Lead Set PRE HEATING SYSTEM 1ND TV STARTING SYSTEM 1ND TV Equipment Ammeter Ohmmeter Service wire Torque wrench Voltmeter BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 60: ...RIVE SHAFT 1ND TV 09520 32040 Shocker Set FRONT DRIVE SHAFT 1ND TV 09521 24010 Rear Axle Shaft Puller FRONT DRIVE SHAFT 1ND TV 09527 10011 Rear Axle Shaft Bearing Remover FRONT DRIVE SHAFT 1ND TV 09608 16042 Front Hub Bearing Adjusting Tool FRONT DRIVE SHAFT 1ND TV 09608 02021 Bolt Nut FRONT DRIVE SHAFT 1ND TV 09608 02041 Retainer FRONT DRIVE SHAFT 1ND TV 09628 62011 Ball Joint Puller FRONT DRIVE ...

Page 61: ...VE SHAFT 1ND TV 09951 07100 Handle 100 FRONT DRIVE SHAFT 1ND TV Recommended Tools 09011 12301 Socket Wrench 30 mm FRONT DRIVE SHAFT 1ND TV 09040 00011 Hexagon Wrench Set FRONT DRIVE SHAFT 1ND TV 09043 20060 Socket Hexagon Wrench 6 FRONT DRIVE SHAFT 1ND TV 09905 00012 Snap Ring No 1 Expander FRONT DRIVE SHAFT 1ND TV Equipment Torque wrench Lubricant Item Capacity Front drive shaft Outboard joint gr...

Page 62: ...rench 14mm BRAKE BOOSTER ASSY 1ND TV BRAKE MASTER CYLINDER SUB ASSY 1ND TV Recommended Tools 09041 00030 Torx Driver T30 BRAKE MASTER CYLINDER SUB ASSY 1ND TV 09905 00013 Snap Ring Pliers BRAKE MASTER CYLINDER SUB ASSY 1ND TV Torx is registered trademark of Textron Inc Equipment Torque wrench BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP ...

Page 63: ... MANUAL TRANSAXLE ASSY C53 MANUAL TRANSAXLE ASSY C53A FRONT DIFFERENTIAL OIL SEAL C53A C53 09670 00010 Front Crossmember Guide Tool MANUAL TRANSAXLE ASSY C53 MANUAL TRANSAXLE ASSY C53A 09710 20011 Front Suspension Bushing Tool Set FRONT DIFFERENTIAL OIL SEAL C53A C53 09710 06071 Replacer FRONT DIFFERENTIAL OIL SEAL C53A C53 09726 36010 Lower Control Arm Bushing Replacer FRONT DIFFERENTIAL OIL SEAL...

Page 64: ...FLOOR SHIFT SHIFT LEVER ASSY C53A 09090 04020 Engine Sling Device MANUAL TRANSAXLE ASSY C53 MANUAL TRANSAXLE ASSY C53A Equipment Torque wrench Lubricant Item Capacity Classification Manual transaxle oil C53A C53 w Differential oil 1 9 liters 2 0 US qts 1 7 lmp qts API GL 4 or GL 5 SAE 75W 90 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1...

Page 65: ...3 Universal Joint Bearing Remover Replacer CLUTCH UNIT C53A C53 Recommended Tools 09040 00011 Hexagon Wrench Set CLUTCH PEDAL SUB ASSY C53 09082 00040 TOYOTA Electrical Tester CLUTCH START SWITCH ASSY C53 Equipment Torque wrench Vernier calipers Dial indicator with magnetic base Lubricant Item Capacity Classification Brake fluid SAE J1704 or FMVSS No 116 DOT 4 BACK TO CHAPTER INDEX TO MODEL INDEX ...

Page 66: ...ND TV 07117 58090 Quick Disconnect Adapter COOLER COMPRESSOR ASSY 1ND TV 07117 78050 Refrigerant Charging Gauge COOLER COMPRESSOR ASSY 1ND TV 07117 88060 Refrigerant Charging Hose COOLER COMPRESSOR ASSY 1ND TV 07117 88070 Refrigerant Charging Hose COOLER COMPRESSOR ASSY 1ND TV 07117 88080 Refrigerant Charging Hose COOLER COMPRESSOR ASSY 1ND TV 07117 48130 Vacuum Pump 220 V COOLER COMPRESSOR ASSY 1...

Page 67: ...ND TV 95416 00140 Gas Leak Detector Halogen Leak Detector DENSO Part No COOLER COMPRESSOR ASSY 1ND TV Equipment Vinyl tape Vise pliers Gas leak detector Belt tension gauge Dial indicator Torque wrench Lubricant Item Capacity Classification Compressor oil ND OIL 8 or equivalent BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 68: ...UE SPECIFICATION 03 19 STARTING CHARGING 03 20 SERVICE DATA 03 20 TORQUE SPECIFICATION 03 21 DRIVE SHAFT PROPELLER SHAFT AXLE 03 22 TORQUE SPECIFICATION 03 22 BRAKE 03 23 SERVICE DATA 03 23 TORQUE SPECIFICATION 03 24 MANUAL TRANSMISSION TRANSAXLE 03 25 SERVICE DATA 03 25 TORQUE SPECIFICATION 03 26 27 CLUTCH 03 28 SERVICE DATA 03 28 TORQUE SPECIFICATION 03 29 HEATER AIR CONDITIONER 03 30 SERVICE DA...

Page 69: ...ICE SPECIFICATIONS STANDARD BOLT 03 1 COROLLA Supplement RM1129E STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 70: ... 1 1 25 1 25 1 25 1 5 1 5 8 19 39 71 110 170 80 195 400 730 1 100 1 750 69 in lbf 14 29 53 80 127 9 21 44 80 125 90 210 440 810 1 250 78 in lbf 15 32 59 90 7T 6 8 10 12 14 16 1 1 25 1 25 1 25 1 5 1 5 10 5 25 52 95 145 230 110 260 530 970 1 500 2 300 8 19 38 70 108 166 12 28 58 105 165 120 290 590 1 050 1 700 9 21 43 76 123 8T 8 10 12 1 25 1 25 1 25 29 61 110 300 620 1 100 22 45 80 33 68 120 330 69...

Page 71: ...OW TO DETERMINE NUT STRENGTH HINT Use the nut with the same number of the nut strength classification or greater than the bolt strength classifi cation number when tightening parts with a bolt and nut Example Bolt 4T Nut 4N or more BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 72: ...on sensor Voltage Standard 1 EG 3 B 4 75 to 5 25 V Mass air flow meter Resistance Standard 4 THA 5 E2 13 6 to 18 4 kΩ at 20_C 4_F 2 21 to 2 69 kΩ at 20_C 68_F 0 493 to 0 667 kΩ at 60_C 140_F Engine coolant temperature sensor Resistance Standard 1 E2 2 THW 2 32 to 2 59 kΩ at 20_C 68_F 0 310 to 0 326 kΩ at 80_C 176_F Throttle control motor Resistance Standard 1 DUTY 3 E 0 3 to 100 Ω at 20_C 68_F Cra...

Page 73: ...ody 6 0 60 53 in lbf Air hose No 4 x Air tube No 2 6 0 60 53 in lbf Air hose No 2 x Air tube No 1 25 255 18 Accelerator pedal assy x Body 5 4 55 44 in lbf Camshaft position sensor x Vacuum pump assy 8 0 80 71 in lbf Crankshaft position sensor x Cylinder block sub assy 8 0 80 71 in lbf ECM bracket No 1 x ECM 3 0 30 27 in lbf ECM bracket No 3 x ECM 3 0 30 27 in lbf ECM bracket No 2 x ECM 3 0 30 27 i...

Page 74: ...or assy Resistance at 20_C 68_F 0 215 to 0 295 Ω Common rail assy Resistance Fuel pressure control valve at 20_C 68_F 3 42 to 3 78 Ω Fuel heater assy Resistance at 20_C 68_F 0 5 to 2 0 Ω Level warning switch Resistance When the float is up When the float is down Below 1 Ω 10 kΩ or higher Compression spring Exhaust pipe assy front x Exhaust manifold Free length Minimum 41 5 mm 1 6339 in Compression...

Page 75: ...inder head sub assy 20 204 15 Fuel inlet pipe sub assy x Common rail assy With SST Without SST 23 25 235 255 17 18 Fuel inlet pipe sub assy x Supply pump assy With SST Without SST 23 25 235 255 17 18 Common rail assy x Cylinder head sub assy 26 265 19 Fuel filter assy x Fuel filter support 18 178 13 Fuel tank band No 1 x Body HATCH BACK 40 408 30 Fuel tank band No 1 x Body SEDAN STATION WAGON 39 3...

Page 76: ...ONTROL SERVICE DATA 1ND TV EGR valve assy Resistance B1 EGR1 B1 EGR3 B2 EGR2 B2 EGR4 19 6 1 4 Ω at 20_C 68_F 19 6 1 4 Ω at 20_C 68_F 19 6 1 4 Ω at 20_C 68_F 19 6 1 4 Ω at 20_C 68_F BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 77: ...attery negative terminal x Battery 5 4 55 48 in lbf EGR valve assy x Intake air connector 20 204 15 EGR cooler assy x EGR connector 20 204 15 EGR cooler assy x EGR valve assy 11 112 8 EGR cooler assy x Cylinder head sub assy 11 112 8 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 78: ...39 2 kPa 0 40 kgf cm2 5 69 psi 0 7 to 1 0 V Apply pressure 58 8 kPa 0 60 kgf cm2 8 53 psi 1 0 to 1 3 V Apply pressure 78 5 kPa 0 80 kgf cm2 11 4 psi 1 3 to 1 6 V Apply pressure 98 0 kPa 1 00 kgf cm2 14 2 psi Vacuum regulating valve Resistance Standard 1 2 1 Body 2 Body 10 to 14 Ω at 20_C 68_F 10 kΩ or higher 10 kΩ or higher Compression spring Free length Minimum 41 5 mm 1 634 in for front 38 5 mm ...

Page 79: ...1 110 8 Turbo oil outlet pipe x Turbocharger sub assy 11 110 8 Turbo oil outlet pipe x Cylinder block sub assy 13 5 140 10 Exhaust manifold converter sub assy x Turbocharger sub assy 26 265 19 Manifold support bracket x Exhaust manifold converter sub assy 37 375 27 Manifold support bracket x Cylinder block sub assy 37 375 27 Turbo insulator No 1 x Turbocharger sub assy 6 0 60 53 in lbf Turbo insul...

Page 80: ...90 to 686 N 50 to 70 kgf 110 to 154 lb Idle speed 720 to 820 rpm Maximum speed 5100 to 5250 rpm Compression pressure 2700 kPa 27 5 kgf cm2 391 psi or more Minimum pressure 2200 kPa 22 5 kgf cm2 320 psi Difference between each cylinder 500 kPa 5 0 kgf cm2 71 psi or less Valve clearance cold Intake Exhaust 0 11 to 0 17 mm 0 004 to 0 007 in 0 14 to 0 20 mm 0 006 to 0 008 in Cylinder head set bolt out...

Page 81: ...0 204 15 Cylinder head cover sub assy x Cylinder head cover No 2 5 5 56 49 in lbf Engine mounting insulator FR x Engine mounting bracket FR 52 530 38 Engine mounting insulator RR x Engine mounting bracket RR 87 887 64 Front suspension member brace rear LH RH x Body Nut Bolt A Bolt B 133 80 1356 816 98 59 Engine mounting member sub assy center x Body 39 398 29 Engine mounting insulator LH x Engine ...

Page 82: ...T COROLLA Supplement RM1129E EXHAUST SERVICE DATA Compression spring Free length Minimum Front Rear 41 5 mm 1 634 in 38 5 mm 1 516 in BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 83: ...ned N m kgf cm ft lbf Exhaust pipe assy front x Exhaust manifold converter sub assy 43 440 32 Exhaust pipe assy tail x Exhaust pipe assy front 43 440 32 Front panel brace front x Body 29 6 300 22 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 84: ... Cooling fan relay Specified condition Between terminals 3 5 Between terminals 3 5 10 kΩ or higher Below 1Ω Apply battery voltage to terminals 1 and 2 Cooling fan relay No 2 Specified condition Between terminals 3 4 Between terminals 3 4 Between terminals 3 5 Between terminals 3 5 Below 1Ω 10 kΩ or higher Apply battery voltage to terminals 1 and 2 10 kΩ or higher Below 1Ω Apply battery voltage to ...

Page 85: ...pulley x Water pump assy 15 153 11 Water inlet x Cylinder block assy 9 92 80 in lbf Fun shroud assy x Radiator assy 7 5 76 66 in lbf Radiator support upper x Body 19 194 14 Relay block x Radiator support upper 5 4 55 48 in lbf Pressure sensor x Fun shroud assy 5 51 44 in lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 86: ...nt RM1129E LUBRICATION SERVICE DATA Oil pressure at idle speed at 3000 rpm 29 kPa 0 3 kgf cm2 4 3 psi or more 150 to 550 kPa 1 5 to 5 6 kgf cm2 22 to 80 psi BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 87: ...mounting bracket x Cylinder block assy Cylinder head assy 55 561 41 Oil pump assy x Cylinder block assy Cylinder head assy Bolt A Bolt B Bolt C Bolt D Nut 11 24 11 24 24 112 245 112 245 245 8 1 18 8 1 18 18 Engine mounting insulator sub assy x Body 52 530 38 Crankshaft damper sub assy x Crankshaft 180 1835 133 Battery negative terminal x Battery negative cable 5 4 55 48 in lbf Front wheel x Front ...

Page 88: ... to 2 Battery Voltage Standard 12 5 to 12 9 V at 20_C 68_F Charging circuit without load Amperage Standard Voltage Standard 10 A or less 13 2 to 14 8 V Charging circuit with load Amperage Standard 30 A or less Glow plug assy Resistance Standard Glow plug terminal Ground 0 6 Ω at 20_C 68_F Glow plug relay assy Resistance Standard 1 2 10 kΩ or higher Below 1 Ω Apply battery voltage to terminal 3 to ...

Page 89: ...r x Oil pump assy 11 110 8 1 Generator assy x Fan belt adjusting bar 18 5 190 14 Generator assy x Cylinder block sub assy 32 325 24 Wire harness protector x Fan belt adjusting bar 12 8 130 9 Generator wire x Generator assy 9 8 100 7 2 Glow plug assy x Cylinder head sub assy 12 5 125 9 Glow plug connector x Glow plug assy 1 6 15 14 in lbf Glow terminal x Glow plug connector 3 8 40 34 in lbf BACK TO...

Page 90: ...UK TMMT made TMC made 44 74 449 755 32 55 Speed sensor x Steering knuckle 8 0 82 71 in lbf Axle hub x Front drive shaft 216 2 200 159 Manual transaxle oil drain plug 39 400 29 Steering knuckle x Suspension lower arm 89 908 66 Front drive shaft bearing case set bolt 64 650 47 Flexible hose and speed sensor wire harness x Shock absorber TMC TMMT made TMUK made 29 19 296 194 21 14 BACK TO CHAPTER IND...

Page 91: ...BRAKE 03 23 COROLLA Supplement RM1129E BRAKE SERVICE DATA Negative pressure of vacuum pump assy More than 86 kPa 650 mmHg BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 92: ...master cylinder x Reservoir 8 0 82 71 in lbf Brake master cylinder x Brake booster 25 255 18 Brake line union nut 10 mm 14 mm 15 2 29 155 296 11 21 Brake booster x Body 12 7 130 9 Vacuum pump x Engine 21 214 15 Vacuum pump x Cam position sensor 9 0 92 80 in lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 93: ...ck solenoid Resistance 2 6 at 20_C 68_F 30 to 35 Ω Transmission shift main switch Resistance 4 8 for M position for E position Below 1 Ω 10 kΩ or higher Shift lever position sensor Resistance 4 9 10 13 for R position 2 4 6 10 for N position 2 3 4 13 for E and M position 5 11 for position 5 11 12 for M position 11 12 for position Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω 10 kΩ or higher Below 1 Ω BAC...

Page 94: ... 530 38 Manual transaxle assy x Engine 33 340 24 Engine mounting bracket LH x Transaxle 52 530 38 Engine mounting insulator LH set bolt Bolt A Bolt B 52 80 530 816 38 59 Transaxle x Wire harness clamp Bolt A Bolt B 26 25 260 255 19 18 Transaxle x Wire harness clamp 9 0 92 80 in lbf Transaxle x Wire harness clamp 13 130 9 Fuel filter assy set bolt 18 180 13 Air tube No 1 x Transaxle Bolt Nut Clamp ...

Page 95: ...8 180 13 Air tube No 1 x Transaxle Bolt Nut Clamp 25 6 0 255 61 18 53 in lbf Air tube No 2 x Transaxle Bolt Clamp 25 6 0 255 61 18 53 in lbf Battery carrier x Body 13 131 9 Battery clamp sub assy x Body Bolt Nut 5 0 3 5 51 36 44 in lbf 31 in lbf Hood set bolt 13 132 10 Front wheel set nut 103 1 050 76 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MAN...

Page 96: ...h pedal push rod play at pedal top 1 0 to 5 0 mm 0 039 to 0 197 in Clutch release point from pedal full stroke end position 25 mm 0 98 in or more Clutch disc rivet head depth Minimum 0 3 mm 0 012 in Clutch disc assy runout Maximum 0 8 mm 0 031 in Diaphragm spring finger wear Maximum depth Maximum width 0 5 mm 0 020 in 6 0 mm 0 236 in Flywheel sub assy runout Maximum 0 1 mm 0 004 in Diaphragm tip a...

Page 97: ...ch master cylinder x Body 12 120 9 Clutch release cylinder bleeder plug 8 4 85 74 in lbf Clutch release cylinder x Transaxle housing 12 120 9 Clutch line clamp x Clutch release cylinder 12 120 9 Clutch release cylinder x Flexible hose tube 15 155 11 Clutch actuator assy set bolt 17 173 13 Flexible hose tube clamp x Clutch accumulator assy LHD steering position type 12 120 9 Clutch accumulator assy...

Page 98: ...ment RM1129E HEATER AIR CONDITIONER SERVICE DATA Refrigerant charge volume Standard 450 30 g 15 9 1 1 oz Magnetic clutch clearance 1ND TV 0 20 0 45 mm 0 008 0 018 in BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 99: ...utch hub x Cooler compressor assy 13 134 9 7 Compressor and magnetic clutch x Engine 29 295 21 Cooler refrigerant discharge hose No 1 x Compressor and magnetic clutch 9 8 100 87 in lbf Cooler refrigerant suction hose No 1 x Compressor and magnetic clutch 9 8 100 87 in lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 100: ...21 05 145 P1229 05 146 152 P1520 05 153 156 P1600 05 157 159 P2227 05 160 ECM POWER SOURCE CIRCUIT 05 161 165 STARTER SIGNAL CIRCUIT 05 166 168 MIL CIRCUIT 05 169 171 MULTI MODE MANUAL TRANSMISSION SYSTEM 05 172 PRECAUTION 05 172 173 LOCATION 05 174 177 SYSTEM DIAGRAM 05 178 179 SYSTEM DESCRIPTION 05 180 185 CLAMP POSITION ADJUSTMENT 05 186 189 INITIALIZATION AND LEARNING 05 190 195 SYNCHRONIZATIO...

Page 101: ... 05 370 373 TERMINALS OF ECU 05 374 377 ENGINE IMMOBILIZER SYSTEM 1ND TV 05 378 HOW TO PROCEED WITH TROUBLESHOOTING 05 378 379 CUSTOMER PROBLEM ANALYSIS CHECK 05 380 PRE CHECK 05 381 383 DIAGNOSTIC TROUBLE CODE CHART 05 384 LOCATION 05 385 386 TERMINALS OF ECU 05 387 391 PROBLEM SYMPTOMS TABLE 05 392 B2799 05 393 REFER TO FOLLOWING REPAIR MANUALS Manual Name Pub No COROLLA Repair Manual RM925E COR...

Page 102: ...ation codes are unique 10 digit alphanumeric codes printed on the head portion of each injector b When an injector is replaced the injector s compensation code must be input into the ECM When the ECM is changed all of the existing injector compensation codes must be input into the new ECM see page 14 1 14 6 c If an incorrect injector compensation code is input into the ECM the engine assembly may ...

Page 103: ...c Pressure Sensor Common Rail Assy Pressure Control Valve Assy Engine Room R B and J B F EFI MAIN Relay F EFI Fuse Engine Coolant Temperature Sensor VRV Crankshaft Position Sensor Intake Shutter Assy R B No 3 F ST Relay Instrument Panel J B F GAUGE Fuse F STOP Fuse Glow Plug Relay Injector Common Rail Assy 05 2 DIAGNOSTICS ECD SYSTEM 1ND TV COROLLA Supplement RM1129E LOCATION BACK TO CHAPTER INDEX...

Page 104: ...inspect the DLC3 NEXT 4 CHECK DTC AND FREEZE FRAME DATA See page 05 33 HINT Record or print DTCs and freeze frame data if necessary NEXT 5 CLEAR DTC AND FREEZE FRAME DATA See page 05 33 NEXT 6 CONDUCT VISUAL INSPECTION NEXT 7 SET CHECK MODE DIAGNOSIS See page 05 34 NEXT 8 CONFIRM PROBLEM SYMPTOMS HINT If the engine does not start perform steps 10 and 12 first Result Proceed To Malfunction does not...

Page 105: ...C INSPECTION See page 05 8 Result Proceed To Malfunctioning parts not confirmed A Malfunctioning parts confirmed B B GO TO STEP 17 A 13 REFER TO PROBLEM SYMPTOMS TABLE See page 05 10 Result Proceed To Malfunctioning circuit confirmed A Malfunctioning parts confirmed B B GO TO STEP 17 A 14 CHECK ECM POWER SOURCE CIRCUIT See page 05 161 NEXT BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index...

Page 106: ...function confirmed B B GO TO STEP 18 A 16 CHECK FOR INTERMITTENT PROBLEMS See page 05 7 NEXT GO TO STEP 18 17 CONDUCT PARTS INSPECTION NEXT 18 IDENTIFY PROBLEM NEXT 19 ADJUST AND OR REPAIR NEXT 20 CONDUCT CONFIRMATION TEST NEXT END BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 107: ...em Occurs Weather Engine Operation Engine Temp Place Outdoor Temperature Constant Sometimes times per day month Once only Other Fine Cloudy Rainy Snowy Various Other Hot Warm Cool Highway Suburbs Inner city Uphill Downhill Rough road Other Cold Warming up Warmed up Any temp Other Starting Just after starting min Idling Revving up Driving Constant speed Acceleration Deceleration A C switch ON OFF O...

Page 108: ...ses 1 trip detection logic which is more sensitive to malfunctions than normal mode default that uses 2 trip detection logic a Clear DTCs see page 05 33 b Switch the ECM from normal mode to check mode using the intelligent tester II see page 05 34 c Perform a simulation test see page 01 22 d Check and wiggle the harness es connector s and terminal s see page 01 32 BACK TO CHAPTER INDEX TO MODEL IN...

Page 109: ...HECK BATTERY VOLTAGE NOTICE Carry out this check with the engine stopped and ignition switch OFF OK NG Voltage 11 V or more Less than 11 V NG CHARGE OR REPLACE BATTERY OK 2 CHECK IF ENGINE WILL CRANK NG PROCEED TO PROBLEM SYMPTOMS TABLE ON PAGE 05 10 OK 3 CHECK AIR FILTER a Visually check that the air filter is not excessively contaminated with dirt or oil NG CLEAN OR REPLACE OK 4 CHECK FUEL QUALI...

Page 110: ... 1 NG ADD OR REPLACE OK 9 CHECK ENGINE COOLANT See page 16 1 NG ADD OR REPLACE ENGINE COOLANT See page 16 7 OK 10 CHECK IDLING SPEED AND MAXIMUM SPEED See page 14 1 NG REPLACE INJECTION OR SUPPLY PUMP ASSY See page 11 16 OK 11 CHECK DIAGNOSTIC CIRCUIT NG REPAIR OR REPLACE OK 12 CHECK VACUUM PUMP NG REPAIR OR REPLACE VACUUM PUMP OK PROCEED TO PROBLEM SYMPTOMS TABLE See page 05 10 BACK TO CHAPTER IN...

Page 111: ...air temperature sensor 13 Crankshaft position sensor 14 Camshaft position sensor 15 Pressure control valve 05 166 11 8 11 25 14 1 10 15 11 16 11 20 10 9 19 12 10 2 10 2 10 2 10 2 11 5 Difficult to start with warm engine 1 STA signal circuit 2 Injector 3 Fuel filter 4 Compression 5 EC 6 Supply pump 7 Fuel pressure sensor 8 Intake shutter throttle valve 9 Low fuel tank level 10 Engine coolant temper...

Page 112: ...essure sensor 7 Pressure control valve 8 Engine coolant temperature sensor 9 Fuel temperature sensor 11 8 05 166 10 15 11 16 11 20 11 5 10 2 11 5 Low engine idling speed Poor idling 1 A C signal circuit 2 Injector 3 EGR system 4 Compression 5 Valve clearance 6 Fuel line Air bleeding 7 EC 8 Supply pump 9 Fuel pressure sensor 10 Intake shutter throttle valve 11 Pressure control valve 12 Engine coola...

Page 113: ...14 1 14 6 10 15 11 16 11 20 10 9 11 5 10 2 11 5 Hesitation Poor acceleration Poor driveability 1 Injector 2 Fuel filter 3 EGR system 4 Compression 5 EC 6 Supply pump 7 Fuel pressure sensor 8 Intake shutter throttle valve 9 Pressure control valve 10 Turbocharger 11 Manifold absolute pressure sensor 11 8 11 25 12 4 14 1 10 15 11 16 11 20 10 9 11 5 13 3 13 3 Knocking Poor driveability 1 Injector 2 EG...

Page 114: ... 7 Intake shutter throttle valve 8 Pressure control valve 12 4 11 8 11 25 10 15 11 16 11 20 10 9 11 5 Surging Hunting Poor driveability 1 Injector 2 EC 3 Supply pump 4 Fuel pressure sensor 5 Pressure control valve 6 Fuel filter 7 Vehicle speed sensor 8 Clutch switch 11 8 10 15 11 16 11 20 11 5 05 139 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANU...

Page 115: ... the tester ON f Clear DTC P0603 stored in the ECM using the tester see page 05 33 2 When you replace the ECM with a new one input all the injectors compensation codes into the new ECM as follows a Prior to replacing the ECM read and save each injector s compensation code stored in the original ECM using the intelligent tester II see page 05 14 b After installing a new ECM input the saved compensa...

Page 116: ...ster If compensation codes are already stored in tester Confirm to Overwrite Confirm to Save Save Option Dialog Continue Reading Saving Operation Save Error END Not read and save other compensation codes Read and save other compensation codes Proceed to Registration Procedure see page 05 19 DIAGNOSTICS ECD SYSTEM 1ND TV 05 15 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alpha...

Page 117: ...intelligent tester II to the DLC3 b Turn the ignition switch to ON c Turn the tester ON NOTICE Do not start the engine during this operation HINT An injector compensation code is imprinted on the head portion of each injector d Select the following menu items Enter Powertrain En gine and ECT Utility Injector Compensation e Press the Next button on the tester screen f Press the Next button again to...

Page 118: ...y fail due to a problem with the wire har ness or a bad connection with the DLC3 Check the wire har ness and the DLC3 connection If no problem is found with ei ther it is supposed that the ECM is malfunctioning Check the ECM and restart this operation k Check the injector compensation code in the form of a 10 digit alphanumeric code which is displayed on the tester screen l Press the Save button o...

Page 119: ...ists in the tester 1 Ascertain that the compensation code displayed on the tester screen is correct HINT The existing compensation code is overwritten with the new compensation code and deleted from the tester 2 Press the Replace button on the screen HINT The saving process may fail due to a problem with the wire har ness or a bad connection with the DLC3 Check the wire har ness and the DLC3 conne...

Page 120: ...ensation code stored in the original ECM using the intelligent tester II see page 05 14 b After installing a new ECM input the saved compensation codes into the new ECM using the tester see page 05 19 c Turn the tester OFF and then turn the ignition switch to OFF d Wait for at least 30 seconds e Turn the ignition switch to ON and then turn the tester ON f Clear DTC P0603 stored in the ECM using th...

Page 121: ...ot stored in tester Confirm Compensation Code Register Compensation Code Registration Error Option Dialog Continue Registration Not continue with other compensation code registrations Continue with registrations for other cylinders END When registering compensation codes by manual input Injector replacement etc When registering compensation codes that are already stored in intelligent tester ll EC...

Page 122: ...tester ON NOTICE Do not start the engine during this operation HINT An injector compensation code is imprinted on the head portion of each injector d Select the following menu items Enter Powertrain En gine and ECT Utility Injector Compensation e Press the Next button on the tester screen f Press the Next button again to proceed BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Ind...

Page 123: ... the cylinder corresponding to the in jector compensation code that you want to read j Press the Next button k If a new injector s was were installed the injector com pensation code for the selected cylinder does not exist in the tester 1 Press the Input button on the screen BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 124: ...ected on the tester 3 Check the compensation code is correct for the se lected cylinder and then press the OK button on the screen proceed to step m l If a new ECM was installed and all the injectors com pensation codes have been saved in the tester 1 Press the Open button on the screen 2 Press the Open button again to retrieve the saved compensation code HINT If the retrieving process fails a man...

Page 125: ...he ECM and re start this operation n Press the Next button on the screen to set the compensa tion code to the ECM HINT S If the setting process fails the compensation code may be incorrect Ascertain the compensation code again S If the attempted compensation code is correct a problem with the wire harness or a bad connection with the DLC3 may cause the failure Check the wire harness and the DLC3 c...

Page 126: ... to 15 GREL E24 81 E1 E24 2 G R W B Glow plug relay Idling at warmed engine 0 to 1 5 VPA1 E24 15 EVPA1 E24 54 G Y 1 Y L 2 Accelerator pedal position sensor for engine con trol Ignition switch ON accelerator ped al fully released 0 5 to 1 1 VPA1 E24 15 EVPA1 E24 54 G Y 1 Y L 2 Accelerator pedal position sensor for engine con trol Ignition switch ON accelerator ped al fully depressed 3 0 to 4 6 VPA2...

Page 127: ... W Fuel temperature sensor Idling 0 5 to 3 4 THW E23 40 ETHW E23 29 B W L Engine coolant tempera ture sensor Idling engine coolant temperature at 80 C 176 F 0 2 to 1 0 ALT E23 5 E1 E24 2 B R W B 3 B L W B 4 5 Generator alternator duty ratio Idling Pulse generation LUSL E23 13 E1 E24 2 B W W B Intake shutter duty signal Racing engine Pulse generation See waveform 4 PRV E23 4 E1 E24 2 W W B Pressure...

Page 128: ...m com bination meter Ignition switch ON rotate driving wheel slowly Pulse generation See waveform 7 STA E24 9 E1 E24 2 SB B W 4 W B SB B R 3 5 W B Starter signal Cranking 6 0 or more CE E24 79 E1 E24 2 W R Y W B MIL MIL illuminated 0 to 3 CE E24 79 E1 E24 2 W R Y W B MIL MIL not illuminated 9 to 15 GIND E24 19 E1 E24 2 W R W B Glow lamp Glow lamp illuminated 0 to 3 GIND E24 19 E1 E24 2 W R W B Glo...

Page 129: ...oses and the waveform may disappear WAVEFORM 4 Intake shutter signal ECM Terminal Name Between LUSL and E1 Tester Range 5 V Division 2 msec Division Condition Idling with warm engine HINT The waveform varies depending on the intake shutter opera tion WAVEFORM 5 Pressure regulator valve signal ECM Terminal Name Between PRV and E1 Tester Range 10 V Division 0 5 msec Division Condition Idling with wa...

Page 130: ...ehicle speed signal ECM Terminal Name Between SPD and E1 Tester Range 1 V Division 10 msec Division Condition Rotate driving wheel HINT The wavelength becomes shorter as the vehicle speed in creases BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 131: ...ed by ISO 15031 4 are recorded in the ECM memory If the malfunction does not recur in 3 consecutive trips the MIL turns off automatically but the DTCs remain recorded in the ECM memory To check the DTCs connect an intelligent tester II to the DLC3 The tester displays DTCs freeze frame data and variety of en gine data The DTCs and freeze frame data can be erased with the tester refer to DTC CHECK C...

Page 132: ... 4 Chassis ground Body ground 1 Ω or less Always SG 5 Signal ground Body ground 1 Ω or less Always BAT 16 Battery positive Body ground 9 to 14 V Always HINT The DLC3 is the interface prepared for reading various data from the vehicle s ECM After connecting the cable of an intelli gent tester ll turn the ignition switch to ON and turn the tester on If a communication failure message NO INFORMATION ...

Page 133: ...not running HINT If the MIL is not illuminated check the MIL circuit refer to MIL CIRCUIT on page 05 169 b The MIL should turn off when the engine is started If the MIL remains illuminated the diagnosis system has de tected a malfunction or abnormality in the system BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 134: ...rite them down e See page 05 41 to confirm the details of the DTCs 2 CLEAR DTCS AND FREEZE FRAME DATA using the intelligent tester II a Connect the intelligent tester II to the DLC3 b Turn the ignition switch to ON do not start the engine and turn the tester ON c Select the following menu items Powertrain Engine and ECT DTC Clear d Erase DTCs and freeze frame data by pressing the yes button on the...

Page 135: ...DTCs and freeze frame data CHECK MODE PROCEDURE a Make sure that the vehicle is in the following condition 1 Battery voltage 11 V or more 2 Throttle valve fully closed 3 Transmission in the neutral position 4 A C switched OFF b Turn the ignition switch to OFF where ON c Connect an intelligent tester II to the DLC3 d Turn the ignition switch to ON and turn the tester ON e Select the following menu ...

Page 136: ...Low Input Limits engine power Ignition switch OFF P0123 05 77 Throttle Pedal Position Sensor Switch A Circuit High Input Limits engine power Ignition switch OFF P0182 05 80 Fuel Temperature Sensor A Circuit Low Input P0183 05 80 Fuel Temperature Sensor A Circuit High Input P0190 05 83 Fuel Rail Pressure Sensor Circuit Limits engine power Ignition switch OFF P0191 05 86 Fuel Rail Pressure Sensor Ci...

Page 137: ...P0500 05 124 Vehicle Speed Sensor A P0603 05 127 Internal Control Module Keep Alive Memory KAN Error P0605 05 51 Internal Control Module Read Only Memory ROM Error Stalls engine or limits engine power Ignition switch OFF P0642 05 128 Sensor Reference Voltage A Circuit Low Limits engine power S Accelerator position sensor is fixed at 0 Ignition switch OFF P0643 05 128 Sensor Reference Voltage A Cir...

Page 138: ...e or limits engine power Ignition switch OFF P1271 05 52 Fuel Regulator Circuit Malfunction EDU Drive Stalls engine Ignition switch OFF P1272 05 153 Fuel Pressure Regulator Malfunction Stalls engine or limits engine power Ignition switch OFF P1520 05 153 Stop Light Switch Circuit Malfunction P1600 05 157 ECM BATT Malfunction P1633 05 51 ECM Malfunction ETCs Circuit Stalls engine Ignition switch OF...

Page 139: ...m s S MAF meter power source circuit open S VG circuit open or shorted If valve 135 gm s or more S E2G circuit open PIM PIM Absolute pressure inside intake manifold Min 0 kPa Max 255 kPa S 85 to 110 kPa Idling S 90 to 115 kPa Engine running at 2 000 rpm Coolant Temp COOLANT TEMP Engine coolant temperature Min 40_C Max 215_C 80 to 95 C 176 to 203 F After warming up engine If value 40_C or 140_C sen...

Page 140: ...epressed S OFF Brake pedal released Starter SIG STARTER SIG Starter signal ON or OFF ON Cranking Check Mode CHECK MODE Check mode ON or OFF ON Check mode ON EGR Step POS EGR STEP POS EGR step position status Min 0 step Max 125 step 45 to 65 step Idling Electrical Load Signal ELECT LOAD SIG Electrical load signal ON or OFF ON Deffoger switch ON Clutch Upper Switch CLUTCH UPPER SW Clutch switch ON o...

Page 141: ...ing table Intelligent Tester II Display Abbreviation Test Details Control Range Diagnostic Notes Fuel leak test FUEL LEAK TEST Pressurize common rail internal fuel pressure in order to see if fuel leaks ON OFF S Fuel pressure inside common rail pressurized to 135 MPa and en gine speed increased to 2 000 rpm when ON selected S Above conditions preserved while test ON Injector cut 1 INJECTOR CUT 1 C...

Page 142: ...ion in mass air flow meter S ECM f f P0101 05 61 Mass or Volume Air Flow Circuit Range Performance Problem S Open or short in mass air flow meter circuit S Mass air flow meter S Contamination in mass air flow meter S EGR valve assembly S Open or short in EGR circuit S EGR passage S Open or short in intake shutter control motor circuit S Intake shutter S Vacuum hose S ECM f f P0110 05 64 Intake Air...

Page 143: ...ctor circuit cylinder No 2 S Injector cylinder No 2 S ECM f f P0203 05 87 Injector Circuit Open Cylin der 3 S Open or short in injector circuit cylinder No 3 S Injector cylinder No 3 S ECM f f P0204 05 87 Injector Circuit Open Cylin der 4 S Open or short in injector circuit cylinder No 4 S Injector cylinder No 4 S ECM f f P0234 05 91 Turbo Super Charger Overboost Condition S VRV Vacuum Regulating ...

Page 144: ...103 Cylinder 3 Contribution Balance Main Trouble Area S Injector S Open or short in engine wire harness S Connector connection S Compression pressure S Valve clearance Related Trouble Area S Valve timing S ECM S Low quality fuel S Injector compensation code f f P0272 05 103 Cylinder 4 Contribution Balance Main Trouble Area S Injector S Open or short in engine wire harness S Connector connection S ...

Page 145: ... Exhaust Gas Recirculation Throttle Position Control Circuit S Open or short in intake shutter circuit S ECM f f P0488 05 73 Exhaust Gas Recirculation Throttle Position Control Range Performance S Intake shutter stuck S Intake shutter does not move smoothly S Open or short in intake shutter circuit S Open or short in intake shutter position sensor circuit S Intake shutter position sensor built in ...

Page 146: ...Position Sen sor Circuit Malfunction S Open or short in accelerator pedal position sensor circuit S Accelerator pedal position sensor S ECM f f P1121 05 145 Accelerator Pedal Position Sen sor Range Performance Problem S Accelerator pedal position sensor f f P1228 05 100 Injection Pump Fuel Metering Control A Range Performance Cam Rotor Injector S Open or short in fuel metering unit circuit S Fuel ...

Page 147: ...ery is fitted DTC P1600 is output S ECM f f P1633 05 51 ECM Malfunction ETCS Circuit S ECM f f P2146 05 87 Fuel Injector Group A Supply Voltage Circuit Open S Open or short in injector circuit S Injector S ECM f f P2227 05 160 Barometric Pressure Circuit Range Performance S ECM f f f MIL Malfunction Indicator Lamp illuminates MIL does not illuminate BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabet...

Page 148: ... revolutions or more S This DTC shows that the camshaft has been installed toward the crankshaft at an incorrect angle for example due to a jumped tooth of the timing chain WIRING DIAGRAM Refer to DTCs P0335 on page 05 107 and DTC P0340 on page 05 111 INSPECTION PROCEDURE HINT Read freeze frame data using an intelligent tester ll Freeze frame data record the engine condition when malfunctions are ...

Page 149: ...MING GEAR ASSY See page 14 45 OK 4 CHECK CRANKSHAFT POSITION SENSOR PLATE TEETH OF SENSOR PLATE CRANCSHAFT TIMING GEAR a Check the tooth of the sensor plate OK No deformation on the tooth of the sensor plate NG REPLACE CRANKSHAFT POSITION SENSOR PLATE CRANKSHAFT TIMING GEAR See page 14 45 OK REPLACE ECM See page 10 15 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA C...

Page 150: ... the flow rate and pressure of the exhaust gas that is input to the turbocharger DTC No DTC Detection Condition Trouble Areas P0045 Open or short in VRV circuit for 3 0 seconds or more The MIL is illuminated as well as a DTC being set immediately malfunction is detected S VRV Vacuum Regulating Valve itself S Open or short in VRV circuit S ECM HINT DTC P0045 is set when the ignition switch is in th...

Page 151: ...nector b Disconnect the E23 ECM connector c Remove the EFI MAIN relay from the engine room R B d Check the resistance Standard Check for open Tester Connection Specified Condition VNT E23 33 V2 2 Below 1 Ω EFI MAIN relay 3 V2 1 Below 1 Ω Standard Check for short Tester Connection Specified Condition VNT E23 33 or V2 2 Body ground 10 kΩ or higher EFI MAIN relay 3 or V2 1 Body ground 10 kΩ or higher...

Page 152: ...ndition Trouble Area P0046 ECM internal error P0046 P0605 ECM internal error The MIL is illuminated as well as a DTC being set immediately S ECM P0605 P1633 The MIL is illuminated as well as a DTC being set immediately malfunction is detected S ECM HINT These DTCs are set when the ignition switch is in the ON position INSPECTION PROCEDURE REPLACE ECM See page 10 15 05CPY 13 BACK TO CHAPTER INDEX T...

Page 153: ...rouble Areas P0089 S Open or short in pressure control valve circuit DTC P1271 set simultaneously The MIL is illuminated as well as a DTC being set immediately malfunction is detected S ECM internal error DTC P1271 not set The MIL is illuminated as well as a DTC being set immediately malfunction is detected S Open or short in pressure control valve circuit S Open or short in pressure control valve...

Page 154: ...ter ll to the DLC3 b Turn the ignition switch to ON and turn the intelligent tester ll ON c Select the following menu items Powertrain Engine and ECT DTC d Read DTCs Result Display DTC Output Proceed To P1271 or P0089 and P1271 A Only P0089 B B REPLACE ECM See page 10 15 A 2 INSPECT COMMON RAIL ASSY PRESSURE CONTROL VALVE ASSY a Disconnect the V9 pressure control valve connector b Measure the resi...

Page 155: ...rom the engine room R B d Check the resistance Standard Check for open Tester Connection Specified Condition PRV E23 4 V9 1 Below 1 Ω EFI MAIN relay 3 V9 2 Below 1 Ω Standard Check for short Tester Connection Specified Condition PRV E23 4 or V9 1 Body ground 10 kΩ or higher EFI MAIN relay 3 or V9 2 Body ground 10 kΩ or higher e Reconnect the pressure control valve connector f Reconnect the ECM con...

Page 156: ...meter The voltage level is pro portional to the flow of the air passing through the sensor The ECM interprets this voltage as the intake air amount The circuit is constructed so that the platinum hot wire and temperature sensor provide a bridge circuit and the power transistor is controlled so that the potential of A and B remains equal to maintain the predeter mined temperature HINT When the mass...

Page 157: ...Air Flow Value g second Malfunction Always approximately 0 3 or less S Open in mass air flow meter power source circuit S Open or short in VG circuit Always 110 0 or more S Open in EVG circuit WIRING DIAGRAM INSPECTION PROCEDURE HINT Read freeze frame data using an intelligent tester ll Freeze frame data record the engine condition when malfunctions are detected When troubleshooting freeze frame d...

Page 158: ...anged when the throttle valve is open or closed B Go to step 7 C CHECK FOR INTERMITTENT PROBLEMS See page 05 7 A 2 INSPECT MASS AIR FLOW METER VISUAL INSPECTION OK The sensor area of the mass air flow meter has not been contaminated NG REPLACE MASS AIR FLOW METER OK 3 INSPECT MASS AIR FLOW METER POWER SOURCE a Disconnect the A8 mass air flow meter connector b Turn the ignition switch to ON c Measu...

Page 159: ...e Reinstall the mass air flow meter NG REPLACE MASS AIR FLOW METER OK 5 CHECK HARNESS AND CONNECTOR MASS AIR FLOW METER ECM a Disconnect the A8 mass air flow meter connector b Disconnect the E23 ECM connector c Check the resistance Standard Check for open Tester Connection Specified Condition VG A8 3 VG E23 36 Below 1 Ω E2G A8 2 EVG E23 15 Below 1 Ω Standard Check for short Tester Connection Speci...

Page 160: ...ndition B A8 1 or EFI relay 3 Body ground 10 kΩ or higher d Reconnect the mass air flow meter connector e Reinstall the EFI relay NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK INSPECT ECM POWER SOURCE CIRCUIT See page 05 161 7 INSPECT MASS AIR FLOW METER VISUAL INSPECTION OK The sensor area of the mass air flow meter has not been contaminated NG REPLACE MASS AIR FLOW METER OK 8 CHECK HARNESS AND CO...

Page 161: ...nto the mass air flow meter OK The voltage fluctuates e Reinstall the mass air flow meter NG REPLACE MASS AIR FLOW METER OK REPLACE ECM See page 10 15 10 CHECK HARNESS AND CONNECTOR MASS AIR FLOW METER ECM a Disconnect the A8 mass air flow meter connector b Disconnect the E23 ECM connector c Check the resistance Standard Check for open Tester Connection Specified Condition E2G A8 2 EVG E23 15 Belo...

Page 162: ...eter S EGR valve assembly S Open or short in EGR circuit S EGR passage S Open or short in intake shutter control motor circuit S Intake shutter S Vacuum hose S ECM HINT This DTC is set in either of the following conditions S When the ignition switch is turned from OFF to ON S When the vehicle decelerates while driving INSPECTION PROCEDURE HINT Read freeze frame data using an intelligent tester ll ...

Page 163: ...OW METER OK 4 INSPECT MASS AIR FLOW METER a Remove the mass air flow meter b Apply battery voltage across terminals 1 B and 2 E2G c Using a voltmeter connect the positive tester probe to terminal 3 VG and negative tester probe to terminal 2 E2G d Blow air into the mass air flow meter OK The voltage fluctuates e Reinstall the mass air flow meter NG REPLACE MASS AIR FLOW METER OK 5 CHECK CHECK INTAK...

Page 164: ...HUTTER ASSY See page 10 2 B REPLACE INTAKE SHUTTER ASSY See page 10 9 A 7 CHECK EGR VALVE See page 12 4 NG REPLACE EGR VALVE See page 14 26 OK REPLACE MASS AIR FLOW METER BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 165: ...ve the driveability during cold engine operation HINT When the IAT sensor output is outside the normal range the ECM determines this as a malfunction DTC No DTC Detecting Condition Trouble Area P0110 Condition a or b continues for 2 0 seconds or more a IAT sensor output is less than 40 C 40 F The MIL is illuminated and a DTC is set when the same mal function is detected on 2 consecutive trips One ...

Page 166: ...rom the time the malfunction occurred 1 READ VALUE USING INTELLIGENT TESTER II INTAKE AIR TEMPERATURE a Connect an intelligent tester ll to the DLC3 b Turn the ignition switch to ON and turn the intelligent tester ll ON c Select the following menu items Powertrain Engine and ECT Data List Intake Air d Read the value OK Temperature value Same as the actual intake air temperature Result Temperature ...

Page 167: ...he intelligent tes ter ll ON e Select the following menu items Powertrain Engine and ECT Data List Intake Air f Read the value Standard Temperature value 135 C 275 F or more g Reconnect the mass air flow meter connector OK CONFIRM GOOD CONNECTION AT SENSOR IF OK REPLACE MASS AIR FLOW METER NG 3 CHECK HARNESS AND CONNECTOR MASS AIR FLOW METER ECM a Disconnect the A8 mass air flow meter connector b ...

Page 168: ...d Temperature value Less than 40 C 40 F f Reconnect the mass air flow meter connector OK REPLACE MASS AIR FLOW METER NG 5 READ VALUE USING INTELLIGENT TESTER II CHECK FOR SHORT IN ECM a Disconnect the E23 ECM connector b Disconnect the A8 mass air flow meter connector c Turn the ignition switch to ON and turn the intelligent tes ter ll ON d Select the following menu items Powertrain Engine and ECT...

Page 169: ...olant temperature is less than 35 C 95 F at engine start engine coolant temperature change for 240 se conds is less than 1 C 34 F on while engine coolant tem perature sensor vehicle is highly loaded The MIL is illuminated and a DTC is set when the same mal function is detected on 2 consecutive trips One trip is counted when the ignition switch is turned from OFF to ON and back to OFF S When engine...

Page 170: ...s are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not and other data from the time the malfunction occurred 1 READ OUTPUT DTCS DTC P0115 AND OR P0116 a Connect an intelligent tester ll to the DLC3 b Turn the ignition switch to ON and turn the intelligent tester ll ON c Select the following menu items Powe...

Page 171: ...l indicates less than 40 C 40 F S If there is a short circuit the intelligent tester ll indicates more than 140 C 284 F B Go to step 5 C CHECK FOR INTERMITTENT PROBLEMS See page 05 7 A 3 READ VALUE USING INTELLIGENT TESTER II CHECK FOR OPEN IN WIRE HARNESS a Disconnect the E22 engine coolant temperature sensor connector b Connect terminals 1 and 2 of the engine coolant tempera ture sensor wire har...

Page 172: ...engine coolant temperature sensor con nector e Reconnect the ECM connector NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM See page 10 15 5 READ VALUE USING INTELLIGENT TESTER II CHECK FOR SHORT IN WIRE HARNESS a Disconnect the E22 engine coolant temperature sensor connector b Turn the ignition switch to ON and turn the intelligent tes ter ll ON c Select the following menu items Powertrai...

Page 173: ... intelligent tester ll to the DLC3 d Turn the ignition switch to ON and turn the intelligent tes ter ll ON e Select the following menu items Powertrain Engine and ECT Data List Coolant Temp f Read the value Standard Temperature value Less than 40 C 40 F g Reconnect the engine coolant temperature sensor con nector h Reconnect the ECM connector OK REPAIR OR REPLACE HARNESS OR CONNECTOR NG REPLACE EC...

Page 174: ...itch is next turned to ON S Intake shutter stuck S Intake shutter does not move smoothly S Open or short in intake shutter circuit S Open or short in intake shutter position sensor circuit S Intake shutter position sensor built in intake shutter valve S ECM P0487 Open or short in intake shutter circuit The MIL is illuminated as well as a DTC being set immediately malfunction is detected S Open or ...

Page 175: ...B 1 2 Instrument Panel J B B R W II 05 74 DIAGNOSTICS ECD SYSTEM 1ND TV COROLLA Supplement RM1129E WIRING DIAGRAM INSPECTION PROCEDURE HINT Read freeze frame data using an intelligent tester ll Freeze frame data record the engine condition when malfunctions are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or ...

Page 176: ...lay DTC output Proceed to P0121 P0487 and or P0488 A P0121 P0487 and or P0488 and P0122 and or P0123 B B GO TO RELEVANT DTC CHART See page 05 41 A 2 INSPECT INTAKE SHUTTER ASSY a Disconnect the I10 intake shutter connector b Measure the resistance between the terminals of the in take shutter Standard Tester Connection Specified Condition DUTY 1 E 3 0 3 to 100 Ω at 20_C 68_F c Reconnect the intake ...

Page 177: ...ector c Check the resistance Standard Check for open Tester Connection Specified Condition LUSL E23 13 DUTY I10 1 Below 1 Ω Standard Check for short Tester Connection Specified Condition LUSL E23 13 or DUTY I10 1 Body ground 10 kΩ or higher d Reconnect the intake shutter connector e Reconnect the ECM connector NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INTAKE SHUTTER ASSY See page 10 9 B...

Page 178: ...pening angle of the intake shutter This sensor is electronically controlled and uses Hall effect elements DTC No DTC Detection Condition Trouble Area P0122 Intake shutter position sensor output VLU is less than 0 2 V The MIL is illuminated as well as a DTC being set immediately malfunction is detected S Intake shutter position sensor S Open or short in VLU circuit S Open in VC circuit S ECM P0123 ...

Page 179: ... and other data from the time the malfunction oc curred 1 CHECK HARNESS AND CONNECTOR INTAKE SHUTTER THROTTLE VALVE POSITION SENSOR ECM a Disconnect the T14 intake shutter position sensor con nector b Disconnect the E23 ECM connectors c Check the resistance Standard Check for open Tester Connection Specified Condition VVLU E23 24 VC T14 1 VLU E23 35 VTA T14 3 Below 1 Ω ELU E23 14 E2 T14 2 Standard...

Page 180: ...e page 10 9 GO 4 CHECK IF DTC OUTPUT RECURS DTC P0122 AND OR P0123 a Connect the intelligent tester ll to the DLC3 b Turn the ignition switch to ON and turn the intelligent tester ll ON c Select the following menu items Powertrain Engine and ECT DTC Clear d Clear DTCs e Let the engine idle for 60 seconds and repeat quick engine RPM accelerations to 2 500 rpm for 30 seconds f Select the following m...

Page 181: ...n the resistance value of the fuel temperature sensor changes in ac cordance with the fuel temperature the voltage at terminal THF also changes Based on this signal the ECM corrects the pres sure control compensation of the supply pump and errors HINT When the fuel temperature sensor output isoutside the normal range the ECM determines this as a malfunc tion DTC No DTC Detection Condition Trouble ...

Page 182: ...ester ll Freeze frame data record the engine condition when malfunctions are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not and other data from the time the malfunction occurred 1 INSPECT FUEL TEMPERATURE SENSOR See page 11 5 OK The fuel temperature sensor resistance is within the standard range NG REPLA...

Page 183: ... fuel temperature sensor connector b Disconnect the E23 ECM connector c Check the resistance Standard Check for open Tester Connection Specified Condition THF E23 39 F20 1 Below 1 Ω d Reconnect the fuel temperature sensor connector e Reconnect the ECM connector NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM See page 10 15 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub ...

Page 184: ... Condition Trouble Areas P0190 Fuel pressure sensor output voltage 0 2 V or less or 4 8 V or more for 0 5 seconds The MIL is illuminated as well as a DTC being set when a malfunction is detected S Open or short in fuel pressure sensor circuit S Fuel pressure sensor S ECM HINT S DTC P0190 is set when the engine idles for approximately 15 seconds S When DTC P0190 is set check the internal fuel press...

Page 185: ...e and ECT Data List Common Rail Pressure d Check that the internal fuel pressure of the common rail is within the specification below Standard Engine Speed Fuel Pressure MPa Idling Approximately 25 to 36 2 000 rpm No engine load Approximately 27 to 46 3 000 rpm No engine load Approximately 34 to 69 NG Go to step 3 OK 2 CHECK IF DTC OUTPUT RECURS FUEL PRESSURE SENSOR DTCS a Connect the intelligent ...

Page 186: ...er Connection Specified Condition PC E23 37 F19 2 VPC E23 26 F19 3 Below 1 Ω EPC E23 16 F19 1 Standard Check for short Tester Connection Specified Condition PC E23 37 or F19 2 Body ground VPC E23 26 or F19 3 Body ground 10 kΩ or higher EPC E23 16 or F19 1 Body ground g d Reconnect the ECM connector e Reconnect the fuel pressure sensor connector NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ...

Page 187: ... the engine idles for 30 seconds after the ignition switch was turned to OFF WIRING DIAGRAM Refer to DTC P0089 on page 05 52 and DTC P0190 on page 05 83 INSPECTION PROCEDURE HINT Read freeze frame data using an intelligent tester ll Freeze frame data record the engine condition when malfunctions are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or sta...

Page 188: ...injector circuit cylinder No 3 for 0 5 seconds or more The MIL is illuminated as well as a DTC being set immediately malfunction is detected S Open or short in injector circuit cylinder No 3 S Injector cylinder No 3 S ECM P0204 Open or short in injector circuit cylinder No 4 for 0 5 seconds or more The MIL is illuminated as well as a DTC being set immediately malfunction is detected S Open or shor...

Page 189: ... ECD SYSTEM 1ND TV COROLLA Supplement RM1129E WIRING DIAGRAM INSPECTION PROCEDURE HINT Read freeze frame data using an intelligent tester ll Freeze frame data record the engine condition when malfunctions are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not and other data from the time the malfunction oc c...

Page 190: ...d ECT DTC d Read DTCs Result Display DTC Output Proceed To P0201 P0202 P0203 and or P0204 and P2146 A Only P2146 B B REPLACE ECM See page 10 15 A 2 INSPECT FUEL INJECTOR ASSY a Disconnect the I5 I6 I7 and or I8 injector connector b Measure the resistance between the terminals of the in jector assy Standard 0 215 to 0 295 Ω at 20_C 68_F c Reconnect the injector connector NG REPLACE FUEL INJECTOR AS...

Page 191: ... 1 Below 1 Ω PINJ3 E23 3 I7 1 Below 1 Ω PINJ4 E23 20 I8 1 Below 1 Ω Standard Check for short Tester Connection Specified Condition 10 E23or21 or I5 2 Body ground 10 kΩ or higher 20 E23 30 or I6 2 Body ground 10 kΩ or higher 30 E23 31 or I7 2 Body ground 10 kΩ or higher 40 E23 32 or I8 2 Body ground 10 kΩ or higher PINJ1 E23 1 or I5 1 Body ground 10 kΩ or higher PINJ2 E23 2 or I6 1 Body ground 10 k...

Page 192: ...hutter S Manifold absolute pressure sensor S Vacuum hose S ECM HINT These DTCs are set while steady speed driving with a highly engine load at an engine speed of 3 000 rpm or more WIRING DIAGRAM Refer to DTC P0045 on page 05 49 INSPECTION PROCEDURE HINT Read freeze frame data using an intelligent tester ll Freeze frame data record the engine condition when malfunctions are detected When troublesho...

Page 193: ...b Warm up the engine coolant temperature to more than 75 C 167 F c Check the vacuum at the engine speed of idling Result Vacuum Proceed To 0 kPa 0 mmHg 0 in Hg to 50 kPa 375 mmHg 14 8 in Hg A Above 50 kPa 375 mmHg 14 8 in Hg B B Go to step 7 A 4 INSPECT VACUUM REGULATING VALVE ASSY OPERATION See page 13 5 OK The VRV operates normally NG REPLACE VACUUM REGULATING VALVE See page 11 8 OK 5 INSPECT VA...

Page 194: ... R B d Check the resistance Standard Check for open Tester Connection Specified Condition VNT E23 33 V2 2 Below 1 Ω EFI MAIN relay 3 V2 1 Below 1 Ω Standard Check for short Tester Connection Specified Condition VNT E23 33 or V2 2 Body ground 10 kΩ or higher EFI MAIN relay 3 or V2 1 Body ground 10 kΩ or higher e Reconnect the VRV connector f Reconnect the ECM connector g Reinstall the EFI MAIN rela...

Page 195: ...Standard Tester Connection Specified Condition DUTY 1 E 3 0 3 to 100 Ω at 20_C 68_F c Reconnect the intake shutter connector NG REPLACE INTAKE SHUTTER ASSY See page 10 9 OK 9 CHECK HARNESS AND CONNECTOR INTAKE SHUTTER ECM a Disconnect the I10 intake shutter connector b Disconnect the E23 ECM connector c Check the resistance between the wire harness side con nectors Standard Check for open Tester C...

Page 196: ... AND CONNECTOR EGR VALVE ASSY ECM a Disconnect the E21 EGR valve connector b Disconnect the E24 ECM connector c Check the resistance Standard Check for open Tester Connection Specified Condition EGR1 E24 12 E21 4 Below 1 Ω EGR2 E24 11 E21 1 Below 1 Ω EGR3 E24 31 E21 6 Below 1 Ω EGR4 E24 30 E21 3 Below 1 Ω Standard Check for short Tester Connection Specified Condition EGR1 E24 12 or E21 4 Body grou...

Page 197: ...ody ground Correct waveform shown E21 5 Body ground Correct waveform shown E21 4 Body ground Correct waveform shown E21 3 Body ground Correct waveform shown d Reconnect the EGR valve connector NG REPLACE ECM See page 10 15 OK 13 CHECK FOR DEPOSIT EGR VALVE ASSY OK No deposit NG REMOVE FOREIGN OBJECT AND CLEAN EGR VALVE OK 14 CHECK FOR DEPOSIT EGR PSSAGE OK No deposit NG REPAIR OR REPLACE MALFUNCTI...

Page 198: ... sensor circuit S Manifold absolute pressure sensor S ECM P0237 P0238 Open or short in manifold absolute pressure sensor circuit for 2 seconds or more The MIL is illuminated as well as a DTC being set immediately malfunction is detected S Open or short in manifold absolute pressure sensor circuit S Manifold absolute pressure sensor S ECM HINT S DTC P0236 is set while idling for 10 seconds or more ...

Page 199: ...ne condition when malfunctions are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not and other data from the time the malfunction occurred 1 READ VALUE USING INTELLIGENT TESTER II MANIFOLD ABSOLUTE PRESSURE a Connect the intelligent tester ll to the DLC3 b Turn the ignition switch to ON and turn the intelli...

Page 200: ...nection Specified Condition PIM T3 2 or PIM E23 38 Body ground VC T3 3 or VPIM E23 27 Body ground 10 kΩ higher E2 T3 1 or EPIM E23 17 Body ground g d Reconnect the manifold absolute pressure sensor con nector e Reconnect the ECM connector NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR See page 16 12 GO 4 CHECK IF DTC OUTPUT RECURS DTC P0236 HINT After clea...

Page 201: ...unit circuit S Fuel metering unit S ECM P1228 Open or short in fuel metering unit circuit for more than 0 5 seconds The MIL is illuminated as well as a DTC being set immediately malfunction is detected S Open or short in fuel metering unit circuit S Fuel metering unit S ECM HINT S These DTCs are set when the engine idles for approximately 60 seconds S When DTC P0252 and or P1228 is set check the i...

Page 202: ...re detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not and other data from the time the malfunction oc curred 1 READ OUTPUT DTCS DTC P0252 AND OR P1228 a Connect an intelligent tester ll to the DLC3 b Turn the ignition switch to ON and turn the intelligent tester ll ON c Select the following menu items Powert...

Page 203: ...E INJECTION OR SUPPLY PUMP ASSY FUEL METERING UNIT See page 11 16 OK 3 CHECK HARNESS AND CONNECTOR FUEL METERING UNIT ECM a Disconnect the M6 fuel metering unit connector b Disconnect the E23 ECM connector c Check the resistance Standard Check for open Tester Connection Specified Condition PCV E23 12 M6 2 Below 1 Ω Standard Check for short Tester Connection Specified Condition PCV E23 12 or M6 2 B...

Page 204: ...ue for Revised Injection Volume 1 2 3 and 4 that varies from other cylinders may be malfunctioning S If only DTCs P0263 P0266 P0269 P0272 and or P0300 are present an injector mechanical malfunc tion valve clearance etc or insufficient compression has probably occurred An open or short malfunc tion of the ECM or injector circuit is unlikely DTC No DTC Detection Condition Main Trouble Area Related T...

Page 205: ...igent tester ll ON c Select the following menu items Powertrain Engine and ECT DTC Result Display DTC Output Proceed To P0263 P0266 P0269 P0272 and or P0300 A P0263 P0266 P0269 P0272 and or P0300 and other DTCs B HINT If any DTCs other than P0263 P0266 P0269 P0272 and or P0300 are output troubleshoot those DTCs first B GO TO RELEVANT DTC CHART See page 05 41 A 2 CHECK INJECTOR COMPENSATION CODE Se...

Page 206: ...y cylinder not identified A Faulty cylinder identified B B Go to step 6 A 5 PERFORM ACTIVE TEST USING INTELLIGENT TESTER II INJECTION CUT FOR IDENTIFYING MALFUNCTIONING CYLINDER a Connect the intelligent tester ll to the DLC3 b Start the engine and turn the intelligent tester ll ON c Select the following menu items Powertrain Engine and ECT Active Test Injector cut 1 2 3 and 4 d Check the four cyl...

Page 207: ...s after warming up and then confirm that DTC P0263 P0266 P0269 P0272 and or P0300 is not present again OK No DTC output OK CHECK FOR INTERMITTENT PROBLEMS See page 05 7 NG 9 REPLACE INJECTOR ASSY See page 11 8 GO CHECK IF DTC OUTPUT RECURS DTC P0263 P0266 P0269 P0272 AND OR P0300 HINT After clearing the DTC let the engine idle for 10 minutes after warming up and then confirm that DTC P0263 P0266 P...

Page 208: ...lculations the common rail system is controlled DTC No DTC Detection Condition Trouble Area P0335 No crankshaft position sensor signal to ECM while cranking The MIL is illuminated as well as a DTC being set immediately malfunction is detected S Open or short in crankshaft position sensor circuit S Crankshaft position sensor S Crankshaft position sensor plate S ECM HINT DTC P0335 is detected when t...

Page 209: ...tart the engine and turn the intelligent tester II ON c Select the following menu items Powertrain Engine and ECT Data List Engine SPD S The engine speed can be confirmed in the Data List using the intelligent tester II If there are no NE signals from the crankshaft position sensor despite the engine revolving the engine speed will be indi cated as zero If the voltage output of the crankshaft posi...

Page 210: ...ft position sensor connector NG REPLACE CRANKSHAFT POSITION SENSOR See page 10 13 OK 2 CHECK HARNESS AND CONNECTOR CRANKSHAFT POSITION SENSOR ECM a Disconnect the C4 crankshaft position sensor connector b Disconnect the E23 ECM connector c Check the resistance Standard Check for open Tester Connection Specified Condition Crankshaft position sensor C4 1 NE E23 10 Below 1 Ω Crankshaft position senso...

Page 211: ...plate OK The plate does not have any cracks or deformation NG REPLACE CRANKSHAFT POSITION SENSOR CRANKSHAFT OK 5 REPLACE CRANKSHAFT POSITION SENSOR GO 6 CHECK IF DTC OUTPUT RECURS DTC P0335 a Start the engine b Connect the intelligent tester II to the DLC3 c Select the following menu item Powertrain Engine and ECT DTC Pending codes Result Display DTC Output Proceed To No output A P0335 B HINT If t...

Page 212: ...40 The MIL is illuminated as well as a DTC being set immediately malfunction is detected CMP sensor S Camshaft timing gear or sprocket S ECM HINT DTC P0340 is detected when the engine cranks 5 revolutions or more and also detected when idling Reference Inspection using the oscilloscope HINT S The correct waveform is as shown on the left S G stands for the camshaft position sensor signal and NE sta...

Page 213: ... sensor C1 2 or G E23 23 Body ground 10 kΩ or higher Camshaft position sensor C1 1 or EG E23 34 Body ground Below 1 Ω d Reconnect the camshaft position sensor connector e Reconnect the ECM connector NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 CHECK SENSOR INSTALLATION CAMSHAFT POSITION SENSOR a Check the camshaft position sensor installation OK The sensor has been installed correctly NG SECUREL...

Page 214: ... for at least 10 seconds c Connect an intelligent tester II to the DLC3 d Select the following menu item Powertrain Engine and ECT DTC Pending codes Result Display DTC Output Proceed To No output A P0340 B B REPLACE ECM See page 10 15 A END BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 215: ...oolant temperature when the ignition switch is turned to ON The ECM then turns on the glow plug relay and permits the current to flow through the glow plug based on the ECM s calculated time The glow plug is then heated and enhances fuel combustion with a cold engine DTC No DTC Detection Condition Trouble Area P0380 When glow plug is turned from OFF to ON current does not flow through glow plug re...

Page 216: ...nection Specified Condition 3 4 10 kΩ or higher 3 4 Below 1 Ω When battery voltage applied to terminals 1 and 2 c Reinstall the glow plug relay NG REPLACE GLOW PLUG RELAY ASSY OK 2 CHECK HARNESS AND CONNECTOR GLOW PLUG RELAY ECM a Disconnect the E24 ECM connector b Remove the glow plug relay c Check the resistance Standard Check for open Tester Connection Specified Condition S Glow plug relay term...

Page 217: ...e resistance Standard Check for open Tester Connection Specified Condition L Glow plug relay terminal 3 Glow plug wire Below 1 Ω B Glow plug relay terminal 4 Battery positive terminal Below 1 Ω d Reinstall the glow plug relay e Reconnect the glow plug wire NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM See page 10 15 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index...

Page 218: ...eas P0400 Target and actual mass air flow rates differ The MIL is illuminated and a DTC is set when the same mal function is detected on 2 consecutive trips One trip is counted when the ignition switch is turned from OFF to ON and back to OFF S Open or short in EGR circuit S EGR valve assembly S EGR passage S Intake shutter S Mass air flow meter S Contamination in mass air flow meter S ECM HINT S ...

Page 219: ...roceed To P0400 A P0400 and other DTCs B HINT If any DTCs other than P0400 are output troubleshoot those DTCs first B GO TO RELEVANT DTC CHART See page 05 41 A 2 INSPECT EGR VALVE ASSY a Disconnect E21 EGR valve connector b Measure the resistance between the terminals of the EGR valve Standard Tester Connection Specified Condition B1 5 EGR1 4 19 6 1 4 Ω B1 5 EGR3 6 19 6 1 4 Ω B2 2 EGR2 1 19 6 1 4 ...

Page 220: ...d 10 kΩ or higher EGR2 E24 11 or E21 1 Body ground 10 kΩ or higher EGR3 E24 31 or E21 6 Body ground 10 kΩ or higher EGR4 E24 30 or E21 3 Body ground 10 kΩ or higher d Reconnect the EGR valve connector e Reconnect the ECM connector NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 INSPECT ECM EGR VALVE ASSY VOLTAGE a Disconnect the E21 EGR valve connector b Inspect the ECM using an oscilloscope c Whil...

Page 221: ...TS AND AREA OK 7 CHECK FOR EXHAUST GAS LEAKS OK No leakage NG REPAIR EXHAUST GAS LEAKAGE POINT OK 8 INSPECT INTAKE SHUTTER ASSY See page 10 1 OK No malfunction NG REPLACE MASS AIR FLOW METER OK 9 INSPECT MASS AIR FLOW METER VISUAL INSPECTION OK The sensor area of the mass air flow meter has not been contaminated NG REPLACE MASS AIR FLOW METER OK BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical...

Page 222: ...als 1 B and 2 E2G c Using a voltmeter connect the positive tester probe to terminal 3 VG and negative tester probe to terminal 2 E2G d Blow air into the mass air flow meter OK The voltage fluctuates e Reinstall the mass air flow meter NG REPLACE MASS AIR FLOW METER OK REPLACE EGR VALVE ASSY See page 14 26 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR...

Page 223: ...IRING DIAGRAM Refer to DTC P0400 on page 05 117 INSPECTION PROCEDURE HINT Read freeze frame data using an intelligent tester ll Freeze frame data record the engine condition when malfunctions are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not and other data from the time the malfunction oc curred 1 INSPE...

Page 224: ...low 1 Ω EGR2 E24 11 E21 1 Below 1 Ω EGR3 E24 31 E21 6 Below 1 Ω EGR4 E24 30 E21 3 Below 1 Ω Standard Check for short Tester Connection Specified Condition EGR1 E24 12 or E21 4 Body ground 10 kΩ or higher EGR2 E24 11 or E21 1 Body ground 10 kΩ or higher EGR3 E24 31 or E21 6 Body ground 10 kΩ or higher EGR4 E24 30 or E21 3 Body ground 10 kΩ or higher d Reconnect the EGR valve connector e Reconnect t...

Page 225: ...e ECM The ECM determines the vehicle speed based on the frequency of these pulse signals DTC No DTC Detection Condition Trouble Area P0500 No vehicle speed sensor signal to ECM While vehicle driven with highly loaded engine and in high gear The MIL is illuminated and a DTC is set when the same mal function is detected on 2 consecutive trips One trip is counted when the ignition switch is turned fr...

Page 226: ...g freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not and other data from the time the malfunction oc curred 1 CHECK OPERATION OF SPEEDOMETER a Check the speedometer reading in the combination meter HINT If the vehicle speed sensor has any malfunctions the speedometer shows abnormal readings OK The speedometer operates normally NG CHECK S...

Page 227: ...actual vehicle speed YES CHECK FOR INTERMITTENT PROBLEMS See page 05 7 NO 3 CHECK HARNESS AND CONNECTOR ECM COMBINATION METER a Disconnect the E24 ECM connector b Disconnect the C11 combination meter connector c Check the resistance Standard Check for open Tester Connection Specified Condition SPD E24 66 Combination meter C11 10 Below 1 Ω Standard Check for short Tester Connection Specified Condit...

Page 228: ...F d Wait for at least 30 seconds e Turn the ignition switch to ON and then turn the tester ON f Clear DTC P0603 stored in the ECM using the tester see page 05 33 HINT S Each injector has different fuel injection characteristics In order to optimize the fuel injections the ECM uses the compensation codes to balance the different fuel injections between each injector S When you first turn the igniti...

Page 229: ... appropriate thresholds The MIL is illuminated as well as a DTC being set immediately malfunction is detected S Intake shutter position sensor S Open or short in intake shutter position sensor circuit S Accelerator pedal position sensor S Open or short in accelerator pedal position sensor circuit S ECM HINT These DTCs are set when the ignition switch is in the ON position WIRING DIAGRAM Refer to D...

Page 230: ...ow 1 Ω VLU E23 35 VTA T14 3 Below 1 Ω EVLU E23 14 E2 T14 2 Below 1 Ω Standard Check for short Tester Connection Specified Condition VVLU E23 24 or VC T14 1 Body ground 10 kΩ or higher VLU E23 35 or VTA T14 3 Body ground 10 kΩ or higher EVLU E23 14 or E2 T14 2 Body ground 10 kΩ or higher d Reconnect the intake shutter position sensor connector e Reconnect the ECM connector NG REPAIR OR REPLACE HARN...

Page 231: ...accelerator pedal position sensor connector b Disconnect the E24 ECM connector c Check the resistance Standard Check for open Tester Connection Specified Condition VPA1 A21 5 VPA1 E24 15 Below 1 Ω EP1 A21 1 EVPA1 E24 54 Below 1 Ω VCP1 A21 4 VVPA1 E24 34 Below 1 Ω VPA2 A21 2 VPA2 E24 14 Below 1 Ω EP2 A21 3 EVPA2 E24 53 Below 1 Ω VCP2 A21 6 VVPA2 E24 33 Below 1 Ω Standard Check for short Tester Conn...

Page 232: ...s well as a DTC being set immediately malfunction is detected S Accelerator pedal position sensor S Open or short in accelerator pedal position sensor circuit S ECM HINT These DTCs are set when the ignition switch is in the ON position WIRING DIAGRAM Refer to DTC P1120 on page 05 141 INSPECTION PROCEDURE 1 CHECK OTHER DTC OUTPUT IN ADDITION TO DTC P0652 AND OR P0653 a Connect an intelligent tester...

Page 233: ...the A21 accelerator pedal position sensor connector b Disconnect the E24 ECM connector c Check the resistance Standard Check for open Tester Connection Specified Condition VPA1 A21 5 VPA1 E24 15 Below 1 Ω EP1 A21 1 EVPA1 E24 54 Below 1 Ω VCP1 A21 4 VVPA1 E24 34 Below 1 Ω VPA2 A21 2 VPA2 E24 14 Below 1 Ω EP2 A21 3 EVPA2 E24 53 Below 1 Ω VCP2 A21 6 VVPA2 E24 33 Below 1 Ω Standard Check for short Tes...

Page 234: ... Area P0685 S After ignition switch is turned to OFF voltage supplied to ter minal B is cut earlier than minimum threshold duration A DTC is set when a malfunction is detected but the MIL is not illuminated S After ignition switch is turned to OFF voltage supplied to ter minal B continues after threshold duration elapsed A DTC is set when a malfunction is detected but the MIL is not illuminated S ...

Page 235: ...OR SHORT IN ALL HARNESSES AND COMPONENTS CONNECTED TO FUSE OK 2 INSPECT EFI MAIN RELAY a Remove the EFI MAIN relay from the engine room R B b Check the EFI MAIN relay resistance Standard Tester Connection Specified Condition 3 5 10 kΩ or higher 3 5 Below 1 Ω When battery voltage applied to terminals 1 and 2 c Reinstall the EFI MAIN relay NG REPLACE EFI MAIN RELAY OK BACK TO CHAPTER INDEX TO MODEL ...

Page 236: ...igher EFI fuse 2 or B E24 61 Body ground 10 kΩ or higher 4 Reinstall the EFI fuse 5 Reconnect the ECM connector b Check the harness and connector between the EFI fuse and battery 1 Remove the EFI fuse from the engine room R B 2 Disconnect the positive battery cable 3 Check the resistance Standard Check for open Tester Connection Specified Condition Positive battery cable terminal EFI fuse 1 Below ...

Page 237: ...ediately malfunction is detected S Open or short in fuel pressure sensor circuit S Fuel pressure sensor S Open or short in manifold absolute pressure sensor circuit S Manifold absolute pressure sensor S ECM HINT These DTCs are set when the ignition switch is in the ON position WIRING DIAGRAM Refer to DTC P0190 on page 05 83 and DTC P0236 on page 05 97 INSPECTION PROCEDURE 1 CHECK OTHER DTC OUTPUT ...

Page 238: ...PC E23 26 F19 3 Below 1 Ω EPC E23 16 F19 1 Below 1 Ω Standard Check for short Tester Connection Specified Condition PC E23 37 or F19 2 Body ground 10 kΩ or higher VPC E23 26 or F19 3 Body ground 10 kΩ or higher EPC E23 16 or F19 1 Body ground 10 kΩ or higher d Reconnect the ECM connector e Reconnect the fuel pressure sensor connector NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 INSPECT MANIFOLD ...

Page 239: ... Tester Connection Specified Condition PIM T3 2 PIM E23 38 Below 1 Ω VC T3 3 VPIM E23 27 Below 1 Ω E2 T3 1 EPIM E23 17 Below 1 Ω Standard Check for short Tester Connection Specified Condition PIM T3 2 or PIM E23 38 Body ground 10 kΩ higher VC T3 3 or VPIM E23 27 Body ground 10 kΩ higher E2 T3 1 or EPIM E23 17 Body ground 10 kΩ higher d Reconnect the manifold absolute pressure sensor con nector e R...

Page 240: ...en the same mal function is detected on 2 consecutive trips One trip is counted when the ignition switch is turned from OFF to ON and back to OFF S Open or short in clutch switch circuit S Clutch switch circuit S ECM HINT DTC P0704 is set when the gears are shifted more than 10 times WIRING DIAGRAM INSPECTION PROCEDURE 1 READ VALUE USING INTELLIGENT TESTER II CLUTCH UPPER SWITCH a Connect an intel...

Page 241: ...all the clutch switch NG REPLACE CLUTCH SWITCH ASSY OK 3 CHECK HARNESS AND CONNECTOR CLUTCH SWITCH ECM a Disconnect the C20 clutch switch connector b Disconnect the E24 ECM connector c Check the resistance Standard Check for open Tester Connection Specified Condition CLSW E24 69 C20 2 Below 1 Ω Standard Check for short Tester Connection Specified Condition CLSW E24 69 or C20 2 Body ground 10 kΩ or...

Page 242: ...CM changes between 0 V and 5 V in proportion to the opening angle of the accelerator pedal The VPA1 is a signal to indicate the actual accelerator pedal opening angle which is used for engine control and the VPA2 is a signal which is used for detecting a malfunction in the sensor DTC No DTC Detection Condition Trouble Area P1120 S Condition a or b continues for 0 5 seconds or more a VPA1 less than...

Page 243: ...5 5 05 142 DIAGNOSTICS ECD SYSTEM 1ND TV COROLLA Supplement RM1129E HINT When DTC P1120 is set check the accelerator pedal position sensor output voltage by selecting the follow ing menu items on the intelligent tester ll Powertrain Engine and ECT Data List Accel Position Reference Accelerator Pedal Position T bl A Fully Closed Fully Open Trouble Area 0 0 S Open in VVPA1 or VVPA2 circuit S Open or...

Page 244: ...tandard Accelerator Pedal Operation Specified Condition Depressed 100 Released 0 OK REPLACE ECM See page 10 15 NG 2 INSPECT ACCELERATOR PEDAL ASSY ACCELERATOR PEDAL POSITION SENSOR a Disconnect the A21 accelerator pedal position sensor connector b Measure the resistance between each pair of terminals Standard Tester Connection Specified Condition EP1 1 VCP1 4 1 5 kΩ to 6 0 kΩ at 20_C 68_F EP2 3 VC...

Page 245: ...34 Below 1 Ω VPA2 A21 2 VPA2 E24 14 Below 1 Ω EP2 A21 3 EVPA2 E24 53 Below 1 Ω VCP2 A21 6 VVPA2 E24 33 Below 1 Ω Standard Check for short Tester Connection Specified Condition VPA1 A21 5 or VPA1 E24 15 Body ground 10 kΩ or higher EP1 A21 1 or EVPA1 E24 54 Body ground 10 kΩ or higher VCP1 A21 4 or VVPA1 E24 34 Body ground 10 kΩ or higher VPA2 A21 2 or VPA2 E24 14 Body ground 10 kΩ or higher EP2 A21...

Page 246: ...engine condition when malfunctions are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not and other data from the time the malfunction oc curred 1 CHECK OTHER DTC OUTPUT IN ADDITION DTC P1121 a Connect an intelligent tester ll to the DLC3 b Turn the ignition switch to ON and turn the intelligent tester ll ON...

Page 247: ...S Fuel filter element is clogged S Fuel leak S Injector S Lack of fuel S ECM HINT S DTC P1299 is set when the vehicle is driven including acceleration and deceleration at vehicle speed of over 50 km h for more than 5 minutes while the fuel temperature is more than 10_C and the engine coolant temperature is higher than the fuel temperature S DTC P1272 is set when the vehicle is driven including acc...

Page 248: ...YSTEM 1ND TV 05 147 COROLLA Supplement RM1129E WIRING DIAGRAM INSPECTION PROCEDURE HINT Read freeze frame data using an intelligent tester ll Freeze frame data record the engine condition when malfunctions are detected When troubleshooting freeze frame data can help determine if the vehicle was moving or stationary if the engine was warmed up or not and other data from the time the malfunction oc ...

Page 249: ... tester ll to the DLC3 b Start the engine and turn the intelligent tester ll ON c Select the following menu items Powertrain Engine and ECT Active Test Fuel leak test d Visually check the supply pump injector and fuel line located between the supply pump and common rail for fuel leaks Also perform the same check on the fuel line between the common rail and the injec tor HINT There may be fuel leak...

Page 250: ...n fuel low A S Fuel run out recently S Quick turns repeated when fuel low B B DTC IS CAUSED BY RUNNING OUT OF FUEL A 5 INSPECT COMMON RAIL ASSY PRESSURE REGULATOR VALVE ASSY a Disconnect the V9 pressure regulator valve connector b Measure the resistance between the terminals of the pressure regulator valve Standard 3 42 to 3 78 Ω at 20_C 68_F c Reconnect the pressure regulator valve connector NG R...

Page 251: ...I MAIN relay 3 V9 2 Below 1 Ω Standard Check for short Tester Connection Specified Condition PRV E23 4 or V9 1 Body ground 10 kΩ or higher EFI MAIN relay 3 or V9 2 Body ground 10 kΩ or higher e Reconnect the pressure regulator valve connector f Reconnect the ECM connector g Reinstall the EFI MAIN relay NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 7 INSPECT INJECTION OR SUPPLY PUMP ASSY FUEL METERI...

Page 252: ...ody ground 10 kΩ or higher d Reconnect the fuel metering unit connector e Reconnect ECM connector NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 9 REPLACE COMMON RAIL ASSY PRESSURE REGULATOR VALVE See page 11 20 GO 10 CHECK IF DTC OUTPUT RECURS DTC P1229 AND OR P1272 HINT After clearing the DTC s conduct the following driving patterns S The vehicle is driven at a vehicle speed of 50 km h for more th...

Page 253: ...uct the following driving patterns S The vehicle is driven at a vehicle speed of 50 km h for more than 5 minutes while the fuel temperature is more than 10_C S The vehicle is drive at a vehicle speed of 50 km h for more than 5 minutes while the fuel temperature is less than 10_C GO 14 READ OUTPUT DTC DTC P1229 AND OR P1272 a Connect an intelligent tester ll to the DLC3 b Turn the ignition switch t...

Page 254: ... table below Signal Brake Pedal Released In Transition Brake Pedal Depressed STP1 OFF ON ON STP2 ON ON OFF DTC No DTC Detection Condition Trouble Area P1520 Conditions a b and c continue for 5 0 seconds or more a Ignition switch ON b Brake pedal depressed c STP1 signal OFF when STP2 signal OFF The MIL is illuminated and a DTC is set when the same mal function is detected on 2 consecutive trips One...

Page 255: ...T 6 5 6 5 2S 2S 1 2 G W 1 SB G W 2 G W G W SB SB SB G W 2 SB R W 2 R W 1 2 52 62 1 W 39 29 E24 E24 27 8 STP1 STP2 1 10 3 G R 1 G R 1 G R 1 LG B Y G R ECU IG IG1 Relay 2F 5 11 EE1 1 II I11 Ignition Switch R W 2 B 2 B O 2 1 3 Instrument Panel J B Engine Room R B and J B Instrument Panel J B W R B No 6 SB B Y 2 W B 05 154 DIAGNOSTICS ECD SYSTEM 1ND TV COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO...

Page 256: ...t the stop lamps illuminate when the brake pedal is depressed and turn off when the brake pedal is released OK The stop lamps illuminate and turn off according to the brake pedal operation OK CHECK FOR INTERMITTENT PROBLEMS See page 05 7 NG 2 INSPECT STOP LAMP SWITCH ASSY a Remove the S14 stop lamp switch b Check the resistance Standard Switch Position Tester Connection Specified Condition Switch ...

Page 257: ...ion Specified Condition Stop lamp switch S14 1 STP1 E24 8 Below 1 Ω Stop lamp switch S14 3 STP2 E24 27 Below 1 Ω Standard Check for short Tester Connection Specified Condition Stop lamp switch S14 1 or STP1 E24 8 Body ground 10 kΩ or higher Stop lamp switch S14 3 or STP2 E24 27 Body ground 10 kΩ or higher d Reconnect the ECM connector e Reconnect the stop lamp switch connector NG REPAIR OR REPLACE...

Page 258: ...al circuit S Tired battery S Electrical overwork S Generator S Battery If 24 V battery is fitted DTC P1600 is output S ECM HINT DTC P1600 is set when the engine idles for 60 seconds or more WIRING DIAGRAM Refer to DTC P0685 on page 05 133 INSPECTION PROCEDURE 1 CHECK FUSE EFI FUSE a Remove the EFI fuse from the engine room R B b Check the EFI fuse resistance Standard Below 1 Ω c Reinstall the EFI ...

Page 259: ...e harness and connector between the EFI fuse and battery 1 Remove the EFI fuse from the engine room R B 2 Disconnect the positive battery cable 3 Check the resistance Standard Check for open Tester Connection Specified Condition Positive battery cable terminal EFI fuse 1 Below 1 Ω Standard Check for short Tester Connection Specified Condition Positive battery cable terminal or EFI fuse 1 Body grou...

Page 260: ...5 159 COROLLA Supplement RM1129E 4 CHECK BATTERY See page 19 6 NG REPAIR OR REPLACE BATTERY OK REPLACE ECM See page 10 15 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 261: ... MIL is illuminated as well as a DTC being set immediately malfunction is detected S ECM HINT DTC P2227 is set when the ignition switch is in the ON position INSPECTION PROCEDURE 1 CHECK OTHER DTC OUTPUT IN ADDITION TO DTC P2227 a Connect an intelligent tester ll to the DLC3 b Turn the ignition switch to ON and turn the intelligent tester ll ON c Select the following menu items Powertrain Engine a...

Page 262: ...AIN Relay 2 3 5 1 1 1 R W R W Engine Room R B W B IK J C B B J20 J20 J21 B W B W B E24 E24 E1 E1 1 A A 41 2 B W B W DIAGNOSTICS ECD SYSTEM 1ND TV 05 161 COROLLA Supplement RM1129E ECM POWER SOURCE CIRCUIT CIRCUIT DESCRIPTION When the ignition switch is turned to ON the battery voltage is applied to terminal IGSW of the ECM The ECM MREL output signal causes a current to flow to the coil closing the...

Page 263: ...or open Tester Connection Specified Condition E1 E24 2 Body ground Below 1 Ω E1 E24 41 Body ground Below 1 Ω c Reconnect the ECM connector NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 INSPECT FUSE IG2 FUSE a Remove the IG2 fuse from the instrument panel J B b Check the IG2 fuse resistance Standard Below 1 Ω c Reinstall the IG2 fuse NG CHECK FOR SHORT IN ALL HARNESSES AND COMPONENTS CONNECTED TO ...

Page 264: ...IN ALL HARNESSES AND COMPONENTS CONNECTED TO FUSE OK 4 INSPECT EFI MAIN RELAY a Remove the EFI MAIN relay from the engine room R B b Check the EFI MAIN relay resistance Standard Tester Connection Specified Condition 3 5 10 kΩ or higher 3 5 Below 1 Ω When battery voltage applied to terminals 1 and 2 c Reinstall the EFI MAIN relay NG REPLACE EFI MAIN RELAY OK BACK TO CHAPTER INDEX TO MODEL INDEX To ...

Page 265: ...round 10 kΩ or higher EFI fuse 2 or B E24 61 Body ground 10 kΩ or higher 4 Reinstall the EFI fuse 5 Reconnect the ECM connector b Check the harness and connector between the EFI fuse and battery 1 Remove the EFI fuse from the engine room R B 2 Disconnect the positive battery cable 3 Check the resistance Standard Check for open Tester Connection Specified Condition Positive battery cable terminal E...

Page 266: ...t Tester Connection Specified Condition EFI MAIN relay 1 or MREL E24 42 Body ground 10 kΩ or higher 4 Reinstall the EFI MAIN relay 5 Reconnect the ECM connector b Check the resistance between the EFI MAIN relay and body ground 1 Remove the EFI MAIN relay from the engine room R B 2 Check the resistance Standard Check for open Tester Connection Specified Condition EFI MAIN relay 2 Body ground Below ...

Page 267: ...SB B R B W SB B W 4 SB IE4 1 IE4 18 1 2 N8 4 Neutral Start Switch B W 4 IE4 12 4 B W 4 M9 M9 M9 3 4 TMN STRL STA B W B W J44 J43 J43 B B B B W SB B R B 3 4 6 TMMT Made and TMUK Made J C 4 3 ST2 AM2 4 R B R 4 05 166 DIAGNOSTICS ECD SYSTEM 1ND TV COROLLA Supplement RM1129E STARTER SIGNAL CIRCUIT CIRCUIT DESCRIPTION While the engine is being cranked a current flows from terminal ST2 of the ignition s...

Page 268: ... Starter B IE1 7 B 2C 2C 2 1 1 2 ST 2O 2O 4 2 8 1 SB B W STA ECM Instrument Panel J B 2C 2C 4 1 3 2 Short Pin Engine Room R B and J B 1 LHD 2 RHD TMC Made E24 9 DIAGNOSTICS ECD SYSTEM 1ND TV 05 167 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 269: ...Ignition Switch Position ON START Starter SIG OFF ON OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE See page 05 10 NG 2 CHECK HARNESS AND CONNECTOR ECM IGNITION SWITCH a Disconnect the E24 ECM connector b Disconnect the I11 ignition switch connector c Check the resistance Standard Check for open Tester Connection Specified Condition STA E24 9 Ignition switch connector ST2 I1...

Page 270: ...10 1 2 2P 2P 65 75 SB B O J5 J C 13 23 W R Y Instrument Panel J B 1 LHD 2 RHD B R 1 2 Instrument Panel J B DIAGNOSTICS ECD SYSTEM 1ND TV 05 169 COROLLA Supplement RM1129E MIL CIRCUIT CIRCUIT DESCRIPTION If the ECM detects a malfunction the MIL is illuminated At this time the ECM records the DTC in its memory WIRING DIAGRAM 05B62 26 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub ...

Page 271: ...re are DTCs e Select the following menu items Powertrain Engine and ECT DTC Clear f Clear DTCs g Check if the MIL turns off OK The MIL should turn off OK REPAIR CIRCUIT INDICATED BY OUTPUT DTC See page 05 41 NG 2 CHECK HARNESS AND CONNECTOR CHECK FOR SHORT IN WIRE HARNESS a Disconnect the E24 ECM connector b Turn the ignition switch to ON c Check that the MIL is not illuminated OK The MIL is not i...

Page 272: ...R ASSY MIL CIRCUIT OK The combination meter circuit is normal NG REPAIR OR REPLACE BULB OR COMBINATION METER ASSEMBLY OK CHECK AND REPAIR HARNESS AND CONNECTOR COMBINATION METER ECM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 273: ... 05 186 After installa tion S TRANSMISSION CONTROL ECU S CLUTCH ACTUATOR S CLUTCH DISC AND CLUTCH DISC COVER S FLYWHEEL S CRANKSHAFT S CLUTCH RELEASE BEARING S CLUTCH RELEASE FORK S END PLATE S When the clutch actuator is removed from the transmission assy during installation of any of the following parts S TRANSMISSION ASSY S TRANSMISSION PARTS INSID GEAR BOX 1 INITIALIZATION OF MULTI MODE MANUAL...

Page 274: ...t lever back to the position it was parked to and then moving it to the N position b When the vehicle is parked with the shift lever in the N position S If the shift lock is released by the shift lock release button the engine can be started even if the shift lever is moved to another position as the gear position is in neutral S The multi mode manual transmission system will not operate as the ge...

Page 275: ...T Relay D AMT Fuse Engine Room R B and J B D AM1 Fuse D AM2 Fuse 05 174 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM COROLLA Supplement RM1129E LOCATION BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 276: ...ECU D Buzzer ECM Parking Brake Switch Pattern Select Switch Kick Down Switch DLC3 Shift Lever Assy Shift Lock Release Button Transmission Shift Main Switch Shift Lock Solenoid Accelerator Pedal Position Sensor Shift Lever Position Sensor DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 175 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA...

Page 277: ...Control ECU D Buzzer ECM Parking Brake Switch Pattern Select Switch DLC3 Shift Lever Assy Shift Lock Release Button Transmission Shift Main Switch Shift Lock Solenoid Shift Lever Position Sensor Accelerator Pedal Position Sensor 05 176 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA ...

Page 278: ...or Shift Motor Shift Motor Shaft 1st 3rd 5th Shift Operation Select Operation 1st 2nd 2nd 4th Rev 5th Rev Select Stroke Sensor Shift Stroke Sensor Select Motor Shift and Select Lever Shaft Select Motor Shaft DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 177 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 11...

Page 279: ...ransmission Revolution Sensor Parking Brake Switch Kick Down Switch 1 1 LHD Shift Lock Solenoid Link1 Circuit VSL1 E2L1 VCL1 VSL2 E2L2 VCL2 VSS1 E2S1 VCS1 VSS2 E2S2 VCS2 VSR1 E2R1 VCR1 VSR2 E2R2 VCR2 MSL MSL MSF MSF MCL MCL PWR TMN RSW ST STP LSRC LSWR LSSC LSWS LSNC LSWN LSW LSW NIP NIP PKB KD MDSW SLS Transmission Shift Main Switch Link2 Circuit 05 178 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION ...

Page 280: ...CAN CAN W NE ECM ACC IG1 IG2 ST2 ST B TC SIL SPD INDC INDA IG STRL STA BM MREL GND PGND CAN CAN NE AMT 1 Crankshaft Position Sensor Throttle Position Sensor VSC System J C DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 179 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 281: ...ol ECU to the transmission control ECU Multi mode Manual Transmission Indicator Combination Meter Lights up to alert the driver when a malfunction occurs in the multi mode manual transmission system Gear Position Indicator Light Combination Meter Indicates the present gear position In addition this indicator lights flashes if the actual gear posi tion and the shift lever position do not match Es I...

Page 282: ...k engine warning light illuminate or blink to inform the driver Transmission Control ECU Buzzer Sounds a built in buzzer during system warning ECM S Outputs each sensor information via CAN communication to transmission control ECU S Effects fuel injection control per request from transmission control ECU Air Flow Meter Intake Air Temp Sensor Detects the external air temperature and outputs it to t...

Page 283: ...he current gear position is maintained depending on the degree of road inclination to obtain engine brake power When the brake pedal is depressed the transmission control ECU automatically down shifts to improve vehicle driving force control performance e AI Artificial Intelligence SHIFT CONTROL In addition to the switching of the shift pattern through the pattern select switch the AI SHIFT contro...

Page 284: ...o park the vehicle with the gear engaged HINT The shift lever can be in any position N E M or R to park the vehicle The multi mode manual transmission system does not have a park position The vehicle can be parked with the gear engaged when the shift lever is in the E M or R position The vehicle may not be parked if the ignition switch is turned off before gear shift is complete BACK TO CHAPTER IN...

Page 285: ...ATION PROCEDURES OF MULTI MODE MANUAL TRANSMISSION SYSTEM HINT The multi mode manual transmission differs from the conventional manual transmission The following op erations are necessary when removing and installing the component parts a CLUTCH POSITION ADJUSTMENT CLUTCH CLAMP POSITION S Preload is applied to the clutch actuator push rod installed on the vehicle S Clutch position adjustment is ne...

Page 286: ...to a difference from removal installation of parts Therefore the transmission control ECU learn ing values must be cleared S Learning of the multi mode manual transmission system is performed when there is no learning value in the ECU It is therefore necessary to perform initialization of the multi mode manual transmission ECU before performing learning of the multi mode manual transmission system...

Page 287: ...adjustment system S If the clutch position adjustment operation input has failed perform the operation again from step a more than 15 seconds after turning the ignition switch off NOTICE Do not depress the brake pedal while using the intelligent tester II a Prepare the vehicle S Stop the vehicle S Shift the lever into the N position S Turn the ignition switch off S Make sure that the engine is sto...

Page 288: ...ormation k Press the Next key l Read information m Press the Next key n On the Multi Mode M T Utility screen select Step 1 Move Clutch Position o Press the Next key p Read information q Press the Next key r Complete clutch position adjustment s Turn the main switch of the intelligent tester II off t Turn the ignition switch off u Replace the parts BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetic...

Page 289: ...normal operation of the load controlled clutch cover adjustment system S If the clutch position adjustment operation input has failed perform the operation again from step a more than 15 seconds after turning the ignition switch off a Prepare the vehicle S Stop the vehicle S Shift the lever into the N position S Turn the ignition switch off S Make sure that the engine is stopped S Apply the parkin...

Page 290: ...he procedures from step a again if the buzzer does not sound once g Depress the brake pedal 3 times or more within 2 se conds 1 The buzzer sounds twice at intervals of 0 25 se conds h Prepare the vehicle 1 Depress the brake pedal 2 Shift the lever to the position 3 Release the brake pedal i Turn the ignition switch off j Wait at least 10 seconds k Complete clutch position adjustment l Disconnect t...

Page 291: ...oved To clear all the stored information initialize the transmission control ECU S Perform the procedure below to ensure that the initialized transmission control ECU memorizes the adjusted clutch position or gear position S There may be a malfunction with the shift lever position sensor NE signals or CAN communication when initialization cannot be performed normally a Prepare the vehicle S Stop t...

Page 292: ...on i After checking the vehicle condition press the Next key j Read information k Press the Next key l Read information m Press the Next key n On the Multi Mode M T Utility screen select Step 3 Initial Learning o Press the Next key p Select an operation q Press the Next key BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 293: ...t key t Wait 10 seconds HINT Countdown from 10 seconds to 0 u Read information v Press the Next key w Wait 40 seconds HINT Countdown from 40 seconds to 0 x Press the Exit key y Complete initialization and learning z Turn the main switch of the intelligent tester II off aa Turn the ignition switch off BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANU...

Page 294: ...e replaced or removed and installed Operation TRANSMISSION CONTROL ECU CLUTCH ACTUATOR CLUTCH DISC AND CLUTCH DISC COVER FLYWHEEL CRANKSHAFT CLUTCH RELEASE BEARING CLUTCH RELEASE FORK END PLATE S When the clutch actuator is removed from the transmission assy during installation of any of the following parts TRANSMISSION ASSY TRANSMISSION PARTS INSIDE GEAR BOX Initialization of multi mode manual tr...

Page 295: ... E M M M M E N S When initializing the clutch N E M M M M E N S When initializing the transmission N E M M M M E N 3 Release the brake pedal g Depress the brake pedal 1 The buzzer sounds at intervals of 0 5 seconds as follows An interval of 0 25 seconds exists for each cycle S Twice when initializing the ECU one cycle S Three times when initializing the clutch one cycle S Four times when initializ...

Page 296: ...he procedure below to ensure that the initialized transmission control ECU memorizes the adjusted clutch position or gear position S If the input of learning of the multi mode manual transmission system has failed perform the operation again from step a more than 15 seconds after turning the ignition switch off a Prepare the vehicle S Stop the vehicle S Shift the lever into the N position S Turn t...

Page 297: ...ion Vehicle Speed UP SHIFT 1st 2nd 2nd 3rd 3rd 4th 4th 5th More than 25 km h 15 5 mph More than 47 km h 29 2 mph More than 69 km h 42 9mph More than 93 km h 57 8 mph DOWN SHIFT 5th 4th 4th 3rd 3rd 2nd 2nd 1st More than 93 km h 57 8 mph More than 69 km h 42 9 mph More than 47 km h 29 2 mph More than 25 km h 15 5 mph HINT S Interval between gear changes is more than 2 seconds S If there is a shock w...

Page 298: ... is connected to the CAN communication system Therefore before starting trouble shooting make sure to check that there is no trouble in the CAN communication system CAN SYSTEM DTC IS OUTPUT PROCEED TO CAN COMMUNICATION SYSTEM NO CAN SYSTEM DTC GO TO STEP 5 5 CHECK DTC AND FREEZE FRAME DATA SEE PAGE 05 200 AND 05 203 HINT Record or print DTCs and freeze frame data if needed NEXT 6 CLEAR DTC AND FRE...

Page 299: ...1 DTC CHECK SEE PAGE 05 203 TROUBLE CODE Go to step 12 NO CODE Go to step 13 12 DTC CHART SEE PAGE 05 221 NEXT Go to step 14 13 PROBLEM SYMPTOMS TABLE SEE PAGE 05 219 NEXT 14 CIRCUIT INSPECTION SEE PAGE 05 225 TO 05 364 NEXT 15 IDENTIFICATION OF PROBLEM NEXT 16 ADJUSTMENT REPAIR NEXT 17 CONFIRMATION TEST NEXT END BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLL...

Page 300: ...n Engine R Just after starting Starting Cloudy Rainy Snowy Inner city Various Other Rough road Suburbs Highway Incline Slight slope Paved road Decline Cold After warming up During warming up min after engine start Off Uncertain On Sound pattern Problem cannot be simulated Off Uncertain M N E 1 2 3 4 5 Off Uncertain Blinking R N E km h mph Problem can be simulated How From km h mph Idling Racing Ju...

Page 301: ...rom the usual troubleshooting pro cedure is that the OBD scan tool complying with ISO 15031 4 or the intelligent tester II have to be con nected to the vehicle and various data output from the vehicle s ECUs have to be read out S Euro OBD regulations require that the vehicle s on board computer illuminates the check engine warning light MIL in the combination meter when the ECU detects a malfuncti...

Page 302: ...tection log ic is used to ensure accurate detection of malfunctions Check mode is also available to technicians as an op tion In check mode 1 trip detection logic is used for simulating malfunction symptoms and increasing the sys tem s ability to detect malfunctions including intermittent malfunctions Intelligent Tester II only 3 2 TRIP DETECTION LOGIC a When a malfunction is first detected the ma...

Page 303: ...s con nected to another vehicle the problem is probably in the tool itself Consult the Service Department listed in the tool s instruction manual Symbol Terminal No Name Reference terminal Result Condition SIL 7 Bus line 5 Signal ground Pulse generation During transmission CG 4 Chassis ground Body ground 1 Ω or less Always SG 5 Signal ground Body ground 1 Ω or less Always BAT 16 Battery positive B...

Page 304: ... II to the Data Link Connec tor 3 DLC3 c Turn the ignition switch on d Confirm the DTCs and freeze frame data and then write them down e See page 05 221 to confirm the details of the DTCs NOTICE When simulating a symptom with the scan tool to check the DTCs use normal mode For codes on DIAGNOSTIC TROUBLE CODE CHART subjected to 2 trip detection logic perform the following actions f Turn the igniti...

Page 305: ... If the multi mode manual transmission warning light does not blink in DTC blinking patterns or in the normal system code blinking pattern inspect the following circuits Relevant Circuit See page TC circuit 05 354 Multi mode manual transmission warning light circuit 05 349 3 CLEAR DTC WITH INTELLIGENT TESTER II a Connect the Intelligent Tester II to the DLC3 b Turn the ignition switch on c Clear t...

Page 306: ...r the following menu Utility Check Mode f Change the transmission control ECU to check mode Make sure the multi mode manual transmission warning light flashes as shown in the illustration NOTICE All DTCs and freeze frame data recorded will be erased if 1 the intelligent tester II is used to change the transmis sion control ECU from normal mode to check mode or vice versa or 2 during check mode the...

Page 307: ...km h 5 59 mph b Pass condition is detected and the ignition switch is OFF S P0725 13 Engine speed input circuit S Convert the engine revolution signal into the CAN communica tion signal S No effect a All of the following conditions are met S Pass condition is detected S Clutch position adjustment is per formed b Pass condition is detected and the ignition switch is OFF S P0500 42 S P0715 19 S Tran...

Page 308: ...n is detected and the engine switch is OFF S U0001 A2 CAN communication signal circuit S Gear does not change S Possible to drive only in 1st or re verse gear after the vehicle stops a All of the following conditions are met S Pass condition is detected S Vehicle is stopped S Accelerator pedal released S Brake pedal depressed b Pass condition is detected and the ignition switch is OFF S P0562 96 T...

Page 309: ...d is displayed When vehicle speed signal has any malfunction value calculated by input revolution signal will be shown Drive Mile after Malfunction Accumulated driving mileage after the malfunction Min 0 km Max 65 535 km Normal 0 km 0 mile The driving distance from the oc currence of the diagnosis malfunc tion is displayed Vehicle Speed Signal Vehicle speed signal Min 0 km h Max 327 675 km h Vehic...

Page 310: ...ch Position within 4 0 mm 0 16 in to 15 0 mm 0 59 in are accept able Clutch Clamp Position Clutch clamp position Min 0 mm Max 127 998 mm Learning value is shown The differences between Clutch Touch Position and Clutch Clamp Position within 36 0 mm 1 42 in to 44 0 mm 1 73 in are accept able Neutral Position Shift Neutral position shift position Min 0 mm Max 34 mm Learning value is shown The middle ...

Page 311: ...e differences between Re verse Gear Position Shift and 4th Gear Position Shift within 2 5 mm 0 10 in are accept able 4th Gear Position Select 4th gear position select position Min 0 mm Max 31 999 mm Learning value is shown The differences between Reverse Gear Position Select and 4th Gear Position Select within 5 5 mm 0 22 in to 8 5 mm 0 34 in are acceptable 5th Gear Position Shift 5th gear positio...

Page 312: ...ever Switch Signal 4 Shift lever switch signal 4 GND ON OPEN OFF R OPEN N GND E OPEN M OPEN OPEN OPEN When there is any malfunction the indicator keeps showing either ON or OFF no matter where the lever position is Shift Lever Switch Signal 3 Shift lever switch signal 3 GND ON OPEN OFF R OPEN N OPEN E GND M GND GND GND When there is any malfunction the indicator keeps showing either ON or OFF no m...

Page 313: ... calibration procedure is complete If only YES is displayed even after retrying several times the assem bly must be faulty Learn Clutch Standby Point Clutch standby position calibration NOTEXEC FAIL EXEC EXEC is displayed when calibration procedure is complete If only FAIL is displayed even after retrying several times the assem bly must be faulty Learning T M Learning of T M system NOTEXET FAIL E...

Page 314: ...uator assy does not move to the gear indicated there could be some malfunctions in the follow ing parts S Shift stroke sensor S Select stroke sensor S Shift and select actuator assy Shift motor Select motor S AMT Relay Shift motor and select motor main relay S Transmission S Transmission control ECU S Poor attachment of shift and select actuator assy Target Clutch Control Test Details Target clutc...

Page 315: ...NC GND M8 11 M8 6 B O W B Shift lever position sensor Ignition switch ON Shift lever position N Non N 10 to 14 V Below 1 V LSSC GND M8 12 M8 6 W R W B Shift lever position sensor Ignition switch ON Shift lever position E M R N 10 to 14 V Below 1 V LSRC GND M8 13 M8 6 GR R W B Shift lever position sensor Ignition switch ON Shift lever position R Non R 10 to 14 V Below 1 V LSW GND M8 15 M8 6 R L W B...

Page 316: ... to 14 V MREL GND M9 5 M8 6 L R W B AMT relay motor power source Ignition switch OFF ON Below 1 V 10 to 14 V STA GND M9 6 M8 6 B W W B Starter relay operate signal input Ignition switch OFF Shift lever position N start er operates brake pedal depressed Below 1 V 10 to 14 V RSW GND M9 9 M8 6 R B W B Back up lamp switch Ignition switch ON Shift lever position non R R Below 1 V 10 to 14 V NE GND M9 1...

Page 317: ...B Clutch stroke sensor ground Sub Always Below 1 Ω VSR2 GND M9 34 M8 6 BR Y W B Clutch stroke sensor volt age monitor Sub Ignition switch ON 0 5 to 4 5 V VCR2 GND M9 35 M8 6 R Y W B Clutch stroke sensor bat tery Sub Ignition switch ON Approx 5 V MSF GND M7 1 M8 6 B W B Shift actuator Ignition switch OFF ON Below 1 V 5 to 10 V BM GND M7 2 M8 6 B R W B AMT relay motor power source Ignition switch OF...

Page 318: ...uge set 1 V DIV 50 µs DIV S Condition Ignition switch ON Waveform 3 Crankshaft Position Sensor Terminal S Terminal NE GND S Gauge set 5 V DIV 1 ms DIV S Condition Engine idling Waveform 4 Transmission Revolution Sensor S Terminal NIP NIP S Gauge set 1 V DIV 2 ms DIV S Condition Vehicle speed at about 30 km h 19 mph BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA CORO...

Page 319: ...form 1 NEO E1 E24 22 E24 62 B W B Crankshaft position sensor Engine idling Pulse generation see waveform 2 E1 Body ground E24 62 Body ground W B Body ground Ground Always Below 1 Ω Waveform 1 CAN Communication Terminal S Terminal CAN H CAN L S Gauge set 1 V DIV 50 µs DIV S Condition Ignition switch ON Waveform 2 Crankshaft Position Sensor Terminal S Terminal NEO E1 S Gauge set 5 V DIV 1 ms DIV S C...

Page 320: ...1 Multi mode manual transmission warning light circuit 2 IG signal circuit 3 Transmission control ECU 05 349 05 342 41 33 DTC check cannot be performed 1 Multi mode manual transmission warning light circuit 2 TC terminal circuit 05 349 05 354 Transmission control ECU buzzer does not sound when an incor rect operation occurs Built in ECU 1 Transmission control ECU 41 33 Multi mode manual transmissi...

Page 321: ... lever position sensor 2 Transmission control ECU 41 11 41 33 Shift down timing delays occur during M mode driving 1 Kick down switch LHD 2 Acceleration pedal position sensor 3 Transmission control ECU 05 361 05 3 41 33 Engine cannot be started 1 ECD system 1ND TV 2 Starter circuit 3 Neutral position switch 4 Stop lamp switch 5 Shift position sensor 6 Starter assy 7 Transmission control ECU 05 3 0...

Page 322: ...ECU f f P0715 19 05 238 INPUT TURBINE SPEED SENSOR A CIRCUIT S Open or short in transmission rev olution sensor circuit S Transmission revolution sensor S Transmission control ECU f f P0725 13 05 241 ENGINE SPEED INPUT CIRCUIT S Crankshaft position sensor S Open or short in NE circuit S Transmission control ECU S ECM f f P0806 29 05 246 CLUTCH POSITION SENSOR CIRCUIT RANGE PERFORMANCE S Clutch str...

Page 323: ... Shift lever position sensor S Open in shift lever position signal circuit S Transmission control ECU f f P0820 73 05 272 GEAR LEVER X Y POSITION SENSOR CIRCUIT S Shift lever position sensor S Open in shift lever position signal circuit S Transmission control ECU f f P0820 74 05 272 GEAR LEVER X Y POSITION SENSOR CIRCUIT S Shift lever position sensor S Short in shift lever position signal circuit ...

Page 324: ...pen or short in select stroke sen sor circuit S Transmission control ECU f f f P0907 56 05 291 GATE SELECT POSITION CIRCUIT HIGH S Select stroke sensor S Open or short in select stroke sen sor circuit S Transmission control ECU f f f P0907 58 05 291 GATE SELECT POSITION CIRCUIT HIGH S Select stroke sensor S Open or short in select stroke sen sor circuit S Transmission control ECU f f f P0909 37 05...

Page 325: ...hort in shift stroke sen sor circuit S Open or short in shift motor circuit S Synchronizer ring S Shift fork S Hub sleeve S Transmission control ECU f f P0920 41 05 331 GEAR SHIFT FORWARD ACTUATOR CIRCUIT S Shift and select actuator assy Shift motor S Open or short in shift motor circuit S Transmission control ECU f f P1875 22 05 335 BUZZER MALFUNCTION S Transmission control ECU f f U0001 A2 2 05 ...

Page 326: ...form shaping circuit in side the combination meter it is then transmitted to the transmission control ECU The transmission control ECU determines vehicle speed based on the frequency of these pulse signals DTC No DTC Detecting Condition Trouble Area P0500 42 The transmission control ECU detects the following conditions simultaneously a Vehicle is being driven Transmission revolution sensor signal ...

Page 327: ...pected INSPECTION PROCEDURE 1 CHECK OPERATION OF SPEEDOMETER a Drive the vehicle and check if the function of the speedometer in the combination meter is normal OK Actual vehicle speed and the speed indicated on the speedometer are the same HINT The vehicle speed sensor is functioning normally when the indication on the speedometer is normal NG CHECK SPEEDOMETER CIRCUIT Refer to CO ROLLA Repair Ma...

Page 328: ... stopped 0 km h 0 mph HINT Actual vehicle speed is displayed When the vehicle speed signal has any malfunction the value calcu lated by the input revolution signal will be shown OK The speed displayed on the tester screen is almost the same as that indicated on the combina tion meter Result NG A OK When troubleshooting according to the PROBLEM SYMPTOM TABLE B OK When troubleshooting according to t...

Page 329: ...ehicle d Measure the voltage between terminal SPD of the trans mission control ECU and body ground Standard Symbol Terminal No Specified Condition SPD M9 23 Body ground Waveform appears HINT The output voltage fluctuates up and down similar to the dia gram on the left when the wheel is turned slowly NG Go to step 4 OK REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 BACK TO CHAPTER INDEX TO MO...

Page 330: ... ECU COM BINATION METER a Disconnect the M9 connector of the transmission control ECU and the C11 connector of the combination meter b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified Value SPD M9 23 C11 10 Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub...

Page 331: ...asure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified Value SPD M9 23 Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE WIRE HARNESS OR EACH ECU OK REPLACE COMBINATION METER ASSY Refer to COROLLA Repair Manual Pub No RM1106E on page 71 6 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MAN...

Page 332: ...em can be activated with terminal GND disconnected The power is supplied to the transmission control ECU via terminal B or IG If an open circuit occurs in B with the ignition switch on DTC P0562 92 is recorded and the multi mode manual transmission warning light comes on The transmission control ECU stops operating immediately when the ignition switch is turned from on to off with the B terminal c...

Page 333: ... Symbol Tester No Condition Specified value GND M8 6 Body ground Always Below 1 Ω PGND M7 8 Body ground Always Below 1 Ω c Measure the voltage according to the value s in the table below Standard Symbol Tester No Condition Specified value B M8 1 GND M8 6 Always 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR TRANSMISSION CONTROL ECU BATTERY OR BODY GROUND OK REPLACE TRANSMISSION CONTROL ECU A...

Page 334: ...control ECU When this DTC is output it is necessary to replace the transmission control ECU DTC No DTC Detecting Condition Trouble Area P0603 98 S Check errors S Transmission control ECU P0613 99 S CPU communication malfunction S Transmission control ECU INSPECTION PROCEDURE 1 REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 05L4B 02 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index T...

Page 335: ...operates to enable normal driving even if there is a malfunction in the stop lamp signal circuit HINT Before performing the inspection procedure depress the brake pedal and check that the stop lamps come on DTC No DTC Detection Condition Trouble Area P0703 95 Conditions a b and c are detected simultaneously for 1 0 second or more a Ignition switch ON b STP signal OFF c ST1 signal OFF S ECU IG fuse...

Page 336: ...B Y G W G R SB SB R W R W From AM1 Fuse From IG1 Relay R W R W G W G W G R B O G W B Y G R G R J C SB G W 1 2 1 2 1 2 2 1 2 2 2 1 2 2 1 1 2 1 1 1 G R 2 6 5 1 26 9 6 5 1 2 5 2 39 9 52 62 2 1 4 3 10 4 1 2 3 4 E B E B B O 2 W DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 235 COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA...

Page 337: ...function the indicator keeps showing either ON or OFF no matter where the switch position is Brake Switch Signal 2 Brake switch signal 2 ON or OFF ON Brake pedal released OFF Brake pedal depressed Always ON or OFF STP Switch Signal STP switch signal ON or OFF ON Brake operation Always ON or OFF OK When the brake pedal is operated the normal conditions listed above are shown on the display NG Go to...

Page 338: ...NTROL ECU ASSY a Reconnect the stop lamp switch connector b Disconnect the M8 connector from the transmission con trol ECU c Turn the ignition switch on d Measure the voltage according to the value s in the table below Standard Pedal condition Tester connection Symbol Specified value Depressed M8 34 STP Body ground 10 to 14 V Released M8 34 STP Body ground Below 1 V Depressed M8 35 ST1 Body ground...

Page 339: ... ECU calculates the input shaft speed based on the voltage If the input shaft speed falls below a threshold when the vehicle is running the ECU interprets this as a mal function The ECU sets this DTC and illuminates the multi mode manual transmission warning light DTC No DTC Detection Condition Trouble Area P0715 19 The transmission control ECU detects the following conditions simultaneously a Veh...

Page 340: ...e Input Revolution Transmission input revolution Min 0 rpm Max 12 800 rpm Vehicle stopped 0 rpm When the input revolution signal has any malfunction the value cal culated by the vehicle speed sig nal will be shown 1 CHECK TRANSMISSION REVOLUTION SENSOR a Check the transmission revolution sensor installation OK The installation bolt is tightened properly and there is no clearance between the sensor...

Page 341: ...he transmission control ECU connector c Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value NIP M9 16 NIP M9 15 at 20_C 68_F 560 to 680 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR TRANSMISSION REVOLUTION SENSOR TRANSMISSION CONTROL ECU OK REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 BACK TO CHAPTER INDEX TO MODEL INDEX To...

Page 342: ...s DTC and illuminates the multi mode manual transmission warning light DTC No DTC Detection Condition Trouble Area P0725 13 S When the following condition lasts for a certain period the transmission control ECU detects this DTC The engine speed signal which is sent to the transmission control ECU from the ECM by the CAN communication differs from the engine speed signal from terminal NEO of the EC...

Page 343: ...E M9 10 E24 22 B 5 V NEO IG 05 242 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 344: ...olution Min 0 rpm Max 16 383 75 rpm Idling 650 to 750 rpm Even if the NE signal circuit is open or shorted the back up en gine speed from the CAN commu nication can be shown OK The engine speed displayed on the tester screen is almost the same as that indicated on the combination meter OK CHECK FOR INTERMITTENT PROBLEMS HINT Intelligent Tester II only Inspect the vehicle s ECU using check mode Int...

Page 345: ... switch on b Check the signal waveform between terminal NE and body ground OK A waveform similar to that in the illustration to the left is output HINT S Terminal NE Body ground S Gauge set 5 V DIV 1 ms DIV S Condition Engine idling OK REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 NG BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 11...

Page 346: ...nnector of the transmission control ECU and the E24 connector of the ECM b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value NE M9 10 NEO E24 22 Always Below 1 Ω NE M9 10 Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM SEE PAGE 10 15 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetica...

Page 347: ... arm rotation angle The clutch stroke sensor utilizes the main sensor and sub sensor to correctly determine the strokes of the clutch motor HINT S The clutch stroke sensor consists primarily of 2 Hall ICs main and sub and a magnetic yoke that ro tates together with the rotation of the clutch motor S The 2 Hall ICs convert the changes in the magnetic flux that are caused by the rotation of the clut...

Page 348: ...ontrol ECU P0807 25 Clutch stroke sensor main voltage is 0 2 V or less for 0 5 sec or more S Clutch stroke sensor S Open or short in clutch stroke sensor circuit S Transmission control ECU P0807 27 Clutch stroke sensor sub voltage is 0 2 V or less for 0 5 sec or more S Clutch stroke sensor S Open or short in clutch stroke sensor circuit S Transmission control ECU P0808 26 Clutch stroke sensor main...

Page 349: ...16 L B P W R B Y G Y 6 4 5 3 1 2 Hall IC Sub Hall IC Main IE4 IE4 IE4 IE4 IE4 5 V M9 M9 M9 M9 M9 GR R Y 1 2 B Y G Y 1 TMUK Made 2 TMMT Made 05 248 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 350: ... display is within the normal range HINT 0 A is shown on the display when the clutch actuator assy is not operating The value changes when the actuator is operating although it will only operate momentarily There may be a short in the actuator circuit if 1 A or more is shown for several seconds OK CHECK FOR INTERMITTENT PROBLEMS HINT Intelligent Tester II only Inspect the vehicle s ECU using check...

Page 351: ...inal 1 2 output voltage V 55_ Approx 4 5 V 0_ Approx 2 5 V 55_ Approx 0 5 V c Check the voltage of the clutch stroke sensor sub 1 Connect 3 dry cell batteries 1 5 V in series 2 Connect the positive battery lead to terminal 6 and the negative battery lead to terminal 5 3 Check the voltage between terminals 4 and 5 when moving the sensor arm Standard Combined dry cell battery voltage at 4 5 V Sensor...

Page 352: ...lue VCR2 M9 35 C22 6 Always Below 1 Ω VSR2 M9 34 C22 4 Always Below 1 Ω E2R2 M9 33 C22 5 Always Below 1 Ω VCR1 M9 27 C22 3 Always Below 1 Ω VSR1 M9 26 C22 1 Always Below 1 Ω E2R1 M9 25 C22 2 Always Below 1 Ω VCR2 M9 35 Body ground Always 10 kΩ or higher VSR2 M9 34 Body ground Always 10 kΩ or higher E2R2 M9 33 Body ground Always 10 kΩ or higher VCR1 M9 27 Body ground Always 10 kΩ or higher VSR1 M9 ...

Page 353: ...C Detection Condition Trouble Area P0810 35 The transmission control ECU detects the following conditions simultaneously a Clutch motor current is 22 A or more for 2 0 sec b The difference between the target clutch position and the actual clutch position is 0 3 mm 0 0118 in or more c The amount of clutch stroke movement is 122 mm 4 80 in sec or less S Clutch stroke sensor S Clutch actuator assy Cl...

Page 354: ... IE4 IE4 IE4 IE4 IE4 CPU C21 Clutch Actuator Assy Clutch Motor M 1 2 W L B Y 6 7 M7 M7 CPU MCL MCL 5 V Hall IC Sub Hall IC Main G Y GR 1 2 W R B Y G Y R Y 1 TMUK Made 2 TMMT Made DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 253 COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 355: ...played OK The value on the display is within the normal range HINT 0 A is shown on the display when the clutch actuator assy is not operating The value changes when the actuator is operating although it will only operate momentarily There may be a short in the actuator circuit if 1 A or more is shown for several seconds Result NG Clutch Motor Current MMT is defective A NG Clutch Position Current i...

Page 356: ...1 to 100 Ω NG REPLACE CLUTCH ACTUATOR ASSY SEE PAGE 42 26 OK 3 CHECK HARNESS AND CONNECTOR CLUTCH ACTUATOR ASSY TRANSMIS SION CONTROL ECU a Disconnect the M7 connector of the transmission control ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value MCL M7 6 C21 1 Always Below 1 Ω MCL M7 7 C21 2 Always Below 1 Ω MCL M7 6 Body...

Page 357: ...value MCL M7 6 GND M8 6 Ignition SW OFF ON Below 1 V 5 to 10 V MCL M7 7 GND M8 6 Ignition SW OFF ON Below 1 V 5 to 10 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK OPERATION CHECK HINT If the symptom still occurs even after checking the following parts for dirt wear etc and replacing the defec tive parts replace the transmission control ECU S Clutch Disc and Clutch Disc Cover see pa...

Page 358: ...inal 1 2 output voltage V 55_ Approx 4 5 V 0_ Approx 2 5 V 55_ Approx 0 5 V c Check the voltage of the clutch stroke sensor sub 1 Connect 3 dry cell batteries 1 5 V in series 2 Connect the positive battery lead to terminal 6 and the negative battery lead to terminal 5 3 Check the voltage between terminals 4 and 5 when moving the sensor arm Standard Combined dry cell battery voltage of 4 5 V Sensor...

Page 359: ... No Condition Specified value VCR2 M9 35 C22 6 Always Below 1 Ω VSR2 M9 34 C22 4 Always Below 1 Ω E2R2 M9 33 C22 5 Always Below 1 Ω VCR1 M9 27 C22 3 Always Below 1 Ω VSR1 M9 26 C22 1 Always Below 1 Ω E2R1 M9 25 C22 2 Always Below 1 Ω VCR2 M9 35 Body ground Always 10 kΩ or higher VSR2 M9 34 Body ground Always 10 kΩ or higher E2R2 M9 33 Body ground Always 10 kΩ or higher VCR1 M9 27 Body ground Alway...

Page 360: ...V VSR1 M9 26 E2R1 M9 25 Ignition SW ON 0 5 to 4 5 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK OPERATION CHECK HINT If the symptom still occurs even after checking the following parts for dirt wear etc and replacing the defec tive parts replace the transmission control ECU S Clutch Disc and Clutch Disc Cover see page 42 29 S Release Bearing see page 42 29 S Clutch Release Fork see ...

Page 361: ...sconnect the M7 connector of the transmission control ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value MCL M7 6 C21 1 Always Below 1 Ω MCL M7 7 C21 2 Always Below 1 Ω MCL M7 6 Body ground Always 10 kΩ or higher MCL M7 7 Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK BACK TO CHAPTER INDEX ...

Page 362: ...inal 1 2 output voltage V 55_ Approx 4 5 V 0_ Approx 2 5 V 55_ Approx 0 5 V c Check the voltage of the clutch stroke sensor sub 1 Connect 3 dry cell batteries 1 5 V in series 2 Connect the positive battery lead to terminal 6 and the negative battery lead to terminal 5 3 Check the voltage between terminals 4 and 5 when moving the sensor arm Standard Combined dry cell battery voltage of 4 5 V Sensor...

Page 363: ...l No Condition Specified value VCR2 M9 35 C22 6 Always Below 1 Ω VSR2 M9 34 C22 4 Always Below 1 Ω E2R2 M9 33 C22 5 Always Below 1 Ω VCR1 M9 27 C22 3 Always Below 1 Ω VSR1 M9 26 C22 1 Always Below 1 Ω E2R1 M9 25 C22 2 Always Below 1 Ω VCR2 M9 35 Body ground Always 10 kΩ or higher VSR2 M9 34 Body ground Always 10 kΩ or higher E2R2 M9 33 Body ground Always 10 kΩ or higher VCR1 M9 27 Body ground Alwa...

Page 364: ...Ignition SW OFF ON Below 1 V 5 to 10 V VCR2 M9 35 E2R2 M9 33 Ignition SW ON Approx 5 V VSR2 M9 34 E2R2 M9 33 Ignition SW ON 0 5 to 4 5 V VCR1 M9 27 E2R1 M9 25 Ignition SW ON Approx 5 V VSR1 M9 26 E2R1 M9 25 Ignition SW ON 0 5 to 4 5 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK OPERATION CHECK HINT If the symptom still occurs even after checking the following parts for dirt wear etc...

Page 365: ...osition that the transmission control ECU detects from the shift sensor and the select sensor differs from the signal from the back up lamp switch S The transmission control ECU detects the following condi tions a 1 Shift and select stroke sensors send R position signal to transmission control ECU 2 Back up lamp switch is OFF for 0 5 seconds b 1 Shift and select stroke sensors send non R position ...

Page 366: ...1 24 20 21 22 BR W GR R R L ID9 16 11 12 14 15 13 L B GR W L B L G R 6 4 5 3 1 2 ID9 ID9 ID9 ID9 ID9 RSW 9 M9 R B B B J C J48 J47 11 IE4 R W 1 2 B1 Back Up Lamp Switch From GAUGE Fuse 5 V 5 V M9 M9 M9 M9 M9 R L W L B L G R M9 M9 M9 M9 M9 R B R B DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 265 COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical In...

Page 367: ...al GND ON OPEN OFF Shift R position ON When there is any malfunction the indicator keeps showing either ON or OFF no matter where the gear position is OK When the shift lever is operated the normal condition listed above is shown on the display OK Go to step 4 NG 2 INSPECT BACK UP LAMP SWITCH ASSY a Remove the back up lamp switch b Measure the resistance according to the value s in the table below...

Page 368: ...l ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value RSW M9 9 B1 1 Always Below 1 Ω RSW M9 9 Body ground Always 10 kΩ or higher c Turn the ignition switch on d Measure the voltage according to the value s in the table below Standard Terminal No Condition Specified value B1 2 Body ground Ignition SW ON 10 to 14 V NG REPAIR ...

Page 369: ...nal 1 2 output voltage V 55_ Approx 4 5 V 0_ Approx 2 5 V 55_ Approx 0 5 V c Check the voltage of the shift stroke sensor sub 1 Connect 3 dry cell batteries 1 5 V in series 2 Connect the positive battery lead to terminal 6 and the negative battery lead to terminal 5 3 Check the voltage between terminals 4 and 5 when moving the sensor arm Standard Combined dry cell battery voltage of 4 5 V Sensor a...

Page 370: ...S2 M9 30 S25 6 Always Below 1 Ω VSS2 M9 29 S25 4 Always Below 1 Ω E2S2 M9 28 S25 5 Always Below 1 Ω VCS1 M9 19 S25 3 Always Below 1 Ω VSS1 M9 18 S25 1 Always Below 1 Ω E2S1 M9 17 S25 2 Always Below 1 Ω VCS2 M9 30 Body ground Always 10 kΩ or higher VSS2 M9 29 Body ground Always 10 kΩ or higher E2S2 M9 28 Body ground Always 10 kΩ or higher VCS1 M9 19 Body ground Always 10 kΩ or higher VSS1 M9 18 Bod...

Page 371: ...inal 1 2 output voltage V 55_ Approx 4 5 V 0_ Approx 2 5 V 55_ Approx 0 5 V c Check the voltage of the select stroke sensor sub 1 Connect 3 dry cell batteries 1 5 V in series 2 Connect the positive battery lead to terminal 6 and the negative battery lead to terminal 5 3 Check the voltage between terminals 4 and 5 when moving the sensor arm Standard Combined dry cell battery voltage of 4 5 V Sensor...

Page 372: ...w 1 Ω VSL2 M9 32 S22 4 Always Below 1 Ω E2L2 M9 24 S22 5 Always Below 1 Ω VCL1 M9 20 S22 3 Always Below 1 Ω VSL1 M9 21 S22 1 Always Below 1 Ω E2L1 M9 22 S22 2 Always Below 1 Ω VCL2 M9 31 Body ground Always 10 kΩ or higher VSL2 M9 32 Body ground Always 10 kΩ or higher E2L2 M9 24 Body ground Always 10 kΩ or higher VCL1 M9 20 Body ground Always 10 kΩ or higher VSL1 M9 21 Body ground Always 10 kΩ or h...

Page 373: ...ft lever and a Link 2 circuit that detects the and positions The circuits are connected to the shift lever via the respective links The contact switches 6 contact switches for Link 1 and 2 con tact switches for Link 2 of the circuits turn on and off in accordance with the fore aft movement of the shift lever The transmission control ECU determines the present shift lever position in accordance wit...

Page 374: ... 05 273 COROLLA Supplement RM1129E C t t P i t Shift Lever Position Contact Point R N E M SWRC OFF ON ON ON ON ON SWR ON OFF OFF OFF OFF OFF Li k 1 SWSC ON ON OFF OFF OFF OFF Link 1 SWS OFF OFF ON ON ON ON SWNC ON OFF ON ON ON ON SWN OFF ON OFF OFF OFF OFF Li k 2 SW OFF OFF OFF OFF ON OFF Link 2 SW OFF OFF OFF OFF OFF ON Transmission Shift Main Switch OFF OFF OFF ON ON ON BACK TO CHAPTER INDEX TO ...

Page 375: ...oth the LSWS signal and the LSSC signal are ON is detected 10 times within 15 0 seconds S Shift lever position sensor S Open in shift lever position signal circuit S Transmission control ECU P0820 73 P0820 76 The transmission control ECU detects the following condition a b or c a Both the LSWR signal and the LSRC signal are OFF for 5 0 seconds b Both the LSWR signal and the LSRC signal are ON for ...

Page 376: ... 9 10 11 12 13 15 16 17 18 19 11 12 13 IG IG IG IG IG IG M N R E M IG 4 2 RHD Instrument Panel J B 2T 4 M8 A GR SB W B SB W B J19 J C 29 7 M8 M8 M8 M8 M8 GR R W L W R B L B O G Y W B W B J C J12 B B J12 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 275 COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANU...

Page 377: ...ition is Shift Lever Switch Signal 5 Shift lever switch signal 5 GND ON OPEN OFF R OPEN N OPEN E OPEN M OPEN OPEN GND When there is any malfunction the indicator keeps showing either ON or OFF no matter where the lever position is Shift Lever Switch Signal 4 Shift lever switch signal 4 GND ON OPEN OFF R OPEN N GND E OPEN M OPEN OPEN OPEN When there is any malfunction the indicator keeps showing ei...

Page 378: ... 9 10 9 11 9 13 10 11 10 13 11 13 Below 1 Ω N position 2 4 2 6 2 10 2 11 4 6 4 10 4 11 6 10 6 11 10 11 Below 1 Ω E position 2 3 2 4 2 11 2 13 3 4 3 11 3 13 4 11 4 13 11 13 Below 1 Ω M position 2 3 2 4 2 11 2 13 3 4 3 11 3 13 4 11 4 13 11 13 Below 1 Ω position 2 3 2 4 2 11 2 13 3 4 3 11 3 13 4 11 4 12 4 13 11 12 11 13 Below 1 Ω position 2 3 2 4 2 11 2 13 3 4 3 11 3 13 4 5 4 11 4 13 5 11 11 13 Below...

Page 379: ... 1 Ω SWSC S26 10 LSSC M8 12 Always Below 1 Ω SWR S26 9 LSWR M8 18 Always Below 1 Ω SWN S26 6 LSWN M8 16 Always Below 1 Ω SW S26 5 LSW M8 19 Always Below 1 Ω SWS S26 3 LSWS M8 17 Always Below 1 Ω SWRC S26 2 LSRC M8 13 Always Below 1 Ω LSNC M8 11 Body ground Always 10 kΩ or higher LSW M8 15 Body ground Always 10 kΩ or higher LSSC M8 12 Body ground Always 10 kΩ or higher LSWR M8 18 Body ground Always...

Page 380: ...asure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value COM S26 4 Body ground Always Below 1 Ω COM S26 11 Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUP...

Page 381: ...n switch the transmission control ECU detects whether the shift lever position is in the E or M position Refer to DTC P0820 71 on page 05 272 DTC No DTC Detecting Condition Trouble Area P0821 79 The transmission control ECU detects the following conditions simultaneously a Shift lever position is N or R b MDSW signal is ON for 1 0 second S Transmission shift main switch Built into shift lever assy...

Page 382: ...K 2 CHECK HARNESS AND CONNECTOR TRANSMISSION SHIFT MAIN SWITCH BODY GROUND TRANSMISSION CONTROL ECU a Disconnect the M8 connector of the transmission control ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value MDSW T16 4 MDSW M8 10 Always Below 1 Ω GND T16 8 Body ground Always Below 1 Ω MDSW T16 4 Body ground Always 10 kΩ o...

Page 383: ... is open or disconnected DTC No DTC Detecting Condition Trouble Area P0885 17 The transmission control ECU detects the following conditions simultaneously a Voltage is supplied to MREL circuit b BM voltage is 6 29 V or less for 0 5 seconds S AMT fuse S AMT relay S Open in MREL signal circuit S Open in PGND signal circuit S Open in BM signal circuit S Transmission control ECU P0887 18 The transmiss...

Page 384: ...6 5 1 2 L R J C FL MAIN Battery EB EP M7 W B PGND W B 8 J47 D 6 6 6 6 6 1 2 W B L B L R B DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 283 COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 385: ...Ω When battery voltage is applied to terminals 1 2 NG REPLACE RELAY OK 2 INSPECT TRANSMISSION CONTROL ECU ASSY a Disconnect the M7 connector from the transmission con trol ECU b Turn the ignition switch on c Measure the voltage according to the value s in the table below Standard Symbol Terminal No Condition Specified value BM M7 2 PGND M7 8 Ignition SW ON 10 to 14 V NG Go to step 3 OK END NO FAUL...

Page 386: ...ition switch on b Measure the voltage according to the value s in the table below Standard Symbol Terminal No Condition Specified value MREL M9 5 Body ground Turn ignition SW OFF ON Below 1 V 10 to 14 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 387: ...nnector of the transmission control ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value MREL M9 5 AMT relay terminal 1 Always Below 1 Ω AMT relay terminal 2 Body ground Always Below 1 Ω PGND M7 8 Body ground Always Below 1 Ω MREL M9 5 Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK BACK TO CH...

Page 388: ...b Turn the ignition switch on c Measure the voltage according to the value s in the table below Standard Symbol Terminal No Condition Specified value BM M7 2 PGND M7 8 Turn ignition SW OFF ON Below 1 V 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA RE...

Page 389: ...rol ECU detects the following condition a b or c a 1 Clutch motor voltage is 0 5 V or less or 14 V or more for 0 5 seconds 2 BM voltage is 10 V or more b 1 Voltage is supplied to clutch motor 2 Clutch motor current is 5 A or more 3 Clutch motor current is 1 A or less 4 BM voltage is 10 V or more c 1 No voltage is supplied to clutch motor 2 Difference of maximum and minimum voltage of clutch motor ...

Page 390: ...ctuator is operating although it will only operate momentarily There may be a short in the actuator circuit if 1 A or more is shown for several seconds Result NG A OK When troubleshooting according to the PROBLEM SYMPTOM TABLE B OK When troubleshooting according to the DTC chart C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE SEE PAGE 05 219 C CHECK FOR INTERMITTENT PROBLEMS...

Page 391: ...CTUATOR ASSY SEE PAGE 42 20 OK 3 CHECK HARNESS AND CONNECTOR CLUTCH ACTUATOR ASSY TRANSMIS SION CONTROL ECU a Disconnect the M7 connector of the transmission control ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value MCL M7 6 C21 1 Always Below 1 Ω MCL M7 7 C21 2 Always Below 1 Ω MCL M7 6 Body ground Always 10 kΩ or higher...

Page 392: ...rmine the strokes of the select motor S The shift and select stroke sensors consist of 2 Hall ICs and a magnetic yoke that rotates together with the select motor The shift and select stroke sensors convert the changes in the magnetic flux that are caused by the rotation of the shift motor and the selector motor hence the rotation of the magnetic yoke into electric signals and output them to the tr...

Page 393: ...control ECU P0906 55 S Select stroke sensor main voltage is 0 2 V for 0 5 seconds or more S Select stroke sensor S Open or short in select stroke sensor circuit S Transmission control ECU P0906 57 S Select stroke sensor sub voltage is 0 2 V for 0 5 seconds or more S Select stroke sensor S Open or short in select stroke sensor circuit S Transmission control ECU P0907 56 S Select stroke sensor main ...

Page 394: ...R R R L BR W B L G R 1 2 3 4 5 6 20 21 22 24 31 32 14 15 13 16 12 11 Hall IC Sub Hall IC Main R L W L B L G R M9 M9 M9 M9 M9 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 293 COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 395: ... The value on the display is within the normal range when moving the shift lever Result NG A OK When troubleshooting according to the PROBLEM SYMPTOM TABLE B OK When troubleshooting according to the DTC chart C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE SEE PAGE 05 219 C CHECK FOR INTERMITTENT PROBLEMS HINT Intelligent Tester ll only Inspect the vehicle s ECU using check ...

Page 396: ...inal 1 2 output voltage V 55_ Approx 4 5 V 0_ Approx 2 5 V 55_ Approx 0 5 V c Check the voltage of the select stroke sensor sub 1 Connect 3 dry cell batteries 1 5 V in series 2 Connect the positive battery lead to terminal 6 and the negative battery lead to terminal 5 3 Check the voltage between terminals 4 and 5 when moving the sensor arm Standard Combined dry cell battery voltage of 4 5 V Sensor...

Page 397: ...lue VCL2 M9 31 S22 6 Always Below 1 Ω VSL2 M9 32 S22 4 Always Below 1 Ω E2L2 M9 24 S22 5 Always Below 1 Ω VCL1 M9 20 S22 3 Always Below 1 Ω VSL1 M9 21 S22 1 Always Below 1 Ω E2L1 M9 22 S22 2 Always Below 1 Ω VCL2 M9 31 Body ground Always 10 kΩ or higher VSL2 M9 32 Body ground Always 10 kΩ or higher E2L2 M9 24 Body ground Always 10 kΩ or higher VCL1 M9 20 Body ground Always 10 kΩ or higher VSL1 M9 ...

Page 398: ... malfunctions DTC No DTC Detecting Condition Trouble Area P0909 37 The transmission control ECU detects the following conditions simultaneously a Select motor current is 20 A or more for 2 0 seconds b A difference between the target select stroke and the actual select stroke is 0 3 mm 0 0118 in or more c The amount of select stroke movements is 125 mm 4 92 in sec or less S Select stroke sensor S S...

Page 399: ...2 L B GR L MSL B L G R GR R R L W L BR W VCL1 VSL1 E2L1 B M MSL 5 V 1 2 4 5 14 15 13 16 12 11 21 22 24 31 32 20 1 2 3 4 5 6 Hall IC Sub Hall IC Main B L G R W L R L 05 298 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 400: ...le ver Select Motor Current MMT Select motor current Min 50 A Max 50 A Normal value 0 to 20 A When not operating shift lever 0 A OK The value on the display is within the normal range when moving the shift lever Result NG Select Motor Current MMT is defective A NG Select Position is defective B NG Both items are defective C OK D B Go to step 5 C Go to step 8 D OPERATION CHECK HINT If symptoms stil...

Page 401: ...T SELECT ACTUATOR ASSY Refer to C53A MANUAL TRANSAXLE Repair Manual Pub No RM1117E OK 3 CHECK HARNESS AND CONNECTOR SELECT MOTOR TRANSMISSION CON TROL ECU a Disconnect the M7 connector of the transmission control ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value MSL M7 4 S24 1 Always Below 1 Ω MSL M7 5 S24 2 Always Below ...

Page 402: ... MSL M7 5 GND M8 6 Ignition SW OFF ON Below 1 V 5 to 10 V MSL M7 4 GND M8 6 Ignition SW OFF ON Below 1 V 5 to 10 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK OPERATION CHECK HINT If symptoms still occur even after checking the shift head for dirt wear etc and replacing the defective parts replace the transmission control ECU When a malfunction is found with the shift head replace t...

Page 403: ...inal 1 2 output voltage V 55_ Approx 4 5 V 0_ Approx 2 5 V 55_ Approx 0 5 V c Check the voltage of the select stroke sensor sub 1 Connect 3 dry cell batteries 1 5 V in series 2 Connect the positive battery lead to terminal 6 and the negative battery lead to terminal 5 3 Check the voltage between terminals 4 and 5 when moving the sensor arm Standard Combined dry cell battery voltage of 4 5 V Sensor...

Page 404: ... No Condition Specified value VCL2 M9 31 S22 6 Always Below 1 Ω VSL2 M9 32 S22 4 Always Below 1 Ω E2L2 M9 24 S22 5 Always Below 1 Ω VCL1 M9 20 S22 3 Always Below 1 Ω VSL1 M9 21 S22 1 Always Below 1 Ω E2L1 M9 22 S22 2 Always Below 1 Ω VCL2 M9 31 Body ground Always 10 kΩ or higher VSL2 M9 32 Body ground Always 10 kΩ or higher E2L2 M9 24 Body ground Always 10 kΩ or higher VCL1 M9 20 Body ground Alway...

Page 405: ... SW ON 0 5 to 4 5 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK OPERATION CHECK HINT If symptoms still occur even after checking the shift head for dirt wear etc and replacing the defective parts replace the transmission control ECU When a malfunction is found with the shift head replace the shift and select actuator assy refer to C53A MANUAL TRANSAXLE Repair Manual Pub No RM1117E 8...

Page 406: ... M7 connector of the transmission control ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value MSL M7 4 S24 1 Always Below 1 Ω MSL M7 5 S24 2 Always Below 1 Ω MSL M7 4 Body ground Always 10 kΩ or higher MSL M7 5 Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK BACK TO CHAPTER INDEX TO MODEL IND...

Page 407: ...inal 1 2 output voltage V 55_ Approx 4 5 V 0_ Approx 2 5 V 55_ Approx 0 5 V c Check the voltage of the select stroke sensor sub 1 Connect 3 dry cell batteries 1 5 V in series 2 Connect the positive battery lead to terminal 6 and the negative battery lead to terminal 5 3 Check the voltage between terminals 4 and 5 when moving the sensor arm Standard Combined dry cell battery voltage of 4 5 V Sensor...

Page 408: ...Symbol Terminal No Condition Specified value VCL2 M9 31 S22 6 Always Below 1 Ω VSL2 M9 32 S22 4 Always Below 1 Ω E2L2 M9 24 S22 5 Always Below 1 Ω VCL1 M9 20 S22 3 Always Below 1 Ω VSL1 M9 21 S22 1 Always Below 1 Ω E2L1 M9 22 S22 2 Always Below 1 Ω VCL2 M9 31 Body ground Always 10 kΩ or higher VSL2 M9 32 Body ground Always 10 kΩ or higher E2L2 M9 24 Body ground Always 10 kΩ or higher VCL1 M9 20 Bo...

Page 409: ... V VSL2 M9 32 E2L2 M9 24 Ignition SW ON 0 5 to 4 5 V VSL1 M9 21 E2L1 M9 22 Ignition SW ON 0 5 to 4 5 V MSL M7 5 GND M8 6 Ignition SW OFF ON Below 1 V 5 to 10 V MSL M7 4 GND M8 6 Ignition SW OFF ON Below 1 V 5 to 10 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK OPERATION CHECK HINT If symptoms still occur even after checking the shift head for dirt wear etc and replacing the defectiv...

Page 410: ...cts the following condition a b or c a 1 Select motor voltage is 0 5 V or less or 14 V or more for 0 5 seconds 2 BM voltage is 10 V or more b 1 Voltage is supplied to select motor 2 Select motor current is 5 A or more 3 Select motor current is 1 A or less 4 BM voltage is 10 V or more c 1 No voltage is supplied to select motor 2 Difference of maximum and minimum voltage of select motor terminal MSL...

Page 411: ...al range when moving the shift lever Result NG A OK When troubleshooting according to the PROBLEM SYMPTOM TABLE B OK When troubleshooting according to the DTC chart C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE SEE PAGE 05 219 C CHECK FOR INTERMITTENT PROBLEMS HINT Intelligent Tester II only Inspect the vehicle s ECU using check mode Intermittent prob lems are easier to de...

Page 412: ...onnect the select motor connector b Measure the resistance according to the value s in the table below Standard Terminal No Specified value 1 2 0 1 to 100 Ω NG REPLACE SHIFT SELECT ACTUATOR ASSY Refer to C53A MANUAL TRANSAXLE Repair Manual Pub No RM1117E OK BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 413: ...ission control ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value MSL M7 4 S24 1 Always Below 1 Ω MSL M7 5 S24 2 Always Below 1 Ω MSL M7 4 Body ground Always 10 kΩ or higher MSL M7 5 Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 BACK TO ...

Page 414: ...of the main sensor and sub sensor to correctly determine the strokes of the select motor S The shift and select stroke sensors consist of 2 Hall ICs and a magnetic yoke that rotates together with the shift motor The shift and select stroke sensors convert the changes in the magnetic flux that are caused by the rotation of the shift motor and the selector motor hence the rotation of the magnetic yo...

Page 415: ...mission control ECU P0916 45 S Shift stroke sensor main voltage is 0 2 V for 0 5 seconds or more S Shift stroke sensor S Open or short in shift stroke sensor circuit S Transmission control ECU P0916 47 S Shift stroke sensor sub voltage is 0 2 V for 0 5 seconds or more S Shift stroke sensor S Open or short in shift stroke sensor circuit S Transmission control ECU P0917 46 S Shift stroke sensor main...

Page 416: ... L B GR B G R W 1 2 3 4 5 6 BR R 4 5 3 6 2 7 17 18 19 28 29 30 Hall IC Sub Hall IC Main GR B W G M9 M9 M9 M9 M9 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 315 COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 417: ...value on the display is within the normal range when moving the shift lever Result NG A OK When troubleshooting according to the PROBLEM SYMPTOM TABLE B OK When troubleshooting according to the DTC chart C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE SEE PAGE 05 219 C CHECK FOR INTERMITTENT PROBLEMS HINT Intelligent Tester II only Inspect the vehicle s ECU using check mode ...

Page 418: ...nal 1 2 output voltage V 55_ Approx 4 5 V 0_ Approx 2 5 V 55_ Approx 0 5 V c Check the voltage of the shift stroke sensor sub 1 Connect 3 dry cell batteries 1 5 V in series 2 Connect the positive battery lead to terminal 6 and the negative battery lead to terminal 5 3 Check the voltage between terminals 4 and 5 when moving the sensor arm Standard Combined dry cell battery voltage of 4 5 V Sensor a...

Page 419: ...ue VCS2 M9 30 S25 6 Always Below 1 Ω VSS2 M9 29 S25 4 Always Below 1 Ω E2S2 M9 28 S25 5 Always Below 1 Ω VCS1 M9 19 S25 3 Always Below 1 Ω VSS1 M9 18 S25 1 Always Below 1 Ω E2S1 M9 17 S25 2 Always Below 1 Ω VCS2 M9 30 Body ground Always 10 kΩ or higher VSS2 M9 29 Body ground Always 10 kΩ or higher E2S2 M9 28 Body ground Always 10 kΩ or higher VCS1 M9 19 Body ground Always 10 kΩ or higher VSS1 M9 1...

Page 420: ...ons DTC No DTC Detecting Condition Trouble Area P0919 36 The transmission control ECU detects the following conditions simultaneously a Shift motor current is 32 A or more for 2 0 seconds b A difference between the target shift stroke and the actual shift stroke is 0 3 mm 0 0118 in or more c The amount of shift stroke movements is 125 mm 4 92 in sec or less S Shift stroke sensor S Shift and select...

Page 421: ...GR W MSF B G R W VCS1 VSS1 E2S1 B M MSF 5 V 1 2 3 1 4 5 3 6 2 7 18 17 28 30 29 19 1 2 3 4 5 6 BR R Hall IC Sub Hall IC Main M9 M9 M9 M9 M9 M7 GR B G W 05 320 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 422: ...operating shift le ver Shift Motor Current MMT Shift motor current Min 50 A Max 50 A Normal value 0 to 32 A when not operating shift lever 0 A OK The value on the display is within the normal range when moving the shift lever Result NG Shift Motor Current MMT is defective A NG Shift Position is defective B NG Both items are defective C OK D B Go to step 5 C Go to step 8 D OPERATION CHECK HINT If s...

Page 423: ... SELECT ACTUATOR ASSY Refer to C53A MANUAL TRANSAXLE Repair Manual Pub No RM1117E OK 3 CHECK HARNESS AND CONNECTOR SHIFT MOTOR TRANSMISSION CON TROL ECU a Disconnect the M7 connector of the transmission control ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value MSF M7 3 S23 1 Always Below 1 Ω MSF M7 1 S23 2 Always Below 1 ...

Page 424: ...tion Specified value MSF M7 1 GND M8 6 Ignition SW OFF ON Below 1 V 5 to 10 V MSF M7 3 GND M8 6 Ignition SW OFF ON Below 1 V 5 to 10 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK OPERATION CHECK HINT If symptoms still occur even after checking the following parts for dirt wear etc and replacing the defective parts replace the transmission control ECU S Synchronizer Ring S Shift Fork...

Page 425: ...nal 1 2 output voltage V 55_ Approx 4 5 V 0_ Approx 2 5 V 55_ Approx 0 5 V c Check the voltage of the shift stroke sensor sub 1 Connect 3 dry cell batteries 1 5 V in series 2 Connect the positive battery lead to terminal 6 and the negative battery lead to terminal 5 3 Check the voltage between terminals 4 and 5 when moving the sensor arm Standard Combined dry cell battery voltage of 4 5 V Sensor a...

Page 426: ...No Condition Specified value VCS2 M9 30 S25 6 Always Below 1 Ω VSS2 M9 29 S25 4 Always Below 1 Ω E2S2 M9 28 S25 5 Always Below 1 Ω VCS1 M9 19 S25 3 Always Below 1 Ω VSS1 M9 18 S25 1 Always Below 1 Ω E2S1 M9 17 S25 2 Always Below 1 Ω VCS2 M9 30 Body ground Always 10 kΩ or higher VSS2 M9 29 Body ground Always 10 kΩ or higher E2S2 M9 28 Body ground Always 10 kΩ or higher VCS1 M9 19 Body ground Always...

Page 427: ... E2S1 M9 17 Ignition SW ON 0 5 to 4 5 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK OPERATION CHECK HINT If symptoms still occur even after checking the following parts for dirt wear etc and replacing the defective parts replace the transmission control ECU S Synchronizer Ring S Shift Fork S Hub sleeve Refer to C53A MANUAL TRANSAXLE Repair Manual Pub No RM1117E 8 INSPECT SHIFT SELEC...

Page 428: ...M7 connector of the transmission control ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value MSF M7 3 S23 1 Always Below 1 Ω MSF M7 1 S23 2 Always Below 1 Ω MSF M7 3 Body ground Always 10 kΩ or higher MSF M7 1 Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK BACK TO CHAPTER INDEX TO MODEL INDE...

Page 429: ...inal 1 2 output voltage V 55_ Approx 4 5 V 0_ Approx 2 5 V 55_ Approx 0 5 V c Check the voltage of the shift stroke sensor sub 1 Connect 3 dry cell batteries 1 5 V in series 2 Connect the positive battery lead to terminal 6 and the negative battery lead to terminal 5 3 Check the voltage between terminals 4 and 5 when moving the sensor arm Standard Combined dry cell battery voltage of 4 5 V Sensor ...

Page 430: ...ymbol Terminal No Condition Specified value VCS2 M9 30 S25 6 Always Below 1 Ω VSS2 M9 29 S25 4 Always Below 1 Ω E2S2 M9 28 S25 5 Always Below 1 Ω VCS1 M9 19 S25 3 Always Below 1 Ω VSS1 M9 18 S25 1 Always Below 1 Ω E2S1 M9 17 S25 2 Always Below 1 Ω VCS2 M9 30 Body ground Always 10 kΩ or higher VSS2 M9 29 Body ground Always 10 kΩ or higher E2S2 M9 28 Body ground Always 10 kΩ or higher VCS1 M9 19 Bod...

Page 431: ...2S1 M9 17 Ignition SW ON Approx 5 V MSF M7 1 GND M8 6 Ignition SW OFF ON Below 1 V 5 to 10 V MSF M7 3 GND M8 6 Ignition SW OFF ON Below 1 V 5 to 10 V VSS2 M9 29 E2S2 M9 28 Ignition SW ON 0 5 to 4 5 V VSS1 M9 18 E2S1 M9 17 Ignition SW ON 0 5 to 4 5 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK OPERATION CHECK HINT If symptoms still occur even after checking the following parts for di...

Page 432: ...U detects the following condition a b or c a 1 Shift motor voltage is 0 5 V or less or 14 V or more for 0 5 seconds 2 BM voltage is 10 V or more b 1 Voltage is supplied to shift motor 2 Shift motor current is 5 A or more 3 Shift motor current is 1 A or less 4 BM voltage is 10 V or more c 1 No voltage is supplied to shift motor 2 Difference of maximum and minimum voltage of shift motor terminal MSF...

Page 433: ...ormal range when moving the shift lever Result NG A OK When troubleshooting according to the PROBLEM SYMPTOM TABLE B OK When troubleshooting according to the DTC chart C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE SEE PAGE 05 219 C CHECK FOR INTERMITTENT PROBLEMS HINT Intelligent Tester II only Inspect the vehicle s ECU using check mode Intermittent prob lems are easier to...

Page 434: ...onnect the shift motor connector b Measure the resistance according to the value s in the table below Standard Terminal No Specified value 1 2 0 1 to 100 Ω NG REPLACE SHIFT SELECT ACTUATOR ASSY Refer to C53A MANUAL TRANSAXLE Repair Manual Pub No RM1117E OK BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 435: ...ssion control ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value MSF M7 3 S23 1 Always Below 1 Ω MSF M7 1 S23 2 Always Below 1 Ω MSF M7 3 Body ground Always 10 kΩ or higher MSF M7 1 Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 BACK TO C...

Page 436: ... Area P1875 22 The transmission control ECU detects the following conditions simultaneously a The buzzer does not sound b Buzzer operation voltage is 3 V or less for 5 0 seconds S Transmission control ECU INSPECTION PROCEDURE 1 CHECK BUZZER a Turn the ignition switch on b Shift the lever into reverse OK The buzzer sounds NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK 2 CHECK OTHER DTCs...

Page 437: ...ission control ECU and ECM communicate with each other via the CAN communication line DTC No DTC Detecting Condition Trouble Area U0001 A2 S No communication from the ECM S Open or short in CAN signal circuit S ECM S Transmission control ECU 05MQ6 01 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 438: ... CANL W B CAN LOW CAN HIGH 7 1 1 E24 44 E24 24 CG BAT 16 4 2T 4 2F 2 2T 7 2F 6 2F 11 2F 11 2B 1 1D 1 1A 1 Battery EA II A J4 J C W SB W B Engine Room R B J B ALT 1 2 B FL MAIN R G Y1 Yaw Rate Sensor D5 DLC3 ECM SB W B OBD Instrument Panel J B S13 Steering Sensor 1 J C 1 Shielded 2 LHD 3 RHD 7 49 J19 J C DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 337 COROLLA Supplement RM1129E WIRING DIAG...

Page 439: ... under Normal Condition are reference values Do not depend solely on these reference values when deciding whether a part is faulty or not a Warm up the engine b Turn the ignition switch off c Connect the intelligent tester II to the DLC3 d Turn the ignition switch on e Following the display on the tester read the DATA LIST Item Measurement Item Range Normal Condition Diagnostic Note Backup Engine ...

Page 440: ...ard Tester connection Condition Specified value Result D5 6 CANH D5 14 CANL Ignition SW OFF 54 to 69 Ω OK D5 6 CANH D5 14 CANL Ignition SW OFF 67 Ω or more NG A D5 6 CANH D5 14 CANL Ignition SW OFF 54 Ω or less NG B NG A CHECK CAN MAIN BUS LINE FOR DISCONNECTION NG B CHECK CAN BUS LINES FOR SHORT CIRCUIT OK 2 CHECK CAN BUS LINE CAN H FOR SHORT TO B a Measure the resistance according to the value s...

Page 441: ...on SW OFF 1 MΩ or more NG CHECK CAN BUS LINE CAN L FOR SHORT TO B OK 4 CHECK CAN BUS LINE CAN H FOR SHORT TO GND a Measure the resistance according to the value s in the table below Standard Tester connection Condition Specified value D5 4 CG D5 6 CANH Ignition SW OFF 100 Ω or more NG CHECK CAN BUS LINE CAN H FOR SHORT TO GND OK 5 CHECK CAN BUS LINE CAN L FOR SHORT TO GND a Measure the resistance ...

Page 442: ...and CAN of the transmission control ECU OK The correct waveforms are as shown on the left HINT Gauge set 1 V DIV 50 µs DIV NG REPLACE ECM SEE PAGE 10 15 OK REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK GO TO VSC SYSTEM Refer to COROLLA Repair Manual Pub No RM925E on page 05 662 If the problem reoccurs even after replacement replace the ECM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabet...

Page 443: ... 4 1 1 2 1 1 2 1 2 1 2 1 05 342 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM COROLLA Supplement RM1129E IG SIGNAL CIRCUIT CIRCUIT DESCRIPTION When the ignition switch is turned on positive battery voltage is applied to terminal IG of the transmission control ECU Power is supplied to the transmission control ECU via terminal B or IG WIRING DIAGRAM 05L4T 02 BACK TO CHAPTER INDEX TO MODEL INDEX ...

Page 444: ... Turn the ignition switch on c Measure the voltage according to the value s in the table below Standard Symbols Terminal No Condition Voltage IG M8 3 Body ground Ignition SW OFF ON Below 1 V 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE SEE PAGE 05 219 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Inde...

Page 445: ...SYSTEM COROLLA Supplement RM1129E SHIFT LOCK SOLENOID CIRCUIT CIRCUIT DESCRIPTION Receiving the shift lock cancellation signal from the transmission control ECU the shift lock solenoid built into shift lever assy starts working WIRING DIAGRAM 05L4U 02 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 446: ... Specified value 2 6 at 20_C 68_F 30 to 35 Ω NG REPLACE SHIFT LOCK SOLENOID SEE PAGE 41 11 OK 2 CHECK HARNESS AND CONNECTOR SHIFT LOCK SOLENOID TRANSMISSION CONTROL ECU BODY GROUND a Disconnect the M8 connector of the transmission control ECU b Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value SLS M8 5 IG T16 2 Always Below 1 Ω...

Page 447: ...ion switch on c Measure the voltage according to the value s in the table below Standard Symbol Terminal No Condition Specified value SLS M8 5 Body ground Brake pedal depressed Released 10 to 14 V Below 1 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE SEE PAGE 41 33 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical...

Page 448: ...MISSION SYSTEM 05 347 COROLLA Supplement RM1129E NEUTRAL POSITION SWITCH ASSY CIRCUIT CIRCUIT DESCRIPTION The neutral switch detects the neutral of the transmission gear position and sends a signal to the transmis sion control ECU Based on the signal the ECU detects the gear position neutral The engine starts when the ignition switch is turned on with the brake pedal depressed and the gear in neu ...

Page 449: ...ASSY SEE PAGE 41 32 OK 2 CHECK HARNESS AND CONNECTOR TRANSMISSION CONTROL ECU BAT TERY a Reconnect the neutral position switch connector b Disconnect the M9 connector of the transmission control ECU c Turn the ignition switch on d Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value TMN M9 3 Body ground Shift lever position non N ...

Page 450: ... the INDC and INDA circuits and illuminates the warning light or sounds the buzzer inside the meter The contents of signals from the INDC and INDA circuits and the states of the multi mode manual transmis sion warning light and buzzer are shown in the table below When ignition switch is ON INDA circuit state When signal is normal When inconsistent signal is received for 3 sec or more When communic...

Page 451: ... combination meter OFF OFF OFF ON OFF ON Condition for sleep mode When receiving communication in terruption signal from INDC circuit When receiving communication in terruption signal from INDC circuit 8 sec after receiv ing communication interruption signal from INDA circuit Vehicle state when ignition switch is off Open or short in INDC circuit Noise occurs when receiving S Transmission control ...

Page 452: ...V 5 V CPU Buzzer Multi mode Manual Transmission Warning Light 15 6 5 J5 J C SB L Y SB L Y SB LG SB LG DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 351 COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 453: ...transmission warning light does not come on there may be a malfunction in the INDA and or INDC circuits 1 CHECK HARNESS AND CONNECTOR TRANSMISSION CONTROL ECU COM BINATION METER a Disconnect the M8 connector of the transmission control ECU and the combination meter connector b Measure the resistance according to the table below Standard Symbol Terminal No Condition Specified value INDC M8 29 C12 1...

Page 454: ...e table below Standard Terminal No Condition Specified value C12 10 Body ground Ignition SW OFF ON Approx 3 64 V Approx 1 44 V C12 11 Body ground Always Approx 1 44 V NG REPLACE COMBINATION METER ASSY Refer to COROLLA Repair Manual Pub No RM1106E on page 71 6 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE SEE PAGE 05 219 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical I...

Page 455: ...M1129E TC TERMINAL CIRCUIT CIRCUIT DESCRIPTION This circuit outputs trouble codes on the combination meter when terminals TC and CG of the DLC3 are con nected 05L4X 02 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 456: ...2F II W B P B 4 13 25 28 28 68 P B 8 11 1 LHD 2 RHD W EMPS ECU TC E24 J4 J C Instrument Panel J B P B W 2H 2L 2L 2P 2T 2F P B 7 3 7 4 11 11 SB W B SB W B SB P B W 1 2 1 2 1 2 SB W B 1 2 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 355 COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 457: ... is suspected INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR TC of DLC3 TRANSMISSION CONTROL ECU a Disconnect the M8 connector from the transmission con trol ECU b Measure the resistance according to the value s in the table below Standard Tester connection Condition Specified condition DG M8 25 TC D5 13 Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR DLC3 TRANSMISSION CON TROL ECU ...

Page 458: ...nd Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR DLC3 BODY GROUND OK 3 CHECK HARNESS AND CONNECTOR TC of DLC3 BODY GROUND a Measure the resistance according to the value s in the table below Standard Tester connection Condition Specified condition TC D5 13 Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE WIRE HARNESS OR EACH ECU OK REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE...

Page 459: ...RCUIT DESCRIPTION When the shift lever is in the E position the most appropriate gear is automatically selected according to the accelerator pedal opening angle and vehicle speed During automatic shift control shift control can be switched between normal E and sports Es modes by pressing the pattern select switch WIRING DIAGRAM 05L4Y 02 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To...

Page 460: ... kΩ or higher NG REPLACE PATTERN SELECT SWITCH ASSY SEE PAGE 41 11 OK 2 CHECK HARNESS AND CONNECTOR TRANSMISSION CONTROL ECU BODY GROUND a Reconnect the pattern select switch connector b Disconnect the M8 connector of the transmission control ECU c Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value PWR M8 23 Body ground Pattern ...

Page 461: ...ording to the value s in the table below Standard Symbol Terminal No Condition Specified value PWR M8 23 Body ground Ignition SW ON pattern select SW OFF ON 10 to 14 V Below 1 8 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE SEE PAGE 05 219 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA...

Page 462: ...PTION LHD vehicles are equipped with a kick down switch along with the normal automatic shift control E position When the kick down switch is turned on the most appropriate gear is automatically selected according to the vehicle speed The kick down switch can also detect when the throttle valve is fully open WIRING DIAGRAM 05L4Z 02 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub ...

Page 463: ...higher Below 1 Ω NG REPLACE KICK DOWN SWITCH OK 2 CHECK HARNESS AND CONNECTOR TRANSMISSION CONTROL ECU BODY GROUND a Reconnect the kick down switch connector b Disconnect the M8 connector of the transmission control ECU c Measure the resistance according to the value s in the table below Standard Symbol Terminal No Condition Specified value KD M8 27 Body ground Kick down SW OFF ON 10 kΩ or higher ...

Page 464: ...re the voltage according to the value s in the table below Standard Symbol Terminal No Condition Specified value KD M8 27 Body ground Ignition SW ON kick down SW OFF ON 10 to 14 V Below 1 8 V NG REPLACE TRANSMISSION CONTROL ECU ASSY SEE PAGE 41 33 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE SEE PAGE 05 219 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub ...

Page 465: ...pedal is pressed the transmission control ECU turns on the shift lock solenoid in order to release shift lock b When the shift lever is shifted into the N position the transmission control ECU detects that the shift lever position is N using the shift position sensor c When the ignition switch is turned to the START position the start signal is sent to the transmission control ECU through the neut...

Page 466: ... J44 2C 2S 2M 2B J21 S2 2M 2S 3 1 3 3 3 3 1 4 6 B 2 8 3 B B 1 6 8 3 2 1 5 3 2 1 A A 7 A B 1 1 B B R B W SB B W SB B W B R B W B R W B B B R B R 1 LHD 2 RHD 1 2 1 2 1 2 DIAGNOSTICS MULTI MODE MANUAL TRANSMISSION SYSTEM 05 365 COROLLA Supplement RM1129E WIRING DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 467: ... switch to the START position c Measure the voltage according to the value s in the table below Standard Symbol Terminal No Condition Specified value STA M9 6 Body ground Ignition SW OFF START Below 1 V 10 to 14 V OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE SEE PAGE 05 219 NG 3 INSPECT TRANSMISSION CONTROL ECU ASSY STRL a Turn the ignition switch to the START position b M...

Page 468: ...minal No Condition Specified value STRL M9 4 STA M9 6 Always Below 1 Ω STRL M9 4 ST relay terminal 1 Always Below 1 Ω STRL M9 4 Body ground Always 10 kΩ or higher ST relay terminal 2 Body ground Always Below 1 Ω ST relay terminal 3 S3 1 Always Below 1 Ω ST relay terminal 3 Body ground Always 10 kΩ or higher d Measure the voltage according to the value s in the table below Standard Symbol Terminal ...

Page 469: ...ission control ECU cancels the take off assist control WIRING DIAGRAM INSPECTION PROCEDURE 1 INSPECT PARKING BRAKE SWITCH ASSY a Remove the parking brake switch b Measure the resistance according to the value s in the table below Standard Tester connection Condition Specified resistance 1 Switch body OFF When shaft is pressed 10 kΩ or higher 1 Switch body ON When shaft is not pressed Below 1 Ω NG ...

Page 470: ...Parking Brake SW OFF ON 10 kΩ or higher Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT TRANSMISSION CONTROL ECU ASSY a Reconnect the transmission control ECU connector b Turn the ignition switch on c Measure the voltage according to the value s in the table below Standard Symbol Terminal No Condition Specified value PKB M8 4 Body ground Ignition SW ON Parking Brake SW OFF ON 10 t...

Page 471: ...1 05 370 DIAGNOSTICS COMBINATION METER 1ND TV COROLLA Supplement RM1129E COMBINATION METER 1ND TV SYSTEM DIAGRAM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 472: ...BELT IN C11 11 P BELT IN C11 7 FUEL C11 16 KEY SWITCH C11 22 FUEL EARTH ILLUMINATION ILLUMINATION MMT LCD BEAM TAIL DOOR TURN L TURN R Fr FOG Rr FOG I F RESET SHAFT FUEL WNG OIL LEVEL MMT I F I F I F I F I F I F I F I F I F LCD ODO TRIP LCD MMT LCD POWER SPEED TACHO FUEL TEMP I F I F ES D BELT CPU C11 15 ST I F I F C11 20 DIAGNOSTICS COMBINATION METER 1ND TV 05 371 COROLLA Supplement RM1129E BACK ...

Page 473: ...OIL PRESSURE C12 3 VSC C12 2 SLIP C12 4 TRC OFF C12 12 CRUISE CRUISE TRC OFF SLIP VSC AIR BAG A B ACTIVE ABS ACTIVE EMPS ACTIVE EBD ACTIVE CHECK E G GLOW BRAKE P S ABS OIL P C11 39 AIRBAG C11 32 IG2 05 372 DIAGNOSTICS COMBINATION METER 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 474: ...Ignition Switch 32 IG2 Fuse 33 ECM Check Engine 34 35 Brake Fluid Level Warning Switch 36 Brake Actuator Assy ABS 1 ABS Traction Actuator Assy VSC 2 37 Brake Actuator Assy ABS 1 ABS Traction Actuator Assy VSC 2 38 EMPS ECU 39 Airbag Sensor Assy Center 40 Rear Fog Lamp Switch 5 Fog Lamp Switch 6 C12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ABS Traction Actuator Assy VSC 2 ABS Traction Actuator Assy V...

Page 475: ...ig nal Turn the ignition switch ON coolant temperature is 80 to 95_C 176 to 203_F Pulse generation See wave form 2 SI C11 9 Body ground W Body ground Speed signal Input Turn the ignition switch ON and turn the wheel slowly Pulse generation See wave form 3 4P OUT C11 10 Body ground W Body ground Speed signal Output Turn the ignition switch ON and turn the wheel slowly Pulse generation See wave form...

Page 476: ...Body ground CHECK ENGINE signal CHECK ENGINE warning light ON OFF Below 2 V 8 to 14 V BRAKE LEVEL SW C11 35 Body ground W R Y Body ground Brake fluid level signal Brake fluid level warning light ON OFF Below 1 V 8 to 14 V EBD C11 36 Body ground W R W Body ground ABS or VSC signal EBD warning light ON OFF 5 to 9 V Below 1 V ABS C11 37 Body ground W W R Body ground ABS signal ABS warning light ON OF...

Page 477: ...nal Ignition switch ON and CRUISE in dicator light ON OFF Below 1 V 10 to 14 V 1 w Daytime running light 2 w o Daytime running light 3 w VSC 4 Diesel The wiring color differs depending on the vehicle Wave Form 1 Reference Using oscilloscope Item Condition Tool setting 5 V DIV 10 ms DIV Vehicle condition Passenger seat belt indicator light blinks Wave Form 2 Reference Using oscilloscope Item Condit...

Page 478: ...scope Item Condition Tool setting 5 V DIV 10 ms DIV Vehicle condition Engine idle speed Wave Form 5 Reference Using oscilloscope Item Condition Tool setting 1 V DIV 1 ms DIV Vehicle condition Ignition switch ON BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 479: ...GINE FOR MORE THAN 10 SECONDS NEXT 4 CHECK FOR DTC a Check if DTC B2799 is output or not Result Result Proceed to DTC B2799 is not output A DTC B2799 is output B B Go to step 7 A 5 CHECK FOR CODE a Check for codes and note any codes that are output b Turn the ignition switch OFF c Recheck for codes Based on the code output in a try to force output of the same code by simulating the operation indic...

Page 480: ...ed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 8 A 7 OVERALL ANALYSIS AND TROUBLESHOOTING a Pre check see page 05 381 b Terminals of ECU see page 05 387 NEXT 8 REPAIR OR REPLACE NEXT 9 CONFIRMATION TEST NEXT END BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 481: ...ot set Engine starts with unregistered key codes Weather Conditions When Problem Occurred Weather Outdoor Temperature Only once Fine Various Other Cloudy Rainy Snowy Hot Approx _C _F Warm Cool ENGINE IMMOBILIZER SYSTEM Check Sheet Production Date VIN License Plate No Odometer Reading Cold 05 380 DIAGNOSTICS ENGINE IMMOBILIZER SYSTEM 1ND TV COROLLA Supplement RM1129E CUSTOMER PROBLEM ANALYSIS CHECK...

Page 482: ...ed Condition SIL 7 SG 5 Bus line During transmission Pulse generation CG 4 Body ground Chassis ground Always Below 1 Ω SG 5 Body ground Signal ground Always Below 1 Ω BAT 16 Body ground Battery positive Always 11 to 14 V If the result is not as specified the DLC3 may have a malfunction Repair or replace the harness and connec tor HINT Connect the cable of the intelligent tester ll to the DLC3 turn...

Page 483: ...the DTCs by following the directions on the tester s screen HINT Refer to the intelligent tester ll operator s manual for further de tails 3 CHECK TRANSPONDER KEY ECU CODE NOT USING INTELLIGENT TESTER ll a Using SST connect terminal 8 OPA and 4 CG of the DLC3 SST 09843 18040 b Turn the ignition switch ON c Read the code from the security indicator HINT S If 2 or more codes are detected at the same...

Page 484: ...der and immobilizer system is OFF 22 Sub key is inserted in ignition key cylinder and immobilizer system is OFF 31 Key code recorded in transponder key ECU differs from code of key inserted in ignition key cylinder 32 Transponder key code cannot be read 33 Key code cannot be read because format of chip inside key is wrong 34 Transponder key ECU has no memory space to register key code 4 CLEAR DTC ...

Page 485: ...E The DTC for the immobilizer system is specified If other codes are output check the DTC chart of the ECD system DTC No See Page Detection Item Trouble Area B2799 05 393 Engine Immobiliser System Malfunction S Wire harness S ECM BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 486: ... Indicator ECM Front Door Courtesy Switch Assy DLC3 Unlock Warning Switch Assy Engine Room R B J B F AM1 Fuse F AM2 Fuse Transponder Key Amplifier DIAGNOSTICS ENGINE IMMOBILIZER SYSTEM 1ND TV 05 385 COROLLA Supplement RM1129E LOCATION BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 487: ...fier R B No 6 RHD Engine Room R B J B F AM1 Fuse F AM2 Fuse Security Indicator ECM Front Door Courtesy Switch Assy DLC3 Unlock Warning Switch Assy 05 386 DIAGNOSTICS ENGINE IMMOBILIZER SYSTEM 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 488: ...y inserted 10 to 14 V CODE T6 2 GND T6 3 P R Demodulated signal of transponder ID data No key in ignition key cylinder Pulse generation see waveform 1 CODE T6 2 GND T6 3 P R Demodulated signal of transponder ID data Key inserted Pulse generation see waveform 1 RXCK T6 4 GND T6 3 V R Clock signal No key in ignition key cylinder Pulse generation see waveform 2 RXCK T6 4 GND T6 3 V R Clock signal Key...

Page 489: ...tion Condition Specified Condition B T7 1 GND T7 14 SB R G W B Battery Always 10 to 14 V IG T7 2 GND T7 14 B W 1 W B SB B W 2 W B Ignition power supply Ignition switch OFF 0 V IG T7 2 GND T7 14 B W 1 W B SB B W 2 W B Ignition power supply Ignition switch ON 10 to 14 V KSW T7 9 GND T7 14 L B W B Unlock warning switch No key in ignition key cylinder 10 kΩ or higher KSW T7 9 GND T7 14 L B W B Unlock ...

Page 490: ...D T7 12 V R Transponder key amplifier communication signal No key in ignition key cylinder Pulse generation see waveform 3 RXCK T7 5 AGND T7 12 V R Transponder key amplifier communication signal Key inserted Pulse generation see waveform 3 EFIO T7 11 GND T7 14 LG R W B ECM output signal Ignition switch OFF Pulse generation see waveform 4 EFIO T7 11 GND T7 14 LG R W B ECM output signal Ignition swi...

Page 491: ...ed Waveform 3 Reference Terminal RXCK GND Tool Setting 10 V DIV 20 msec DIV Condition No key in ignition key cylinder key inserted Waveform 4 Reference Terminal EFIO GND Tool Setting 5 V DIV 5 msec DIV Condition Ignition switch OFF ON Waveform 5 Reference Terminal EFII GND Tool Setting 5 V DIV 5 msec DIV Condition Ignition switch OFF ON BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To...

Page 492: ...m 1 IMI E24 6 E1 E24 2 LG R W B Transponder key ECU in put signal Ignition switch ON Pulse generation see waveform 2 E1 E24 2 Body ground W B Body ground Ground Always Below 1 Ω E1 E24 41 Body ground W B Body ground Ground Always Below 1 Ω E1 E24 62 Body ground W B Body ground Ground Always Below 1 Ω If the result is not as specified the ECM may have a malfunction b Inspect using an oscilloscope W...

Page 493: ...ourtesy lamp switch assy S Wire harness S Transponder key ECU assy 05 412 Ignition switch is ON but code 13 is not output ignition or starter switch assy circuit may be malfunctioning 1 Ignition switch assy circuit S IG2 Fuse S Wire harness S Transponder key ECU assy 05 403 Master key is used to turn ignition switch ON but code 21 is not output transponder key amplifier circuit may be malfunctioni...

Page 494: ...ECU 2 the ECM detects errors in the communication lines and 3 the ECU communication ID of the trans ponder key ECU and the ECM are different DTC No DTC Detection Condition Trouble Area B2799 S Error in communication between ECM and transponder key ECU assy S Error in communication line S Communication ID is different during communication be tween transponder key ECU and ECM S Wire harness S ECM WI...

Page 495: ... WIRE HARNESS TRANSPONDER KEY ECU ASSY ECM a Disconnect the T7 ECU connector b Disconnect the E24 ECM connector c Measure the resistance of the wire harness side connec tors Standard Tester Connection Specified Condition T7 11 EFIO E24 6 IMI Below 1 Ω T7 10 EFII E24 4 IMO Below 1 Ω T7 11 EFIO or E24 6 IMI Body ground 10 kΩ or higher T7 10 EFII or E24 4 IMO Body ground 10 kΩ or higher NG REPAIR OR ...

Page 496: ...ed in the ECU is inserted into the ignition key cylinder Code No Detection Condition Trouble Area 31 Key with unregistered key code is inserted Key INSPECTION PROCEDURE 1 REREGISTER KEY a Reregister the key and check that the engine starts with the key OK Engine starts NG REPLACE KEY OK END 05B0G 13 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUA...

Page 497: ...IPTION When a key is inserted into the ignition key cylinder but no communication occurs between the key and trans ponder key ECU code 32 is output When a key is inserted into the ignition key cylinder but a communication error occurs between the key and transponder key ECU code 33 is output Code No Detection Condition Trouble Area 32 No communication S Wire harness S Transponder key amplifier S T...

Page 498: ...Y TRANSPONDER KEY AMPLIFIER a Disconnect the T7 ECU connector b Disconnect the T6 amplifier connector c Measure the resistance of the wire harness side connec tors Standard Tester Connection Specified Condition T7 6 VC12 T6 5 B Below 1 Ω T7 4 CODE T6 2 CODE Below 1 Ω T7 13 TXCT T6 1 TXCT Below 1 Ω T7 12 AGND T6 3 GND Below 1 Ω T7 5 RXCK T6 4 RXCK Below 1 Ω T7 6 VC12 or T6 5 B Body ground 10 kΩ or ...

Page 499: ...er replacing the transponder key amplifier with a normally functioning transponder key amplifier check that the engine starts OK Engine starts NG REPLACE TRANSPONDER KEY ECU ASSY OK END TRANSPONDER KEY AMPLIFIER DEFECTIVE BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 500: ...CH CIRCUIT CIRCUIT DESCRIPTION The unlock warning switch is ON while the key is in the ignition key cylinder WIRING DIAGRAM INSPECTION PROCEDURE 1 CHECK FOR CODE a Insert the key into the ignition key cylinder b Check for code see page 05 381 OK Code 11 is output NG Go to step 2 OK END NORMAL 05KGT 06 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MAN...

Page 501: ...Ω 1 2 Not pushed 10 kΩ or higher NG REPLACE UNLOCK WARNING SWITCH ASSY OK 3 CHECK WIRE HARNESS UNLOCK WARNING SWITCH ASSY TRANSPONDER KEY ECU ASSY AND BODY GROUND a Disconnect the T7 ECU connector b Disconnect the U1 switch connector c Measure the resistance of the wire harness side connec tors Standard Tester Connection Specified Condition T7 9 KSW U1 2 Below 1 Ω U1 1 Body ground Below 1 Ω NG REP...

Page 502: ... LHD 2 RHD Engine Room J B R B 1 1B W 1 2 ALT 14 1 2 6 6 W R B No 6 B DIAGNOSTICS ENGINE IMMOBILIZER SYSTEM 1ND TV 05 401 COROLLA Supplement RM1129E ECU POWER SOURCE CIRCUIT CIRCUIT DESCRIPTION This circuit provides power to the transponder key ECU WIRING DIAGRAM 05KGV 06 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 503: ...NG REPLACE FUSE OK 2 CHECK WIRE HARNESS TRANSPONDER KEY ECU ASSY BATTERY AND BODY GROUND a Disconnect the T7 ECU connector b Measure the resistance and voltage of the wire harness side connector Standard Tester Connection Specified Condition T7 1 B Body ground 10 to 14 V T7 14 GND Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE TRANSPONDER KEY ECU ASSY BACK TO CHAPTER I...

Page 504: ... 1 Engine Room R B J B 1 2 1 1 1A AM2 B R B Main Battery J4 J C J12 J C W B W B B B A II 1 LHD 2 RHD 4 1 SB B W 2 DIAGNOSTICS ENGINE IMMOBILIZER SYSTEM 1ND TV 05 403 COROLLA Supplement RM1129E IGNITION SWITCH CIRCUIT CIRCUIT DESCRIPTION This circuit provides power to operate the transponder key ECU WIRING DIAGRAM 05MPW 01 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYO...

Page 505: ...panel J B b Remove the AM2 fuse from the engine room R B c Measure the resistance of the fuses Standard Below 1 Ω NG REPLACE FUSE OK 3 CHECK WIRE HARNESS TRANSPONDER KEY ECU BATTERY AND BODY GROUND a Measure the resistance of the switch Standard Tester Connection Switch Condition Specified Condition 1 IG2 4 AM2 LOCK 10 kΩ or higher 1 IG2 4 AM2 ON Below 1 Ω NG REPLACE IGNITION SWITCH ASSY OK BACK T...

Page 506: ...easure the resistance and voltage of the wire harness side connector Standard Tester Connection Condition Specified Condition T7 2 IG Body ground Ignition switch OFF 0 V T7 2 IG Body ground Ignition switch ON 10 to 14 V T7 14 GND Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE TRANSPONDER KEY ECU ASSY BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To ...

Page 507: ...CIRCUIT DESCRIPTION Inserting the key into the ignition key cylinder will activate the transponder key ECU and it will begin commu nication with the transponder key amplifier WIRING DIAGRAM INSPECTION PROCEDURE 1 CHECK FOR CODE a Insert the master key or sub key into the ignition key cylinder b Check for code see page 05 381 OK Code 21 or 22 is output NG Go to step 2 OK END 05LVG 02 BACK TO CHAPTE...

Page 508: ...dard Tester Connection Specified Condition T7 6 VC12 T6 5 B Below 1 Ω T7 4 CODE T6 2 CODE Below 1 Ω T7 13 TXCT T6 1 TXCT Below 1 Ω T7 12 AGND T6 3 GND Below 1 Ω T7 5 RXCK T6 4 RXCK Below 1 Ω T7 6 VC12 or T6 5 B Body ground 10 kΩ or higher T7 4 CODE or T6 2 CODE Body ground 10 kΩ or higher T7 13 TXCT or T6 1 TXCT Body ground 10 kΩ or higher T7 12 AGND or T6 3 GND Body ground 10 kΩ or higher T7 5 RX...

Page 509: ...CT SECURITY INDICATOR a Apply 12 V to the terminals of the indicator and check the lighting condition of the security indicator OK Tester Connection Specified Condition Battery potitive 3 IND Battery negative 1 GND Illuminates NOTICE S If the positive lead and the negative lead are in correctly connected the security indicator does not illuminate S If the voltage is too low the security indicator ...

Page 510: ...D BODY GROUND a Disconnect the S10 indicator connector b Disconnect the T7 ECU connector c Measure the resistance of the wire harness side connec tors Standard Tester Connection Specified Condition S10 3 T7 7 IND Below 1 Ω S10 1 Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE TRANSPONDER KEY ECU ASSY BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Inde...

Page 511: ...NOSTICS ENGINE IMMOBILIZER SYSTEM 1ND TV COROLLA Supplement RM1129E OPA AND CG TERMINAL CIRCUIT CIRCUIT DESCRIPTION Connecting terminals OPA and CG of the DLC3 causes the transponder key ECU to display the DTC through security indicator blinking patterns WIRING DIAGRAM 05LVI 02 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 512: ...NESS DLC3 TRANSPONDER KEY ECU ASSY AND BODY GROUND a Disconnect the T7 ECU connector b Measure the resistance of the wire harness side connec tors Standard Tester Connection Specified Condition D5 8 OPA T7 3 D Below 1 Ω D5 4 CG Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE TRANSPONDER KEY ECU ASSY BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index...

Page 513: ...CRIPTION The switch turns ON when the driver side door is opened and turns OFF when the driver side door is closed WIRING DIAGRAM INSPECTION PROCEDURE 1 INSPECT FRONT DOOR COURTESY LAMP SWITCH ASSY DRIVER SIDE a Measure the resistance of the switch Standard Tester Connection Switch Condition Specified Condition 1 Body ground OFF Below 1 Ω 1 Body ground ON 10 kΩ or higher NG REPLACE FRONT DOOR COUR...

Page 514: ...NT DOOR COURTESY LAMP SWITCH ASSY a Disconnect the T7 ECU connector b Disconnect the D9 switch connector c Measure the resistance of the wire harness side connec tor Standard Tester Connection Specified Condition T7 8 CTY D9 1 Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE TRANSPONDER KEY ECU ASSY BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROL...

Page 515: ...PLACEMENT 10 9 11 CAMSHAFT POSITION SENSOR 1ND TV 10 12 REPLACEMENT 10 12 CRANKSHAFT POSITION SENSOR 1ND TV 10 13 REPLACEMENT 10 13 ACCELERATOR PEDAL ASSY 1ND TV 10 14 REPLACEMENT 10 14 ECM 1ND TV 10 15 REPLACEMENT 10 15 REFER TO COROLLA REPAIR MANUAL Pub No RM925E NOTE The above pages contain only the points which differ from the above listed manual TO MODEL INDEX To Alphabetical Index To Sub Ind...

Page 516: ...No 1 Accelerator POS No 2 5 Operate the accelerator pedal then check that the Accelerator POS No 1 and Accelerator POS No 2 values is within the specifications Standard Accelerator POS No 1 Accelerator Pedal Condition Specified Condition Released 0 5 to 1 1 V Depressed 3 0 to 4 6 V Accelerator POS No 2 Accelerator Pedal Condition Specified Condition Released 0 9 to 2 3 V Depressed 3 4 to 5 0 V If ...

Page 517: ...ative tester prove to terminal 2 E2G 3 Blow air into the mass air flow meter then check that the voltage fluctuates If the voltage does not fluctuate replace the mass air flow me ter b Check the resistance 1 Using an ohmmeter measure the resistance be tween the terminals Standard Tester Connection Specified Condition 4 THA 5 E2 13 6 to 18 4 kΩ at 20_C 4_F 4 THA 5 E2 2 21 to 2 69 kΩ at 20_C 68_F 4 ...

Page 518: ...lt is not as specified replace the engine coolant tem perature sensor 3 INSPECT DIESEL THROTTLE BODY ASSY a Check the resistance 1 Using an ohmmeter measure the resistance be tween the terminals Standard Tester Connection Specified Condition 1 DUTY 3 E 0 3 to 100 Ω at 20_C 68_F If the result is not as specified replace the diesel throttle body 4 INSPECT ACCELERATOR PEDAL ASSY a Check the resistanc...

Page 519: ...mperature of the coils them selves Cold is from 10 to 50_C 14 to 122_F and Hot is from 50 to 100_C 122 to 212_F If the result is not as specified replace the crankshaft position sensor 6 INSPECT MAIN RELAY a Check the resistance 1 Using an ohmmeter measure the resistance be tween the terminals Standard Tester Connection Specified Condition 3 5 10 kΩ or higher 3 5 Below 1 Ω Apply battery voltage to...

Page 520: ...r flow meter connector b Remove the 2 screws and mass air flow meter 3 INSTALL MASS AIR FLOW METER a Install the mass air flow meter with the 2 screws NOTICE Make sure that the O ring is not cracked or jammed when installing b Connect the mass air flow meter connector 4 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55 kgf cm 48 in lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetica...

Page 521: ...e engine coolant temperature sen sor and gasket SST 09817 33190 4 INSTALL ENGINE COOLANT TEMPERATURE SENSOR a Install a new gasket onto the engine coolant temperature sensor b Using SST install the engine coolant temperature sensor SST 09817 33190 Torque 19 6 N m 200 kgf cm 14 ft lbf c Connect the engine coolant temperature sensor connec tor 5 ADD ENGINE COOLANT See page 16 7 6 CONNECT CABLE TO NE...

Page 522: ... ENGINE CONTROL SYSTEM DIESEL THROTTLE BODY ASSY 1ND TV 10 7 COROLLA Supplement RM1129E DIESEL THROTTLE BODY ASSY 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 523: ...Air Tube No 2 z Non reusable part N m kgf cm ft lbf Specified torque x2 20 205 15 25 255 18 Vacuum Hose Hose Clamp 6 0 60 53 in lbf 6 0 60 53 in lbf 10 8 ENGINE CONTROL SYSTEM DIESEL THROTTLE BODY ASSY 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 524: ...age 13 17 3 REMOVE AIR HOSE NO 4 a Disconnect the vacuum hose from the vacuum transmit ting pipe No 1 b Remove the 2 bolts c Loosen the 2 hose clamp bolts and remove the air hose No 4 4 REMOVE DIESEL THROTTLE BODY ASSY a Disconnect the throttle control motor connector b Disconnect the throttle position sensor connector BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA ...

Page 525: ...le body and gasket 5 INSTALL DIESEL THROTTLE BODY ASSY a Install a new gasket and the diesel throttle body with the 4 bolts Torque 20 N m 205 kgf cm 15 ft lbf b Connect the throttle position sensor connector c Connect the throttle control motor connector BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 526: ...gn the paint mark of the air hose No 4 with triangle mark of the air tube No 2 S Align the paint mark of the air hose No 4 with rib mark of the diesel throttle body S Make sure that the hose clamp is at the correct angle when installing b Install the air tube No 2 with the 2 bolts Torque 25 N m 255 kgf cm 18 ft lbf c Connect the vacuum hose to the vacuum transmitting pipe No 1 7 INSTALL ENGINE COV...

Page 527: ...asoline or spindle oil to a new O ring then install it onto the camshaft position sensor b Apply a light coat of gasoline or spindle oil to the O ring of the camshaft position sensor again then install the camshaft position sensor with the bolt Torque 8 0 N m 80 kgf cm 71 in lbf NOTICE Make sure that the O ring is not cracked or jammed when installing c Connect the camshaft position sensor connect...

Page 528: ...t the crankshaft position sensor connector b Remove the bolt and crankshaft position sensor 6 INSTALL CRANKSHAFT POSITION SENSOR a Install the crankshaft position sensor with the bolt Torque 8 0 N m 80 kgf cm 71 in lbf b Connect the crankshaft position sensor connector 7 INSTALL ENGINE UNDER COVER LH EXCEPT TMC MADE See page 13 17 8 INSTALL ENGINE UNDER COVER LH TMC MADE See page 13 17 9 INSTALL E...

Page 529: ...OR PEDAL ASSY a Disconnect the accelerator position sensor connector b Remove the 2 bolts and accelerator pedal 4 INSTALL ACCELERATOR PEDAL ASSY a Install the accelerator pedal with the 2 bolts Torque 5 4 N m 55 kgf cm 48 in lbf b Connect the accelerator position sensor connector 5 INSTALL INSTRUMENT PANEL UNDER COVER SUB ASSY NO 1 a Engage the claw and pin and install the instrument panel under c...

Page 530: ...he ECM adjusts the injection duration of each cylinder The ECM stores and uses compensation data in the form of a 10 digit alphanumeric value that is imprinted on the head portion of each injector as the injector compensation code S When installing a new injector its individual injector compensation code needs to be registered with the ECM Also when replacing the ECM the compensation codes of all ...

Page 531: ...ment RM1129E c Remove the 2 bolts and ECM d Remove the 2 screws and ECM bracket No 1 e Remove the 2 screws and ECM bracket No 2 f Remove the 2 screws and ECM bracket No 3 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 532: ... the ECM bracket No 1 with the 4 screws Torque 3 0 N m 30 kgf cm 27 in lbf b Install the ECM bracket No 3 with the 2 screws Torque 3 0 N m 30 kgf cm 27 in lbf c Install the ECM bracket No 2 with the 2 screws Torque 3 0 N m 30 kgf cm 27 in lbf d Install the ECM bracket No 1 with the 2 screws Torque 3 0 N m 30 kgf cm 27 in lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index T...

Page 533: ...ER COVER SUB ASSY NO 2 7 INSTALL GLOVE COMPARTMENT DOOR ASSY 8 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55 kgf cm 48 in lbf 9 REGISTRATION OF INJECTOR COMPENSATION CODE See page 05 19 10 CLEAR DTC a Turn the ignition switch to OFF then wait for 30 seconds or longer b Turn the ignition switch to ON then clear DTC P0603 using the intelligent tester II see page 05 33 BACK TO CHAPTER ...

Page 534: ... FUEL HEATER ASSY 1ND TV 11 27 REPLACEMENT 11 27 FUEL TANK ASSY 1ND TV HATCH BACK 11 28 COMPONENTS 11 28 31 Removal Installation and Disassembly Reassembly 11 32 42 FUEL TANK ASSY 1ND TV SEDAN STATION WAGON 11 43 COMPONENTS 11 43 46 Removal Installation and Disassembly Reassembly 11 47 REFER TO COROLLA REPAIR MANUAL Pub No RM925E NOTE The above pages contain only the points which differ from the a...

Page 535: ...cted fuel tank main tube fuel tube joint and fuel tube connector with a vinyl bag to prevent damage and the intrusion of foreign ob jects b Take the following precautions when disconnecting the fuel tube connector quick type A HINT The structure of the fuel tube connector is as shown in the il lustration 1 Check the fuel tube connector and pipe for dirt and mud before removing the fuel tube connec...

Page 536: ... until it comes into contact with the seat then push the retainer up until the claws lock 2 After connecting the fuel tube connector check that the fuel tube connector and pipe are securely con nected by pulling them d Take the following precautions when disconnecting the fuel tube connector quick type B 1 Check the pipe and around the connector for dirt and mud before disconnecting them Clean the...

Page 537: ...he piping by bending the nylon tube g Take the following precautions when disconnecting the fuel tube connector quick type C 1 Check the pipe and around the connector for dirt and mud before disconnecting them Clean them if necessary 2 Remove the checker of the fuel tube connector from the pipe 3 Pinch the retainer of the fuel tube connector then pull out the fuel tube connector to disconnect the ...

Page 538: ...4 Check for fuel leakage 2 CHECK FOR FUEL LEAKAGE a Check that there are no fuel leakage after doing maintenance on the fuel system see page 11 8 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 539: ...o 2 75 Ω at 20_C 68_F 1 2 1 06 to 1 29 Ω at 40_C 104_F 1 2 0 54 to 0 66 Ω at 60_C 140_F 1 2 0 29 to 0 36 Ω at 80_C 176_F 1 2 0 17 to 0 20 Ω at 100_C 212_F If the result is not as specified replace the supply pump assem bly 2 INSPECT INJECTOR ASSY a Check the resistance 1 Using an ohmmeter measure the resistance be tween the terminals Standard Tester Connection Specified Condition 1 2 0 215 to 0 29...

Page 540: ...ester Connection Specified Condition 1 2 0 5 to 20 Ω at 20_C 68_F If the result is not as specified replace the fuel heater assembly 5 INSPECT LEVEL WARNING SWITCH a Check the resistance 1 Using an ohmmeter measure the resistance be tween the terminals Specified condition When the float is up Below 1 Ω When the float is down 10 kΩ or higher If the result is not as specified replace the level warni...

Page 541: ...t x4 x4 x4 x4 11 112 8 20 204 15 20 204 15 Vacuum Regulating Valve z Gasket Injection Pipe Clamp No 1 z Injection Pipe Sub assy Nozzle Holder Clamp x4 x4 x3 z Gasket z Non reusable part Use SST 23 235 17 25 255 18 23 235 17 25 255 18 Specified torque x2 x2 N m kgf cm ft lbf EGR Cooler Assy FUEL INJECTOR ASSY 1ND TV 11 7 COROLLA Supplement RM1129E INJECTOR ASSY 1ND TV COMPONENTS BACK TO CHAPTER IND...

Page 542: ... with the ECM because the new ECM has no codes until they are registered S When the ECM is replaced DTC P0603 will be present when turning the ignition switch to ON The injector compensation codes need to be registered with the ECM In order to clear the DTC register the compensation codes first then turn the ignition switch to OFF and wait for 30 seconds or longer 1 DISCONNECT CABLE FROM NEGATIVE ...

Page 543: ...h vinyl tape and cover the injector inlet with a vinyl or plastic bag in order to prevent dust and foreign objects from entering 10 REMOVE INJECTION PIPE SUB ASSY NO 2 SST 09023 38401 HINT Perform the same procedures as for injection pipe No 1 11 REMOVE INJECTION PIPE SUB ASSY NO 3 SST 09023 38401 HINT Perform the same procedures as for injection pipe No 1 12 REMOVE INJECTION PIPE SUB ASSY NO 4 SS...

Page 544: ...ction nozzle seats from the injector or cylinder head NOTICE When removing the injector check that the injector nozzle seat is not attached to the injector or remaining in the cyl inder head 15 REGISTRATION OF INJECTOR COMPENSATION CODE REPLACEMENT OF THE NEW INJECTORS See page 05 19 16 INSTALL INJECTOR ASSY NOTICE S When installing clean the sealing surface of the in jector injection pipe and com...

Page 545: ...er head c Install the injector onto the cylinder head NOTICE Fit the injectors into the seats d Install the 4 nozzle holder clamp seats onto the cylinder head e Install the 4 nozzle holder clamps onto the injectors f Set the washer on the nozzle holder clamp as shown il lustration g Temporarily tighten the 4 nozzle holder clamp bolts h Temporarily install the 4 injection pipes onto the injector an...

Page 546: ...he injec tion pipe on the injector side SST 09023 38401 Torque 23 N m 235 kgf cm 17 ft lbf with SST 25 N m 255 kgf cm 18 ft lbf without SST HINT S Use a torque wrench with a fulcrum length of 30 cm 11 81 in S After the injection pipe has been reassembled check that the used pipe has no deflection and is installed properly If it has deflection or could not be installed properly rep lace the used pi...

Page 547: ...NO 1 CONNECTOR See page 19 14 22 INSTALL EGR COOLER ASSY See page 12 5 23 ADD ENGINE COOLANT See page 16 7 24 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55 kgf cm 48 in lbf 25 CHECK FOR FUEL LEAKAGE CAUTION Since the fuel pressure in the common rail becomes 160 MPa 1 632 kgf cm2 23 205 psi check the fuel leakage with great care to avoid the fuel from spraying on your eyes hands and ...

Page 548: ...elect the following menu items Powertrain Engine and ECT Active test Fuel Leak Test f If you do not have an intelligent tester II depress the ac celerator pedal to increase the engine speed to 3 000 rpm to 3 800 rpm and keep it for 15 seconds g Check that there are no leakage from any part of the fuel system HINT If fuel leakage could be found on any specific parts replace them with new parts 26 C...

Page 549: ... lbf z Fuel Inlet Pipe Sub assy Injection Pipe Clamp No 1 23 235 17 25 255 18 23 235 17 25 255 18 Vacuum Regulating Valve x3 20 204 15 z Gasket z Gasket 11 112 8 11 112 8 x2 x3 x2 x2 z O ring EGR Cooler Assy FUEL INJECTION OR SUPPLY PUMP ASSY 1ND TV 11 15 COROLLA Supplement RM1129E INJECTION OR SUPPLY PUMP ASSY 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Ind...

Page 550: ... fuel inlet pipe cover the common rail with vinyl tape and cover the injector inlet with a vinyl or plastic bag in order to prevent dust and foreign objects from entering 10 REMOVE INJECTION OR SUPPLY PUMP ASSY a Disconnect the 2 fuel hoses b Disconnect the 2 connectors c Remove the 3 bolts then remove the supply pump d Remove the supply pump driving coupling e Remove the O ring NOTICE When removi...

Page 551: ... fuel inlet pipe to supply pump and common rail NOTICE Install the pipe and union nut vertically not at a tilt b Tighten the 3 bolts of the supply pump Torque 20 N m 204 kgf cm 15 ft lbf c Using SST tighten the fuel inlet pipe union nut of the fuel inlet pipe on the common rail side SST 09023 38401 Torque 23 N m 235 kgf cm 17 ft lbf with SST 25 N m 255 kgf cm 18 ft lbf without SST HINT S Use a tor...

Page 552: ...nd is installed properly If it has deflection or could not be installed properly rep lace the used pipe with a new one 13 INSTALL NOZZLE LEAKAGE PIPE ASSY See page 11 8 14 INSTALL INJECTION PIPE CLAMP NO 1 See page 11 8 15 INSTALL VACUUM REGULATING VALVE See page 11 8 16 INSTALL EGR COOLER ASSY See page 12 5 17 INSTALL AIR CLEANER CAP SUB ASSY See page 13 17 18 ADD ENGINE COOLANT See page 16 7 19 ...

Page 553: ...7 25 255 18 23 235 17 25 255 18 23 235 17 25 255 18 9 0 92 80 in lbf 9 0 92 80 in lbf 26 265 19 Engine Cover No 1 11 112 8 11 112 8 20 204 15 Vacuum Regulating Valve z Gasket x3 z Gasket x2 x2 x2 20 204 15 EGR Cooler Assy FUEL COMMON RAIL ASSY 1ND TV 11 19 COROLLA Supplement RM1129E COMMON RAIL ASSY 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA CO...

Page 554: ...on rail side SST 09023 38401 c After removing the injection pipe cover the common rail with vinyl tape and cover the injector inlet with a vinyl or plastic bag in order to prevent dust and foreign objects from entering 9 REMOVE INJECTION PIPE SUB ASSY NO 2 SST 09023 38401 HINT Perform the same procedures as for injection pipe No 1 10 REMOVE INJECTION PIPE SUB ASSY NO 3 SST 09023 38401 HINT Perform...

Page 555: ...e 2 bolts and common rail NOTICE Do not remove the fuel pressure sensor and fuel pressure regulator 14 INSTALL COMMON RAIL ASSY Torque 26 N m 265 kgf cm 19 ft lbf 15 INSTALL FUEL INLET PIPE SUB ASSY NOTICE S When replacing the common rail the fuel inlet pipe must also be replaced S Replace the fuel inlet pipe with a new one when the fuel inlet pipe has been removed and reinstalled for more than 5 ...

Page 556: ... nut of the fuel inlet pipe on the supply pump side SST 09023 38401 Torque 23 N m 235 kgf cm 17 ft lbf with SST 25 N m 255 kgf cm 18 ft lbf without SST HINT S Use a torque wrench with a fulcrum length of 30 cm 11 81 in S After the fuel inlet pipe has been reassembled check that the used pipe has no deflection and is installed properly If it has deflection or could not be installed properly rep lac...

Page 557: ...thout SST HINT S Use a torque wrench with a fulcrum length of 30 cm 11 81 in S After the injection pipe has been reassembled check that the used pipe has no deflection and is installed properly If it has deflection or could not be installed properly rep lace the used pipe with a new one 17 INSTALL INJECTION PIPE SUB ASSY NO 2 SST 09023 38401 HINT Perform the same procedures as for injection pipe N...

Page 558: ...129E 26 CHECK FOR FUEL LEAKAGE See page 11 8 27 CHECK FOR ENGINE COOLANT LEAKAGE See page 16 1 28 INSTALL ENGINE COVER SUB ASSY NO 1 See page 14 6 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 559: ...he 2 fuel hoses from the fuel filter c Disconnect the 2 connectors d Remove the 2 bolts then remove the fuel filter 4 DRAIN FUEL a Loosen the drain plug then drain the fuel from the fuel filter 5 REMOVE LEVEL WARNING SWITCH a Clamp the fuel filter in a soft jaw vise b Using pliers remove the level warning switch NOTICE Be careful not to damage the level warning switch 6 REMOVE FUEL FILTER ELEMENT ...

Page 560: ...warning switch onto the fuel filter by hand 9 INSTALL FUEL FILTER ASSY a Install the fuel filter with the 2 bolts Torque 18 N m 178 kgf cm 13 ft lbf b Connect the 2 connectors c w stove heater Connect the 3 fuel hoses onto the fuel filter d w o stove heater Connect the 2 fuel hoses onto the fuel filter e Carry out priming work until the hand pump is felt hard while pushing it since filling a fuel ...

Page 561: ...E FUEL HEATER ASSY a Disconnect the connector and connector clamp b Remove the 2 screws then remove the fuel heater as sembly 4 INSTALL FUEL HEATER ASSY 5 INSTALL AIR CLEANER CAP SUB ASSY See page 13 17 6 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55 kgf cm 48 in lbf 7 CHECK FOR FUEL LEAKAGE See page 11 8 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA...

Page 562: ...ack Assy RH Rear Door Scuff Plate LH Rear Seat Side Cover LH 40 411 30 30 303 22 5 Door Hatch Back Rear Seat Cushion Assy RH Rear Seat Cushion Assy LH 43 441 32 43 441 32 30 303 22 30 303 22 43 441 32 11 28 FUEL FUEL TANK ASSY 1ND TV HATCH BACK COROLLA Supplement RM1129E FUEL TANK ASSY 1ND TV HATCH BACK COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROL...

Page 563: ... Assy LH Rear Seat Back Assy RH Front Door Scuff Plate LH 30 303 22 40 411 30 30 303 22 3 Door Hatch Back Quarter Trim Panel Assy Front LH Rear Seat Cushion Assy RH Rear Seat Cushion Assy LH 43 441 32 30 303 22 43 441 32 43 441 32 FUEL FUEL TANK ASSY 1ND TV HATCH BACK 11 29 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANU...

Page 564: ... 1 43 440 22 5 4 55 48 in lbf Fuel Evaporation Tube Sub assy No 2 5 4 55 48 in lbf Exhaust Pipe Assy Front Fuel Tank Band No 1 Fuel Tank Return Tube z Gasket 43 440 32 40 408 30 5 4 55 48 in lbf Compression Spring Compression Spring 30 302 22 43 440 32 Compression Spring Compression Spring 5 4 55 48 in lbf 5 4 55 48 in lbf Fuel Tank Band No 1 11 30 FUEL FUEL TANK ASSY 1ND TV HATCH BACK COROLLA Sup...

Page 565: ... Sub assy Screw Fuel Tank Return Tube Tube Joint Clip Fuel Tank Main Tube Fuel Evaporation Tube Sub assy No 2 z Fuel Pump Gauge Retainer FUEL FUEL TANK ASSY 1ND TV HATCH BACK 11 31 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 566: ... 3 DOOR HATCH BACK BODY TYPE See Pub No RM925E on page 76 48 10 REMOVE QUARTER TRIM PANEL ASSY FRONT LH 3 DOOR HATCH BACK BODY TYPE See Pub No RM925E on page 76 48 11 REMOVE QUARTER TRIM PANEL ASSY FRONT RH 3 DOOR HATCH BACK BODY TYPE See Pub No RM925E on page 76 48 12 REMOVE REAR DOOR SCUFF PLATE LH 5 DOOR HATCH BACK BODY TYPE See Pub No RM925E on page 76 56 13 REMOVE REAR DOOR SCUFF PLATE RH 5 D...

Page 567: ...ected part by covering it with a vi nyl bag and gum tape after disconnecting the fuel tube 18 DISCONNECT FUEL TANK MAIN TUBE SUB ASSY a Pinch the tube connector and pull out the fuel tank main tube NOTICE S Remove any dirt or foreign objects on the fuel tube joint before performing this work S Avoid any scratches or foreign objects on the parts when disconnecting as the fuel tube joint has the O r...

Page 568: ...turn the nylon tube S Protect the disconnected part by covering it with a vi nyl bag and gum tape after disconnecting the fuel tube S When the connector and pipe are stuck push and pull the connector to release it Pull out the connector from the pipe carefully 20 REMOVE FUEL AND EVAPORATION VENT TUBE SUB ASSY a Using SST loosen the retainer SST 09808 14020 09808 01410 09808 01420 09808 01430 b Rem...

Page 569: ...st pipe supports No 5 c Remove the gasket from the exhaust manifold d Remove the gasket from the exhaust pipe front 24 REMOVE FUEL TANK PROTECTOR NO 1 a Remove the 4 bolts then remove the fuel tank protector No 1 25 DISCONNECT PARKING BRAKE CABLE ASSY NO 2 a Remove the 2 bolts then disconnect the parking brake cable No 2 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOT...

Page 570: ...s then disconnect the parking brake cable No 3 27 REMOVE FUEL TANK ASSY a Loosen the hose clamp then disconnect the fuel tank breather hose b Loosen the hose clamp then disconnect the fuel tank to filler pipe hose c Disconnect the fuel tank return tube BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 571: ...ng that seals the pipe S Perform this work by hand Do not use any tools S Do not forcibly bend twist or turn the nylon tube S Protect the connected part by covering it with a vinyl bag after disconnecting the fuel tank main tube S If the fuel tube connector and pipe are stuck push and pull to release them e Hold the fuel tank using a transmission jack f Remove the 4 bolts then remove the 2 fuel ta...

Page 572: ...N NO 1 a Install 2 new fuel tank cushions No 1 onto the fuel tank 33 INSTALL FUEL TANK MAIN TUBE SUB ASSY 34 INSTALL FUEL EVAPORATION TUBE SUB ASSY NO 2 35 INSTALL FUEL TANK RETURN TUBE 36 INSTALL FUEL TANK ASSY a Set the fuel tank on a transmission jack b Operate the transmission jack and install the fuel tank into the vehicle c Install the 2 fuel tank bands No 1 with the 4 bolts Torque 40 N m 40...

Page 573: ...se g Connect the fuel tank breather hose 37 INSTALL PARKING BRAKE CABLE ASSY NO 3 Torque 5 4 N m 55 kgf cm 48 in lbf 38 INSTALL PARKING BRAKE CABLE ASSY NO 2 Torque 5 4 N m 55 kgf cm 48 in lbf 39 INSTALL FUEL TANK PROTECTOR NO 1 Torque 5 4 N m 55 kgf cm 48 in lbf 40 INSTALL EXHAUST PIPE ASSY FRONT a Check the free length 1 Using vernier calipers measure the free length of the compression spring Mi...

Page 574: ...cm 32 ft lbf 41 INSTALL FLOOR PANEL BRACE FRONT See page 15 2 42 ADD FUEL 43 INSTALL FUEL AND EVAPORATION VENT TUBE SUB ASSY a Align the arrow marks of the fuel pump bracket and the fuel tank b Temporarily install the retainer c Mount SST to the retainer SST 09808 14020 09808 01410 09808 01420 09808 01430 d Tighten the retainer until the arrow mark located on the re tainer is positioned within the...

Page 575: ... the collar of the connector S After installing the tube joint clip check that the con nector cannot be pulled out 47 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55 kgf cm 48 in lbf 48 CHECK FOR FUEL LEAKAGE See page 11 8 49 CHECK FOR EXHAUST GAS LEAKAGE 50 INSTALL REAR FLOOR SERVICE HOLE COVER 51 INSTALL REAR SEAT SIDE COVER RH 5 DOOR HATCH BACK BODY TYPE 52 INSTALL REAR SEAT SIDE C...

Page 576: ...Supplement RM1129E 62 INSTALL REAR SEAT BACK ASSY LH See Pub No RM925E on page 72 26 63 REAR SEAT CUSHION ASSY RH 64 REAR SEAT CUSHION ASSY LH BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 577: ...hor Bracket Sub assy LH N m kgf cm ft lbf Specified torque 30 303 22 30 303 22 FUEL FUEL TANK ASSY 1ND TV SEDAN STATION WAGON 11 43 COROLLA Supplement RM1129E FUEL TANK ASSY 1ND TV SEDAN STATION WAGON COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 578: ...te LH Child Restraint Seat Anchor Bracket Sub assy LH 30 303 22 42 420 30 Station Wagon Rear Seat Cushion Assy RH Rear Seat Cushion Assy LH 30 303 22 30 303 22 30 303 22 30 303 22 30 303 22 11 44 FUEL FUEL TANK ASSY 1ND TV SEDAN STATION WAGON COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 579: ...5 48 in lbf x2 39 398 29 Fuel Tank Protector No 1 Parking Brake Cable Assy No 2 5 4 55 48 in lbf x2 Compression Spring Compression Spring 43 440 32 5 4 55 48 in lbf x2 43 440 32 Floor Panel Brace Front 30 302 22 43 440 32 43 440 32 Compression Spring z Gasket Compression Spring FUEL FUEL TANK ASSY 1ND TV SEDAN STATION WAGON 11 45 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To A...

Page 580: ...Rear Floor Service Hole Cover x8 Tube Joint Clip Fuel Sender Gauge Assy N m kgf cm ft lbf Specified torque Tank Suction Tube Support z Gasket x5 3 5 36 31 in lbf Fuel Tank Filler Pipe Sub assy Lower Tube Joint Clip 6 0 61 53 in lbf 11 46 FUEL FUEL TANK ASSY 1ND TV SEDAN STATION WAGON COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA R...

Page 581: ...SCUFF PLATE LH WAGON BODY TYPE See Pub No RM925E on page 76 40 10 REMOVE REAR DOOR SCUFF PLATE RH WAGON BODY TYPE See Pub No RM925E on page 76 40 11 REMOVE REAR FLOOR SERVICE HOLE COVER a Pull up the floor carpet assembly front b Remove the butyl tape then remove the rear floor service hole cover c Disconnect the fuel sender gage connector 12 DISCONNECT FUEL TANK RETURN TUBE a Remove the tube join...

Page 582: ...fter disconnecting the fuel tube 14 DISCONNECT FUEL EVAPORATION TUBE SUB ASSY NO 2 a Pinch the tube connector then pull out the fuel evapora tion tube sub assembly No 2 NOTICE S Remove any dirt or foreign objects on the fuel tube joint before performing this work S Avoid any scratches or foreign objects on the parts when disconnecting as the fuel tube joint has the O ring that seals the plug S Per...

Page 583: ...nder gauge 17 DRAIN FUEL 18 REMOVE FLOOR PANEL BRACE FRONT See page 15 2 19 REMOVE EXHAUST PIPE ASSY FRONT a Remove the 4 bolts and 4 compression springs b Remove the exhaust pipe front from the 2 exhaust pipe supports No 5 c Remove the gasket from the exhaust manifold d Remove the gasket from the exhaust pipe front 20 REMOVE FUEL TANK PROTECTOR NO 1 a Remove the 3 bolts then remove the No 1 fuel ...

Page 584: ...SSY NO 3 a Remove the 2 bolts then disconnect the parking brake cable No 3 23 REMOVE FUEL TANK ASSY a Loosen the hose clamp bolt then disconnect the breather tube fuel hose from the fuel tank b Disengage the claw fitting then remove the fuel hose pro tector c Loosen the hose clamp bolt then disconnect the fuel tank to filler pipe hose from the fuel tank BACK TO CHAPTER INDEX TO MODEL INDEX To Alph...

Page 585: ...g after disconnecting the fuel tank main tube S If the fuel tube connector and pipe are stuck push and pull to release them e Disconnect the fuel tank main tube sub assembly 1 Pinch the projections of the retainer to remove the lock claws then pull out the fuel tank main tube NOTICE S Remove any dirt or foreign objects on the fuel tube connector before performing this work S Do not allow any scrat...

Page 586: ...ing it little by little NOTICE S The fuel cut off valve is made of resin and easily dam aged if removed or installed forcibly Handle the part properly when removing the sealing S After removing check that the contact surface of the fuel cut off valve on the fuel tank is not damaged c Remove the gasket from the fuel tank 27 REMOVE TANK SUCTION TUBE SUPPORT a Remove the tank suction tube support fro...

Page 587: ...FUEL TUBE CLAMP No 3 34 INSTALL TANK SUCTION TUBE SUPPORT 35 INSTALL FUEL EVAPORATION TUBE SUB ASSY NO 2 a Install a new gasket onto the fuel tank b Apply a light coat of oil around the new fuel cut off valve as shown in the illustration then insert it into the tank with out force NOTICE Make sure that the gasket does not drop into the fuel tank c Check that the there is no gap between the bottom ...

Page 588: ...hen push in the fuel tube connector until the retainer makes a click sound to connect the fuel tank main tube to the pipe NOTICE S Check that there are no scratches or foreign objects around the disconnected part of the fuel tube connec tor and pipe before performing this work S After connecting and pipe fuel tank main tube check that the fuel pump tube is securely connected by pull ing the fuel t...

Page 589: ...EL TANK SENDER GAUGE ASSY a Install a new gasket onto the fuel tank sender gauge assembly b Install the fuel tank sender gauge assembly onto the fuel tank 46 INSTALL FUEL TANK VENT TUBE SET PLATE Torque 6 0 N m 61 kgf cm 53 in lbf 47 CONNECT FUEL EVAPORATION TUBE SUB ASSY NO 2 a Push the tube connector into the pipe until the connector makes a click sound NOTICE S Check if there is any damage or f...

Page 590: ...ount on the convex of the floor panel when installing d Install the floor carpet front 51 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55 kgf cm 48 in lbf 52 CHECK FOR FUEL LEAKAGE See page 11 8 NOTICE Check for fuel leakage with the fuel tank sender gauge connector connected 53 CHECK FOR EXHAUST GAS LEAKAGE 54 INSTALL REAR DOOR SCUFF PLATE RH WAGON BODY TYPE 55 INSTALL REAR DOOR SCUF...

Page 591: ...VEHICLE INSPECTION 12 1 INSPECTION 12 2 EGR SYSTEM 1ND TV 12 3 ON VEHICLE INSPECTION 12 3 INSPECTION 12 4 EGR VALVE ASSY 1ND TV 12 5 REPLACEMENT 12 5 TO MODEL INDEX To Alphabetical Index To Sub Index BACK TO MAIN INDEX TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 592: ...mbly are cracked leaking or damaged HINT Air induction other than air intake system such as disconnection of the engine oil dipstick oil filler cap PCV hose etc may cause the engine to run improperly Disconnection looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run improperly BACK TO CHAPTER IND...

Page 593: ...M1129E INSPECTION 1 INSPECT FUEL TANK CAP ASSY a Check the appearance 1 Visually check whether the fuel tank cap and gasket are deformed or damaged If necessary replace the fuel tank cap BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 594: ...dard MAF reading is between 7 5 g s and 9 5 g s 6 Stop the engine with turning the engine switch to OFF then connect the EGR valve connector 7 Clear the DTC s See page 05 33 e EGR valve operation Full Open 1 Start the engine and let it idle 2 Turn the intelligent tester ll ON 3 Select the following menu items Powertrain En gine and ECT Data List MAF and EGR Step POS 4 Warm up the engine The coolan...

Page 595: ... ohmmeter measure the resistance between the terminals Terminal Resistance at 20 C 68 F 5 B1 4 EGR1 19 6 1 4 Ω 5 B1 6 EGR3 19 6 1 4 Ω 2 B2 1 EGR2 19 6 1 4 Ω 2 B2 3 EGR4 19 6 1 4 Ω If the result is not as specified replace the EGR valve assembly BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 596: ...Disconnect the EGR valve connector and hose b Remove the 2 nuts then remove the EGR valve assy c Remove the gasket 5 INSTALL EGR VALVE ASSY a Install a new gasket b Install the EGR valve assy with the 2 nuts Torque 20 N m 204 kgf cm 15 ft lbf c Connect the EGR valve connector and hose 6 INSTALL EGR COOLER ASSY a Install 2 new gaskets b Install the EGR cooler assy with the bolt and 4 nuts Torque 11...

Page 597: ...O NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55kgf cm 48 in lbf 8 ADD ENGINE COOLANT See page 16 7 9 CHECK FOR ENGINE COOLANT LEAKAGE See page 16 1 10 CHECK FOR EXHAUST GAS LEAKAGE BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 598: ...3 14 COMPONENTS 13 14 16 REPLACEMENT 13 17 30 VACUUM REGULATING VALVE 1ND TV 13 31 REPLACEMENT 13 31 32 TURBO PRESSURE SENSOR ASSY 1ND TV 13 33 REPLACEMENT 13 33 REFER TO COROLLA REPAIR MANUAL Pub No RM925E NOTE The above pages contain only the points which differ from the above listed manual TO MODEL INDEX To Alphabetical Index To Sub Index BACK TO MAIN INDEX TOYOTA COROLLA REPAIR MANUAL SUPP 112...

Page 599: ...charger assembly Do not drop grasp or shock eas ily deformed assembly parts such as the actuator or push rod when removing or reinstalling the assembly e Before removing cover both the intake and exhaust ports and the oil inlet to prevent dirt or foreign objects from be ing introduced f If replacing the turbocharger check the oil pipe for depos its If necessary replace the oil pipe too g Thoroughl...

Page 600: ...rbine wheels run at an extremely high speed running the engine without the air cleaner case cover and hose damages the turbine wheel due to the introduction of foreign particles BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 601: ...ce Cracked in components Check and replace 3 CHECK TURBOCHARGING PRESSURE a Warm up the engine b Using a 3 way connector connect SST turbocharger pressure gauge to the hose leading to the intake air con nector SST 09992 00242 c While depressing the clutch pedal press the accelerator pedal down fully Measure the turbocharging pressure at the maximum speed 5 100 to 5 250 rpm Standard 15 to 45 kPa 0 ...

Page 602: ...nd ECM 6 Using SST a turbocharger pressure gauge apply pressure to the turbo pressure sensor of 19 6 kPa 0 20 kgf cm2 2 84 psi to 98 0 kPa 1 00 kgf cm2 14 2 psi SST 09992 00242 7 Measure the voltage increase between step 3 and step 6 Voltage up Applied Pressure kPa kgf cm2 psi Voltage Increase V 19 6 0 20 2 84 0 1 to 0 4 39 2 0 40 5 69 0 4 to 0 7 58 8 0 60 8 53 0 7 to 1 0 78 5 0 80 11 4 1 0 to 1 3...

Page 603: ...ndard Tester Connection Specified Condition 1 Body 1 MΩ or higher 2 Body 1 MΩ or higher If the result is not as specified replace the vacuum regulation valve b Check the air tightness 1 Apply a vacuum to the vacuum inlet port 2 Check that the needle of the vacuum pump indi cates decrease of 66 7 kPa 500 mmHg 19 7 in Hg or less If the air tightness is not as specified replace the vacuum regu lation...

Page 604: ...ine Under Cover Clip x4 Except TMC Made TMC Made Engine Under Cover LH x2 x2 x2 x2 x7 x8 x5 x2 13 6 INTAKE INTERCOOLER ASSY 1ND TV COROLLA Supplement RM1129E INTERCOOLER ASSY 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 605: ...m kgf cm ft lbf Specified torque 5 0 50 44 in lbf Hatchback Front Bumper Cover x2 x3 Clip w Fog Lamp Fog Lamp Connector x2 Clip x4 RadiatorSupport OpeningCover x2 INTAKE INTERCOOLER ASSY 1ND TV 13 7 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 606: ...er Hose No 1 w Head Lamp Cleaner Head Lamp Cleaner Hose No 1 Radiator Grille 5 0 50 44 in lbf x2 Sedan Station Wagon RadiatorSupport OpeningCover Clip x4 x2 13 8 INTAKE INTERCOOLER ASSY 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 607: ...ied torque 1 Vacuum Transmitting Hose Assy 5 0 50 44 in lbf 7 0 70 62 in lbf Cooling Fan Resistor x2 Intercooler Assy Air Hose No 3 6 0 60 53 in lbf Hose Clamp 6 0 60 53 in lbf Air Hose No 2 6 0 60 53 in lbf INTAKE INTERCOOLER ASSY 1ND TV 13 9 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 608: ...DIATOR GRILLE SEDAN STATION WAGON BODY TYPE See Pub No RM 925E page 76 2 8 REMOVE FRONT FENDER LINER LH See Pub No RM925E page 76 2 76 5 HINT Follow the same procedures as those for the front fender liner LH 9 REMOVE FRONT FENDER LINER RH 10 REMOVE FRONT BUMPER COVER See Pub No RM925E page 76 2 76 5 11 REMOVE INTERCOOLER COOLING AIR DUCT SUB ASSY a Remove the 2 wire harness clamps b Remove the 2 b...

Page 609: ... and cooling fan resistor and inter cooler 15 INSTALL INTERCOOLER ASSY a Install the inter cooler and cooling fan resistor with the 3 bolts and nut Torque 7 0 N m 70 kgf cm 62 in lbf 16 INSTALL AIR HOSE NO 3 a Install the vacuum transmitting hose onto the air hose No 3 with vinyl tape as shown in the illustration Specification Area Measurement a 182 mm 7 165 in b 89 8 mm 3 535 in c 7 4 mm 0 291 in...

Page 610: ... hose clamp is at the correct angle when installing c Connect the vacuum transmitting hose to the inter cooler and vacuum transmitting pipe NOTICE S Insert the vacuum transmitting hose into the corner end of the intercooler S Insert the vacuum transmitting hose into the marking of the vacuum transmitting pipe 17 INSTALL AIR HOSE NO 2 a Install the air hose No 2 with the 2 hose clamps Torque 6 0 N ...

Page 611: ...NT BUMPER COVER 20 INSTALL FRONT FENDER LINER LH 21 INSTALL FRONT FENDER LINER RH 22 INSTALL RADIATOR GRILLE SEDAN STATION WAGON BODY TYPE 23 INSTALL RADIATOR SUPPORT OPENING COVER See page 14 6 24 INSTALL ENGINE UNDER COVER RH EXCEPT TMC MADE MT See page 13 17 25 INSTALL ENGINE UNDER COVER LH EXCEPT TMC MADE See page 13 17 26 INSTALL ENGINE UNDER COVER LH TMC MADE See page 13 17 27 INSTALL ENGINE...

Page 612: ...p Clip Clip Clip Clip Clip Clip Clip Except TMC Made TMC Made Engine Under Cover LH x2 x2 x2 x8 x7 x2 x2 x5 x2 x5 13 14 INTAKE TURBOCHARGER SUB ASSY 1ND TV COROLLA Supplement RM1129E TURBOCHARGER SUB ASSY 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 613: ... cm ft lbf Specified torque x2 29 6 300 22 7 5 75 66 in lbf Mass Air Flow Meter Connector Compression Spring 43 440 32 z Exhaust Pipe Gasket 43 440 32 x2 x2 Floor Panel Brace Front x4 w Cold Area Exhaust Pipe INTAKE TURBOCHARGER SUB ASSY 1ND TV 13 15 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 614: ...37 375 27 z Turbo to Exhaust Manifold Gasket 11 110 8 6 0 60 53 in lbf Intercooler Air Hose z Turbo Oil Inlet Pipe Gasket 24 245 18 6 0 60 53 in lbf 37 375 27 Turbo Oil Outlet Pipe Turbocharger Assy 6 0 60 53 in lbf 53 540 39 x3 z Turbo Oil Outlet Gasket No 1 Hose Clamp Hose Clamp z Turbo Oil Inlet Pipe Gasket 24 245 18 x2 13 16 INTAKE TURBOCHARGER SUB ASSY 1ND TV COROLLA Supplement RM1129E BACK T...

Page 615: ...cover 2 REMOVE ENGINE UNDER COVER LH TMC MADE a Remove the 2 screws 8 clips and engine under cover 3 REMOVE ENGINE UNDER COVER RH TMC MADE a Remove the 2 screws 8 clips and engine under cover 4 REMOVE ENGINE UNDER COVER LH EXCEPT TMC MADE a Remove the 4 screws 8 clips and engine under cover BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 11...

Page 616: ... See page 17 11 7 REMOVE FLOOR PANEL BRACE FRONT See page 15 2 8 REMOVE EXHAUST PIPE ASSY FRONT a Remove the 4 bolts and 4 compression springs b Remove the exhaust pipe front from the 2 exhaust pipe supports No 5 c Remove the gasket from the exhaust pipe front d Remove the gasket from the exhaust manifold convertor BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA CORO...

Page 617: ...B ASSY NO 1 a Disengage the 4 pins and remove the engine cover No 1 11 REMOVE AIR CLEANER CAP SUB ASSY a Disconnect the mass air flow meter connector b Remove the 2 wire harness clamps c Remove the wire harness from the air cleaner cap d Disconnect the ventilation hose from the cylinder head cover BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL ...

Page 618: ...ir cleaner hose No 1 from the turbocharger f Unfasten the 4 hook clamps and remove the air cleaner cap g Remove the air cleaner filter element from the air cleaner case 12 REMOVE TURBO INSULATOR NO 1 a Remove the 3 bolts and turbo insulator No 1 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 619: ...ve the 3 nuts and exhaust manifold converter c Remove the gasket from the turbocharger 14 REMOVE TURBO OIL INLET PIPE a Remove the wire harness clamp b Remove the bolt c Remove the 2 union bolts oil inlet pipe and 4 gaskets 15 REMOVE INTERCOOLER AIR HOSE a Loosen the 2 hose clamp bolts and remove the intercool er air hose BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYO...

Page 620: ...b Disconnect the vacuum hose from the turbocharger c Remove the 3 nuts and turbocharger d Remove the gasket from the exhaust manifold e Remove the gasket from the turbocharger 17 REMOVE TURBO OIL OUTLET PIPE a Remove the 2 nuts and turbo oil outlet pipe BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 621: ...8 INSTALL TURBO OIL OUTLET PIPE a Install a new gasket onto the cylinder block b Temporary install the turbo oil outlet pipe with the 2 new nuts 19 INSTALL TURBOCHARGER SUB ASSY a Install a new gasket onto the turbocharger b Install a new gasket onto the exhaust manifold BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 622: ...s Torque 13 5 N m 140 kgf cm 10 ft lbf 20 INSTALL INTERCOOLER AIR HOSE a Install the inter cooler air hose with the 2 hose clamps Torque 6 0 N m 60 kgf cm 53 in lbf Specification Area Measurement a 0 to 2 mm 0 to 0 079 in b 2 to 7 mm 0 079 to 0 276 in NOTICE S Align the paint mark of the inter cooler air hose with location mark of the turbocharger S Align the paint mark of the inter cooler air hos...

Page 623: ...s clamp 22 INSTALL EXHAUST MANIFOLD CONVERTER SUB ASSY a Install a new gasket onto the turbocharger b Temporarily install the exhaust manifold convertor with 3 new nuts c Temporarily install the manifold support bracket with the 3 bolts d Tighten the 3 nuts Torque 26 N m 265 kgf cm 19 ft lbf e Tighten the 3 bolts Torque 37 N m 375 kgf cm 27 ft lbf 23 INSTALL TURBO INSULATOR NO 1 a Install the turb...

Page 624: ...all the air cleaner cap onto the air cleaner case then hung the 4 hook clamps c Align the matchmarks of the air cleaner hose No 1 and turbocharger and connect the air cleaner hose No 1 to the turbocharger and unfasten the air cleaner hose clamp No 1 NOTICE Make sure that the hose clamp is at the correct angle when installing d Connect the ventilation hose to the cylinder head cover NOTICE Mark sur...

Page 625: ...e compression spring Minimum Areas Measurement Exhaust Pipe Front x Exhaust Manifold Convertor 41 5 mm 1 634 in Exhaust Pipe Front x Exhaust Pipe Tail 38 5 mm 1 516 in If the free length isless than the minimum replace the compres sion spring b Using a wooden block and plastic faced hammer tap in a new gasket until it is flush with the exhaust manifold con vertor NOTICE S Make sure that the gasket...

Page 626: ...ket into the exhaust pipe front by installing the exhaust pipe front ontothe exhaust pipe tail d Install the exhaust pipe front onto the 2 exhaust pipe sup ports No 5 e Tighten the 4 compression springs and 4 bolts Torque 43 N m 440 kgf cm 32 ft lbf 27 ADD ENGINE OIL See page 17 11 28 CHECK FOR ENGINE OIL LEAKAGE 29 CHECK FOR EXHAUST GAS LEAKAGE 30 INSTALL ENGINE COVER SUB ASSY NO 1 a Engage the 4...

Page 627: ...ENGINE UNDER COVER LH EXCEPT TMC MADE a Install the engine under cover with the 4 screws and 8 clips NOTICE Completely pierce the screw through the engine under cov er 34 INSTALL ENGINE UNDER COVER RH TMC MADE a Install the engine under cover with the 2 screws and 8 clips 35 INSTALL ENGINE UNDER COVER LH TMC MADE a Install the engine under cover with the 2 screws and 8 clips BACK TO CHAPTER INDEX ...

Page 628: ...6 INSTALL ENGINE UNDER COVER TMC MADE a Install the engine under cover with the 4 screws and 4 clips NOTICE Completely pierce the screw through the engine under cov er BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 629: ...onnect the vacuum regulation valve connector b Disconnect the 2 vacuum hoses from the vacuum regula tion valve c Remove the 2 bolts and vacuum regulation valve 4 INSTALL VACUUM REGULATING VALVE a Install the vacuum regulation valve with the 2 bolts Torque 3 4 N m 35 kgf cm 30 in lbf b Connect the 2 vacuum hoses to the vacuum regulation valve c Connect the vacuum regulation valve connector BACK TO ...

Page 630: ...plement RM1129E 5 INSTALL CYLINDER HEAD COVER NO 2 See page 13 17 6 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55 kgf cm 48 in lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 631: ...nect the vacuum hose from the turbo pressure sensor c Remove the bolt and turbo pressure sensor bracket d Remove the 2 bolts and turbo pressure sensor 4 INSTALL TURBO PRESSURE SENSOR ASSY a Install the turbo pressure sensor bracket with 2 bolts Torque 5 0 N m 50 kgf cm 44 in lbf b Install the turbo pressure sensor with the bolt Torque 5 0 N m 50 kgf cm 44 in lbf c Connect the vacuum hose to the tu...

Page 632: ...lement RM1129E 5 INSTALL RADIATOR SUPPORT OPENING COVER See page 14 6 6 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55 kgf cm 48 in lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 633: ...T 14 26 41 CHAIN SUB ASSY 1ND TV 14 42 COMPONENTS 14 42 44 REPLACEMENT 14 45 51 CAMSHAFT 1ND TV 14 52 COMPONENTS 14 52 54 REPLACEMENT 14 55 60 CYLINDER HEAD GASKET 1ND TV 14 61 COMPONENTS 14 61 69 REPLACEMENT 14 70 80 OIL PUMP SEAL 1ND TV 14 81 REPLACEMENT 14 81 ENGINE REAR OIL SEAL 1ND TV 14 82 REPLACEMENT 14 82 TO MODEL INDEX To Alphabetical Index To Sub Index BACK TO MAIN INDEX TOYOTA COROLLA R...

Page 634: ...pecified point S When installing a new belt set its tension value to as specified S When checking a belt used for over 5 minutes con firm that the deflection value is within the specified range S When reinstalling a belt used for over 5 minutes check whether its deflection value is within the speci fied range for the used belt S When using a belt tension gauge confirm its accura cy first by using ...

Page 635: ...n the engine switch to ON 3 Inspect the engine idling speed Idle speed 720 to 820 rpm 4 Fully depress the accelerator pedal 5 Check the maximum speed Maximum speed 5100 to 5250 rpm 6 Turn the engine switch to OFF 7 Disconnect the tachometer 8 Remove SST from terminal 9 7 INSPECT COMPRESSION a Warm up and stop the engine b Remove the 4 glow plugs see page 19 14 NOTICE In order to avoid shorting the...

Page 636: ...ncreased to 250 rpm or more S Inspect the other cylinders in the same way S Measure the compression pressure in as short a time as possible If the cylinder compression is low pour a light coat of engine oil into the cylinder through the glow plug hole then inspect it again HINT S If adding oil increases the compression the piston rings and or cylinder bore may be worn or damaged S If the pressure ...

Page 637: ... the fan and generator V belt onto each pulley NOTICE S Before installing the V belt check each pulley for any adhesion of foreign materials such as oil any kind of liquid and chips S Check that the ribs of the V belt are correctly fitted into the grooves of the pulleys 5 ADJUST FAN AND GENERATOR V BELT a Insert a bar between the generator and the engine Pull the bar toward the front of the vehicl...

Page 638: ...9E 6 INSPECT FAN AND GENERATOR V BELT See page 14 1 7 INSTALL ENGINE UNDER COVER RH TMC MADE See page 13 17 8 INSTALL ENGINE UNDER COVER RH EXCEPT TMC MADE See page 13 17 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 639: ... COVER RH EXCEPT TMC MADE See page 13 17 4 REMOVE RADIATOR SUPPORT OPENING COVER a Remove the 4 clips then remove the radiator support opening cover 5 REMOVE ENGINE COVER SUB ASSY NO 1 a Disengage the 4 clips and remove the engine cover sub assy No 1 6 REMOVE CYLINDER HEAD COVER SUB ASSY a Disconnect the injector connectors b Disconnect the supply pump connector BACK TO CHAPTER INDEX TO MODEL INDE...

Page 640: ... the illustration and disengage the wire harness clamp shown in the il lustration e Remove the screw grommet and nut then separate the wire harness f Disconnect the common rail connector g Remove the 3 bolts and the wire harness clamp shown in the illustration and disconnect the engine wire harness BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL...

Page 641: ... illustration i Disconnect the hose shown in the illustration j Disconnect the 2 vacuum hoses shown in the illustration k Disconnect the vacuum hose shown in the illustration l Disconnect the ventilation hose from the cylinder head BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 642: ...e No 1 cylinder to TDC Compression 1 Turn the crankshaft pulley until the grooves of the crankshaft damper and oil pump are aligned 2 Check that the timing mark of the camshaft timing sprocket and the straight pin hole of the crankshaft timing sprocket are in the positions shown in the il lustration HINT If not turn the crankshaft damper 1 revolution 360_ to align them as above BACK TO CHAPTER IND...

Page 643: ...T If the clearance is not as specified record the out of specifica tion measurement then adjust the valve clearance c Check the valve clearance of the No 1 cylinder intake valve and the No 3 cylinder exhaust valve 1 Turn the crankshaft by a further 180_ clockwise 2 Using a feeler gauge measure the clearance be tween the camshaft and valve rocker arm No 1 as shown in the illustration Valve clearanc...

Page 644: ...rance is not as specified record the out of specifica tion measurement then adjust the valve clearance e Check the valve clearance of the No 2 cylinder exhaust valve and No 4 cylinder intake valve 1 Turn the crankshaft by a further 180_ clockwise 2 Using a feeler gauge measure the clearance be tween the camshaft and valve rocker arm No 1 Valve clearance Cold 0 11 to 0 17 mm 0 004 to 0 007 in for i...

Page 645: ...the valve clearance exhaust side Valve clearance Cold 0 17 mm 0 007 in HINT Perform the same procedure as for the intake valve clearance adjustment 9 INSTALL CYLINDER HEAD COVER SUB ASSY a Apply seal packing to the 4 locations as shown in the il lustration then install the cylinder head cover Seal packing Part No 08826 00080 or equivalent NOTICE S Remove any oil from the contact surface S Install ...

Page 646: ...h the 2 bolts Torque 11 N m 112 kgf cm 8 ft lbf e Connect the ventilation hose to the cylinder head f Connect the vacuum hose shown in the illustration g Connect the 2 vacuum hoses shown in the illustration h Connect the hose shown in the illustration BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 647: ...nect the engine wire harness Torque 11 N m 112 kgf cm 8 1 ft lbf for bolt A 13 N m 131 kgf cm 9 5 ft lbf for bolt B k Connect the common rail connector l Install the wire harness with the screw grommet and nut Torque 1 6 N m 16 kgf cm 14 in lbf m Connect the VSV connector and wire harness clamp shown in the illustration BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA...

Page 648: ... harness clamps shown in the illustra tion o Connect the supply pump connector p Connect the injector connectors 10 INSTALL ENGINE COVER SUB ASSY NO 1 a Engage the 4 clips and install the engine cover sub assy No 1 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 649: ...pport opening cover with the 4 clips 12 INSTALL ENGINE UNDER COVER RH TMC MADE See page 13 17 13 INSTALL ENGINE UNDER COVER RH EXCEPT TMC MADE See page 13 17 14 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55 kgf cm 48 in lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 650: ...p Clip TMC Made Engine Under Cover RH TMC Made Engine Under Cover LH x2 x3 x8 x2 x8 x6 x2 x2 x2 x7 ENGINE MECHANICAL PARTIAL ENGINE ASSY 1ND TV 14 17 COROLLA Supplement RM1129E PARTIAL ENGINE ASSY 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 651: ... 2 Fuel Hose No 1 Air Hose No 3 Battery Clamp Battery Battery Tray 25 225 18 x4 Water By pass Hose Radiator Support Upper RH Radiator Support Upper LH Radiator Hose Inlet RadiatorHose Outlet N m kgf cm ft lbf Specified torque z Non reusable part 19 194 14 19 194 14 7 0 71 5 2 in lbf Radiator Assy Air Hose No 2 14 18 ENGINE MECHANICAL PARTIAL ENGINE ASSY 1ND TV COROLLA Supplement RM1129E BACK TO CH...

Page 652: ...Front Drive Shaft Assy LH Front Suspension Arm Sub assy Lower No 1 LH N m kgf cm ft lbf Specified torque z Non reusable part 1 TMC MADE 2 TMUK MADE TMMT MADE 52 530 38 35 360 26 35 360 26 80 816 59 74 755 55 1 44 449 33 2 49 500 36 216 2203 159 43 440 32 43 440 32 89 908 66 X3 Clip Floor Panel Brace Front 29 6 300 22 X2 ENGINE MECHANICAL PARTIAL ENGINE ASSY 1ND TV 14 19 COROLLA Supplement RM1129E ...

Page 653: ...d torque X3 52 530 38 133 1356 98 80 816 59 39 398 29 133 1356 98 80 816 59 Front Suspension Member Brace Rear LH 133 1356 98 87 887 64 133 1356 98 20 204 15 14 20 ENGINE MECHANICAL PARTIAL ENGINE ASSY 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 654: ... Disc Assy Clutch Cover Assy Air Tube No 1 Air Tube No 2 1st 49 500 36 2nd Turn 90_ 25 255 18 25 255 18 25 255 18 x6 ENGINE MECHANICAL PARTIAL ENGINE ASSY 1ND TV 14 21 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 655: ...sy Oil Level Gage Guide z O ring Fan Belt Adjusting Bar Generator Assy 21 214 16 5 5 56 49 in lbf 19 189 14 19 189 14 32 326 24 11 112 8 1 14 22 ENGINE MECHANICAL PARTIAL ENGINE ASSY 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 656: ...ch Assy Intake Air Connector Oil Cooler Hose Sub assy 9 0 92 80 in lbf Water By pass Pipe No 1 20 204 15 20 204 15 20 204 15 20 204 15 11 112 8 11 112 8 20 204 15 20 204 15 20 204 15 z Gasket 25 255 18 Connector Tube 9 0 92 80 in lbf x2 ENGINE MECHANICAL PARTIAL ENGINE ASSY 1ND TV 14 23 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLL...

Page 657: ...ly Pump Drive Coupring Engine Coolant Temperature Sensor Injection Pipe Clamp No 2 Nozzle Holder Clamp Seat Injection Pipe Clamp No 1 Fuel Inlet Pipe Sub assy Injection Pipe Sub assy Use SST 9 0 92 80 in lbf Common Rail Assy X4 11 112 8 X4 11 112 8 26 265 19 1 6 16 14 in lbf 20 204 15 9 0 92 80 in lbf 23 235 17 25 255 18 26 265 19 5 5 56 49 in lbf 14 24 ENGINE MECHANICAL PARTIAL ENGINE ASSY 1ND TV...

Page 658: ... Cover 6 5 86 58 in lbf 6 5 86 58 in lbf Engine Oil Level Sensor Oil Pan Cover Manifold Stay 6 0 60 53 in lbf z Gasket z Gasket 6 0 60 53 in lbf 6 0 60 53 in lbf 37 377 27 26 265 19 37 377 27 8 0 82 71 in lbf 24 245 18 5 5 56 49 in lbf 14 143 10 5 5 56 49 in lbf 43 438 32 x5 x5 7 0 71 62 in lbf ENGINE MECHANICAL PARTIAL ENGINE ASSY 1ND TV 14 25 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO M...

Page 659: ...ER SUB ASSY NO 1 See page 14 6 13 REMOVE AIR CLEANER CAP SUB ASSY See page 13 17 14 REMOVE AIR CLEANER FILTER ELEMENT SUB ASSY 15 REMOVE AIR CLEANER CASE SUB ASSY a Remove 3 bolts then remove the air cleaner case 16 REMOVE FAN AND GENERATOR V BELT See page 14 4 17 SEPARATE COOLER COMPRESSOR ASSY W AIR CONDITIONING a Disconnect the cooler compressor connector b Remove the 4 bolts then separate the ...

Page 660: ...mp 23 DISCONNECT HEATER INLET WATER HOSE 24 DISCONNECT HEATER OUTLET WATER HOSE 25 DISCONNECT ENGINE WIRE a Disconnect the engine wire harness from the ECM and junction block b Pull the engine wire harness disconnected from the ECM and junction block out toward the engine room c Disconnect the engine wire from the engine room 26 REMOVE COLUMN HOLE COVER SILENCER SHEET See Pub No RM1106E on Page 50...

Page 661: ...ND SUB ASSY LH See page 30 3 37 DISCONNECT TIE ROD END SUB ASSY RH HINT Perform the same procedure as above on the opposite side 38 DISCONNECT FRONT SUSPENSION ARM SUB ASSY LOWER NO 1 LH See page 30 3 39 DISCONNECT FRONT SUSPENSION ARM SUB ASSY LOWER NO 1 RH HINT Perform the same procedure as above on the opposite side 40 DISCONNECT FRONT AXLE ASSY LH See page 30 3 41 DISCONNECT FRONT AXLE ASSY RH...

Page 662: ...s shown in the illustration g Operate the engine lifter then remove the engine with transaxle from the vehicle 45 REMOVE FRONT SUSPENSION CROSSMEMBER W CENTER MEMBER a Remove the bolt then remove the engine cover bracket No 3 b Install the engine hanger and bolt Torque 40 N m 408 kgf cm 30 ft lbf NOTICE Be sure to use new bolts to install the engine hanger c Using a chain block and engine sling de...

Page 663: ...bolt and loosen the hose clamp then remove the air tube No 1 48 REMOVE STARTER ASSY See page 19 3 49 REMOVE MANUAL TRANSAXLE ASSY HINT S Manual transaxle C53 See page 41 49 S Manual transaxle C53A See page 41 36 50 REMOVE CLUTCH COVER ASSY See page 42 29 51 REMOVE CLUTCH DISC ASSY See page 42 29 52 REMOVE FLYWHEEL SUB ASSY See page 14 82 SST 09960 10010 09962 01000 09963 01000 53 REMOVE CRANKSHAFT...

Page 664: ...CTOR a Disconnect the vacuum hose and the water hose b Remove the 4 bolts then remove the intake air connector 64 REMOVE EGR PIPE CONNECTOR a Remove the 3 bolts then remove the EGR pipe connec tor 65 REMOVE OIL COOLER HOSE SUB ASSY a Remove the oil cooler hose 66 REMOVE EGR PIPE NO 1 HOSE a Remove the water by pass hose BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA...

Page 665: ...01 77 REMOVE FUEL INLET PIPE SUB ASSY See page 11 16 SST 09023 38401 78 REMOVE COMMON RAIL ASSY See page 11 20 79 REMOVE NOZZLE LEAKAGE PIPE ASSY See page 11 8 80 REMOVE INJECTOR ASSY See page 11 8 81 REMOVE INJECTION OR SUPPLY PUMP ASSY See page 11 16 82 REMOVE DIESEL ENGINE ENGINE COOLANT TEMPERATURE SENSOR a Using SST remove the engine coolant temperature sen sor SST 09817 33190 83 REMOVE ENGIN...

Page 666: ...DE COVER a Remove 2 bolts then remove the cylinder block side cov er 92 REMOVE CRANKSHAFT POSITION SENSOR a Remove the bolt then remove the crankshaft position sensor 93 REMOVE ENGINE OIL LEVEL SENSOR a Remove the 4 bolts then remove the engine oil level sen sor 94 REMOVE OIL PAN COVER a Remove the 3 bolts then remove the oil pan cover 95 INSTALL OIL PAN COVER a Install the oil pan cover with the ...

Page 667: ...rque 43 N m 438 kgf cm 32 ft lbf b Install the exhaust manifold heat insulator No 1 with the 2 bolts Torque 6 N m 61 kgf cm 53 in lbf c Install the manifold stay with the 2 bolts Torque 37 N m 377 kgf cm 27 ft lbf 100 INSTALL TURBO OIL OUTLET PIPE See page 13 17 101 INSTALL TURBO OIL INLET PIPE See page 13 17 102 INSTALL EXHAUST MANIFOLD CONVERTER SUB ASSY See page 13 17 103 INSTALL TURBO INSULATO...

Page 668: ...14 INSTALL INJECTION PIPE SUB ASSY NO 2 See page 11 8 SST 09023 38401 115 INSTALL INJECTION PIPE SUB ASSY NO 3 See page 11 8 SST 09023 38401 116 INSTALL INJECTION PIPE SUB ASSY NO 4 See page 11 8 SST 09023 38401 117 INSTALL INJECTION PIPE CLAMP NO 1 See page 11 8 118 INSTALL INJECTION PIPE CLAMP NO 2 See page 11 8 119 INSTALL GLOW PLUG ASSY See page 19 14 120 INSTALL GLOW PLUG NO 1 CONNECTOR See p...

Page 669: ... bolts Torque 20 N m 204 kgf cm 15 ft lbf b Connect the vacuum hose and water hose 127 INSTALL EGR VALVE ASSY See page 12 5 128 INSTALL VACUUM REGULATING VALVE See page 11 8 129 INSTALL EGR COOLER ASSY See page 12 5 130 INSTALL OIL LEVEL GAGE GUIDE See page 14 70 131 INSTALL VACUUM PUMP ASSY See page 32 3 132 INSTALL TIMING CHAIN COVER NO 2 See page 17 5 133 INSTALL GENERATOR ASSY See page 19 9 13...

Page 670: ...BE NO 2 a Install the air tube No 2 with the 2 bolts Torque 25 N m 255 kgf cm 18 ft lbf NOTICE Use a new air hose 144 INSTALL FRONT SUSPENSION CROSSMEMBER W CENTER MEMBER a Install the engine mounting insulator FR and Engine mounting bracket FR with the through bolt and nut Torque 52 N m 530 kgf cm 38 ft lbf b Install the engine mounting insulator RR and Engine mounting bracket RR with the through...

Page 671: ... 149 INSTALL FRONT AXLE ASSY RH HINT Perform the same procedure as above on the opposite side 150 INSTALL FRONT SUSPENSION ARM SUB ASSY LOWER NO 1 LH See page 30 3 151 INSTALL FRONT SUSPENSION ARM SUB ASSY LOWER NO 1 RH HINT Perform the same procedure as above on the opposite side 152 INSTALL TIE ROD END SUB ASSY LH See page 30 3 153 INSTALL TIE ROD END SUB ASSY RH HINT Perform the same procedure ...

Page 672: ...CE FRONT See page 15 2 162 INSTALL STEERING SLIDING YOKE SUB ASSY See Pab No RM1106E on Page 50 6 163 INSTALL COLUMN HOLE COVER SILENCER SHEET See Pab No RM1106E on Page 50 6 164 INSTALL ENGINE WIRE 165 INSTALL HEATER OUTLET WATER HOSE 166 INSTALL HEATER INLET WATER HOSE 167 INSTALL FUEL HOSE NO 1 a Connect the fuel hose No 1 to the supply pump 168 INSTALL FUEL HOSE NO 2 a Connect the fuel hose No...

Page 673: ...air cleaner case with the 3 bolts Torque 7 0 N m 71 kgf cm 5 2 in lbf 175 INSTALL AIR CLEANER FILTER ELEMENT SUB ASSY 176 INSTALL AIR CLEANER CAP SUB ASSY See page 13 17 177 INSTALL RADIATOR ASSY See page 16 12 178 INSTALL BATTERY TRAY 179 INSTALL BATTERY 180 ADD MANUAL TRANSAXLE OIL 181 ADD ENGINE OIL 182 ADD ENGINE COOLANT See page 16 7 183 INSPECT MANUAL TRANSAXLE OIL LEVEL See page 41 4 184 CH...

Page 674: ...ee page 13 17 192 INSTALL ENGINE UNDER COVER RH EXCEPT TMC MADE See page 13 17 193 INSTALL ENGINE UNDER COVER LH EXCEPT TMC MADE See page 13 17 194 INSTALL FRONT WHEELS Torque 103 N m 1050 kgf cm 76 ft lbf 195 ADJUST FRONT WHEEL ALIGNMENT See Pab No RM1106E on Page 26 1 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 675: ...nder Cover RH TMC Made Engine Under Cover RH Clip N m kgf cm ft lbf Specified torque Clip Clip Clip Clip x3 52 530 38 52 530 38 19 189 14 19 189 14 32 326 24 x4 52 530 38 x2 x3 x2 x8 14 42 ENGINE MECHANICAL CHAIN SUB ASSY 1ND TV COROLLA Supplement RM1129E CHAIN SUB ASSY 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E...

Page 676: ...ified torque z Non reusable part x3 x2 x4 x10 x4 x12 x2 z Oil Pump Seal Crankshaft Damper Sub assy 11 112 8 15 153 11 11 112 8 1 55 561 41 15 153 11 24 245 18 5 5 56 49 in lbf 21 214 16 11 112 8 13 133 10 x2 x3 11 112 8 1 Apply multi purpose grease 180 1 835 133 ENGINE MECHANICAL CHAIN SUB ASSY 1ND TV 14 43 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Su...

Page 677: ...ation Damper No 1 Crankshaft Timing Sprocket N m kgf cm ft lbf Specified torque 20 204 15 9 0 92 80 in lbf 20 204 15 20 204 15 14 44 ENGINE MECHANICAL CHAIN SUB ASSY 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 678: ...3 REMOVE VACUUM PUMP ASSY See page 32 3 14 SET NO 1 CYLINDER TO TDC COMPRESSION a Set the No 1 cylinder to TDC Compression 1 Turn the crankshaft pulley until the grooves of the crankshaft damper and oil pump are aligned 2 Check that the timing mark of the camshaft timing sprocket and the straight pin hole of the camshaft timing sprocket are in the positions shown in the il lustration HINT If not t...

Page 679: ... to lock the plunger d Insert a 2 5 mm 0 098 in diameter bar into the hole of the stopper plate with the plunger locked HINT If the stopper plate is not completely pulled down and a 2 5 mm 0 098 in diameter bar cannot be inserted unlock and pull out the plunger slightly The stopper plate could then be completely pulled down and a 2 5 mm 0 098 in diameter bar could be in serted easily e Remove the ...

Page 680: ...lts then remove the camshaft timing sprocket c Remove the camshaft timing sprocket crankshaft timing sprocket and chain together 25 INSTALL CHAIN SUB ASSY a Turn the camshaft to set the straight pin in the position shown in the illustration NOTICE When turning the camshaft to set the position turn the crankshaft to set the key in the 70_ BTDC position b Turn the crankshaft to set the key in the po...

Page 681: ...s on the camshaft timing sprocket and crankshaft timing sprocket d Install the chain camshaft timing sprocket and crankshaft timing sprocket together onto the engine e Fix the camshaft timing sprocket using SST and install the camshaft timing sprocket with the 3 bolts SST 09960 10010 09962 01000 09963 01000 Torque 20 N m 204 kgf cm 15 ft lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Ind...

Page 682: ...plate to unlock the plunger b Push in the plunger to the end with the plunger unlocked c Pull down the stopper plate with the plunger pushed to the end to lock the plunger d Insert a 2 5 mm 0 098 in diameter bar into the hole of the stopper plate with the plunger locked HINT If the stopper plate is not completely pulled down and a 2 5 mm 0 098 in diameter bar cannot be inserted unlock and pull out...

Page 683: ...INSTALL ENGINE MOUNTING INSULATOR SUB ASSY RH See page 17 5 34 INSTALL CRANKSHAFT DAMPER SUB ASSY See page 17 5 SST 09960 10010 09962 01000 09963 01000 35 INSTALL VACUUM PUMP ASSY See page 32 3 36 INSTALL CYLINDER HEAD COVER SUB ASSY See page 14 6 37 INSTALL WATER PUMP ASSY See page 16 9 38 INSTALL WATER PUMP PULLEY See page 16 9 SST 09960 10010 09962 01000 09963 00700 39 INSTALL GENERATOR ASSY Se...

Page 684: ...L ENGINE COVER SUB ASSY NO 1 See page 14 6 49 INSTALL RADIATOR SUPPORT OPENING COVER See page 14 6 50 INSTALL ENGINE UNDER COVER RH TMC MADE See page 13 17 51 INSTALL ENGINE UNDER COVER RH EXCEPT TMC MADE See page 13 17 52 INSTALL FRONT WHEEL RH Torque 103 N m 1050 kgf cm 76 ft lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 685: ...ine Under Cover RH Clip Clip N m kgf cm ft lbf Specified torque Clip Clip TMC Made Engine Under Cover RH X2 X3 X8 X2 X8 14 52 ENGINE MECHANICAL CAMSHAFT 1ND TV COROLLA Supplement RM1129E CAMSHAFT 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 686: ...15 9 0 92 80 in lbf Fuel Inlet Pipe Sub assy Injection Pipe Clamp No 1 23 235 17 25 255 18 23 235 17 25 255 18 Vacuum Regulating Valve x3 20 204 15 z Gasket z Gasket 11 112 8 11 112 8 x2 x3 x2 x2 EGR Cooler Assy ENGINE MECHANICAL CAMSHAFT 1ND TV 14 53 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 687: ...ft Bearing Cap Camshaft Bearing Cap X4 Camshaft X3 20 204 15 Vacuum Pump 21 214 16 X2 z O ring N m kgf cm ft lbf Specified torque z Non reusable part 14 54 ENGINE MECHANICAL CAMSHAFT 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 688: ...M REGULATING VALVE See page 11 8 13 REMOVE INJECTION PIPE CLAMP NO 1 See page 11 8 14 REMOVE NOZZLE LEAKAGE PIPE ASSY See page 11 8 15 REMOVE FUEL INLET PIPE SUB ASSY See page 11 16 SST 09023 38401 16 REMOVE INJECTION OR SUPPLY PUMP ASSY See page 11 16 17 REMOVE CAMSHAFT a Set the No 1 cylinder to TDC Compression 1 Turn the crankshaft pulley until the grooves of the crankshaft damper and oil pump ...

Page 689: ...rew plug d Insert a flathead screwdriver from the chain tensioner ser vice hole and hold the chain tensioner stopper plate in a raised position e Use a wrench to turn the hexagonal service portion of the camshaft and keep the chain tensioner plunger de pressed BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 690: ...cure the 2 5 mm 0 098 in diameter bar using tape or equivalent to keep it from falling off g While holding the hexagonal service portion of the cam shaft with a wrench loosen the 3 bolts h Remove the 10 bolts of the camshaft bearing caps in the sequence shown in the illustration and then remove the 5 camshaft bearing caps NOTICE S Using several steps uniformly loosen the bolts while keeping the ca...

Page 691: ...t timing sprocket and cam shaft with the 3 bolts e Examine the front marks and numbers and check that the sequence order is as shown in the illustration Then tem porarily tighten the camshaft with the camshaft bearing caps and bolts f Using several steps temporarily tighten the bolts in the sequence shown in the illustration and then tighten the bolts to the specified torque Torque 19 N m 194 kgf ...

Page 692: ... INJECTION OR SUPPLY PUMP ASSY See page 11 16 22 INSTALL FUEL INLET PIPE SUB ASSY See page 11 16 SST 09023 38401 23 INSTALL NOZZLE LEAKAGE PIPE ASSY See page 11 8 24 INSTALL INJECTION PIPE CLAMP NO 1 See page 11 8 25 INSTALL VACUUM REGULATING VALVE See page 11 8 26 INSTALL EGR COOLER ASSY See page 12 5 27 INSTALL AIR CLEANER CAP SUB ASSY See page 13 17 28 INSTALL VACUUM PUMP ASSY See page 32 3 29 ...

Page 693: ...GINE UNDER COVER RH TMC MADE See page 13 17 37 INSTALL ENGINE UNDER COVER RH EXCEPT TMC MADE See page 13 17 38 INSTALL FRONT WHEEL RH Torque 103 N m 1050 kgf cm 76 ft lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 694: ...er Cover LH Clip Clip TMC Made Engine Under Cover RH Clip Clip Clip Clip Clip Clip Clip Clip x2 x2 x2 x8 x7 x2 TMC Made Engine Under Cover LH x2 x2 x5 x5 ENGINE MECHANICAL CYLINDER HEAD GASKET 1ND TV 14 61 COROLLA Supplement RM1129E CYLINDER HEAD GASKET 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 695: ... ft lbf Specified torque Water By pass Pipe Heater Water Hose Radiator Inlet Hose 52 530 38 52 530 38 52 530 38 19 189 14 19 189 14 32 326 24 9 92 80 in lbf 52 530 38 14 62 ENGINE MECHANICAL CYLINDER HEAD GASKET 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 696: ... lbf Specified torque w Cold Area Exhaust Pipe x2 29 6 300 22 7 5 75 66 in lbf Mass Air Flow Meter Connector Compression Spring 43 440 32 z Exhaust Pipe Gasket 43 440 32 x2 x2 Floor Panel Brace Front x4 ENGINE MECHANICAL CYLINDER HEAD GASKET 1ND TV 14 63 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 697: ... Manifold Gasket 11 110 8 6 0 60 53 in lbf Intercooler Air Hose No 1 24 245 18 6 0 60 53 in lbf 37 375 27 Turbo Oil Inlet Pipe Turbocharger Assy 6 0 60 53 in lbf 53 540 39 x3 z Turbo Oil Outlet Gasket No 1 Hose Clamp Hose Clamp 24 245 18 x2 Turbo Oil Outlet Pipe z Turbo Oil Inet Pipe Gasket z Turbo Oil Inet Pipe Gasket 14 64 ENGINE MECHANICAL CYLINDER HEAD GASKET 1ND TV COROLLA Supplement RM1129E ...

Page 698: ...t Washer Nozzle Holder Clamp Seat x4 x4 x4 x4 Injection Pipe Clamp No 1 Injection Pipe Sub assy Nozzle Holder Clamp x4 x4 z Non reusable part Use SST 23 235 17 25 255 18 23 235 17 25 255 18 N m kgf cm ft lbf Specified torque ENGINE MECHANICAL CYLINDER HEAD GASKET 1ND TV 14 65 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MA...

Page 699: ...et Pipe Sub assy Injection Pipe Clamp No 1 23 235 17 25 255 18 23 235 17 25 255 18 Vacuum Regulating Valve x3 20 204 15 z Gasket z Gasket 11 112 8 11 112 8 x2 x3 x2 x2 EGR Cooler Assy 14 66 ENGINE MECHANICAL CYLINDER HEAD GASKET 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 700: ...ed torque z Non reusable part x3 x2 x4 x10 x4 x12 x2 z Oil Pump Seal Crankshaft Damper Sub assy 11 112 8 15 153 11 180 1 835 133 11 112 8 1 55 561 41 15 153 11 24 245 18 5 5 56 49 in lbf 21 214 16 11 112 8 13 133 10 x2 x3 11 112 8 1 Apply multi purpose grease ENGINE MECHANICAL CYLINDER HEAD GASKET 1ND TV 14 67 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To...

Page 701: ...on Damper No 1 Crankshaft Timing Sprocket N m kgf cm ft lbf Specified torque 20 204 15 9 0 92 80 in lbf 20 204 15 20 204 15 14 68 ENGINE MECHANICAL CYLINDER HEAD GASKET 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 702: ... assy Oil Level Gage Guide 1st 68 693 50 2nd Turn 90_ 3rd Turn 90_ X2 x10 x2 Exhaust Manifold z Gasket x5 x5 Exhaust Manifold Heat Insulator No 1 37 377 27 6 0 61 53 in lbf 43 438 32 Manifold Stay Camshaft Bearing Cap No 1 ENGINE MECHANICAL CYLINDER HEAD GASKET 1ND TV 14 69 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANU...

Page 703: ...se clamp shown in the illustration c Separate the vacuum hose from the vacuum transmitting pipe No 1 d Remove the 2 bolts and air tube No 2 with air hose No 4 12 REMOVE AIR CLEANER CAP SUB ASSY See page 13 17 13 REMOVE GLOW PLUG NO 1 CONNECTOR See page 19 14 14 REMOVE GLOW PLUG ASSY See page 19 14 15 REMOVE EGR COOLER ASSY See page 12 5 16 REMOVE VACUUM REGULATING VALVE See page 11 8 17 REMOVE INJ...

Page 704: ... WATER PUMP PULLEY See page 16 9 SST 09960 10010 09962 01000 09963 00700 40 REMOVE WATER PUMP ASSY See page 16 9 41 REMOVE CYLINDER HEAD COVER SUB ASSY See page 14 6 42 REMOVE VACUUM PUMP ASSY See page 32 3 43 SET NO 1 CYLINDER TO TDC COMPRESSION See page 14 45 44 REMOVE CRANKSHAFT DAMPER SUB ASSY See page 17 5 SST 09960 10010 09962 01000 09963 01000 45 REMOVE ENGINE MOUNTING INSULATOR SUB ASSY RH...

Page 705: ...GUIDE a Remove the oil level gage from the oil level gage guide b Remove the bolt then remove the oil level gage guide 57 REMOVE CYLINDER HEAD SUB ASSY a Disconnect the vacuum hose shown in the illustration b Disconnect the vacuum hose shown in the illustration c Disconnect the 2 water hoses shown in the illustration BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA CO...

Page 706: ...rs NOTICE S When removing the bolts do not drop the washer into the engine S Removing the cylinder head bolts in the wrong order may cause damage to the cylinder head 58 REMOVE CYLINDER HEAD GASKET 59 INSPECT CYLINDER HEAD SET BOLT a Using vernier calipers measure the minimum outer diam eter of the compressed thread at the measuring point Standard outer diameter 11 7 to 12 0 mm 0 461 to 0 472 in M...

Page 707: ... inder block top surface 2 Measure the protrusion height of the piston head of each cylinder at 2 places as shown in the illustra tion b Select a new cylinder head gasket 1 Select the highest protrusion height among the 8 measurement records Use it to select a new cylin der head gasket Piston protrusion Piston protrusion mm in Gasket cutout Gasket size 0 375 to 0 425 1 A 0 425 to 0 475 2 B 0 475 t...

Page 708: ... the top surface of the cylinder head again as shown in the illustration Seal packing Part No 08826 00080 or equivalent 4 Install the cylinder head onto the cylinder block NOTICE S Remove any oil from the contact surface S Install the cylinder head within 3 minutes and tighten the bolts within 15 minutes of applying seal packing 61 INSTALL CYLINDER HEAD SUB ASSY HINT The cylinder head bolts are ti...

Page 709: ...shown in the illustration e Check that each paint mark is now 180_ opposite from the front f Connect each connector and wire harness to the cylinder head g Install the water by pass pipe with the bolt Torque 9 N m 92 kgf cm 80 in lbf h Connect the radiator inlet hose and the heater water hose i Connect the 2 water hoses shown in the illustration j Connect the vacuum hose shown in the illustration ...

Page 710: ...tem end cap valve rocker arm piv ot top surface and valve rocker arm roller portion b Install the 8 valve rocker arms 64 INSTALL CAMSHAFT a Turn the crankshaft to set the key at the 70_ BTDC posi tion b Apply engine oil to the camshaft journal portion and cam portion c Examine the front marks and numbers and check that the sequence order is as shown in the illustration Then tem porarily tighten th...

Page 711: ...e page 16 9 78 INSTALL WATER PUMP PULLEY See page 16 9 SST 09960 10010 09962 01000 09963 00700 79 INSTALL GENERATOR ASSY See page 19 9 80 INSTALL FAN AND GENERATOR V BELT See page 14 4 81 ADJUST FAN AND GENERATOR V BELT See page 14 4 82 INSPECT FAN AND GENERATOR V BELT See page 14 1 83 REMOVE EXHAUST MANIFOLD a Install a new gasket then install the exhaust manifold with the 5 nuts Torque 43 N m 43...

Page 712: ...VALVE See page 11 8 104 INSTALL EGR COOLER ASSY See page 12 5 105 INSTALL GLOW PLUG ASSY See page 19 14 106 INSTALL GLOW PLUG NO 1 CONNECTOR See page 19 14 107 INSTALL AIR CLEANER CAP SUB ASSY See page 13 17 108 INSTALL AIR TUBE NO 2 a Install air tube No 2 with air hose No 4 with the 2 bolts Torque 25 N m 255 kgf cm 18 ft lbf b Connect the vacuum hose to the vacuum transmitting pipe No 1 c Tighte...

Page 713: ...ENGINE COVER SUB ASSY NO 1 See page 14 6 119 INSTALL ENGINE UNDER COVER RH TMC MADE See page 13 17 120 INSTALL ENGINE UNDER COVER LH TMC MADE See page 13 17 121 INSTALL ENGINE UNDER COVER RH EXCEPT TMC MADE See page 13 17 122 INSTALL ENGINE UNDER COVER LH EXCEPT TMC MADE See page 13 17 123 INSTALL FRONT WHEEL RH Torque 103 N m 1050 kgf cm 76 ft lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabeti...

Page 714: ...SEAL a Apply multi purpose grease to a new oil seal lip NOTICE Keep the lip free of foreign objects b Using SST and a hammer tap in the new oil seal until its surface is flush with the oil pimp edge SST 09223 22010 NOTICE S Tap in the oil seal from a vertical position S Wipe any extra grease off the crankshaft 8 INSTALL CRANKSHAFT DAMPER SUB ASSY See page 17 5 SST 09960 10010 09962 01000 09963 010...

Page 715: ...Y a Using SST hold the crankshaft SST 09960 10010 09962 01000 09963 01000 b Remove the 6 bolts and flywheel 5 REMOVE CRANKSHAFT POSITION SENSOR PLATE NO 1 a Remove the crank angle sensor plate No 1 from the crankshaft 6 REMOVE ENGINE REAR OIL SEAL a Using a knife cut off the oil seal lip b Using a screwdriver with its tip wrapped in tape pry out the oil seal NOTICE After removing check the cranksh...

Page 716: ...crankshaft as shown in the illustration 9 INSTALL FLYWHEEL SUB ASSY a Clean the 6 bolts and 6 bolt holes b Apply adhesive to 2 or 3 threads of the 8 bolts Adhesive Part No 08833 00070 THREE BOND 1324 or equiva lent c Using SST hold the crankshaft SST 09960 10010 09962 01000 09963 01000 d Using several steps uniformly install and tighten the 8 bolts in the sequence shown in the illustration Torque ...

Page 717: ...SY See page 42 29 SST 09301 00220 11 INSTALL CLUTCH COVER ASSY See page 42 29 12 INSTALL MANUAL TRANSAXLE ASSY HINT S Manual transaxle C53 See page 41 49 S Manual transaxle C53 A See page 41 36 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 718: ... EXHAUST PIPE ASSY 1ND TV 15 1 COMPONENTS 15 1 Removal Installation and Disassembly Reassembly 15 2 TO MODEL INDEX To Alphabetical Index To Sub Index BACK TO MAIN INDEX TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 719: ...t Pipe Assy Tail Compression Spring Compression Spring Floor Panel Brace Front z Exhaust Pipe Gasket z Exhaust Pipe Gasket 43 440 32 43 440 32 29 6 300 22 Exhaust Pipe Assy Front EXHAUST EXHAUST PIPE ASSY 1ND TV 15 1 COROLLA Supplement RM1129E EXHAUST PIPE ASSY 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 720: ...MOVE EXHAUST PIPE ASSY TAIL a Remove the 2 bolts and 2 compression springs b Remove the exhaust pipe tail from the 2 exhaust pipe supports No 4 c Remove the gasket from the exhaust pipe front 3 REMOVE EXHAUST PIPE ASSY FRONT a Remove the 2 bolts and 2 compression springs b Remove the exhaust pipe front from the 2 exhaust pipe supports No 5 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index...

Page 721: ...ports No 4 from the body 5 REMOVE EXHAUST PIPE SUPPORT NO 5 a Remove the 2 exhaust pipe supports No 5 from the body 6 INSTALL EXHAUST PIPE SUPPORT NO 5 a Install the 2 exhaust pipe supports No 5 onto the body 7 INSTALL EXHAUST PIPE SUPPORT NO 4 a Install the 2 exhaust pipe supports No 4 onto the body BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANU...

Page 722: ...er NOTICE S Make sure that the gasket is in the correct direction when installing S Do not reuse a removed gasket S Never push the gasket into the exhaust manifold by installing the exhaust pipe front onto the exhaust manifold converter c Install the exhaust pipe front onto the 2 exhaust pipe sup ports No 5 d Tighten the 2 compression springs and 2 bolts Torque 43 N m 440 kgf cm 32 ft lbf 9 INSTAL...

Page 723: ...ed gasket S Never push the gasket into the exhaust pipe front by installing the exhaust pipe tail onto the exhaust pipe front c Install the exhaust pipe tail onto the 2 exhaust pipe sup ports No 4 d Tighten the 2 compression springs and 2 bolts Torque 43 N m 440 kgf cm 32 ft lbf 10 INSTALL FLOOR PANEL BRACE FRONT a Install the floor panel brace front with the 2 nuts Torque 29 6 N m 300 kgf cm 22 f...

Page 724: ...E INSPECTION 16 5 INSPECTION 16 6 ENGINE COOLANT 1ND TV 16 7 REPLACEMENT 16 7 8 WATER PUMP ASSY 1ND TV 16 9 REPLACEMENT 16 9 10 THERMOSTAT 1ND TV 16 11 REPLACEMENT 16 11 RADIATOR ASSY 1ND TV 16 12 REPLACEMENT 16 12 TO MODEL INDEX To Alphabetical Index To Sub Index BACK TO MAIN INDEX TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 725: ...radiator cap 2 CHECK ENGINE COOLANT LEVEL AT RESERVOIR a The engine coolant should be between the LOW and FULL lines when the engine is cold If low check for leakage and add Toyota Super Long Life Coolant or similarhigh quality ethylene glycol based non silicate non amine non nitrite and non borate coolant with long life hybrid organic acid technology up to the FULL line 3 CHECK ENGINE COOLANT QUA...

Page 726: ... a possibility of damaging the fins so keep to the following injection distances Injection Pressure kPa kgf cm2 psi Injection Distance mm in 2 942 to 4 903 30 to 50 427 to 711 300 11 811 4 903 to 7 845 50 to 80 711 to 1 138 500 19 685 S If the fins are bent straighten them with a screwdriver or pliers S Be careful not to expose electronic components to water BACK TO CHAPTER INDEX TO MODEL INDEX To...

Page 727: ... If the valve lift is not as specified replace the thermostat d Check that the valve is fully closed when the thermostat is at low temperatures below 77_C 171_F If not fully closed replace the thermostat 2 INSPECT RESERVE TANK CAP SUB ASSY NOTICE S If the radiator cap is contaminated rinse it with water S Before using a radiator cap tester wet the relief valve and pressure valve with engine coolan...

Page 728: ...vacuum valve After the first pumping the pumping speed can be reduced Standard opening pressure 95 to 125 kPa 0 97 to 1 27 kgf cm2 13 8 to 18 1 psi Minimum opening pressure 79 kPa 0 8 kgf cm2 11 5 psi If the opening pressure is less than the minimum replace the radiator cap HINT Use the tester s maximum reading as the opening pressure BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To S...

Page 729: ...n then check for a short circuit between the cooling fan relay and engine coolant temperature sensor e Reconnect the engine coolant temperature sensor con nector 2 CHECK COOLING FAN OPERATION AT HIGH TEM PERATURES Above 96_C 205_F a Start the engine then raise the coolant temperature to above 96_C 205_F HINT Coolant temperature is the value detected by the engine cool ant temperature sensor on the...

Page 730: ...an ohmmeter measure the resistance be tween each terminal Standard Tester Connection Specified Condition 3 4 Below 1 Ω 3 4 10 kΩ or higher Apply battery voltage to terminals 1 and 2 3 5 10 kΩ or higher 3 5 Below 1 Ω Apply battery voltage to terminals 1 and 2 If the result is not as specified replace the relay 3 INSPECT COOLING FAN RESISTOR a Check the resistance 1 Using an ohmmeter measure the res...

Page 731: ...ts 4 7 lmp qts HINT S Use of improper coolants may damage the engine cooling system S Only use Toyota Super Long Life Coolant or similar high quality ethlene glycol based non silicate non amine non nitrite and non borate coolant with long life hybrid organic acid technology coolant with long life hybrid or ganic acid technology consists of a combination of low phosphates and organic acids S New To...

Page 732: ...re h After the engine cools down check that the coolant level is between LOW and FULL lines 4 CHECK FOR ENGINE COOLANT LEAKAGE See page 16 1 5 INSTALL RADIATOR SUPPORT OPENING COVER See page 14 6 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 733: ...age 16 7 6 REMOVE FAN AND GENERATOR V BELT See page 14 4 7 REMOVE GENERATOR ASSY See page 19 9 8 REMOVE WATER PUMP PULLEY a Using SST hold the water pump pulley SST 09960 10010 09962 01000 09963 00700 b Remove the 4 bolts then remove the water pump pulley 9 REMOVE WATER PUMP ASSY a Remove the 3 bolts and 2 nuts then remove the water pump 10 INSTALL WATER PUMP ASSY a Install a new gasket and the wa...

Page 734: ...GENERATOR V BELT See page 14 4 14 ADJUST FAN AND GENERATOR V BELT See page 14 4 15 INSPECT FAN AND GENERATOR V BELT See page 14 1 16 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55 kgf cm 48 in lbf 17 ADD ENGINE COOLANT See page 16 7 18 CHECK FOR ENGINE COOLANT LEAKAGE See page 16 1 19 INSTALL ENGINE UNDER COVER RH TMC MADE See page 13 17 20 INSTALL ENGINE UNDER COVER RH EXCEPT TMC MA...

Page 735: ... a Install a new gasket onto the thermostat b Install the thermostat with the jiggle valve upward HINT The jiggle valve may be set to within 10_ on either side of the prescribed position 8 INSTALL WATER INLET a Install the water inlet with the 2 nuts Torque 9 0 N m 92 kgf cm 80 in lbf 9 ADD ENGINE COOLANT See page 16 7 10 CHECK FOR ENGINE COOLANT LEAKAGE See page 16 1 11 INSTALL ENGINE UNDER COVER...

Page 736: ...MADE See page 13 17 6 DRAIN ENGINE COOLANT See page 16 7 7 REMOVE RADIATOR ASSY a Disconnect the radiator hose inlet from the radiator b Disconnect the water by pass hose from the radiator re serve tank c Disconnect the radiator hose outlet from the radiator d Disconnect the turbo pressure sensor connector e Disconnect the 2 wire harness clamps from the fan shroud f Disconnect the vacuum hose from...

Page 737: ...e fan shroud j Remove the 2 bolts then separate the engine room relay block k Remove the 2 bolts then remove the radiator support up per LH and RH 8 REMOVE W MOTOR FAN ASSY a Disconnect the water by pass hose from the radiator b Remove the 2 bolts then remove the w motor fan BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 738: ...REMOVE RADIATOR DRAIN COCK PLUG a Remove the radiator drain cock plug from the radiator 11 INSTALL RADIATOR DRAIN COCK PLUG a Install the radiator drain cock plug onto the radiator 12 INSTALL RADIATOR SUPPORT LOWER a Install the radiator support lower onto the radiator BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 739: ...m 66 in lbf b Connect the water by pass hose to the radiator 14 INSTALL RADIATOR ASSY a Install the radiator support upper LH and RH with the 2 bolts Torque 19 N m 194 kgf cm 14 ft lbf b Install the engine room relay block with the 2 bolts Torque 5 4 N m 55 kgf cm 48 in lbf BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 740: ... 5 0 N m 51 kgf cm 44 in lbf f Connect the vacuum hose to the turbo pressure sensor g Connect the 2 wire harness clamps to the fan shroud h Connect the turbo pressure sensor connector i Connect the radiator hose outlet to the radiator j Connect the water by pass hose to the radiator reserve tank k Connect the radiator hose inlet to the radiator BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical ...

Page 741: ...HECK FOR ENGINE COOLANT LEAKAGE See page 16 1 18 INSTALL ENGINE UNDER COVER RH TMC MADE See page 13 17 19 INSTALL ENGINE UNDER COVER RH EXCEPT TMC MADE See page 13 17 20 INSTALL ENGINE COVER SUB ASSY NO 1 See page 14 6 21 INSTALL RADIATOR SUPPORT OPENING COVER See page 14 6 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 742: ...SSY 1ND TV 17 3 COMPONENTS 17 3 4 REPLACEMENT 17 5 10 OIL FILTER SUB ASSY 1ND TV 17 11 REPLACEMENT 17 11 12 OIL COOLER ASSY 1ND TV 17 13 COMPONENTS 17 13 14 REPLACEMENT 17 15 TO MODEL INDEX To Alphabetical Index To Sub Index BACK TO MAIN INDEX TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 743: ...oor replace the oil Oil grade Use ACEA B1 API grade CF 4 CF or G DLD 1 You may also use API CE or CD SAE 5W 30 is the best choice for your vehicle in terms of good fuel economy and good starting in cold weather 3 INSPECT OIL PRESSURE a Remove the engine under cover RH TMC made see page 13 17 b Remove the engine under cover RH except TMC made see page 13 17 c Disconnect the oil pressure switch conn...

Page 744: ...24 mm install the oil pressure switch Torque 15 N m 153 kgf cm 11 ft lbf NOTICE Do not start the engine for at least 1 hour after installation k Connect the oil pressure switch connector l Check for engine oil leakage m Install the engine under cover RH TMC made see page 13 17 n Install the engine under cover RH except TMC made see page 13 17 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical In...

Page 745: ... Cover RH TMC Made Engine Under Cover RH Clip N m kgf cm ft lbf Specified torque Clip Clip Clip Clip x3 52 530 38 52 530 38 19 189 14 16 158 11 32 326 24 x4 52 530 38 Clip x3 x2 x8 x2 x8 52 530 38 LUBRICATION OIL PUMP ASSY 1ND TV 17 3 COROLLA Supplement RM1129E OIL PUMP ASSY 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP ...

Page 746: ...Specified torque z Non reusable part x3 x2 x4 x10 x4 x12 x2 z Oil Pump Seal Crankshaft Damper Sub assy 11 112 8 15 153 11 180 1 835 133 11 112 8 1 55 561 41 15 153 11 24 245 18 5 5 56 49 in lbf 21 214 16 11 112 8 13 133 10 x2 x3 11 112 8 1 Apply multi purpose grease 17 4 LUBRICATION OIL PUMP ASSY 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub In...

Page 747: ...9 REMOVE GENERATOR ASSY See page 19 9 10 REMOVE WATER PUMP PULLEY See page 16 9 SST 09960 10010 09962 01000 09963 00700 11 REMOVE WATER PUMP ASSY See page 16 9 12 REMOVE CYLINDER HEAD COVER SUB ASSY See page 14 6 13 REMOVE VACUUM PUMP ASSY See page 32 3 14 REMOVE CRANKSHAFT DAMPER SUB ASSY a Using SST hold the crankshaft damper and loosen the crankshaft bolt SST 09960 10010 09962 01000 09963 01000...

Page 748: ...he 2 bolts then remove the timing cover No 2 18 REMOVE OIL PUMP ASSY a Remove the 16 bolts and nut b Using a screwdriver with its tip wrapped in tape remove the oil pump by prying out between the cylinder head and cylinder block NOTICE Be careful not to damage the contact surfaces of the oil pump assembly cylinder head and cylinder block BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index T...

Page 749: ... PUMP SEAL a Using SST and a hammer tap in the new oil seal until its surface is flush with the oil pump edge SST 09223 22010 NOTICE Tap in the oil seal vertically b Apply multi purpose grease to a new oil seal lip NOTICE Keep the lip free of foreign objects 21 INSTALL OIL PUMP ASSY a Install 2 new O rings onto the 2 portions as shown in the illustration BACK TO CHAPTER INDEX TO MODEL INDEX To Alp...

Page 750: ...packing Part No 08826 00100 or equivalent for Water pump Part No 08826 00080 or equivalent for Others NOTICE S Remove any oil from the contact surface S Install the oil pan within 3 minutes and tighten the bolts within 15 minutes of applying seal packing BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 751: ...or nut NOTICE S Be careful not to let the chain come into contact with seal packing when installing the oil pump S Install the engine mounting bracket RH and water pump within 15 minutes of installing the oil pump HINT The bolt lengths are as follows Bolt A 20 mm 0 79 in Bolt B 30 mm 1 18 in Bolt C 35 mm 1 38 in Bolt D double ended bolt 20 and 14 mm 0 79 and 0 55 in 22 INSTALL TIMING CHAIN COVER N...

Page 752: ...LL WATER PUMP PULLEY See page 16 9 SST 09960 10010 09962 01000 09963 00700 30 INSTALL GENERATOR ASSY See page 19 9 31 INSTALL FAN AND GENERATOR V BELT See page 14 4 32 ADJUST FAN AND GENERATOR V BELT See page 14 4 33 INSPECT FAN AND GENERATOR V BELT See page 14 1 34 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55 kgf cm 48 in lbf 35 ADD ENGINE COOLANT See page 16 7 36 CHECK FOR ENGINE...

Page 753: ... For environmental protection used oil and used oil filters must be disposed of at designated disposal sites 1 DRAIN ENGINE OIL a Remove the oil filler cap b Remove the oil drain plug and drain the oil into a container c Clean and install the oil drain plug with a new gasket Torque 38 N m 387 kgf cm 28 ft lbf 2 REMOVE OIL FILTER SUB ASSY a Remove the screw and open the service cover b Using SST re...

Page 754: ...y Drain and refill with oil filter change 4 3 liters 4 5 US qts 3 8 lmp qts Drain and refill without oil filter change 3 8 liters 4 0 US qts 3 3 lmp qts Dry fill 4 8 liters 5 1 US qts 4 2 lmp qts 5 CHECK FOR ENGINE OIL LEAKAGE BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 755: ...Engine Under Cover RH Clip Clip Clip x8 x8 x3 x2 x2 Clip LUBRICATION OIL COOLER ASSY 1ND TV 17 13 COROLLA Supplement RM1129E OIL COOLER ASSY 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 756: ...ied torque z Non reusable part 66 673 49 Oil Cooler Assy z Oil Filter Sub assy 17 14 LUBRICATION OIL COOLER ASSY 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 757: ... Disconnect oil cooler hose from the oil cooler b Using SST remove the nut then remove oil cooler SST 09229 55010 7 INSTALL OIL COOLER ASSY a Check and clean the oil cooler installation surface b Apply new engine oil to the O ring of a new oil cooler c With the antirotation bracket of the oil cooler in contact with the oil pan side temporarily install the oil cooler with a nut d Using SST tighten ...

Page 758: ...1 9 ADD ENGINE OIL See page 17 11 10 ADD ENGINE COOLANT See page 16 7 11 CHECK FOR ENGINE OIL LEAKAGE 12 CHECK FOR ENGINE COOLANT LEAKAGE See page 16 1 13 INSTALL ENGINE UNDER COVER RH TMC MADE See page 13 17 14 INSTALL ENGINE UNDER COVER RH EXCEPT TMC MADE See page 13 17 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 759: ...V 19 5 PRECAUTION 19 5 ON VEHICLE INSPECTION 19 6 8 GENERATOR ASSY 1ND TV 19 9 REPLACEMENT 19 9 11 PRE HEATING SYSTEM 1ND TV 19 12 ON VEHICLE INSPECTION 19 12 INSPECTION 19 13 GLOW PLUG ASSY 1ND TV 19 14 REPLACEMENT 19 14 TO MODEL INDEX To Alphabetical Index To Sub Index BACK TO MAIN INDEX TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 760: ...tch as shown in the illustration Check that the clutch pinion gear is extended If the clutch pinion gear does not move replace the starter mag netic switch b Perform the hold in test 1 Disconnect the negative lead from terminal C Check that the clutch pinion gear remains ex tended If the clutch pinion gear returns inward replace the starter mag netic switch c Check the operation 1 Disconnect the n...

Page 761: ...y and steadily with the clutch pinion gear extended Check that the ammeter reads the specified current Specified current 90 A or less at 11 5 V for 1 4 kW 100 A or less at 11 5 V for 2 0 kW If the result is not as specified replace the starter 2 INSPECT STARTER RELAY ASSY a Check the resistance 1 Using an ohmmeter measure the resistance be tween the terminals Standard Tester Connection Specified C...

Page 762: ...GINE UNDER COVER RH EXCEPT TMC MADE See page 13 17 6 REMOVE FLYWHEEL HOUSING SIDE COVER a Remove the flywheel housing side cover by raising up and pulling out as shown in the illustration 7 REMOVE STARTER ASSY a Open the terminal cap b Remove the nut and disconnect the starter terminal c Disconnect the starter connector d Remove the wire harness clamp e Remove the 2 bolts and starter 8 INSTALL STA...

Page 763: ...ccurately inserted by hear ing a click sound when installing the flywheel hous ing side cover S If the claw is deformed replace the flywheel housing side cover 10 INSTALL ENGINE UNDER COVER RH EXCEPT TMC MADE See page 13 17 11 INSTALL ENGINE UNDER COVER LH EXCEPT TMC MADE See page 13 17 12 INSTALL ENGINE UNDER COVER RH TMC MADE See page 13 17 13 INSTALL ENGINE UNDER COVER TMC MADE See page 13 17 1...

Page 764: ...battery c Do not perform tests with a high voltage insulation resistance tester d Never disconnect the battery while the engine is running e Check that the charging cable is tightly connected onto terminal B of the generator and the fuse box f Do not check whether the generator generates current or not while terminal F is connected to the other terminals BACK TO CHAPTER INDEX TO MODEL INDEX To Alp...

Page 765: ...urface charge on the battery 2 Turn the ignition switch to OFF 3 Turn the electrical systems to OFF 4 Using a voltmeter measure the battery voltage be tween the negative and positive terminals of the battery Standard 12 5 to 12 9 V at 20_C 68_F If the result is not as specified replace the battery c Check the indicator is as shown in the illustration Indicator Color Condition Green Ready Dark Char...

Page 766: ...or while the engine is running 6 INSPECT CHARGE WARNING LIGHT CIRCUIT a Turn the ignition switch to ON Check that the charge warning light comes on b Start the engine and check that the light goes off If the light does not operate as specified troubleshoot the charge warning light circuit 7 INSPECT CHARGING CIRCUIT WITHOUT LOAD a If a tester is not available connect a voltmeter and amme ter to the...

Page 767: ...the heater blower switch to the HI position b Check the reading on the ammeter Standard 30 A or more S If the ammeter reading is less than the standard amperage repair the generator S If the battery is fully charged the indication will sometimes be less than the standard amperage BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 768: ...emove the terminal cap b Remove the nut and disconnect the generator terminal c Disconnect the generator connector d Remove the wire harness clamp e Remove the 2 bolts and wire harness protector f Loosen the 2 bolts g Release the fan and generator V ribbed belt tension and remove the fan and generator V ribbed belt from each pulley h Remove the bolt nut and fan belt adjusting bar BACK TO CHAPTER I...

Page 769: ...ily install the generator with the bolt b Temporarily install the fan belt adjusting bar with the bolt and tighten the nut to the specified torque Torque 18 5 N m 190 kgf cm 14 ft lbf c Temporarily install the fan and generator V ribbed belt onto each pulley BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 770: ...f cm 14 ft lbf for bolt A 32 N m 325 kgf cm 24 ft lbf for bolt B f Install the wire harness protector with the 2 bolts Torque 12 8 N m 130 kgf cm 9 ft lbf g Install the wire harness clamp h Connect the generator connector i Connect the generator terminal with the nut Torque 9 8 N m 100 kgf cm 7 2 ft lbf j Install the terminal cap 5 INSTALL ENGINE COVER SUB ASSY NO 1 See page 13 17 6 CONNECT CABLE ...

Page 771: ...switch to ON and measure the how long it takes for the battery voltage to be applied to the glow plugs Standard Engine Coolant Temperature Pre heating Time 40_C 104_F or higher 1 second 40_C 104_F or lower As indicated in the illustration 15 seconds at the longest If the result is not as specified check the ECM engine coolant temperature sensor glow plug and glow plug relay b Turn the ignition swi...

Page 772: ... when cleaning S Wipe any oil off the terminal and the Bakelite washer with a dry cloth if they are stained with oil during in spection S Be careful not to apply more than 11 V to the glow plugs as this could cause an open circuit If the result is not as specified replace the glow plug 2 INSPECT GLOW PLUG RELAY ASSY a Check the resistance 1 Using an ohmmeter measure the resistance be tween the ter...

Page 773: ...e 5 screw grommets b Remove the nut and disconnect the glow terminal c Remove the 4 nuts and glow plug connector No 1 4 REMOVE GLOW PLUG ASSY a Using a deep socket wrench 10 mm remove the 4 glow plugs 5 INSTALL GLOW PLUG ASSY a Clean the installation hole of the glow plug of the cylinder head b Using a deep socket wrench 10 mm install the 4 glow plugs Torque 12 5 N m 125 kgf cm 9 ft lbf BACK TO CH...

Page 774: ...gf cm 34 in lbf NOTICE Be careful that the glow terminal is at the correct direction when installing c Install the 5 screw grommets NOTICE Push the screw grommet into the threaded portion of the glow plug by hand and then turn it clockwise 7 INSTALL ENGINE COVER SUB ASSY NO 1 See page 13 17 8 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque 5 4 N m 55 kgf cm 48 in lbf BACK TO CHAPTER INDEX TO MOD...

Page 775: ...WING REPAIR MANUALS Manual Name Pub No COROLLA Repair Manual RM925E COROLLA Repair Manual Supplement RM1106E NOTE The above pages contain only the points which differ from the above listed manuals TO MODEL INDEX To Alphabetical Index To Sub Index BACK TO MAIN INDEX TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 776: ...orque 49 500 36 89 908 66 8 0 82 71 in lbf 64 650 47 64 650 47 Front Drive Shaft LH Hole Snap Ring z Flexible Hose zFront Axle Hub LH Nut z z TMC MADE 74 755 55 TMUK TMMT MADE 44 449 32 TMC TMMT MADE 29 296 21 TMUK MADE 19 194 14 DRIVE SHAFT PROPELLER SHAFT FRONT DRIVE SHAFT 1ND TV 30 1 COROLLA Supplement RM1129E FRONT DRIVE SHAFT 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabeti...

Page 777: ...rive Shaft Bearing Case Sub assy Front Axle Outboard Joint Boot LH No 2 Clamp Inboard Joint Boot Front Drive Outboard Joint Assy Front Axle Outboard Joint Boot LH Clamp Front Axle Inboard Joint Boot LH No 2 Clamp Drive Shaft Bearing Case Sub assy Snap Ring Front Drive Inboard Joint Assy LH Tripod Joint Assy Straight Pin z z z z z z z z z z z z z z z z LH RH 30 2 DRIVE SHAFT PROPELLER SHAFT FRONT D...

Page 778: ...ing the brakes remove the hub LH nut NOTICE Loosen the staked part of the nut completely otherwise the screw of the drive shaft may be damaged 5 SEPARATE FRONT STABILIZER LINK ASSY LH a Remove the nut and separate the front stabilizer link assy LH from the shock absorber assy front LH HINT If the ball joint turns together with the nut use a hexagon wrench 6 mm to hold the stud 6 SEPARATE SPEED SEN...

Page 779: ... drive shaft assy LH from the front axle assy LH NOTICE Be careful not to damage the boot and speed sensor rotor 10 REMOVE FRONT DRIVE SHAFT ASSY LH a Using SST remove the front drive shaft assy LH SST 09520 01010 09520 24010 09520 32040 NOTICE Be careful not to damage the dust cover boot or oil seal HINT In case of not being able to remove the drive shaft by hooking the SST claw to the position A...

Page 780: ...play in the radial direc tion of the inboard joint d Check the boots for damage 14 REMOVE FRONT AXLE INBOARD JOINT BOOT LH NO 2 CLAMP a Using pliers remove the inboard joint boot LH No 2 clamp as shown in the illustration 15 REMOVE FRONT AXLE INBOARD JOINT BOOT LH CLAMP a Remove the inboard joint boot LH clamp by the same procedures as for the inboard joint boot LH No 2 clamp 16 SEPARATE FR AXLE I...

Page 781: ...nt shaft 18 REMOVE DRIVE SHAFT DAMPER a Using pliers remove the damper clamp as shown in the illustration b Remove the drive shaft damper 19 REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH NO 2 CLAMP a Using pliers remove the outboard joint boot LH No 2 clamp as shown in the illustration 20 REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP a Remove the outboard joint boot LH clamp by the same procedures as ...

Page 782: ...rd joint 24 REMOVE FRONT DRIVE SHAFT DUST COVER RH a Using a press remove the dust cover RH NOTICE Be careful not to drop the inboard joint 25 REMOVE DRIVE SHAFT BEARING CASE SUB ASSY SNAP RING RH DRIVE SHAFT a Using a screwdriver remove the drive shaft bearing snap ring 26 REMOVE DRIVE SHAFT BEARING CASE SUB ASSY RH DRIVE SHAFT a Using a press remove the drive shaft bearing case NOTICE Be careful...

Page 783: ...der remove the front drive shaft hole snap ring RH b Using SST and a press remove the drive shaft bearing SST 09527 10011 NOTICE Be careful not to drop the inboard joint c Remove the drive shaft bearing snap ring 29 INSTALL FRONT DRIVE SHAFT BEARING RH DRIVE SHAFT a Using SST and a press install a new drive shaft bearing SST 09950 60020 09951 00710 09950 70010 09951 07100 30 INSTALL DRIVE SHAFT BE...

Page 784: ...A from the tip of the bearing case sub assy to the dust cover reaches the specification as shown in the illustration SST 09726 40010 09527 10011 Distance A 1 0 mm 0 039 in NOTICE S Dust cover should be installed completely S Be careful not to damage the dust cover 33 INSTALL FRONT DRIVE SHAFT DUST COVER RH a Using SST and a press install a new dust cover RH until the distance A from the tip of cen...

Page 785: ...o the outboard joint shaft assy in the fol lowing order 1 Outboard joint boot LH No 2 clamp 2 Outboard joint boot 3 Outboard joint boot LH clamp b Pack the outboard joint shaft and boot with grease in the boot kit Grease capacity 152 to 162 g 5 4 to 5 7 oz 37 INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH NO 2 CLAMP a Mount the drive shaft in a soft vise between two aluminum plates b Secure the clamp o...

Page 786: ...mp 39 INSTALL DRIVE SHAFT DAMPER a Set the distance A as described below Distance A 198 to 202 mm 7 795 to 7 953 in b Set the damper setting clamp to the drive shaft damper NOTICE Be sure to install the clamp in the correct position c Mount the drive shaft in a soft vise between two aluminum plates d Secure the damper setting clamp onto the damper e Place SST onto the damper setting clamp f Tighte...

Page 787: ...int assy c Using a brass bar and a hammer install the tripod joint assy NOTICE Do not tap the roller d Using a snap ring expander install a new inner LH shaft snap ring e Pack the inboard joint sub assy LH with grease in the boot kit Grease capacity 160 to 180 g 5 6 to 6 3 oz f Align the matchmarks and install the inboard joint sub assy LH to the outboard joint shaft assy 41 INSTALL FR AXLE INBOAR...

Page 788: ...ONT AXLE INBOARD JOINT BOOT LH NO 2 CLAMP a Secure the clamp onto the boot b Place SST onto the clamp SST 09521 24010 c Tighten the SST so that the clamp is pinched NOTICE Do not overtighten the SST d Using SST measure the clearance of the clamp SST 09240 00020 09242 00080 Clearance 0 8 mm 0 031 in or less NOTICE When the measured value exceeds the specified value re tighten the clamp 44 INSPECT F...

Page 789: ... known from the sound or feeling when driving it in c Install the fender apron seal LH 46 INSTALL FRONT DRIVE SHAFT ASSY RH a Coat the spline of the inboard joint shaft assy with gear oil b Aline the shaft splines and install the drive shaft assy RH with the 2 bearing lock bolts Torque 64 N m 650 kgf cm 47 ft lbf NOTICE Be careful not to damage the oil seal boot or dust cover 47 INSTALL FRONT AXLE...

Page 790: ...4 ft lbf b Install the speed sensor front LH to the steering knuckle with the bolt Torque 8 0 N m 82 kgf cm 71 in lbf NOTICE S Be careful not to damage the speed sensor S Keep the speed sensor clean S Do not twist the sensor wire when installing the sen sor 51 INSTALL FRONT STABILIZER LINK ASSY LH a Install the front stabilizer link assy LH with the nut Torque TMUK TMMT made 44 N m 449 kgf cm 32 f...

Page 791: ...NSPECT MANUAL TRANSAXLE OIL SEE PAGE 41 4 56 INSPECT AND ADJUST FRONT WHEEL ALIGNMENT SEE PUB No RM1106E PAGE 26 1 57 CHECK ABS SPEED SENSOR SIGNAL a TMC made See pub No RM925E page 05 561 b TMUK TMMT made 1 w VSC See pub No RM925E page 05 666 2 w o VSC See pub No RM925E page 05 614 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 792: ... REPLACEMENT 32 7 12 BRAKE BOOSTER ASSY 1ND TV 32 13 ON VEHICLE INSPECTION 32 13 COMPONENTS 32 14 15 REPLACEMENT 32 16 REFER TO COROLLA REPAIR MANUAL Pub No RM925E NOTE The above pages contain only the points which differ from the above listed manual TO MODEL INDEX To Alphabetical Index To Sub Index BACK TO MAIN INDEX TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 793: ...auge to the vacuum pump d Start the engine e Measure the vacuum with the engine at idle Vacuum at standard sea level atmospheric pres sure 1 013 mbar when 2 minutes or more have elapsed after engine is started More than 86 kpa 650 mmHg HINT Replace the vacuum pump every 200 000 km 124 000 miles BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUP...

Page 794: ...ng z Cam Position Sensor Vacuum Hose Vacuum Pump Assy O ring z 21 214 15 9 0 92 80 in Bolt z 32 2 BRAKE VACUUM PUMP ASSY 1ND TV COROLLA Supplement RM1129E COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 795: ...hen disconnect the vacuum hose and cam position sensor connector b Remove the 2 bolts and vacuum pump c Remove the 2 O rings from the vacuum pump 2 REMOVE CAM POSITION SENSOR a Remove the bolt cam position sensor and O ring from the vacuum pump BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 796: ...m pump assy b Apply engine oil to the oil pipe at the tip of the vacuum pump assy c Install the vacuum pump assy so that the coupling teeth A on the side of the vacuum pump assy can engage with the tip groove of cam shaft B d Install the 2 new bolts to the vacuum pump Torque 21 N m 214 kgf cm 15 ft lbf e Connect the vacuum hose with the clip to the vacuum pump f Connect the cam position sensor con...

Page 797: ...Clip 25 255 18 25 255 18 15 2 155 11 25 255 18 25 255 18 1 w ABS 2 w VSC N m kgf cm ft lbf Specified torque 15 2 155 11 1 29 296 21 2 15 2 155 11 1 29 296 21 2 15 2 155 11 1 29 296 21 2 Fuel Filter Assy w Bracket Air Cleaner Assy w Element 15 2 155 11 15 2 155 11 1 29 296 21 2 BRAKE BRAKE MASTER CYLINDER SUB ASSY 1ND TV 32 5 COROLLA Supplement RM1129E BRAKE MASTER CYLINDER SUB ASSY 1ND TV COMPONEN...

Page 798: ... Guide Vacuum Seal No 1 Piston Sub assy No 2 Piston Sub assy Screw Lithium soap base glycol grease N m kgf cm ft lbf Specified torque 8 0 82 71 in lbf 32 6 BRAKE BRAKE MASTER CYLINDER SUB ASSY 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 799: ...NG POSITION TYPE 3 SEPARATE FUEL FILTER ASSY W BRACKET LHD STEERING POSITION TYPE a Remove the bolt and disengage the clamp b Separate the relay block c Disengage the 3 clamps d Remove the 2 bolts and separate the fuel filter assy e Disengage the clamp f Remove the 3 bolts and the bracket BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129...

Page 800: ...t the brake fluid level switch connector b M T Slide the clip and disconnect the clutch reservoir tube c w ABS Using SST disconnect the 2 brake lines from the master cylinder SST 09023 00101 d w VSC Using SST disconnect the 2 brake lines from the master cylinder SST 09023 38401 e Remove the 2 nuts and pull out the master cylinder 6 REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB ASSY a Using a torx dri...

Page 801: ... angle there is a possibility that the cylin der bore could be damaged HINT Make sure the distance A from the rag to the top of the blocks is at least 100 mm 3 94 in 8 INSPECT BRAKE MASTER CYLINDER a Check the cylinder bore for rust or scoring 9 INSTALL BRAKE MASTER CYLINDER KIT a Apply lithium soap base glycol grease to the No 1 No 2 piston sub assy and piston guide b Install the No 2 and No 1 pi...

Page 802: ...que 15 2 N m 155 kgf cm 11 ft lbf c w ABS Using SST connect the 2 brake lines to the master cylin der SST 09023 00101 Torque 15 2 N m 155 kgf cm 11 ft lbf d w VSC Using SST connect the 2 brake lines to the master cylin der SST 09023 38401 Torque 29 N m 296 kgf cm 21 ft lbf e M T Connect the clutch reservoir tube f Connect the brake fluid level switch connector 12 INSTALL BRAKE MASTER CYLINDER SUB ...

Page 803: ...SITION TYPE a Install the 3 bolts to the bracket b Engage the clamp c Install the 2 bolts to the fuel filter assy d Engage the 3 clamps e Install the bolt and engage the clamp 14 INSTALL AIR CLEANER ASSY LHD STEERING POSITION TYPE 15 FILL RESERVOIR WITH BRAKE FLUID 16 BLEED MASTER CYLINDER SST 09023 00101 17 BLEED BRAKE LINE SEE PUB NO RM925E PAGE 32 5 BACK TO CHAPTER INDEX TO MODEL INDEX To Alpha...

Page 804: ...LLA Supplement RM1129E 18 BLEED CLUTCH PIPE LINE MANUAL TRANSAXLE SEE PAGE 42 14 19 CHECK FLUID LEVEL IN RESERVOIR 20 CHECK BRAKE FLUID LEAKAGE BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 805: ...s no change in the pedal reserve distance after holding the pedal for 30 seconds the booster is airtight b Operating check 1 Depress the brake pedal several times with the igni tion switch OFF and check that there is no change in the pedal reserve distance 2 Depress the brake pedal and start the engine HINT If the pedal goes down slightly operation is normal 2 INSPECT VACUUM CHECK VALVE a Check va...

Page 806: ...e Fluid Level Switch Connector Brake Booster Assy 15 2 155 11 1 29 296 21 2 Brake Tube 15 2 155 11 Clutch Reservoir Tube M T Clip 15 2 155 11 15 2 155 11 N m kgf cm ft lbf Specified torque z Non reusable part Brake Tube Way 1 w ABS 2 w VSC 15 2 155 11 1 29 296 21 2 32 14 BRAKE BRAKE BOOSTER ASSY 1ND TV COROLLA Supplement RM1129E COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index...

Page 807: ...Clip 11 8 120 9 Clip Vacuum Check Valve Grommet 19 194 14 Wave Washer RHD Steering Position Type N m kgf cm ft lbf Specified torque z Non reusable part 1 w ABS 2 w VSC 15 2 155 11 1 29 296 21 2 15 2 155 11 1 29 296 21 2 15 2 155 11 1 29 296 21 2 15 2 155 11 15 2 155 11 1 29 296 21 2 15 2 155 11 1 29 296 21 2 BRAKE BRAKE BOOSTER ASSY 1ND TV 32 15 COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO ...

Page 808: ...STER CYLINDER SUB ASSY LHD STEERING POSITION TYPE SEE PAGE 32 7 SST 09023 00101 6 REMOVE BRAKE MASTER CYLINDER SUB ASSY RHD STEERING POSITION TYPE SEE PAGE 32 7 SST 09023 00101 7 DISCONNECT MASTER CYLINDER PUSH ROD CLEVIS a Loosen the push rod clevis lock nut b Remove the clip wave washer and clevis pin 8 REMOVE FRONT WHEEL LH LHD STEERING POSITION TYPE 9 REMOVE FRONT WHEEL RH RHD STEERING POSITIO...

Page 809: ...the front brake LH b Disconnect the vacuum hose from the brake booster c Remove the 4 nuts and clevis d Pull out the brake booster and gasket 12 INSTALL BRAKE BOOSTER ASSY a Install the clevis to the booster push rod b Install a new gasket and the brake booster with the 4 nuts Torque 12 7 N m 130 kgf cm 9 ft lbf c Connect the vacuum hose to the brake booster d LHD STEERING POSITION TYPE 1 Using SS...

Page 810: ...e tubes to the brake actua tor as shown in the illustration SST 09023 00101 09023 38401 Torque A 15 2 N m 155 kgf cm 11 ft lbf B 29 N m 296 kgf cm 21 ft lbf e Connect the 3 brake lines to the clamp and install the brake tube 16 INSTALL FRONT WHEEL RH RHD STEERING POSITION TYPE 17 INSTALL BRAKE MASTER CYLINDER SUB ASSY LHD STEERING POSITION TYPE SEE PAGE 32 7 SST 09023 00101 18 INSTALL BRAKE MASTER...

Page 811: ...ED BRAKE LINE SEE PUB NO RM925E PAGE 32 5 25 CHECK FLUID LEVEL IN RESERVOIR 26 BLEED CLUTCH PIPE LINE MANUAL TRANSAXLE SEE PAGE 42 14 27 CHECK BRAKE FLUID LEAKAGE BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 812: ...24 REPLACEMENT 41 25 26 SELECT STROKE SENSOR C53A 41 27 REPLACEMENT 41 27 28 TRANSMISSION REVOLUTION SENSOR C53A 41 29 REPLACEMENT 41 29 30 BACK UP LAMP SWITCH ASSY C53A C53 41 31 REPLACEMENT 41 31 PARK NEUTRAL POSITION SWITCH ASSY C53A 41 32 REPLACEMENT 41 32 TRANSMISSION CONTROL ECU ASSY C53A 41 33 REPLACEMENT 41 33 MANUAL TRANSAXLE ASSY C53A 41 34 COMPONENTS 41 34 35 REPLACEMENT 41 36 45 MANUAL...

Page 813: ...When the clutch actuator is removed from the transmission assy during installation of any of the following parts TRANSMISSION ASSY TRANSMISSION PARTS INSIDE GEAR BOX 1 INITIALIZATION OF MULTI MODE MANUAL TRANS MISSION SYSTEM ECU 2 LEARNING OF MULTI MODE MANUAL TRANSMIS SION SYSTEM 3 SYNCHRONIZATION POSITION CALIBRATION 05 190 05 190 05 196 CLUTCH STROKE SENSOR 1 INITIALIZATION OF MULTI MODE MANUAL...

Page 814: ... 2 Oil Wrong 41 4 41 5 Noise 2 Oil Wrong 3 Gear Worn or damaged 41 5 L 3 Gear Worn or damaged 4 Bearing Worn or damaged L L 1 Oil Level too high 41 4 Oil l k 1 Oil Level too high 2 Gasket Damaged 41 4 L Oil leakage 2 Gasket Damaged 3 Oil seal Worn or damaged L 41 5 3 Oil seal Worn or damaged 4 O ring Worn or damaged 41 5 L 1 Shift lever Worn or damaged 41 7 Hard to shift or will not shift 2 Synchr...

Page 815: ... Suspected Area See page Noise 1 Oil Level low 2 Oil Wrong 3 Gear Worn or damaged 4 Bearing Worn or damaged 41 4 41 5 L L Oil leakage 1 Oil Level too high 2 Gasket Damaged 3 Oil seal Worn or damaged 4 O Ring Worn or damaged 41 4 L 41 5 L Hard to shift or will not shift 1 Control cable Faulty 2 Synchronizer ring Worn or damaged 3 Shift key spring Damaged 41 20 L L Jumps out of gear 1 Locking ball s...

Page 816: ...hat the oil surface is within 5 mm 0 20 in from the lowest position of the inner surface of the filler plug open ing NOTICE S An excessively large or small amount of oil may cause problems S After replacing the oil drive the vehicle and check the oil level d Check for oil leakage when the oil level is low e Install the filler plug and a new gasket Torque 39 N m 400 kgf cm 29 ft lbf BACK TO CHAPTER...

Page 817: ...HAFT ASSY LH SEE PAGE 30 3 SST 09520 01010 09520 24010 09520 32040 6 REMOVE FRONT DRIVE SHAFT ASSY RH SEE PAGE 30 3 SST 09520 01010 09520 24010 09520 32040 7 REMOVE TRANSMISSION CASE OIL SEAL a Using SST remove the oil seal SST 09308 00010 8 REMOVE TRANSAXLE CASE OIL SEAL a Using SST remove the oil seal SST 09308 00010 9 INSTALL TRANSMISSION CASE OIL SEAL a Coat a new oil seal lip with MP grease b...

Page 818: ...RONT DRIVE SHAFT ASSY RH SEE PAGE 30 3 13 INSTALL FRONT WHEELS Torque 103 N m 1 050 kgf cm 76 ft lbf 14 ADD MANUAL TRANSAXLE OIL Oil grade API GL 4 or GL 5 Viscosity SAE 75 W 90 Capacity 1 9 liters 2 0 US qts 1 7 lmp qts 15 INSPECT MANUAL TRANSAXLE OIL SEE PAGE 41 4 16 INSPECT FRONT WHEEL ALIGNMENT SEE PUB NO RM1106E PAGE 26 1 17 INSTALL ENGINE UNDER COVER LH 18 INSTALL ENGINE UNDER COVER RH 19 CH...

Page 819: ...s 2 and 6 Resistance 30 to 35 Ω at 20 C 68 F If the resistance is not as specified replace the shift lever assy c Check the solenoid operating sound when applying bat tery voltage across terminals 2 and 6 If the solenoid does not operate replace the shift lever assy d Connect the indicator lamp wire connector 6 INSPECT TRANSMISSION SHIFT MAIN SWITCH a Disconnect the indicator lamp wire connector b...

Page 820: ...0 13 Below 1 Ω N 4 2 10 6 Below 1 Ω E M 4 2 3 13 Below 1 Ω 11 5 Below 1 Ω M 11 5 12 10 kΩ or higher 11 12 Below 1 Ω If the result is not as specified replace the shift lever assy c Connect the shift lever position sensor connector 8 INSTALL CONSOLE BOX SUB ASSY REAR SEE PUB NO RM1106E PAGE 71 6 9 INSTALL PARKING BRAKE HOLE COVER SUB ASSY SEE PUB NO RM1106E PAGE 71 6 10 INSTALL CONSOLE PANEL UPPER ...

Page 821: ...Lever Assy Console Box Sub assy Rear Specified torque N m kgf cm ft lbf 12 122 9 12 122 9 MANUAL TRANSMISSION TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY C53A 41 9 COROLLA Supplement RM1129E COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 822: ...ing Floor Shift Shift Lever Assy Position Indicator Lamp Bulb Indicator Lamp Wire Sub assy Position Indicator Lamp Cap MP grease Position Indicator Housing Lower Shift Lever Knob Sub assy 41 10 MANUAL TRANSMISSION TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY C53A COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 823: ...1 6 5 REMOVE FLOOR SHIFT SHIFT LEVER ASSY a Disconnect the 2 connectors b Remove the 4 bolts and shift lever assy 6 REMOVE SHIFT LEVER KNOB SUB ASSY a Remove the shift lever knob 7 REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB ASSY a Disengage the 4 claws and remove the position indicator housing sub assy from the shift lever assy 8 REMOVE POSITION INDICATOR LIGHT GUIDE a Disengage the 4 claws...

Page 824: ...or housing lower from the shift lever assy 10 REMOVE POSITION INDICATOR SLIDE COVER a Remove the 2 slide covers from the shift lever assy 11 REMOVE SHIFT LOCK RELEASE BUTTON a Remove the shift lock release button and compression spring from the shift lever assy 12 REMOVE INDICATOR LAMP WIRE SUB ASSY a Disconnect the indicator lamp wire connector from the shift lever assy b Remove the bulb and cap ...

Page 825: ...00510 13 INSTALL INDICATOR LAMP WIRE SUB ASSY a Install the marked wire harnesses 2 and 4 to the indicator lamp wire connector as shown in the illustration b Install wire harnesses 6 and 8 to the indicator lamp wire connector as shown in the illustration c Lock the secondary locking device HINT Wire color Y Yellow L R Blue Red d Install the cap and bulb to the indicator lamp wire e Connect the ind...

Page 826: ... POSITION INDICATOR SLIDE COVER a Install the 2 slide covers to the shift lever assy 16 INSTALL POSITION INDICATOR HOUSING LOWER a Install the position indicator housing lower to the shift le ver assy b Connect the indicator lamp wire to the position indicator housing lower 17 INSTALL POSITION INDICATOR LIGHT GUIDE a Install the position indicator light guide to the shift lever assy 18 INSTALL FLO...

Page 827: ...t lever assy with the 4 bolts Torque 12 N m 122 kgf cm 9 ft lbf b Connect the 2 connectors 21 INSTALL CONSOLE BOX SUB ASSY REAR SEE PUB NO RM1106E PAGE 71 6 22 INSTALL PARKING BRAKE HOLE COVER SUB ASSY SEE PUB NO RM1106E PAGE 71 6 23 INSTALL CONSOLE PANEL UPPER SEE PUB NO RM1106E PAGE 71 6 24 CONNECT BATTERY NEGATIVE TERMINAL BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index ...

Page 828: ...elect Cable z Non reusable part z Washer Clip z Clip 18 180 13 Washer Parking Brake Hole Cover Sub assy Clip Clip Clip Clip Transmission Control Cable Assy 5 0 51 44 in lbf 5 0 51 44 in lbf Shift Cable Select Cable z Washer Clip z Clip Washer 12 122 9 12 122 9 Floor Shift Shift Lever Assy TMUK TMMT Made TMC Made 41 16 MANUAL TRANSMISSION TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY C53 COROLLA Supplemen...

Page 829: ... REAR SEE PUB NO RM1106E PAGE 71 6 5 SEPARATE TRANSMISSION CONTROL CABLE ASSY TMUK TMMT MADE a Remove the 2 clips and separate the cable ends of the control cable assy b Release the claws and separate the control cable assy 6 SEPARATE TRANSMISSION CONTROL CABLE ASSY TMC MADE a Remove the 2 clips and separate the cable ends of the control cable assy b Turn the locks and separate the control cable a...

Page 830: ...SSY TMUK TMMT MADE a Connect the end of the select cable to the shift lever assy and install the clip NOTICE S The serrate part of the select cable should face up ward when the select cable is connected S The clip should be installed in the direction shown in the illustration b Connect the end of the shift cable to the shift lever assy and install the clip c Connect the control cable assy to the s...

Page 831: ... shift cable to the shift lever assy and install the clip c Connect the control cable assy to the shift lever retainer NOTICE S The projecting part of the cable outer should face up ward when the control cable assy is connected S After installation make sure that the cable outer lock is projecting from A as shown in the illustration 11 INSTALL CONSOLE BOX SUB ASSY REAR SEE PUB NO RM1106E PAGE 71 6...

Page 832: ...EMOVE EXHAUST PIPE ASSY SEE PAGE 15 2 4 REMOVE FRONT FLOOR HEAT INSULATOR NO 1 a Remove the 3 nuts and heat insulator No 1 5 SEPARATE TRANSMISSION CONTROL CABLE ASSY TMUK TMMT MADE a Remove the 2 clips and separate the cable ends of the control cable assy b Release the claws and separate the control cable assy 6 SEPARATE TRANSMISSION CONTROL CABLE ASSY TMC MADE a Remove the 2 clips and separate th...

Page 833: ... the control cable assy from the transaxle b Remove the 2 clips and separate the control cable assy from the control cable bracket c Remove the 2 nuts d Remove the 2 bolts from the retainer e Pull out the control cable assy from the floor 8 INSTALL TRANSMISSION CONTROL CABLE ASSY a Push in the control cable assy to the floor b Install the control cable assy with the 2 bolts Torque 5 0 N m 51 kgf c...

Page 834: ...RANSMISSION CONTROL CABLE ASSY TMUK TMMT MADE a Connect the end of the select cable to the shift lever assy and install the clip NOTICE S The serrated part of the select cable should face up ward when the select cable is connected S The clip should be installed in the direction shown in the illustration b Connect the end of the shift cable to the shift lever assy and install the clip c Connect the...

Page 835: ...the shift lever assy and install the clip c Connect the control cable assy to the shift lever retainer NOTICE S The projecting part of the cable outer should face up ward when the control cable assy is connected S After installation make sure that the cable outer lock is projecting from A as shown in the illustration 11 INSTALL FRONT FLOOR HEAT INSULATOR NO 1 a Install the heat insulator No 1 with...

Page 836: ...er Head Cover No 2 Air Tube No 2 Air Tube No 1 25 255 18 25 255 18 25 255 18 Clamp 6 0 61 53 in lbf Clamp Clamp Clamp 6 0 61 53 in lbf 6 0 61 53 in lbf 6 0 61 53 in lbf 41 24 MANUAL TRANSMISSION TRANSAXLE SHIFT STROKE SENSOR C53A COROLLA Supplement RM1129E SHIFT STROKE SENSOR C53A COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1...

Page 837: ...E PAGE 41 36 9 REMOVE SHIFT STROKE SENSOR a Disconnect the shift stroke sensor connector b Remove the 2 screws and shift stroke sensor from the shift and select actuator c Remove the O ring from the shift stroke sensor 10 INSTALL SHIFT STROKE SENSOR NOTICE Use the A holes to install the shift stroke sensor Do not use the B holes a Apply MP grease to a new O ring b Install the O ring to the shift s...

Page 838: ...15 INSTALL CYLINDER HEAD COVER NO 2 16 INSTALL ENGINE UNDER COVER LH 17 INSTALL FRONT WHEEL LH 18 CONNECT BATTERY NEGATIVE TERMINAL 19 INITIALIZATION OF MULTI MODE MANUAL TRANSMISSION ECU SEE PAGE 05 190 20 LEARNING OF MULTI MODE MANUAL TRANSMISSION SYSTEM SEE PAGE 05 190 21 SYNCHRONIZATION POSITION CALIBRATION SEE PAGE 05 196 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index...

Page 839: ... SENSOR a Disconnect the select stroke sensor connector b Remove the 2 screws and select stroke sensor from the shift and select actuator c Remove the O ring from the select stroke sensor 10 INSTALL SELECT STROKE SENSOR a Apply MP grease to a new O ring b Install the O ring to the select stroke sensor c Set the select stroke sensor so that the sensor arms are positioned as shown in the illustratio...

Page 840: ...H 18 CONNECT BATTERY NEGATIVE TERMINAL 19 INITIALIZATION OF MULTI MODE MANUAL TRANSMISSION ECU SEE PAGE 05 190 20 LEARNING OF MULTI MODE MANUAL TRANSMISSION SYSTEM SEE PAGE 05 190 21 SYNCHRONIZATION POSITION CALIBRATION SEE PAGE 05 196 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 841: ...ove the drain plug and gasket and drain the oil c Install the drain plug with a new gasket Torque 39 N m 400 kgf cm 29 ft lbf 5 REMOVE TRANSMISSION REVOLUTION SENSOR a Disconnect the transmission revolution sensor connector b Remove the 2 bolts and manual transmission case pro tector from the transaxle c Separate the transmission revolution sensor wire har ness from the 2 clamps d Remove the trans...

Page 842: ...re harness to the 2 clamps c Install the manual transmission case protector to the transaxle with the 2 bolts Torque 8 0 N m 82 kgf cm 71 in lbf d Connect the transmission revolution sensor connector 7 ADD MANUAL TRANSAXLE OIL SEE PAGE 41 5 8 INSPECT MANUAL TRANSAXLE OIL SEE PAGE 41 4 9 INSTALL ENGINE UNDER COVER LH 10 INSTALL FRONT WHEEL LH 11 CONNECT BATTERY NEGATIVE TERMINAL BACK TO CHAPTER IND...

Page 843: ...MOVE BACK UP LAMP SWITCH ASSY a Using SST remove the back up lamp switch and gasket from the manual transmission case SST 09817 16011 7 INSTALL BACK UP LAMP SWITCH ASSY a Using SST install the back up lamp switch to the manual transmission case with a new gasket SST 09817 16011 Torque 40 N m 410 kgf cm 30 ft lbf 8 CONNECT CONNECTOR a Connect the back up lamp switch connector 9 INSTALL AIR TUBE NO ...

Page 844: ... PARK NEUTRAL POSITION SWITCH ASSY a Using SST remove the park neutral position switch and gasket from the manual transmission case SST 09817 16011 7 INSTALL PARK NEUTRAL POSITION SWITCH ASSY a Using SST install the park neutral position switch to the manual transmission case with a new gasket SST 09817 16011 Torque 29 N m 300 kgf cm 22 ft lbf 8 CONNECT CONNECTOR a Connect the park neutral positio...

Page 845: ... 5 INSTALL TRANSMISSION CONTROL ECU ASSY a Install the transmission control ECU assy with the screw and bolt Torque Bolt 5 0 N m 51 kgf cm 44 in lbf b Connect the 2 connectors 6 INSTALL INSTRUMENT PANEL UNDER COVER SUB ASSY NO 2 SEE PUB NO RM1106E PAGE 71 6 7 INSTALL GLOVE COMPARTMENT DOOR ASSY SEE PUB NO RM1106E PAGE 71 6 8 CONNECT BATTERY NEGATIVE TERMINAL 9 INITIALIZATION OF MULTI MODE MANUAL T...

Page 846: ...lutch Actuator Assy 20 200 14 39 400 29 37 380 27 26 260 19 13 133 10 3 5 36 31 in lbf z Gasket Drain Plug 39 400 29 Air Tube No 1 25 255 18 25 255 18 25 255 18 Wire Harness 9 0 92 80 in lbf Fuel Filter Assy 18 180 13 26 260 19 25 255 18 33 340 24 33 340 24 13 130 9 13 130 9 37 380 27 Clamp 6 0 61 53 in lbf Clamp 6 0 61 53 in lbf Clamp 6 0 61 53 in lbf Clamp 6 0 61 53 in lbf Clamp 13 130 9 41 34 M...

Page 847: ...z Cotter Pin 133 1 356 98 8 0 82 71 in lbf 133 1 356 98 Speed Sensor Front LH Front Axle Hub LH Nut 80 816 59 z Gasket 89 908 66 80 816 59 19 192 14 TMUK 29 296 21 TMMT Front Suspension Crossmember Sub assy z Gasket 49 500 36 Crossmember Bracket 52 530 38 52 530 38 Engine Mounting Bracket LH 52 530 38 Engine Mounting Insulator LH 52 530 38 52 530 38 64 653 47 80 816 59 43 440 32 89 908 66 30 302 2...

Page 848: ...TEERING POSITION TYPE SEE PUB NO RM1106E PAGE 50 6 9 REMOVE FRONT WHEELS 10 REMOVE ENGINE UNDER COVER LH 11 REMOVE ENGINE UNDER COVER RH 12 DRAIN TRANSAXLE OIL a Remove the filler plug and gasket b Remove the drain plug and gasket and drain the oil c Install the drain plug with a new gasket Torque 39 N m 400 kgf cm 29 ft lbf 13 REMOVE HOOD SUB ASSY 14 REMOVE RADIATOR SUPPORT OPENING COVER 15 REMOV...

Page 849: ... the 2 clamps and air tube No 1 23 REMOVE CLUTCH ACTUATOR ASSY SEE PAGE 42 20 24 DISCONNECT WIRE HARNESS a Remove the 4 bolts and disconnect the 3 wire harness clamp brackets b Remove the 2 bolts and disconnect the 2 wire harness clamp brackets c Remove the 2 bolts and disconnect the wire harness BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL S...

Page 850: ... DISCONNECT CONNECTOR a Disconnect the back up lamp switch connector and park neutral position switch connector 26 SEPARATE FUEL FILTER ASSY a Remove the 2 bolts and disconnect the fuel filter assy 27 DISCONNECT SHIFT SELECT ACTUATOR ASSY a Disconnect the shift stroke sensor connector and select stroke sensor connector b Disconnect the 2 connectors from the shift and select ac tuator BACK TO CHAPT...

Page 851: ...r 12281 21010 Bolt 91672 81025 Torque 38 N m 387 kgf cm 28 ft lbf b Attach an engine chain hoist to the hangers CAUTION Do not attempt to hang the engine by hooking the chain to any other part 33 REMOVE FRONT SUSPENSION CROSSMEMBER SUB ASSY SEE PUB No RM925E PAGE 51 6 34 SUPPORT MANUAL TRANSAXLE ASSY a Support the transaxle with a transmission jack 35 REMOVE ENGINE MOUNTING INSULATOR LH a Remove t...

Page 852: ...tor FR from the engine mounting bracket FR 39 REMOVE ENGINE MOUNTING BRACKET FR a Remove the 2 bolts and engine mounting bracket FR from the transaxle 40 REMOVE ENGINE MOUNTING INSULATOR RR a Remove the bolt and engine mounting insulator RR from the engine mounting bracket RR 41 REMOVE ENGINE MOUNTING BRACKET RR a Remove the 3 bolts and engine mounting bracket RR from the transaxle BACK TO CHAPTER...

Page 853: ...53 kgf cm 47 ft lbf 45 INSTALL ENGINE MOUNTING INSULATOR RR a Install the engine mounting insulator RR to the engine mounting bracket RR with the bolt Torque 87 N m 887 kgf cm 64 ft lbf 46 INSTALL ENGINE MOUNTING BRACKET FR a Install the engine mounting bracket FR to the transaxle with the 2 bolts Torque 64 N m 653 kgf cm 47 ft lbf 47 INSTALL ENGINE MOUNTING INSULATOR FR a Install the engine mount...

Page 854: ...OR LH a Install the engine mounting insulator LH with the 5 bolts and nut Torque Bolt A 52 N m 530 kgf cm 38 ft lbf Bolt B 80 N m 816 kgf cm 59 ft lbf HINT Insert the bolt from the front side of the vehicle 51 INSTALL FRONT SUSPENSION CROSSMEMBER SUB ASSY SEE PUB No RM925E PAGE 51 6 SST 09670 00010 52 INSTALL EXHAUST PIPE ASSY FRONT SEE PAGE 15 2 53 INSTALL FRONT DRIVE SHAFT ASSY LH SEE PAGE 30 3 ...

Page 855: ...lter assy with the 2 bolts Torque 18 N m 180 kgf cm 13 ft lbf 58 CONNECT CONNECTOR a Connect the back up lamp switch connector and park neutral position switch connector 59 CONNECT WIRE HARNESS a Install the 3 wire harness clamp brackets to the transaxle with the 4 bolts Torque Bolt A 26 N m 260 kgf cm 19 ft lbf Bolt B 25 N m 255 kgf cm 18 ft lbf b Install the 2 wire harness clamp brackets to the ...

Page 856: ...lt nut and 2 clamps as shown in the illustration Torque Bolt Nut 25 N m 255 kgf cm 18 ft lbf Clamp 6 0 N m 61 kgf cm 53 in lbf 61 INSTALL AIR TUBE NO 2 a Install the air tube No 2 with the 2 bolts and 2 clamps as shown in the illustration Torque Bolt 25 N m 255 kgf cm 18 ft lbf Clamp 6 0 N m 61 kgf cm 53 in lbf 62 INSTALL BATTERY CARRIER a Install the battery carrier and clamp with the 4 bolts Tor...

Page 857: ...RHD STEERING POSITION TYPE SEE PUB NO RM1106E PAGE 50 6 78 CONNECT STEERING SLIDING YOKE SUB ASSY LHD STEERING POSITION TYPE SEE PUB NO RM1106E PAGE 50 6 79 INSTALL COLUMN HOLE COVER SILENCER SHEET SEE PUB NO RM1106E PAGE 50 6 80 PLACE FRONT WHEELS FACING STRAIGHT AHEAD 81 CENTER SPIRAL CABLE SEE PUB NO RM1106E PAGE 60 40 82 INSTALL STEERING WHEEL ASSY SEE PUB NO RM1106E PAGE 50 6 83 INSPECT STEER...

Page 858: ...7 0 71 62 in lbf 33 340 24 12 120 9 26 260 19 39 400 29 37 380 27 25 255 18 18 180 13 26 260 19 25 255 18 33 340 24 33 340 24 13 130 9 37 380 27 39 400 29 12 120 9 15 155 11 37 380 27 25 255 18 5 0 51 44 in lbf 37 380 27 15 155 11 37 380 27 15 155 11 37 380 27 5 0 51 44 in lbf 12 122 8 9 15 155 11 5 0 51 44 in lbf 15 155 11 13 133 10 13 133 10 13 131 9 5 0 51 44 in lbf 3 5 36 31 in lbf Air Tube No...

Page 859: ...1 356 98 8 0 82 71 in lbf 133 1 356 98 Speed Sensor Front LH Front Axle Hub LH Nut 80 816 59 z Gasket 89 908 66 80 816 59 19 192 14 TMUK 29 296 21 TMMT Front Suspension Crossmember Sub assy z Gasket 49 500 36 Crossmember Bracket 52 530 38 52 530 38 Engine Mounting Bracket LH Engine Mounting Insulator LH 52 530 38 64 653 47 80 816 59 43 440 32 89 908 66 TMUK TMMT Made 30 302 22 49 500 36 133 1 356 ...

Page 860: ...er Sub assy z Gasket Engine Mounting Bracket LH Engine Mounting Insulator LH 43 440 32 TMC Made 64 653 47 35 360 26 43 440 32 43 440 32 39 398 29 87 887 64 64 653 47 216 2 200 159 74 755 55 52 530 38 49 500 36 8 0 82 71 in lbf 113 1 150 83 74 755 55 89 908 66 29 296 21 49 500 36 52 530 38 52 530 38 80 816 59 52 530 38 52 530 38 52 530 38 64 653 47 64 653 47 89 908 66 157 1 600 116 113 1 150 83 157...

Page 861: ...RING POSITION TYPE SEE PUB NO RM1106E PAGE 50 6 7 REMOVE FRONT WHEELS 8 REMOVE ENGINE UNDER COVER LH 9 REMOVE ENGINE UNDER COVER RH 10 DRAIN TRANSAXLE OIL a Remove the filler plug and gasket b Remove the drain plug and gasket and drain the oil c Install the drain plug with a new gasket Torque 39 N m 400 kgf cm 29 ft lbf 11 REMOVE HOOD SUB ASSY 12 REMOVE CYLINDER HEAD COVER NO 2 13 REMOVE AIR CLEAN...

Page 862: ... 2 wire harness clamp brackets and ground cable 21 DISCONNECT CONNECTOR a Disconnect the back up lamp switch connector 22 SEPARATE FUEL FILTER ASSY a Remove the 2 bolts and disconnect the fuel filter assy 23 SEPARATE TRANSMISSION CONTROL CABLE ASSY a Remove the 2 clips and the 2 washers and disconnect the 2 cables from the transaxle b Remove the 2 clips and disconnect the 2 cables from the control...

Page 863: ...SSY RH SEE PAGE 30 3 SST 09520 01010 09520 24010 09520 32040 30 REMOVE EXHAUST PIPE ASSY FRONT SEE PAGE 15 2 31 SUSPEND ENGINE ASSY a Install 2 hangers in the correct direction Engine hanger 12281 21010 Bolt 91672 81025 Torque 38 N m 387 kgf cm 28 ft lbf b Attach an engine chain hoist to the hangers CAUTION Do not attempt to hang the engine by hooking the chain to any other part 32 REMOVE FRONT SU...

Page 864: ...ansaxle from the engine 37 REMOVE ENGINE MOUNTING INSULATOR FR a Remove the bolt nut and engine mounting insulator FR from the engine mounting bracket FR 38 REMOVE ENGINE MOUNTING BRACKET FR a Remove the 2 bolts and engine mounting bracket FR from the transaxle 39 REMOVE ENGINE MOUNTING INSULATOR RR a Remove the bolt and engine mounting insulator RR from the engine mounting bracket RR BACK TO CHAP...

Page 865: ...L ENGINE MOUNTING INSULATOR RR a Install the engine mounting insulator RR to the engine mounting bracket RR with the bolt Torque 87 N m 887 kgf cm 64 ft lbf 43 INSTALL ENGINE MOUNTING BRACKET FR a Install the engine mounting bracket FR to the transaxle with the 2 bolts Torque 64 N m 653 kgf cm 47 ft lbf 44 INSTALL ENGINE MOUNTING INSULATOR FR a Install the engine mounting insulator FR to the engin...

Page 866: ...que Bolt A 52 N m 530 kgf cm 38 ft lbf Bolt B 80 N m 816 kgf cm 59 ft lbf HINT Insert the bolt from the front side of the vehicle and torque the bolt without turning the nut 48 INSTALL FRONT SUSPENSION CROSSMEMBER SUB ASSY SEE PUB No RM925E PAGE 51 6 SST 09670 00010 49 INSTALL EXHAUST PIPE ASSY FRONT SEE PAGE 15 2 50 INSTALL FRONT DRIVE SHAFT ASSY LH SEE PAGE 30 3 51 INSTALL FRONT DRIVE SHAFT ASSY...

Page 867: ... 2 washers and the 2 clips b Install 2 new clips on the control cable bracket 57 INSTALL FUEL FILTER ASSY a Install the fuel filter assy with the 2 bolts Torque 18 N m 180 kgf cm 13 ft lbf 58 CONNECT CONNECTOR a Connect the back up lamp switch connector 59 CONNECT WIRE HARNESS a Install the 2 wire harness clamp brackets and ground cable to the transaxle with the 4 bolts Torque Bolt A 26 N m 260 kg...

Page 868: ...BATTERY TRAY 64 INSTALL BATTERY 65 INSTALL BATTERY CLAMP SUB ASSY Torque Bolt 5 0 N m 51 kgf cm 44 in lbf Nut 3 5 N m 36 kgf cm 31 in lbf 66 INSTALL AIR CLEANER ASSY 67 INSTALL CYLINDER HEAD COVER NO 2 68 INSTALL HOOD SUB ASSY Torque 13 N m 133 kgf cm 10 ft lbf 69 INSPECT HOOD SUB ASSY SEE PUB No RM925E PAGE 75 1 70 ADJUST HOOD SUB ASSY SEE PUB No RM925E PAGE 75 1 71 ADD MANUAL TRANSAXLE OIL SEE P...

Page 869: ... NO RM1106E PAGE 50 6 81 INSPECT STEERING WHEEL CENTER POINT 82 INSTALL HORN BUTTON ASSY a TMC made See pub No RM1106E page 60 21 b TMUK TMMT made See pub No RM1106E page 60 31 83 INSPECT AND ADJUST FRONT WHEEL ALIGNMENT SEE PUB NO RM1106E PAGE 26 1 84 INSTALL ENGINE UNDER COVER LH 85 INSTALL ENGINE UNDER COVER RH 86 CHECK ABS SPEED SENSOR SIGNAL a TMC made See pub No RM925E page 05 561 b TMUK TMM...

Page 870: ... 21 CLUTCH STROKE SENSOR C53A 42 22 COMPONENTS 42 22 REPLACEMENT 42 23 24 CLUTCH ACCUMULATOR ASSY C53 42 25 COMPONENTS 42 25 REPLACEMENT 42 26 27 CLUTCH UNIT C53A C53 42 28 COMPONENTS 42 28 OVERHAUL 42 29 32 CLUTCH START SWITCH ASSY C53 42 33 ON VEHICLE INSPECTION 42 33 INSPECTION 42 34 REPLACEMENT 42 35 REFER TO FOLLOWING REPAIR MANUALS Manual Name Pub No COROLLA Repair Manual RM925E COROLLA Repa...

Page 871: ...tor is removed from the transmission assy during installation of any of the following parts TRANSMISSION ASSY TRANSMISSION PARTS INSIDE GEAR BOX 1 INITIALIZATION OF MULTI MODE MANUAL TRANS MISSION SYSTEM ECU 2 LEARNING OF MULTI MODE MANUAL TRANSMIS SION SYSTEM 3 SYNCHRONIZATION POSITION CALIBRATION 05 190 05 190 05 196 CLUTCH STROKE SENSOR 1 INITIALIZATION OF MULTI MODE MANUAL TRANS MISSION SYSTEM...

Page 872: ...29 42 29 42 29 42 29 Clutch is noisy 1 Clutch release bearing assy Worn dirty or damaged 2 Clutch disc torsion rubber Damaged 42 29 42 29 Clutch slips 1 Multi mode transmission system Faulty 2 Clutch disc assy Oily 3 Clutch disc assy Worn out 4 Diaphragm spring Damaged 5 Pressure plate Distortion 6 Flywheel sub assy Distortion 05 172 42 29 42 29 42 29 42 29 42 29 Clutch does not disengage 1 Clutch...

Page 873: ...rubber Damaged 42 14 42 17 Clutch is noisy 1 Clutch release bearing assy Worn dirty or damaged 2 Clutch disc torsion rubber Damaged 42 29 42 29 Clutch slips 3 Clutch pedal Free play is out of adjustment 4 Clutch disc assy Oily 5 Clutch disc assy Worn out 6 Diaphragm spring Damaged 7 Pressure plate Distortion 8 Flywheel sub assy Distortion 42 4 42 29 42 29 42 29 42 29 42 29 Clutch does not disengag...

Page 874: ...CH PEDAL HEIGHT a Turn back the floor carpet to expose the asphalt sheet un der the pedal b Check that the pedal height is correct Pedal height from asphalt sheet LHD Steering Position Type 139 5 to 149 5 mm 5 492 to 5 886 in RHD Steering Position Type 147 6 to 157 6 mm 5 811 to 6 205 in c Adjust pedal height 1 Loosen the lock nut and turn the stopper bolt until the correct height is obtained 2 Ti...

Page 875: ... m 120 kgf cm 9 ft lbf 4 After adjusting the pedal free play check pedal height 5 Install the instrument panel air bag assy lower No 1 see pub No RM1106E page 71 6 3 INSPECT CLUTCH RELEASE POINT a Check the clutch release point 1 Pull the parking brake lever and install wheel stop pers 2 Start the engine and run at idle 3 Without depressing the clutch pedal slowly move the shift lever into reverse...

Page 876: ... 12 120 9 16 160 12 z Clutch Pedal Pad Clip Turn Over Spring Seat Compression Spring Clutch Pedal Turn Over Bush Clutch Pedal No 1 Cushion 19 195 14 Clutch Master Cylinder Push Rod Clevis w Hole Pin Clutch Pedal Support Sub assy 12 120 9 z Clutch Pedal Bush Clutch Pedal Sub assy Clutch Pedal Pad Clutch Pedal Turn Over Bush Clutch Start Switch Assy Clutch Pedal Bush z Clutch Master Cylinder Push Ro...

Page 877: ... SEE PUB NO RM1106E PAGE 71 6 3 DISCONNECT CONNECTOR a Disconnect the clutch start switch connector 4 REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W HOLE PIN a Remove the clip and hole pin 5 REMOVE CLUTCH PEDAL SUPPORT SUB ASSY a LHD steering position type Remove the 2 nuts bolt and clutch pedal support assy b RHD steering position type Remove the 2 bolts 2 nuts and clutch pedal support assy BACK...

Page 878: ...tch assy 7 REMOVE TURN OVER SPRING SEAT COMPRESSION SPRING a Mount the clutch pedal in a soft jaw vise b Using a screwdriver remove the spring 8 REMOVE CLUTCH PEDAL TURNOVER BUSH 9 REMOVE CLUTCH PEDAL TURNOVER BUSH a Using a 8 mm hexagon wrench and a hammer remove the turn over bush 10 REMOVE CLUTCH PEDAL SUB ASSY a Remove the bolt and nut b Remove the clutch pedal from the clutch pedal support BA...

Page 879: ...1 CUSHION a LHD steering position type Using needle nose pliers remove the No 1 cushion from the clutch pedal b RHD steering position type Using needle nose pliers remove the 2 No 1 cushions from the clutch pedal 14 REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH a Using a 8 mm hexagon wrench and a hammer remove the clevis bush from the clutch pedal BACK TO CHAPTER INDEX TO MODEL INDEX To Alpha...

Page 880: ... the right side of the vehicle 16 INSTALL CLUTCH PEDAL NO 1 CUSHION a LHD steering position type Using needle nose pliers install the No 1 cushion to the clutch pedal b RHD steering position type Using needle nose pliers install the 2 No 1 cushions to the clutch pedal 17 INSTALL CLUTCH PEDAL BUSH a Apply MP grease to the inner outer and end surfaces of 2 new bushes b Install the 2 bushes to the cl...

Page 881: ...AL TURNOVER BUSH a Apply MP grease to the inside of a new turn over bush b Install the turn over bush to the clutch pedal support 21 INSTALL CLUTCH PEDAL TURNOVER BUSH a Apply MP grease to the inside of the turn over bush b Install the turn over bush to the clutch pedal 22 INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING a Install the spring to the clutch pedal and clutch pedal sup port 23 INSTALL...

Page 882: ...N m 120 kgf cm 9 ft lbf 25 INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W HOLE PIN a Apply MP grease to the contact surfaces of the hole pin and clevis bush b Connect the clevis to the clutch pedal with the hole pin HINT Install the hole pin from the right side of the vehicle c Install the clip to the hole pin 26 CONNECT CONNECTOR a Connect the clutch start switch connector 27 INSTALL INSTRUMENT...

Page 883: ...xible Hose Tube Clutch Reservoir Tube Clutch Master Cylinder Push Rod Clevis w Hole Pin Clutch Master Cylinder Assy Clip z Gasket N m kgf cm ft lbf Specified torque Non reusable part z 12 120 9 12 120 9 15 155 11 15 155 11 MP grease CLUTCH CLUTCH MASTER CYLINDER ASSY C53 42 13 COROLLA Supplement RM1129E CLUTCH MASTER CYLINDER ASSY C53 COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical...

Page 884: ...clutch master cylinder assy HINT Use a container to catch the fluid 5 DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE a Using SST disconnect the flexible hose tube SST 09023 00101 HINT Use a container to catch the fluid 6 REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W HOLE PIN a Remove the clip and hole pin 7 REMOVE CLUTCH MASTER CYLINDER ASSY a Remove the 2 nuts clutch master cylinder as...

Page 885: ... TMMT made Face the white mark upward S TMC made Face the pink mark upward S Ensure that the clutch reservoir tube is not twisted 12 INSTALL BRAKE BOOSTER ASSY LHD STEERING POSITION TYPE SEE PAGE 32 16 13 INSTALL BRAKE MASTER CYLINDER SUB ASSY LHD STEERING POSITION TYPE SEE PAGE 32 7 14 BLEED BRAKE LINE LHD STEERING POSITION TYPE SEE PUB NO RM925E PAGE 32 5 15 BLEED CLUTCH PIPE LINE a Fill the bra...

Page 886: ...85 74 in lbf Release Cylinder Body 12 120 9 Spring z Piston Push Rod Boot Non reusable part 12 120 9 15 155 11 42 16 CLUTCH CLUTCH RELEASE CYLINDER ASSY C53 COROLLA Supplement RM1129E CLUTCH RELEASE CYLINDER ASSY C53 COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 887: ...REMOVE CLUTCH RELEASE CYLINDER ASSY a Remove the 2 bolts and clutch release cylinder assy 11 REMOVE CLUTCH RELEASE CYLINDER KIT a Remove the boot from the cylinder body b Remove the push rod from the cylinder body c Remove the piston from the cylinder body NOTICE Be careful not to damage the inside of the cylinder body d Remove the spring from the cylinder body e Remove the bleeder plug cap from t...

Page 888: ...TO FLEXIBLE HOSE TUBE a Using SST connect the flexible hose tube SST 09023 00100 Torque 15 N m 155 kgf cm 11 ft lbf b Connect the flexible hose tube with the bolt Torque 12 N m 120 kgf cm 9 ft lbf 17 INSTALL AIR TUBE NO 1 SEE PAGE 41 49 18 INSTALL AIR TUBE NO 2 SEE PAGE 41 49 19 INSTALL BATTERY CARRIER SEE PAGE 41 49 20 INSTALL BATTERY TRAY 21 INSTALL BATTERY 22 INSTALL BATTERY CLAMP SUB ASSY 23 I...

Page 889: ...8 25 255 18 Clutch Actuator Assy 6 0 61 53 in lbf 6 0 61 53 in lbf 25 255 18 6 0 61 53 in lbf 6 0 61 53 in lbf 17 173 13 7 0 71 62 in lbf CLUTCH CLUTCH ACTUATOR ASSY C53A 42 19 COROLLA Supplement RM1129E CLUTCH ACTUATOR ASSY C53A COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 890: ...osen the bolts slowly and be careful notto get your fingers caught as the clutch actuator assy moves due to reaction force from the clutch cover S Do not drop the removed clutch actuator assy or im pact it in any way S Do not loosen the nut on the rod tip 10 INSTALL CLUTCH ACTUATOR ASSY NOTICE Perform the following operations a to e only when instal ling a new clutch actuator a Connect the clutch ...

Page 891: ...ted to the concave part i Tighten the 3 bolts by hand while holding the clutch actua tor assy NOTICE Support the clutch actuator assy until all 3 bolts are tight ened j Tighten the 3 bolts to the specified torque in the order of A B and C Torque 17 N m 173 kgf cm 13 ft lbf k Connect the clutch stroke sensor connector and motor connector 11 INSTALL AIR TUBE NO 1 SEE PAGE 41 49 12 INSTALL AIR TUBE N...

Page 892: ...ir Tube No 2 Air Tube No 1 6 0 61 53 in lbf 25 255 18 7 0 71 62 in lbf 6 0 61 53 in lbf 6 0 61 53 in lbf 25 255 18 6 0 61 53 in lbf 25 255 18 42 22 CLUTCH CLUTCH STROKE SENSOR C53A COROLLA Supplement RM1129E CLUTCH STROKE SENSOR C53A COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 893: ...Do not forcibly pull the connector as this may damage the wire harness b Remove the 2 screws and stroke sensor from the clutch actuator assy c Remove the O ring 7 INSTALL CLUTCH STROKE SENSOR a Apply MP grease to a new O ring b Install the O ring to the stroke sensor c Set the stroke sensor so that the clutch stroke sensor arm and the actuator sensor arm are positioned as shown in the illustration...

Page 894: ...NSTALL CYLINDER HEAD COVER NO 2 12 CONNECT BATTERY NEGATIVE TERMINAL 13 INITIALIZATION OF MULTI MODE MANUAL TRANSMISSION ECU SEE PAGE 05 190 14 LEARNING OF MULTI MODE MANUAL TRANSMISSION SYSTEM SEE PAGE 05 190 15 SYNCHRONIZATION POSITION CALIBRATION SEE PAGE 05 196 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 895: ...11 15 155 11 5 0 51 44 in lbf 37 380 27 15 155 11 5 0 51 44 in lbf 15 155 11 Clutch Accumulator Assy Flexible Hose Tube 12 120 9 CLUTCH CLUTCH ACCUMULATOR ASSY C53 42 25 COROLLA Supplement RM1129E CLUTCH ACCUMULATOR ASSY C53 COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 896: ...hose tube c Remove the 2 bolts nut and clutch accumulator assy 10 REMOVE CLUTCH ACCUMULATOR ASSY RHD STEERING POSITION TYPE a Using SST disconnect the 2 flexible hose tubes SST 09023 00101 HINT Use a container to catch the fluid b Remove the 2 bolts nut and clutch accumulator assy 11 INSTALL CLUTCH ACCUMULATOR ASSY LHD STEERING POSITION TYPE a Install the clutch accumulator assy with the nut and t...

Page 897: ...orque 15 N m 155 kgf cm 11 ft lbf 13 INSTALL AIR TUBE NO 1 SEE PAGE 41 49 14 INSTALL AIR TUBE NO 2 SEE PAGE 41 49 15 INSTALL BATTERY CARRIER SEE PAGE 41 49 16 INSTALL BATTERY TRAY 17 INSTALL BATTERY 18 INSTALL BATTERY CLAMP SUB ASSY 19 INSTALL AIR CLEANER ASSY 20 INSTALL CYLINDER HEAD COVER NO 2 21 BLEED CLUTCH PIPE LINE a Fill the brake reservoir tank with brake fluid and bleed the clutch system ...

Page 898: ...ng Assy Release Bearing Hub Clip Clutch Release Fork Sub assy Clutch Cover Assy Clutch Release Fork Boot Release Fork Support 37 375 27 19 194 14 42 28 CLUTCH CLUTCH UNIT C53A C53 COROLLA Supplement RM1129E CLUTCH UNIT C53A C53 COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 899: ...ORK SUPPORT a Remove the release fork support from the transaxle assy 5 REMOVE RELEASE BEARING HUB CLIP 6 REMOVE CLUTCH RELEASE FORK BOOT 7 REMOVE CLUTCH COVER ASSY a Put matchmarks on the clutch cover assy and the flywheel sub assy b Loosen each set bolt one turn at a time until the spring tension is released c Remove the set bolts and pull off the clutch cover assy NOTICE Do not drop the clutch ...

Page 900: ...phragm spring for the depth and width of wear Maximum A Depth 0 5 mm 0 020 in B Width 6 0 mm 0 236 in HINT Replace the clutch cover assy as necessary 11 INSPECT FLYWHEEL SUB ASSY a Using a dial indicator inspect the flywheel sub assy run out Maximum runout 0 1 mm 0 004 in HINT Replace the flywheel sub assy as necessary 12 INSPECT CLUTCH RELEASE BEARING ASSY a Check that the clutch release bearing ...

Page 901: ...checking that the disc is in the cen ter by lightly moving the SST up and down left and right 15 INSPECT AND ADJUST CLUTCH COVER ASSY a Using a dial indicator with a roller instrument check the diaphragm spring tip alignment Maximum non alignment 0 5 mm 0 020 in If the alignment is not as specified adjust the diaphragm spring tip alignment using SST SST 09333 00013 16 INSTALL RELEASE FORK SUPPORT ...

Page 902: ...h release bearing w release fork to the transaxle assy NOTICE After installation move the fork forward and backward to check that the release bearing slides smoothly 19 INSTALL CLUTCH RELEASE FORK BOOT 20 INSTALL MANUAL TRANSAXLE ASSY HINT S Manual transaxle type C53A See page 41 36 S Manual transaxle type C53 See page 41 49 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index T...

Page 903: ...LE INSPECTION 1 CHECK CLUTCH START SYSTEM a Check that the engine does not start when the clutch ped al is released b Check that the engine starts when the clutch pedal is fully depressed If necessary replace the clutch start switch assy BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 904: ...E INSPECTION 1 INSPECT CLUTCH START SWITCH ASSY a Measure the resistance between the terminals when the switch is ON and when it is OFF Switch position Condition ON pushed Below 1 Ω OFF free 10 kΩ or higher BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 905: ... nut and clutch start switch assy from the clutch pedal support 2 INSTALL CLUTCH START SWITCH ASSY a Install the clutch start switch assy with the nut Torque 16 N m 160 kgf cm 12 ft lbf b Connect the clutch start switch connector 3 INSPECT CLUTCH START SWITCH ASSY SEE PAGE 42 33 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 906: ...MENT 55 4 REFER TO FOLLOWING REPAIR MANUALS Manual Name Pub No COROLLA Repair Manual RM925E COROLLA Repair Manual Supplement RM1106E NOTE The above pages contain only the points which differ from the above listed manuals TO MODEL INDEX To Alphabetical Index To Sub Index BACK TO MAIN INDEX TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 907: ...rigerant Discharge Hose No 1 9 8 100 87 in lbf 5 4 55 47 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf N m kgf cm ft lbf Specified torque HEATER AIR CONDITIONER REFRIGERANT LINE 1ND TV 55 1 COROLLA Supplement RM1129E REFRIGERANT LINE 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 908: ...frigerant Suction Hose No 1 9 8 100 87 in lbf 5 4 55 47 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf Air Conditioning Tube Assy N m kgf cm ft lbf Specified torque 55 2 HEATER AIR CONDITIONER REFRIGERANT LINE 1ND TV COROLLA Supplement RM1129E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 909: ...agnet Clutch Washer Snap Ring Cooler Compressor Assy z Snap Ring z HEATER AIR CONDITIONER COOLER COMPRESSOR ASSY 1ND TV 55 3 COROLLA Supplement RM1129E COOLER COMPRESSOR ASSY 1ND TV COMPONENTS BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 910: ...se No 1 from the compressor and magnetic clutch b Remove the O ring from the cooler refrigerant suction hose No 1 NOTICE Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering 3 DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO 1 a Remove the bolt and disconnect the cooler refrigerant discharge hose No 1 from the compressor and magnetic clut...

Page 911: ...e b Using vise pliers hold the magnet clutch hub HINT Cover the magnet clutch with a shop rag when holding the mag net clutch hub to prevent it from being damaged c Remove the bolt magnet clutch hub and magnet clutch washer HINT There is no set number of magnet clutch washers since they are used for adjustment d Using a snap ring expander remove the snap ring and magnet clutch rotor e Remove the s...

Page 912: ...r and a new snap ring with the chamfered side facing up e Install the magnet clutch washer and magnet clutch hub NOTICE Do not change the combination of the magnet clutch wash ers used before disassembly f Using vise pliers hold the magnet clutch hub and install the bolt Torque 13 N m 134 kgf cm 9 7 ft lbf NOTICE Ensure that there is no foreign matter or oil on the compres sor shaft bolt and clutc...

Page 913: ...ty inside new compressor and magnetic clutch 60 10 cc 2 0 0 3 fl oz Re maining oil amount in the removed compressor and magnetic clutch Oil amount to be re moved when replacing NOTICE S When checking the compressor oil level observe the precautions on the cooler removal instal lation S Because compressor oil remains in the pipes of the vehicle if a new compressor and magnetic clutch is installed w...

Page 914: ...charge hose No 1 to the compressor and magnetic clutch with the bolt Torque 9 8 N m 100 kgf cm 87 in lbf 13 INSTALL COOLER REFRIGERANT SUCTION HOSE NO 1 a Remove the attached vinyl tape from the hose b Sufficiently apply compressor oil to a new O ring and the fitting surface of the compressor and magnetic clutch Compressor oil ND OIL8 or equivalent c Install the O ring to the cooler refrigerant su...

Page 915: ...58060 07117 58060 07117 58070 07117 58080 07117 58090 07117 78050 07117 88060 07117 88070 07117 88080 07117 48130 07117 48140 15 WARM UP ENGINE SEE PUB NO RM1106E PAGE 55 7 16 CHECK FOR LEAKAGE OF REFRIGERANT SEE PUB NO RM1106E PAGE 55 7 BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 916: ...ame Pub No COROLLA Repair Manual RM925E COROLLA Repair Manual Supplement RM939E COROLLA Repair Manual Supplement RM1106E NOTE The above pages contain only the points which differ from the above listed manuals TO MODEL INDEX To Alphabetical Index To Sub Index BACK TO MAIN INDEX TOYOTA COROLLA REPAIR MANUAL SUPP 1129E ...

Page 917: ...eshooting procedures 2 MMT ECU 3 Wire Harness or Connector 4 Combination Meter Assy 05 219 05 219 71 32 1 ES Economy sports indicator light does not come on 1 Refer to troubleshooting procedures 2 MMT ECU 3 Wire Harness or Connector 4 Combination Meter Assy 05 219 05 219 71 32 1 HINT 1 Refer to repair manual RM925E BACK TO CHAPTER INDEX TO MODEL INDEX To Alphabetical Index To Sub Index TOYOTA CORO...

Page 918: ... ACCUMULATOR ASSY C53 42 25 COMPONENTS CLUTCH ACTUATOR ASSY C53A 42 19 Page COMPONENTS CLUTCH MASTER CYLINDER ASSY C53 42 13 COMPONENTS CLUTCH PEDAL SUB ASSY C53 42 6 COMPONENTS CLUTCH RELEASE CYLINDER ASSY C53 42 16 COMPONENTS CLUTCH STROKE SENSOR C53A 42 22 COMPONENTS CLUTCH UNIT C53A C53 42 28 COMPONENTS COMMON RAIL ASSY 1ND TV 11 19 COMPONENTS COOLER COMPRESSOR ASSY 1ND TV 55 3 COMPONENTS CYLI...

Page 919: ...IFT LEVER ASSY C53A 41 7 FRONT DIFFERENTIAL OIL SEAL C53A C53 41 5 Page FRONT DOOR COURTESY LAMP SWITCH ASSY CIRCUIT DRIVER SIDE ENGINE IMMOBILIZER SYSTEM 1ND TV 05 412 FRONT DRIVE SHAFT 1ND TV 30 1 FUEL 02 2 FUEL 03 6 FUEL FILTER ASSY 1ND TV 11 25 FUEL HEATER ASSY 1ND TV 11 57 FUEL SYSTEM 1ND TV 11 1 FUEL TANK ASSY 1ND TV HATCH BACK 11 27 FUEL TANK ASSY 1ND TV SEDAN STATION WAGON 11 42 G GENERAL ...

Page 920: ...3 ON VEHICLE INSPECTION EMISSION CONTROL SYSTEM 1ND TV 12 1 ON VEHICLE INSPECTION FLOOR SHIFT SHIFT LEVER ASSY C53A 41 7 ON VEHICLE INSPECTION LUBRICATION SYSTEM 1ND TV 17 1 ON VEHICLE INSPECTION MANUAL TRANSAXLE OIL C53A C53 41 4 ON VEHICLE INSPECTION PRE HEATING SYSTEM 1ND TV 19 12 ON VEHICLE INSPECTION TURBOCHARGER SYSTEM 1ND TV 13 3 ON VEHICLE INSPECTION VACUUM PUMP ASSY 1ND TV 32 1 OPA AND CG...

Page 921: ...5 133 P0698 ECD SYSTEM 1ND TV 05 136 P0703 95 MULTI MODE MANUAL TRANSMISSION SYSTEM 05 234 P0704 A ECD SYSTEM 1ND TV 05 139 P0715 19 MULTI MODE MANUAL TRANSMISSION SYSTEM 05 238 P0725 13 MULTI MODE MANUAL TRANSMISSION SYSTEM 05 241 Page P0806 29 MULTI MODE MANUAL TRANSMISSION SYSTEM 05 246 P0810 35 MULTI MODE MANUAL TRANSMISSION SYSTEM 05 252 P0812 67 MULTI MODE MANUAL TRANSMISSION SYSTEM 05 264 P...

Page 922: ...NE ASSY 1ND TV 14 26 Page REPLACEMENT RADIATOR ASSY 1ND TV 16 12 REPLACEMENT SELECT STROKE SENSOR C53A 41 27 REPLACEMENT SHIFT STROKE SENSOR C53A 41 25 REPLACEMENT STARTER ASSY 1ND TV 19 3 REPLACEMENT THERMOSTAT 1ND TV 16 11 REPLACEMENT TRANSMISSION CONTROL CABLE ASSY C53 41 20 REPLACEMENT TRANSMISSION CONTROL ECU ASSY C53A 41 33 REPLACEMENT TRANSMISSION REVOLUTION SENSOR C53A 41 29 REPLACEMENT TU...

Page 923: ...IFICATION ENGINE CONTROL SYSTEM 03 5 TORQUE SPECIFICATION ENGINE MECHANICAL 03 13 TORQUE SPECIFICATION EXHAUST 03 15 TORQUE SPECIFICATION FUEL 03 7 TORQUE SPECIFICATION HEATER AIR CONDITIONER 03 31 TORQUE SPECIFICATION INTAKE 03 11 TORQUE SPECIFICATION LUBRICATION 03 19 TORQUE SPECIFICATION MANUAL TRANSMISSION TRANSAXLE 03 26 TORQUE SPECIFICATION STARTING CHARGING 03 21 TRANSMISSION CONTROL CABLE ...

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