Toyota Corolla (2004+). Manual — part 100
14-7
ENGINE MECHANICAL
- VALVE CLEARANCE
8.
SET NO. 1 CYLINDER TO TDC/COMPRESSION
Mark
(a) Turn the crankshaft pulley, and align its groove with timing
Mark
mark ”0” of the timing chain cover.
(b) Check that the point marks of the camshaft timing sprock-
et and VVT timing sprocket are in straight line on the tim-
ing chain cover surface as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360_) and align the
Mark
marks as above.
Timing Chain
Cover Surface
Groove
A62185
9.
INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
(1)
Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2)
Record the out-of specification valve clearance
measurements. They will be used later to determine
the required replacement valve lifter.
Valve clearance (Cold):
A01131
Intake 0.15 - 0.25 mm (0.0059 - 0.0098 in.)
Exhaust 0.25 - 0.35 mm (0.0098 - 0.0138 in.)
(b) Turn the crankshaft 1 revolution (360 _) and set No. 4 cyl-
inder to TDC/compression.
(c)
Check only the valves indicated.
(1)
Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2)
Record the out-of specification valve clearance
measurements. They will be used later to determine
the required replacement valve lifter.
Valve clearance (Cold):
Intake 0.15 - 0.25 mm (0.0059 - 0.0098 in.)
A01132
Exhaust 0.25 - 0.35 mm (0.0098 - 0.0138 in.)
14-8
ENGINE MECHANICAL
- VALVE CLEARANCE
10. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V-ribbed belt tensioner slowly clockwise and
loosen it. Then, remove the fan and generator V belt and
put back the V-ribbed belt tensioner little by little and fix
it quietly.
A60622
11. REMOVE ENGINE MOUNTING INSULATOR
SUB-ASSY RH
(a) Remove the PS oil pump reservoir and put it aside.
(b) Place a wooden block between the jack and engine, and
set the jack, then remove the 4 bolts, the 2 nuts and en-
gine mounting insulator RH.
A01045
A64005
12. REMOVE V-RIBBED BELT TENSIONER ASSY
(a) Remove the bolt, nut and V-ribbed belt tensioner.
HINT:
Handle a jack up and down to remove the bolt.
A11858
13. ADJUST VALVE CLEARANCE
NOTICE:
Be sure not to revolve the crankshaft without the chain ten-
sioner.
(a) Set the No. 1 cylinder to the TDC/compression.
Paint Mark
(b) Place match marks on the timing chain and camshaft tim-
ing sprockets.
A62186
14-9
ENGINE MECHANICAL
- VALVE CLEARANCE
(c)
Remove the 2 nuts and chain tensioner.
Push
A62178
(d) Fix the camshaft with a spanner and so on, then loosen
Fix
the camshaft timing gear set bolt.
Tighten
NOTICE:
Be careful not to damage the valve lifter.
A62187
2
4
5
3
1
(e) Loosen the camshaft bearing cap bolts on No. 2 cam-
shaft in the order as shown in the illustration in several
passes,and remove the caps.
A62188
(f)
Remove the camshaft timing gear as shown in the illustra-
tion.
A32124
(g) Loosen the camshaft bearing cap bolts on camshaft in
the order as shown in the illustration in several
passes,and remove the caps.
2
4
3
1
A62189
14-10
ENGINE MECHANICAL
- VALVE CLEARANCE
(h) Remove the camshaft with holding the timing chain.
A32125
(i)
Tie the timing chain with a string as shown in the illustra-
tion.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
A32556
(j)
Remove the valve lifters.
(k)
Using a micrometer, measure the thickness of the re-
moved lifter.
(l)
Calculate the thickness of a new lifter so that the valve
clearance comes within the specified value.
A
Thickness of new lifter
B
Thickness of used lifter
C
Measured valve clearance
A01082
Valve clearance:
Intake A = B + (C - 0.20 mm (0.0079 in.)
Exhaust A = B + (C - 0.30 mm (0.0118 in.)
HINT:
F
Select a new lifter with a thickness as close as possible
to the calculated values.
F
Lifter are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm
(0.2260 in.).
(m) As shown in the illustration, install the timing chain on the
Painted Link
camshaft timing gear, with the painted links aligned with
the timing marks on the camshaft timing sprocket.
Timing Mark
A62195
14-11
ENGINE MECHANICAL
- VALVE CLEARANCE
(n) Examine the front marks and numbers and tighten the
4
1
2
3
bolts in the order shown in the illustration.
Torque: 13 N m (133 kgf cm, 10 ft lbf)
A62196
Painted Link
(o) Put the camshaft No.2 on the cylinder head with the
painted links of the chain aligned with the timing mark on
the camshaft timing sprocket.
Timing Mark
A62197
(p) Tighten the camshaft timing gear set bolt temporarily.
A32124
(q) Examine the front marks and numbers and tighten the
bolts in the order shown in the illustration.
7
Torque: 13 N m (133 kgf cm, 10 ft lbf)
(r)
Install the bearing cap No. 1.
Torque: 23 N m (235 kgf cm, 17 ft lbf)
6
5
3
1
2
4
A62198
(s)
Fix the camshaft with a spanner and so on, then tighten
Fix
the camshaft timing gear set bolt.
Tighten
Torque: 54 N m (551 kgf cm, 40 ft lbf)
NOTICE:
Be careful not damage the valve lifter.
A62187
14-12
ENGINE MECHANICAL
- VALVE CLEARANCE
(t)
Check the match marks on the timing chain and camshaft
Mark
timing sprockets, and then the alignment of the pulley
Mark
groove with timing mark of the chain cover as shown in the
illustration.
Mark
Timing Chain
Cover Surface
Groove
A62185
(u) Install chain tensioner.
(1)
Check the O-ring is clean, and set the hook as
Raise
shown in the illustration.
Push
Hook
Pin
A62177
(2)
Apply engine oil to the chain tensioner and install it
with the 2 nuts.
Torque: 9.0 N m (92 kgf cm, 80 in lbf)
NOTICE:
When installing the tensioner, set the hook again if the
Push
hook release the plunger.
A62178
(3)
Turn the crankshaft counterclockwise, and discon-
nect the plunger knock pin from the hook.
Disconnect
Hook
Pin
Turn
A62180
14-13
ENGINE MECHANICAL
- VALVE CLEARANCE
(4)
Turn the crankshaft clockwise, and check that the
slipper is pushed by the plunger.
HINT:
If the plunger does not spring out, press the slipper into the
chain tensioner with a screwdriver so that the hook is released
from the knock pin and the plunger springs out.
Plunger
Push
Turn
A62181
14. INSTALL V-RIBBED BELT TENSIONER ASSY
(a) Install the V-ribbed belt tensioner with the nut and bolt.
Torque:
29 Nm (296 kgf cm, 21 ft lbf) for Nut
69 Nm (704 kgf cm, 51 ft lbf) for Bolt
A11858
15. INSTALL ENGINE MOUNTING INSULATOR
SUB-ASSY RH
(a) Install engine mounting insulator RH with the 4 bolts and
the 2 nuts.
Torque: 52 N m (530 kgf cm, 38 ft lbf)
A64005
16. INSTALL CYLINDER HEAD COVER SUB-ASSY
Seal Packing
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to 2 locations as shown in the illustra-
tion.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
F
Remove any oil from the contact surface.
F
Install the cylinder head cover within 3 minutes after
A62182
applying seal packing.
F
Do not put into engine oil 2 hours after installing.
14-14
ENGINE MECHANICAL
- VALVE CLEARANCE
(c)
Install the cylinder head cover and cable bracket with the
A
A
A
9 bolts, 2 seal washers and 2 nuts. Uniformly tighten the
bolts and nuts, in the several passes.
A
Torque:
B
B
A 11 Nm (112 kgf cm, 8 ft lbf)
B 9.0 Nm (92 kgf cm, 80 in lbf)
A
A
A
A
A
A65687
17. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
A64023
18. INSTALL ENGINE WIRE
(a) Install the engine wire with the bolt and nut.
Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
A64022
19. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
A65077
14-15
ENGINE MECHANICAL
-
VALVE CLEARANCE
20. CHECK ENGINE OIL LEAK
15-1
EXHAUST
- EXHAUST PIPE ASSY
EXHAUST PIPE
1504H-01
COMPONENTS
Tail Pipe Assy
F Gasket
43 (440, 32)
Oxygen Sensor
44 (450, 33)
43 (440, 32)
Exhaust Pipe Assy Front
F Gasket
Floor Panel Brace Front
43 (440, 32)
30 (302, 22)
N·m (kgf·cm, ft·lbf)
: Specified torque
F Non-reusable part
A65197
15-2
EXHAUST
- EXHAUST PIPE ASSY
1504I-02
Removal & Installation and Disassembly & Reassembly
1.
REMOVE OXYGEN SENSOR
(a) Remove a clip and tear off the floor mat.
(b) Disconnect a oxygen sensor connector.
A65195
(c)
Remove the oxygen sensor.
A65198
2.
REMOVE TAIL PIPE ASSY
(a) Remove 2 bolts, 2 springs and tail pipe assy.
3.
REMOVE FLOOR PANEL BRACE FRONT
(a) Remove 2 nuts and the front floor panel brace front.
A54420
4.
REMOVE EXHAUST PIPE ASSY FRONT
(a) Remove 2 bolts, 2 springs and exhaust pipe assy front.
5.
INSTALL EXHAUST PIPE ASSY FRONT
(a) Using vernier calipers, measure the free length of the compression spring.
Minimum length: 41.5 mm (1.634 in.)
HINT:
If the free length is less than minimum, replace the compression spring.
(b) Install a new gasket on the exhaust manifold.
(c)
Install the exhaust pipe front with 2 bolts and 2 springs.
Torque: 43 N m (440 kgf cm, 32 ft lbf)
15-3
EXHAUST
- EXHAUST PIPE ASSY
6.
INSTALL FLOOR PANEL BRACE FRONT
(a) Install the front panel brace front with 2 nuts.
Torque: 30 N m (302 kgf cm, 22 ft lbf)
7.
INSTALL TAIL PIPE ASSY
(a) Using vernier calipers, measure the free length of the compression spring.
Minimum length: 38.5 mm (1.516 in.)
HINT:
If the free length is less than minimum, replace the compression spring.
(b) Install a new gasket on the exhaust pipe front.
(c)
Install the exhaust tail pipe with 2 bolts and 2 springs.
Torque: 43 N m (440 kgf cm, 32 ft lbf)
8.
INSTALL OXYGEN SENSOR
(a) Install the oxygen sensor to the exhaust pipe front.
Torque: 44 N m (450 kgf cm, 33 ft lbf)
(b) Connect the oxygen sensor connector.
HINT:
After installing oxygen sensor, check that sensor wire is not
twisted. If it is twisted, remove the oxygen sensor and reinstall
it.
A65198
9.
CHECK EXHAUST GAS LEAK
16-7
COOLING
- COOLANT
COOLANT
160C8-01
REPLACEMENT
1.
DRAIN COOLANT
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(a) Remove the radiator cap.
(b) Loosen the radiator and engine drain plugs, and drain the
Radiator Cap
Water Drain Plug
coolant.
(c)
Close the drain plugs.
Torque: 13 N m (130 kgf cm, 9 ft lbf) for engine
Radiator
Drain Plug
Drain Pipe
A64364
2.
ADD COOLANT
(a) Slowly fill the system with coolant.
HINT:
F
Use of improper coolants may damage engine cooling system.
F
Use ”Toyota Long Life Coolant” or equivalent and mix it with plain water according to the manufactur-
er’s directions.
F
Using of coolant with includes more than 50 % (freezing protection down to -35_C (-31_F) or 60 %
(freezing protection down to -50_C (-58_F)) of ethylene-glycol is recommended but not more than
70 %.
NOTICE:
F
Do not use an alcohol type coolant or plain water alone.
F
The coolant should be mixed with plain water (preferably demineralized water).
Capacity: 6.5 liters (6.9 US qts, 5.7 lmp. qts)
3.
CHECK ENGINE COOLANT LEAK
(a) Fill the radiator with coolant and attach a radiator cap tester.
(b) Pump it to 118 kPa and check leakage.
16-6
COOLING
- COOLING FAN SYSTEM
160C7-01
INSPECTION
1.
COOLING FAN RELAY
(a) Inspect the cooling fan relay continuity.
(1)
Using an ohmmeter, check that there is continuity
between terminals 1 and 2.
If there is no continuity, replace the relay.
(2)
Check that there is no continuity between terminals
3 and 5.
If there is continuity, replace the relay.
A31260
(3)
Apply battery voltage across terminals 1 and 2.
(4)
Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
If there is no continuity, replace the relay.
2.
COOLING FAN RELAY NO.2
(a) Inspect the cooling fan relay continuity.
(1)
Using an ohmmeter, check that there is continuity
between terminals 1 and 2.
If there is no continuity, replace the relay.
(2)
Using an ohmmeter, check that there is continuity
between terminals 3 and 4.
If there is no continuity, replace the relay.
A30519
(3)
Check that there is no continuity between terminals
3 and 5.
If there is continuity, replace the relay.
(4)
Apply battery voltage across terminals 1 and 2.
(5)
Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
If there is no continuity, replace the relay.
3.
COOLING FAN RESISTOR
(a) Using an ohmmeter, measure the resistance between the terminals.
Resistance: 1.17 - 1.43
W at 20 FC (68 FF)
16-5
COOLING
- COOLING FAN SYSTEM
COOLING FAN SYSTEM
160C6-02
ON-VEHICLE INSPECTION
1.
CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83 FC (181FF))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
HINT:
If not, check the cooling fan relay and water temperature sensor, and check for separated connector or se-
vered wire between the cooling fan relay and water temperature sensor.
(c)
Disconnect the water temperature sensor connector.
(d) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the
cooling fan relay and water temperature sensor.
(e) Reconnect the water temperature sensor connector.
2.
CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 93 FC (199FF))
(a) Start the engine, and raise coolant temperature to above 93FC (199FF).
HINT:
Coolant temperature is the detected value by the water temperature sensor on the water outlet.
(b) Check that the cooling fan rotates.
HINT:
If not, replace the water temperature sensor.
3.
INSPECT COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the connector.
(c)
Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage:
Approx. 8.0 - 12.0 A at 20 FC (68FF)
(d) Reconnect the cooling fan connector.
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