01 - Introduction.pdf

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INTRODUCTION
PREPARATION
SERVICE SPECIFICATIONS
DIAGNOSTICS
ENGINE CONTROL SYSTEM
FUEL
EMISSION CONTROL
INTAKE
ENGINE MECHANICAL
EXHAUST
COOLING
LUBRICATION
IGNITION
STARTING & CHARGING
FRONT SUSPENTION
REAR SUSPENTION
TIRE & WHEEL
DRIVE SHAFT / PROPELLER SHAFT
BRAKE
PARKING BRAKE
AUTOMATIC TRANSMISSION / TRANS
MANUAL TRANSMISSION/TRANSAXLE
CLUTCH
STEERING COLUMN
POWER STEERING
HEATER & AIR CONDITIONER
SUPPLEMENTAL RESTRAINT SYSTEM
1
2
3
5
10
11
12
13
14
15
16
17
18
19
26
27
28
30
32
33
40
41
42
50
51
55
60
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SEAT BELT
LIGHTING
WIPER & WASHER
AUDIO & VISUAL SYSTEM
WIRING
COMMUNICATION SYSTEM
WINDSHIELD/WINDOWGLASS/MIRROR
INSTRUMENT PANEL/METER
SEAT
THEFT DETTERENT & DOOR LOCK
SLIDING ROOF/CONVERTIBLE
ENGINE HOOD/DOOR
EXTERIOR/INTERIOR TRIM
VEHICLE CONTROL SYSTEM
CRUISE CONTROL
MAINTENANCE
ALPHABETICAL INDEX
61
65
66
67
68
69
70
71
72
73
74
75
76
80
82
99
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FOREWORD
This manual (Volume 2) contains engine, chassis and body and electrical service procedures for the 2004
COROLLA.
Applicable models: ZZE130 series
For preparation, specifications and diagnostics procedures, refer to VOLUME 1 (Pub. No. RM1037U1).
The manual is divided into 39 sections with a thumb index for each section at the edge of the pages.
Please note that the publications below have also been prepared as relevant service manuals for the compo-
nents and systems in this vehicles.
Manual Name
Pub.No.
A245E, A246E Automatic Transaxle Repair Manual
RM941U
2004 COROLLA Electrical Wiring Diagram
EWD533U
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
TOYOTA MOTOR CORPORATION
2003 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: May 9, 2003 01–030509–00
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INTRODUCTION
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HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally, repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting
3. Final Inspection
(c) This manual explains the 1st process of ”Diagnosis” (found in the ”Diagnostics” section), the 2nd pro-
cess of ”Removing and Installing, Replacing, Disassembling, Installing and Checking, and Adjusting”,
but the 3rd process of ”Final Inspection” is omitted.
(d) The following essential operations are not written in this manual. However, these operations must be
performed in actual situations.
(1) Operations with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX section is provided at the end of the book as a reference to help you find the
item to be repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repair situation. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed under the title where necessary.
(b) Non–reusable parts, grease application area, precoated parts and tightening torque are specified in
the component drawings.
Example:
0103I–08
Filler Cap
Float
Clevis Pin
Gasket
Clip
Reservoir Tank
Grommet
Boot
Slotted Spring Pin
12 (120, 9)
Clevis
15 (155, 11)
Snap Ring
Washer
Lock Nut
Push Rod
Piston
Cylinder
N·m (kgf·cm, ft·lbf)
: Specified torque
Non–reusable part
N17080
2004 COROLLA (RM1037U)
Author:
Date:
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INTRODUCTION
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HOW TO USE THIS MANUAL
(c) Tightening torque, grease application area, and non–reusable parts are described as important points
in the procedures.
NOTICE:
There are cases where such information can only be explained by using an illustration. In these
cases, all the information such as torque, oil, etc. are described in the illustration.
(d) Installing procedures are performed in the reverse order of the removal and only the important points
are described.
(e) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notices are placed.
(f) There may be a case where the illustrations of similar models are used. In that case, specific details
may be different from the actual vehicle.
(g) The procedures are presented in a step–by–step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The explanation text tells how to perform the task and gives other information such as specifica-
tions and warnings.
Example:
Illustration:
what to do and where
Task heading: what you will be doing
SST
Detailed text: how to perform task
Set part No.
Component part No.
D31132
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary and the text below provides detailed information. Important
specifications and warnings always are written in bold type to stand out from the rest of the text.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for quick reference.
6. TERMS DEFINITION
CAUTION Indicates the possibility of injury to you or other people.
NOTICE
Indicates the possibility of damage to the components being repaired.
HINT
Provides additional information to help you to perform the repair efficiently.
2004 COROLLA (RM1037U)
Author:
Date:
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