Toyota Corolla 2004 User Manual

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Page 1

C92542

05–297

–DIAGNOSTICS ABS WITH EBD SYSTEM (April, 2003)

057U9–04

PRE–CHECK

1. DIAGNOSIS SYSTEM

(a) Release the parking brake lever. (b) Check the warning lights.

When the ignition switch is turned ON, check that the ABS warning light and brake warning light goes on for 3 sec.

HINT:

! When the parking brake is applied or the level of the brake

fluid is low, the brake warning light is lit.

! If the indicator check result is not normal, proceed to trou-

bleshooting for the ABS warning light circuit (See page 05–332 or 05–335) or brake warning light circuit (See page 05–338).

OFF

Normal Code

2 sec.

Code 11 and 21

0.5 sec.

4 sec.

Code 11

1.5 sec.

2.5 sec.

0.25 sec.

0.5 sec.

Code 21

C52361

R01346

Check the DTC. (1) Using SST, it connects terminal Tc and CG of DLC3. SST 09843–18040 (2) Turn the ignition switch to ON. (3) Read the DTC from the ABS warning light on the

combination meter.

HINT:

! If not code appears, inspect the diagnostic circuit or ABS

warning light circuit (See page 05–332 or 05–335 ).

! As an example, the blinking patterns for normal code and

codes 11 and 21 are shown on the left. (4) Codes are explained in the code table on page

05–303.

If 2 or more malfunctions are indicated at the same time, the lowest numbered DTC will be displayed 1st.

(5) After completing the check, remove the SST from

the DLC3.

SST 09843–18040

(d) In case of using hand–held tester:

Check the DTC. (1) Read the DTC by following the prompts on the tes-

ter screen. HINT: Please refer to the hand–held tester operator’s manual for further details. (e) In case of not using hand–held tester:

Clear DTC. (1) Using SST, it connects the terminal Tc and CG of the

DLC3.

SST 09843–18040 (2) Turn the ignition switch to ON.

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–DIAGNOSTICS ABS WITH EBD SYSTEM (April, 2003)

(3) Clear DTC stored in ECU by depressing the brake

pedal 8 or more times whitin 5 sec.

(4) Check that the ABS warning light shows the normal

code.

(5) Remove the SST from the DLC3.

SST 09843–18040 HINT: Disconnect the battey cable during repairs will not erase the

BR3890

DTC in the ECU. (f) In case of using hand–held tester:

Clear the DTC.

(1) Turn the ignition switch to ON.

(2) Operate the hand–held tester to erase the codes. HINT: Please refer to the hand–held tester operator’s manual for further details.

2. DATA LIST

HINT: According to the DATA LIST displayed by the Hand–held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as a first step of troubleshooting is one of the method to shorten the labor time. (a) Connect the Hand–held tester to the DLC3. (b) Turn the ignition switch to ON. (c) According to the display on tester, read the ”DATA LIST”.

Item

ABS MOT RELAY

SOL RELAY

STOP LIGHT SW

PKB SW

ABS OPERT FR

ABS OPERT FL

ABS OPERT RR

ABS OPERT RL

Measurement Item /

Range (Display)

ABS motor relay / ON or OFF

Solenoid relay / ON or OFF

Stop light switch / ON or OFF

Parking brake switch / ON or OFF

ABS operation (FR) / BEFORE or OPERATE

ABS operation (FL) / BEFORE or OPERATE

ABS operation (RR) / BEFORE or OPERATE

ABS operation (RL) / BEFORE or OPERATE

Normal Condition Diagnostic Note

ON : Brake pedal depressed OFF : Brake pedal released

ON : Parking brake applied OFF : Parking brake released

BEFORE : No ABS operation (FR) OPERATE : During ABS operation (FR)

BEFORE : No ABS operation (FL) OPERATE : During ABS operation (FL)

BEFORE : No ABS operation (RR) OPERATE : During ABS operation (RR)

BEFORE : No ABS operation (RL) OPERATE : During ABS operation (RL)

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–DIAGNOSTICS ABS WITH EBD SYSTEM (April, 2003)

05–299

Item Diagnostic NoteNormal Condition

WHEEL SPD FR

WHEEL SPD FL

WHEEL SPD RR

WHEEL SPD RL

IG VOLTAGE

SFRR

SFRH

SFLR

SFLH

SRRR

SRRH

SRLR

SRLH

AIR BLD SUPPORT

TEST MODE

#CODES

Measurement Item /

Range (Display)

Wheel speed sensor (FR) reading / min.: 0 km/h (0 MPH, max.: 326 km/h (202 MPH)

Wheel speed sensor (FL) reading / min.: 0 km/h (0 MPH, max.: 326 km/h (202 MPH)

Wheel speed sensor (RR) reading / min.: 0 km/h (0 MPH, max.: 326 km/h (202 MPH)

Wheel speed sensor (RL) reading / min.: 0 km/h (0 MPH, max.: 326 km/h (202 MPH)

ECU power supply voltage / NORMAL or TOO LOW

ABS solenoid (SFRR) ON / OFF

ABS solenoid (SFRH) ON / OFF

ABS solenoid (SFLR) ON / OFF

ABS solenoid (SFLH) ON / OFF

ABS solenoid (SRRR) ON / OFF

ABS solenoid (SRRH) ON / OFF

ABS solenoid (SRLR) ON / OFF

ABS solenoid (SRLH) ON / OFF

Air bleed support / SUPPORT or NOT SUP

Test mode / NORMAL or TEST

Number of DTC recorded / min.: 0, max.: 255

Actual wheel speed

NORMAL : 9.5 V or over TOO LOW : Below 9.5 V

Supported

NORMAL : Normal mode TEST : During test mode

Min.: 0, max.: 19

Speed indicated on speedometer

3. ACTIVE TEST

HINT: Performing the ACTIVE TEST using the Hand–held tester allows the relay, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as a first step of troubleshooting is one of the methods to shorten the labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the Hand–held tester to the DLC3. (b) Turn the ignition switch to ON. (c) According to the display on tester, perform the ”ACTIVE TEST”.

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–DIAGNOSTICS ABS WITH EBD SYSTEM (April, 2003)

Item Vehicle Condition / Test Details Diagnostic Note

SFRR Turns ABS solenoid (SFRR) ON / OFF

SFRH Turns ABS solenoid (SFRH) ON / OFF

SFLR Turns ABS solenoid (SFLR) ON / OFF

SFLH Turns ABS solenoid (SFLH) ON / OFF

SRRR Turns ABS solenoid (SRRR) ON / OFF

SRRH Turns ABS solenoid (SRRH) ON / OFF

SRLR Turns ABS solenoid (SRLR) ON / OFF

SRLH Turns ABS solenoid (SRLH) ON / OFF

SFRR & SFRH Turns ABS solenoid SFRR & SFRH ON / OFF

SFLR & SFLH Turns ABS solenoid SFLR & SFLH ON / OFF

SRRH & SRRR Turns ABS solenoid SRH & SRR ON / OFF

SRLR & SRLH Turns ABS solenoid SRLR & SRLH ON / OFF

SFRH & SFLH Turns ABS solenoid SFRH & SFLH ON / OFF

SOL RELAY Turns ABS solenoid relay ON / OFF

ABS MOT RELAY Turns ABS motor relay ON / OFF

ABS WARN LIGHT Turns ABS warning light ON / OFF

BRAKE WRN LIGHT Turns BRAKE warning light ON / OFF

Operation of solenoid (clicking sound) can be heard

Operation of motor can be heard

Observe combination meter

4. FREEZE FRAME DATA

(a) The vehicle (sensor) status memorized during ABS operation or at the time of error code detection can

be displayed using the hand–held tester.

(b) Only one record of freeze frame data is stored and the freeze frame data generated during ABS opera-

tion are constantly updated. Also, the number of the ignition switch’s ”ON” after the freeze frame data

is stored can be memorized up to 31 and it can be displayed. HINT: If the ignition switch ”ON” operation exceeds 31 times, ”31” appears on the display.

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–DIAGNOSTICS ABS WITH EBD SYSTEM (April, 2003)

is stored but the ABS actuation data is deleted.

Hand–held tester display Measurement Item Reference Value*

VEHICLE SPD Vehicle speed Speed indication of a meter

STOP LIGHT SW Stop light switch signal Stop light switch ON: ON, OFF: OFF

# IG ON

SYSTEM Operate system ABS operate: ABS

Numbers of operations of ignition switch ON after memorizing freeze frame data

0 – 31

*: If no conditions are specifically stated for ”Idling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF.

5. SPEED SENSOR SIGNAL CHECK

HINT: If the ignition switch is turned from ON to ACC or LOCK during test mode, DTC will be erased. (a) In case of not using hand–held tester:

Check the speed sensor signal. (1) Turn the ignition switch to ON.

OFF

0.13 sec.

C52361

BR3904

(2) Using SST, it connects the terminal Ts and CG of

DLC3. SST 09843–18040 (3) Start the engine.

(4) Check that the ABS warning light blinks.

HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit and Ts circuit (See page 05–332 or 05–335).

(5) Drive the vehicle straight forward at the speed of 45

km/h (28 mph) or over for several seconds and

check that the ABS warning light comes off.

HINT: The sensor check may not be completed if the wheels spin or the steering wheels steered during check.

(6) Stop the vehicle. (7) Using SST, it connects the terminal Tc and CG of the

DLC3. SST 09843–18040 (8) Read the number of blinks of the ABS warning light.

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05–302

–DIAGNOSTICS ABS WITH EBD SYSTEM (April, 2003)

HINT:

! See the list of DTC shown on the 05–303. ! If every sensor is normal, a normal code is output (A cycle

of 0.25 sec. ON and 0.25 sec. OFF is repeated).

! If 2 or more malfunctions are indicated at the same time,

the lowest numbered code will be displayed.

Malfunction Code (Example Code 72, 76)

72 7 6

OFF

0.5 sec.

1.5 sec.

0.5 sec. 0.5 sec.

2.5 sec.

(b) In case of using hand–held tester:

HINT: Please refer to the hand–held tester operator’s manual for further details.

4 sec.

Repeat

BR3893

(9) After performing the check, turn the ignition switch

to OFF, and remove the SST from the DLC3. SST 09843–18040

Check the speed sensor signal. (1) Do step (3) to (6) on the previous page. (2) Read the DTC by following the prompts on the tes-

ter screen.

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–HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY

OVERHAUL

HINT: COMPONENTS: See page 55–40

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55–11)

SST 07110–58060 (07117–58080, 07117–58090, 07117–78050, 07117–88060, 07117–88070,

07117–88080)

2. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A

(a) Remove the bolt and disconnect the cooler refrigerant liq-

uid pipe A from the w/receiver condenser assy.

(b) Remove the O–ring from the cooler refrigerant liquid pipe

NOTICE: Seal the opening of the disconnected parts using vinyl tape

I31967

to prevent moisture and foreign matter from entering.

55–41

550IY–01

I32450

I32451

3. DISCONNECT DISCHARGE HOSE SUB–ASSY

(a) Remove the bolt and discharge hose sub–assy from the

w/receiver condenser assy.

(b) Remove the O–ring from the discharge hose sub–assy.

NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

4. REMOVE W/RECEIVER CONDENSER ASSY

(a) Remove the 2 bolts and 2 radiator upper supports.

(b) Remove the 2 bolts. (c) Slide the upper part of the radiator assy rearward to re-

move the w/receiver condenser assy.

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I32452

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55–42

14 mm (0.55 in.) Hexagon Wrench

–HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY

5. REMOVE COOLER DRYER

(a) Using a socket hexagon wrench 14 mm (0.55 in.), remove

the cap from the modulator.

Modulator

I30086

(b) Remove the O–ring from the cap.

E55408

I32475

6. INSTALL COOLER DRYER

(a) Using pliers, install the cooler dryer.

E50386

(b) Install the new O–ring to the cap. (c) Sufficiently apply compressor oil to the fit surfaces of the

O–ring and the cap.

Compressor oil: ND–OIL 8 or equivalent

E55408

14 mm (0.55 in.) Hexagon Wrench

2004 COROLLA (RM1037U)

(d) Using a socket hexagon wrench 14 mm (0.55 in.), install

the cap to the modulator.

Torque: 2.9 N⋅m (29 kgf⋅cm, 25 in.⋅lbf)

Modulator

I30086

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I32453

I32451

55–43

–HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY

7. INSTALL W/RECEIVER CONDENSER ASSY

(a) Install the w/receiver condenser assy with the 2 bolts.

Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)

(b) Install the 2 radiator upper supports with the 2 bolts.

8. INSTALL DISCHARGE HOSE SUB–ASSY

(a) Remove the attached vinyl tape from the hose and con-

necting part of the w/receiver condenser assy.

(b) Sufficiently apple compressor oil to the new O–ring and

hose joint.

Compressor oil: ND–OIL 8 or equivalent

I32450

(d) Install the discharge hose sub–assy to the w/receiver

condenser assy with the bolt.

Torque: 5.4 N⋅m (54 kgf⋅cm, 48 in.⋅lbf)

9. INSTALL COOLER REFRIGERANT LIQUID PIPE A

(a) Remove the attached vinyl tape from the pipe and w/re-

ceiver condenser assy.

(b) Sufficiently apple compressor oil to the new O–ring and

pipe joint.

Compressor oil: ND–OIL 8 or equivalent

(d) Install the cooler refrigerant liquid pipe A to the w/receiver

condenser assy with the bolt.

Torque: 5.4 N⋅m (54 kgf⋅cm, 48 in.⋅lbf)

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55–44

–HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY

10. CHARGE REFRIGERANT (See page 55–11)

SST 07110–58060 (07117–58060, 07117–58070, 07117–58080, 07117–58090, 07117–78050,

07117–88060, 07117–88070, 07117–88080), 07117–48130, 07117–48140

Specified amount: 490 ! 30 g (17.28 ! 1.06 oz.)

11. WARM UP ENGINE

12. INSPECT LEAKAGE OF REFRIGERANT (See page 55–11)

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–HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY

W/RECEIVER CONDENSER ASSY

550IW–01

ON–VEHICLE INSPECTION

1. INSPECT W/RECEIVER CONDENSER ASSY

(a) If a fin of the w/receiver condenser assy is dirty, clean it with water and dry it with compressor air.

NOTICE: Do not damage the fin of the w/receiver condenser assy.

(b) If a fin of the w/receiver condenser assy is bent, make it straight using a screwdriver or pliers.

2. INSPECT W/RECEIVER CONDENSER ASSY FOR LEAKAGE OF REFRIGERANT

(a) Using a halogen leak detector, check pipe joints for gas leakage. (b) If gas leakage is detected in a joint, check the torque of the joint.

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55–40

COMPONENTS

–HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY

550IX–01

9.8 (100, 87 in.⋅lbf)

! O–Ring

W/receiver Condenser Assy

5.4 (54, 48 in.⋅lbf)

Cooler Dryer

! O–Ring

N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque

Compressor Oil ND–OIL 8 or equivalent

! Non–reusable part

2004 COROLLA (RM1037U)

Cap

2.9 (29, 25 in.⋅lbf)

I32505

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73–7

–THEFT DETERRENT & DOOR LOCK WIRELESS DOOR LOCK CONTROL SYSTEM

WIRELESS DOOR LOCK CONTROL SYSTEM

730B0–02

PRECAUTION

1. NOTICES WHEN CHECKING

(a) Power door LOCK/UNLOCK function:

The wireless remote control function operates only when the following 3 conditions are met. (1) No key is inserted into the ignition key cylinder. (2) All the doors are closed. However, doors can be unlocked even when any of the doors is opened. (3) The power door lock system operates normally.

HINT:

! The UNLOCK function operates even when a door is open. ! The UNLOCK function operates even when the key is inserted into the ignition key cylinder, however

it must be in the OFF position.

(b) Remote panic function:

The wireless remote control function operates only when the following condition is met.

(1) The ignition switch is OFF. HINT: The key can be inserted, however it must be in the OFF position. (c) The wireless door lock remote control operational area differs depending on the situation.

(1) The operational area differs depending on the operators and the ways the transmitter is held.

(2) In certain areas, the remote control function will only operate partially for the operational area

will be reduced due to the vehicle body shape and the influence of the surrounding environment.

(3) Since the transmitter uses faint electric waves, strong electric waves or noise in the frequency

used may reduce the operational area or the remote control may not function.

(4) When the battery weakens, the operational area is reduced or the remote control may not func-

tion. HINT: If the door control transmitter has been left in a place that is exposed to direct sunlight, such as on the instrument panel, it may cause the battery to weaken or cause other such problems.

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73–8

–THEFT DETERRENT & DOOR LOCK WIRELESS DOOR LOCK CONTROL SYSTEM

730B1–02

ON–VEHICLE INSPECTION

1. INSPECT WIRELESS DOOR LOCK CONTROL FUNCTIONS

HINT:

! The switch described in this text is a switch for transmitting signals (LOCK switch, UNLOCK switch

and PANIC switch) which is built into the door control transmitter.

! All the functions listed below must be checked in the remote control operational area.

(a) Put the vehicle under the conditions that allow the wireless control function to be operated (See PRE-

CAUTION on page 73–7).

(b) Check the basic function.

(1) Check that all the doors lock when the LOCK switch is pressed. (2) Check that only the driver side door unlocks when the UNLOCK switch is pressed once and the

other doors unlock when the UNLOCK switch is pressed again within 3 seconds. (c) Check the chattering prevention function.

(1) Check that the corresponding operation occurs only once and is not repeated continuously while

the switch is held. However, when the switch is operated repeatedly at 1 second intervals, check

that the corresponding operation is carried out. (d) Check the automatic lock function.

(1) Check that all the doors lock automatically as long as none of them have been opened or all the

doors have not been locked within approx. 30 seconds after they are unlocked by pressing the

UNLOCK switch.

(2) Check that the automatic locking function does not operate when any door has been opened or

all of them have been locked within approx. 30 seconds after they are unlocked by pressing the

UNLOCK switch. (e) Check the switch operation fail–safe function.

(1) Check that the doors can not be locked using the switch while the key is in the ignition key cylin-

der. However, this does not apply when the system is in the recognition code registration mode. (f) Check the operation stop function when a door is open or not completely closed.

(1) Check that the doors are not locked by the switch while any door is open or not completely closed.

However, the glass hatch open operation is possible in this situation. (g) Check the repeat function.

(1) Check that all the doors attempt to automatically lock once again 1 second after the LOCK switch

has been pressed while the movement of the driver side door control knob is being restricted

while in the unlocked position. (h) Check the hazard warning lamps flashing functions (answer–back).

(1) When the LOCK switch is pressed, check that the lamps flash once with the locking of all the

doors.

(2) When the UNLOCK switch is pressed once, check that the lamps flash twice with the unlocking

of the driver side door.

(3) When the UNLOCK switch is pressed again within 3 seconds, check that the lamps flash twice

with the unlocking of all the doors. (i) Check the remote panic alarm function.

(1) Check that the horn sounds, and the headlamps, the taillamps and the hazard warning lamps

flash for 60 seconds by the theft alarm function when the PANIC switch is pressed. Also, check

that the horn stops sounding and the lamps stop flashing when either switch of the transmitter

is pressed once again. (j) Check the illuminated entry function.

(1) When all the doors are locked, pressing the UNLOCK switch causes the room lamp (when the

lamp switch is in the DOOR position) to illuminate simultaneously with the unlock operation.

(2) Check that the room lamp goes off in approx. 15 seconds if doors have not been opened.

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–THEFT DETERRENT & DOOR LOCK WIRELESS DOOR LOCK CONTROL SYSTEM

73–9

Door Control Receiver (Wire Harness Side)

B59092

2. CHECK DOOR CONTROL RECEIVER

(a) Disconnect the D3 connector from the door control receiv-

er.

(b) Check the continuity and voltage between the terminals

of the door control receiver connector and the body ground, as shown in the illustration and table.

Standard:

Symbols (Terminal No.) Specified condition

+B (D3– 5) – Body ground 10 – 14 V

GND (D3–1) – Body ground Continuity

If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the connector and check the voltage between

the terminal and body ground.

Standard:

Symbols (Terminal No.) Condition Specified Condition

RDA (D3–2) – Body ground

No key in ignition key cylinder, all doors closed and each transmitter switch OFF → ON

1 V or less → Approx. 6 – 7 V → 1 V or less

If the result is not as specified, the receiver may have a malfunction.

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66–10

–WIPER & WASHER WIPER RUBBER LH

WIPER RUBBER LH

REPLACEMENT

1. REMOVE FR WIPER BLADE LH

(a) Remove the front wiper blade LH from the front wiper arm LH.

NOTICE: Do not fold down the front wiper arm with the front wiper blade being removed from it.

2. REMOVE WIPER RUBBER LH

(a) Remove the front wiper rubber LH from the front wiper blade. (b) Remove the 2 wiper rubber backing plates from the wiper rubber LH.

3. INSTALL WIPER RUBBER LH

Curve

(a) Install the 2 wiper rubber backing plates to the wiper rub-

ber LH.

NOTICE: Be careful to observe and keep direction of curvature for correct replacement.

66072–01

E59361

E57398

(b) Install the wiper rubber LH so that the head part (Larger

side) of the wiper rubber faces the arm axie side.

NOTICE: Push the front wiper blade into the grooves of the wiper rubber to engage them completely.

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66–6

–WIPER & WASHER WINDSHIELD WIPER MOTOR ASSY

WINDSHIELD WIPER MOTOR ASSY

REPLACEMENT

1. REMOVE WINDSHIELD WIPER ARM COVER

2. REMOVE FR WIPER ARM RH

(a) Operate the wiper and stop the windshield wiper motor assy at the automatic stop position. (b) Remove a nut and FR wiper arm RH.

3. REMOVE FR WIPER ARM LH

(a) Remove a nut and FR wiper arm LH.

4. REMOVE HOOD TO COWL TOP SEAL

(a) Using a clipremover, disengage the meshing of 8 clips

and remove the hood to cowl top seal.

66071–01

Claws

E60623

5. REMOVE COWL TOP VENTILATOR LOUVER RH

(a) Remove a clip and release the 5 claws, and remove the

cowl top ventilator louver RH.

E60624

6. REMOVE COWL TOP VENTILATOR LOUVER LH

(a) Remove a clip and release the 5 claws, and remove the

cowl top ventilator louver LH.

E60625

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E60708

66–7

–WIPER & WASHER WINDSHIELD WIPER MOTOR ASSY

7. REMOVE WIPER LINK ASSY

(a) Disconnect the connector. (b) Remove the 2 bolts. (c) Slide the wiper link assy to vehicle’s passengers side. Dis-

engage the meshing of the rubber pin and remove the wiper link assy.

8. REMOVE WINDSHIELD WIPER MOTOR ASSY

(a) Using a screwdriver and disengage the meshing of 2 rods

at the clank arm pivot of the windshield wiper motor assy. HINT: Tape the screwdriver tip before use.

E50396

E50397

E50398

(b) Remove 2 torx bolts and windshield wiper motor assy.

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66–8

–WIPER & WASHER WINDSHIELD WIPER MOTOR ASSY

9. INSTALL WINDSHIELD WIPER MOTOR ASSY

(a) Apply MP grease to the clank arm pivot of the windshield wiper motor assy. (b) Using 2 torx bolts, install the windshield wiper motor assy to the windshield wiper link assy.

Torque: 7.5 N⋅m (76 kgf⋅cm, 66 in.⋅lbf)

10. INSTALL WIPER LINK ASSY

(a) Install the meshing of the rubber pin. (b) Install the windshield wiper link assy.with the 2 bolts.

Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf)

E60709

11. INSTALL FR WIPER ARM LH

(a) Operate the wiper, and stop the windshield wiper motor

assy at the automatic stop position.

Wiper Arm Serration

Wire Brush

Installation Position Mark

(b) Scrape off the serration part of the wiper arm with a round

file or equivalent. (c) Clean the wiper pivot serration with the wire brush.

Wiper Pivot Serration

E58837

(d) Install the front wiper arm LH with a nut at the position as

shown in the illustration.

Torque: 20.5 N⋅m (209 kgf⋅cm, 15 ft⋅lbf)

HINT: Hold down the arm hinge with hand to fasten a nut.

25 + 15.0mm (0.98 + 0.59in.)

2004 COROLLA (RM1037U)

E60710

1708Author!: Date!:

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Installation Position Mark

25 + 15.0mm (0.98 + 0.59in.)

66–9

–WIPER & WASHER WINDSHIELD WIPER MOTOR ASSY

12. INSTALL FR WIPER ARM RH

(a) Scrape off the serration part of the wiper arm with a round

file or equivalent. (b) Clean the wiper pivot serration with the wire brush.

shown in the illustration.

Torque: 20.5 N⋅m (209 kgf⋅cm, 15 ft⋅lbf)

HINT: Hold down the arm hinge with hand to fasten a nut. (d) Operate the wiper while running the water or the washer

fluid over the window, and check the wiping condition and

that the rear wiper does not hit against the vehicle body.

E60711

2004 COROLLA (RM1037U)

1709Author!: Date!:

Page 21

03–52

–SERVICE SPECIFICATIONS WIPER & WASHER

WIPER & WASHER

TORQUE SPECIFICATION

Part Tightened N⋅m kgf⋅cm ft⋅lbf

Wind shield wiper motor assy × Wiper link assy 7.5 76 66 in.⋅lbf

Wiper link assy × Body 5.5 56 49 in.⋅lbf

FR Wiper arm RH × Wiper link 20.5 209 15

FR Wiper arm LH × Wiper link 20.5 209 15

030PT–01

2004 COROLLA (RM1037U)

156Author!: Date!:

Page 22

WIPER & WASHER

PREPARATION

SST

02–47

–PREPARATION WIPER & WASHER

021C7–01

Recomended Tools

Equipment

To r qu e w r en c h

09843–18040

09042–00010

09082–00040

(09083–00150)

Diagnosis Check Wire No.2 WIPER AND WASHER SYSTEM

Torx Socket T30 WINDSHIELD WIPER MOTOR ASSY

TOYOTA Electrical Tester WIPER AND WASHER SYSTEM

Test Lead Set WIPER AND WASHER SYSTEM

2004 COROLLA (RM1037U)

92Author!: Date!:

Page 23

–WIPER & WASHER WINDSHIELD WIPER SWITCH ASSY

WINDSHIELD WIPER SWITCH ASSY

REPLACEMENT

1. REMOVE STEERING COLUMN COVER LWR

(a) Remove 3 screws and steering column cover LWR.

E60462

2. REMOVE WINDSHIELD WIPER SWITCH ASSY

(a) Disconnect the connecter of the windshield wiper switch. (b) Release the claw and pull out the windshield wiper switch

assy as shown in the illustration.

NOTICE: Pressing the claw hard breaks the claw.

66–11

66073–01

Claw

E60688

2004 COROLLA (RM1037U)

1711Author!: Date!:

Page 24

–PREPARATION WINDSHIELD/WINDOWGLASS/MIRROR

WINDSHIELD/WINDOWGLASS/MIRROR

PREPARATION

Recomended Tools

02–51

021CG–01

09070–20010

09082–00040

(09083–00150)

Moulding Remover WINDSHIELD GLASS

TOYOTA Electrical Tester WINDOW DEFOGGER SYSTEM

Test Lead Set POWER WINDOW CONTROL

Equipment

Adhesive

Knife

Piano wire Windshield

Plastic sheet To av o i d su r f a ce d a m ag e .

Sealer gun

To r qu e w r en c h

Tape To av o i d su r f a ce d a m ag e .

Wooden block or similar object For tying both piano wire ends

SSM

POWER MIRROR CONTROL

SYSTEM

POWER WINDOW CONTROL

SYSTEM

08833–00030

08850–00801

Three cement black or equivalent WINDSHIELD GLASS

BACK WINDOW GLASS

Windshield Glass Adhesive Set

or equivalent

WINDSHIELD GLASS

BACK WINDOW GLASS

2004 COROLLA (RM1037U)

96Author!: Date!:

Page 25

70–10

–WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD GLASS

REPLACEMENT

HINT: Installation is according to the reverse order of the removal.

1. REMOVE FR WIPER ARM RH (See page 66–6)

2. REMOVE FR WIPER ARM LH (See page 66–6)

3. REMOVE HOOD TO COWL TOP SEAL (See page 66–6)

4. REMOVE COWL TOP VENTILATOR LOUVER LH (See page 66–6)

5. REMOVE COWL TOP VENTILATOR LOUVER RH (See page 66–6)

6. REMOVE FRONT DOOR WEATHERSTRIP RH (See page 76–21)

7. REMOVE FRONT DOOR WEATHERSTRIP LH (See page 76–21)

8. REMOVE FRONT PILLAR GARNISH RH (See page 76–21)

9. REMOVE FRONT PILLAR GARNISH LH (See page 76–21)

10. REMOVE INNER REAR VIEW MIRROR ASSY (See page 70–27)

11. REMOVE RH VISOR ASSY (See page 76–21)

12. REMOVE LH VISOR ASSY (See page 76–21)

13. REMOVE GLOVE BOX LAMP ASSY (See page 76–21)

14. REMOVE ASSIST GRIP SUB–ASSY (See page 76–21)

15. REMOVE VISOR HOLDER (See page 76–21)

16. REMOVE ROOF HEADLINING ASSY (See page 76–21)

17. REMOVE ROOF DRIP SIDE FINISH MOULDING CENTER RH (See page 76–17)

18. REMOVE ROOF DRIP SIDE FINISH MOULDING CENTER LH (See page 76–17)

700GO–01

2–Piece Type

1–Piece Type

Cut

19. REMOVE WINDSHIELD MOULDING OUTSIDE

(a) Using a knife, cut off the moulding as shown in the illustra-

tion.

NOTICE: Do not damage the body with the knife.

(b) Remove the remaining moulding. HINT: When removing, make a cut partly, pull and remove it by hand.

B50448

20. REMOVE WINDSHIELD GLASS

HINT: Depending on a vehicle type, either a 1–piece type or a 2–piece type of stopper is installed. (a) Push a piano wire through between the body and glass

from the interior. HINT: Apply protective tape to the outer surface to keep the surface from being scratched.

2004 COROLLA (RM1037U)

B58592

1745Author!: Date!:

Page 26

–WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD GLASS

70–11

Stopper

(b) Tie both wire ends to wooden blocks or similar objects.

NOTICE:

! When separating the glass, take care not to damage

the paint and interior/exterior ornaments.

Piano Wire

! To prevent the piano wire to be cut, do not cross it.

NOTICE:

B50449

Leave as much adhesive on the body as possible when cutting off the glass.

21. CLEAN WINDSHIELD GLASS

(a) Using a scraper, remove the damaged stoppers, dam and

adhesive sticking to the glass. (b) Clean the outer circumference of the glass with white gas-

oline.

NOTICE:

! Do not touch the glass after cleaning it. ! Be careful not to damage the body.

BO3986

22. INSTALL WINDSHIELD GLASS STOPPER NO.1

(a) Install 2 new windshield glass stoppers No.1 to the body.

23. INSTALL WINDSHIELD GLASS STOPPER NO.2

(a) Coat the installation part of the stopper with Primer G.

NOTICE:

! Dry the primer coating for 3 minutes or more.

! Do not apply too much primer.

(b) Install 2 new windshield glass stoppers No.2 onto the

glass as shown in the illustration.

A: 40.0 mm (1.575 in.)

B59836

B: 7.7 mm (0.303 in.)

2004 COROLLA (RM1037U)

1746Author!: Date!:

Page 27

70–12

–WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD GLASS

24. INSTALL FRONT PILLAR OUTER DAM

(a) Coat the installation part of the front pillar outer dam with Primer G.

NOTICE:

! Dry the primer coating for 3 minutes or more. ! Do not apply too much primer.

(b) Install 2 new front pillar outer dams with double–stick tape as shown in the illustration.

NOTICE: Do not touch the glass face after cleaning it.

A: 7 mm (0.28 in.) B: 22.5 mm (0.886 in.) C: 45 mm (1.77 in.) D: 5 mm (0.20 in.)

a – a b – b

Adhesive

2004 COROLLA (RM1037U)

BO4420

c – c

Dam

B59167

25. INSTALL WINDSHIELD GLASS

(a) Clean and shape the contact surface of the vehicle’s

body.

(1) Using a knife, cut away any rough areas on the

body. HINT: Leave as much adhesive on the body as possible.

(2) Clean the cut surface of the adhesive with a piece

of shop rag saturated in cleaner. (b) Position the glass.

(1) Using a suction rubber, place the glass in the correct

position.

(2) Check that all the contacting parts of the glass rim

are perfectly even.

(3) Place reference marks between the glass and body.

NOTICE: Check that the stoppers are attached to the body correctly.

HINT: When reusing the glass, check and correct the reference mark’s positions.

1747Author!: Date!:

Page 28

–WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD GLASS

(4) Remove the glass. (c) Coat the contact surface of the body panel with Primer M. (d) Using a brush, coat the exposed part of the contact sur-

face on the vehicle side with Primer M.

NOTICE:

! Dry the primer coating for 3 minutes or more. ! Do not coat the adhesive with Primer M. ! Do not apply too much primer.

(e) Coat the contact surface of the glass with Primer G.

(1) Using a brush or sponge, coat the edge of the glass

and the contact surface with Primer G.

NOTICE:

! Dry the primer coating for 3 minutes or more. ! Do not apply too much primer.

(f) Apply adhesive.

(1) Cut off the tip of the cartridge nozzle as shown in the

illustration.

Part No. 08850–00801 or equivalent

HINT:

a – a b – b

After cutting off the tip, use all adhesive within the time described in the table below.

Temperature Tackfree time

35"C (95"F) 15 minutes

20"C (68"F) 100 minutes

5"C (41"F) 8 hours

(2) Load the sealer gun with the cartridge.

c – c

(3) Coat the glass with adhesive, as shown in the il-

lustration.

A: 8.0 mm (0.315 in.) or more

B: 12.5 mm (0.492 in.) or more

(g) Install the glass.

B59952

(1) Using a suction rubber, position the glass so that the

reference marks are aligned, and press it in gently along the rim.

NOTICE:

! Dry the primer coating for 3 minutes or more. ! Check that the stoppers are attached to the body cor-

rectly.

! Check the clearance between the body and glass.

(2) Lightly press the glass front surface for close con-

tact.

(3) Using a scraper, remove any excess or protruding

adhesive. HINT: Apply adhesive on the glass rim.

26. INSTALL WINDSHIELD MOULDING OUTSIDE

(a) Install a new windshield moulding to the windshield glass before the adhesive has hardened. (b) Hold the

windshield glass in place securely with protective tape or equivalent until the adhesive has

completely hardened.

70–13

2004 COROLLA (RM1037U)

1748Author!: Date!:

Page 29

70–14

–WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD GLASS

NOTICE: Take care not to drive the vehicle during the time described in the table below.

Temperature Tackfree time

35"C (95"F) 1.5 hours

20"C (68"F) 5 hours

5"C (41"F) 24 hours

27. INSPECT FOR LEAK AND REPAIR

(a) Conduct a leak test after the adhesive has completely hardened. (b) Seal any leak with sealant.

2004 COROLLA (RM1037U)

1749Author!: Date!:

Page 30

WINDSHIELD GLASS

COMPONENTS

Assist Grip Sub–assy

Roof Headlining Assy (Partial)

70–9

–WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD GLASS

700GN–01

Glove Box Lamp Assy

Map Lamp Cover

Front Door Opening Trim Weatherstrip RH

Front Pillar Garnish RH

w/ Sliding Roof

RH Visor Assy

Visor Holder

! Windshield Moulding Outside

Visor Holder

LH Visor Assy

Inner Rear View Mirror Assy

! Windshield Glass Stopper*

! Windshield Glass Stopper No.1* ! Windshield Glass Stopper No.2*

! Front Pillar Outer Dam

FR Wiper Arm RH

Cowl Top Ventilator Louver RH

N⋅m (kgf⋅cm ft⋅lbf)

: Specified torque

! Non–reusable part

2004 COROLLA (RM1037U)

20 (205, 15)

Windshield Glass

20 (205, 15)

FR Wiper Arm LH

Hood to Cowl Top Seal

Cowl Top Ventilator Louver LH

Front Pillar Garnish LH

*1:

1–piece type

*2:

2–piece type

Front Door Opening Trim Weatherstrip LH

B59170

1744Author!: Date!:

Page 31

70–22

PROBLEM SYMPTOMS TABLE

Symptom Suspected Area See page

Rear window defogger does not operate (Indicator lamp on)

Rear window defogger does not operate (Indicator lamp off)

–WINDSHIELD/WINDOWGLASS/MIRROR WINDOW DEFOGGER SYSTEM

1. M–HTR/DEF IUP fuse

2. DEF fuse

3. DEF relay

4. Rear window defogger wire

5. Wire harness

1. GAUGE fuse

2. Defogger switch (A/C panel switch)

3. Air control assembly

4. Wire harness

700GS–01

–

68–1

–

70–23

–

2004 COROLLA (RM1037U)

1757Author!: Date!:

Page 32

–WINDSHIELD/WINDOWGLASS/MIRROR WINDOW DEFOGGER SYSTEM

WINDOW DEFOGGER SYSTEM

LOCATION

Instrument Panel J/B

Defogger Relay

70–21

700GR–01

Defogger Wire

Instrument Panel J/B

GAUGE Fuse

2004 COROLLA (RM1037U)

M–HTR/DEF IUP Fuse

Defogger Fuse

B59159

1756Author!: Date!:

Page 33

INSPECTION

B16200

70–23

–WINDSHIELD/WINDOWGLASS/MIRROR WINDOW DEFOGGER SYSTEM

700GT–01

1. INSPECT DEFOGGER RELAY (Marking: DEF)

(a) Remove the defogger relay from the instrument panel

J/B.

(b) Inspect the defogger relay.

Standard:

Terminal No. Condition Specified condition

1 ⇔ 2 Constant Continuity

3 ⇔ 5

Apply B+ between

terminals 1 and 2

Continuity

If the result is not as specified, replace the relay.

2004 COROLLA (RM1037U)

1758Author!: Date!:

Page 34

16–8

WATER PUMP ASSY

REPLACEMENT

1. REMOVE ENGINE UNDER COVER RH

2. DRAIN COOLANT (See page 16–7)

3. REMOVE FAN AND GENERATOR V BELT

–COOLING WATER PUMP ASSY

160C9–01

(See page 14–4)

B00145

B00143

B00147

4. REMOVE GENERATOR ASSY

(a) Disconnect the wire clamp from the wire clip on the recti-

fire end frame.

(b) Remove the rubber cap and nut, and disconnect the alter-

nator wire.

(d) Remove the 2 bolts and alternator.

2004 COROLLA (RM1037U)

5. REMOVE WATER PUMP ASSY

(a) Remove the 6 bolts, water pump and O–ring.

B00150

1190Author!: Date!:

Page 35

16–9

–COOLING WATER PUMP ASSY

6. INSTALL WATER PUMP ASSY

(a) Place a new O–ring on the timing chain cover. (b) Install the water pump with the 6 bolts.

Torque: Bolt A 9.0 N⋅m (92 kgf⋅cm, 80 in⋅lbf) Bolt B 11 N⋅m (113 kgf⋅cm, 8 ft⋅lbf)

A32555

7. INSTALL GENERATOR ASSY Torque: 12 mm head 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) 14 mm head

54 N⋅m (550 kgf⋅cm, 39 ft⋅lbf)

8. ADD COOLANT (See page 16–7)

9. CHECK ENGINE COOLANT LEAK (See page 16–7)

2004 COROLLA (RM1037U)

1191Author!: Date!:

Page 36

16–10

INSPECTION

–COOLING WATER PUMP ASSY

160CA–01

1. INSPECT WATER PUMP ASSY

(a) Visually check the drain hole for coolant leakage.

Hole

B10233

2004 COROLLA (RM1037U)

1192Author!: Date!:

Page 37

66–12

–WIPER & WASHER WASHER NOZZLE

WASHER NOZZLE

66074–01

ADJUSTMENT

1. INSPECT WASHER NOZZLE

(a) With the engine running, check that the point where the washer fluid hits the windshield and the rear

window is within the range indicated by the hatched line.

Ceramic Line

A:150mm(5.91in.)

B:440mm(17.32in.)

C:180mm(7.09in.) D:260mm(10.24in.)

E:455mm(17.91in.)

F:465mm(18.31in.)

G:65mm(2.56in.)

H:70mm(2.76in.) I:200mm(7.87in.) J:155mm(6.10in.)

2004 COROLLA (RM1037U)

E60687

1712Author!: Date!:

Page 38

–DIAGNOSTICS COMBINATION METER

WARNING BUZZER DOES NOT SOUND (KEY REMINDER

WARNING, LIGHT REMINDER WARNING)

WIRING DIAGRAM

Combination Meter

RH J/B

U1 Unlock Warning SW

W–B

L–B(*1)

Instrument Panel J/B

L–B(*1)

L–B(*2)

16 C9

05–659

057T3–02

KEY SW

Integration Relay

DCTY

J6 J/C

*1: w/ Door Lock Control *2: w/o Door Lock Control

R–W

D4 Door Courtesy SW (Driver’s Side)

17 C9

D–DOOR

I32381

INSPECTION PROCEDERE

1 CHECK BUZZER

(a) Check that all of the warning buzzers sound.

A B

Some buzzers sound No buzzer sounds

B CHECK AND REPLACE COMBINATION METER

2004 COROLLA (RM1037U)

ASSY

824Author!: Date!:

Page 39

05–660

–DIAGNOSTICS COMBINATION METER

2 INSPECT FRONT DOOR COURTESY LAMP SWITCH ASSY(See Page 65–7)

NG REPLACE FRONT DOOR COURTESY LAMP

SWITCH ASSY

3INSPECT UN–LOCK WARNING SWITCH ASSY(See Page 05–682)

NG REPLACE UN–LOCK WARNING SWITCH ASSY

4CHECK HARNESS AND CONNECTOR(BETWEEN UN–LOCK WARNING SWITCH

AND COMBINATION METER ASSY)

NG REPAIR OR REPLACE HARNESS OR

CONNECTOR

5CHECK HARNESS AND CONNECTOR(BETWEEN COURTESY LAMP SWITCH AND

COMBINATION METER ASSY)

NG REPAIR OR REPLACE HARNESS OR

CONNECTOR

CHECK AND REPLACE COMBINATION METER ASSY

2004 COROLLA (RM1037U)

825Author!: Date!:

Page 40

05–617

–DIAGNOSTICS AUDIO SYSTEM (April, 2003)

057P4–02

SOUND QUALITY IS BAD IN ALL MODES (VOLUME IS TOO LOW)

WIRING DIAGRAM

See page 05–614

INSPECTION PROCEDURE

1ADJUST SOUND QUALITY

(a) Adjust the sound quality.

(1) Operate the radio receiver assy to adjust the sound quality.

Standard: malfunction disappear.

OK BAD SOUND QUALITY

2 COMPARE IT WITH ANOTHER CAR OF SAME MODEL

(a) Compare it with another vehicle of the same model.

(1) Compare with the vehicle of the same type which does not have a trouble to see if there is any

difference in the condition of trouble occurrence.

Standard: No difference found.

OK SETTING

3CHECK HARNESS AND CONNECTOR(BETWEEN RADIO RECEIVER ASSY AND

SPEAKER)

NG REPAIR OR REPLACE HARNESS OR

CONNECTOR

4INSPECT FRONT NO.1 SPEAKER ASSY

(a) Preparation for Check

(1) Disconnect the connector of the speaker.

(b) Resistance Check

(1) Check the resistance between the terminals of the speaker.

NOTICE: The speaker should not be removed for checking.

Standard value: 4 Ω

2004 COROLLA (RM1037U)

NG REPLACE FRONT NO.1 SPEAKER ASSY

782Author!: Date!:

Page 41

05–618

–DIAGNOSTICS AUDIO SYSTEM (April, 2003)

5INSPECT FRONT NO.2 SPEAKER ASSY

(a) Check that malfunction disappear when a known good speaker is installed.

Standard: malfunction disappear.

HINT: Connect the all connectors of speakers.

NG REPLACE FRONT NO.2 SPEAKER ASSY

6INSPECT REAR SPEAKER ASSY

(a) Preparation for Check

(1) Disconnect the connector of the speaker.

(b) Resistance Check

(1) Check the resistance between the terminals of the speaker.

NOTICE: The speaker should not be removed for checking.

Standard value: 6 Ω

NG REPLACE REAR SPEAKER ASSY

7INSPECT RADIO RECEIVER ASSY(+B, ACC, GND)

ACC

GND

I32244

(a) Check that the continuity between terminals at each

condition, as shown in the chart.

Standard:

Te s te r c o nn e c t i on Condition Specified condition

GND – Body ground Constant Continuity

(b) Check that the voltage between terminals at each condi-

tion, as shown in the chart.

Standard:

Te s te r c o nn e c t i on Condition Specified condition

+B – GND Constant 10 – 14 V

ACC – GND Ignition switch ACC or ON 10 – 14 V

OK CHECK AND REPLACE RADIO RECEIVER

ASSY

REPAIR OR REPLACE HARNESS OR CONNECTOR

2004 COROLLA (RM1037U)

783Author!: Date!:

Page 42

73–14

–THEFT DETERRENT & DOOR LOCK TOYOTA VEHICLE INTRUSION PROTECTION

SYSTEM

TOYOTA VEHICLE INTRUSION PROTECTION SYSTEM

730AV–01

ON–VEHICLE INSPECTION

1. OUTLINE OF TOYOTA VEHICLE INTRUSION PROTECTION (TVIP) SYSTEM

HINT: The theft deterrent system has 2 modes; one is the active mode that is an initially set mode and another is the passive mode that can be switched ON/OFF by the specified method (See step 4). (a) When the theft deterrent system detects any theft, the system will sound the horns and flash the lights

to alert the people around the vehicle to the theft.

HINT: Each mode (active and passive) has 4 states; disarmed state, arming preparation state, armed state, alarm sounding state.

(1) Disarmed state:

! The user is near the vehicle. ! The alarming function does not operate. ! The theft deterrent function does not operate.

(2) Arming preparation state:

! Time from the user locks a door to leave the vehicle. ! Time for transferring to the armed state. ! The theft deterrent function does not operate.

(3) Armed state:

! The user leaves the vehicle completely. ! The theft deterrent function operates.

(4) Alarm sounding state:

Once a theft is detected in the armed state, the system will sound the horns and flash the lights to alert the people around the vehicle to the theft. Refer to the table for the alarming method and time.

Alarming method

Alarming time

Room Light

Headlight

Hazard Warning Light

Vehicle Horn

Illuminating (turn on)

Flashing at a cycle of approx. 0.4 sec.

Flashing at a cycle of flasher relay

Sounding at a cycle of approx. 0.4 sec.

Approx. 60 sec.

HINT: In the alarm sounding state, when either of the front doors is unlocked and no key is inserted in the ignition key cylinder, forced door lock signal is output.

2004 COROLLA (RM1037U)

1806Author!: Date!:

Page 43

2. ACTIVE ARMING MODE

–THEFT DETERRENT & DOOR LOCK TOYOTA VEHICLE INTRUSION PROTECTION

SYSTEM

73–15

Disarmed State

(No key inserted in ignition key cylinder)

Perform any of the followings and the system will go to ”Arming preparation state”:

" With all doors and luggage compartment door closed, lock all doors with key. " With all doors and luggage compartment door closed, lock all doors by the wireless door

lock operation. " With all doors and luggage compartment door closed, open and close either of doors or luggage compartment door, and then close and lock all doors and luggage compartment door.

Perform any of the followings and the system will return to ”Disarmed state”: " Open either of the closed doors or luggage compartment door.

" Unlock either of the locked front doors. " Insert the key in the ignition key cylinder. " Disconnect the battery once, and then

reconnect it.

Continued from next page

Arming Preparation State

Perform the following and the system will go to ”Armed state”: " Allow 30 seconds to elapse with all doors and luggage compartment door closed and locked.

Continued to next page

2004 COROLLA (RM1037U)

1807Author!: Date!:

Page 44

73–16

–THEFT DETERRENT & DOOR LOCK TOYOTA VEHICLE INTRUSION PROTECTION

SYSTEM

Continued to previous page

Perform any of the followings and the system will return to ”Disarmed state”: " Unlock the locked doors by the wireless door lock operation. " Unlock the locked doors with key (except the luggage compartment door). " Insert the key into the ignition key cylinder and turn the ignition ON.

Continued from previous page

Armed State

Perform any of the followings and the system will go to ”Alarm sounding state”:

" Open either of the closed doors. " Unlock either of the locked front doors in any

way other than the key and the wireless door lock operations. " Open the closed luggage compartment door.

" Reconnect the battery terminal. " Turn the ignition switch ON without using the

key. " Theft is detected by the glass breakage sensor.

Alarm Sounding State

Once a theft is detected, lights will flash and horns will sound to alert people around the vehicle to the theft.

After the above specified alarming time (60 sec.) has elapsed, the system will return to ”Armed state”.

2004 COROLLA (RM1037U)

1808Author!: Date!:

Page 45

–THEFT DETERRENT & DOOR LOCK TOYOTA VEHICLE INTRUSION PROTECTION

SYSTEM

Indicator light output:

Condition Indicator light

Disarmed state OFF

Arming preparation state ON

Armed state BLINK

Alarm sounding state ON

HINT: Blinking frequency:

0.2 seconds (ON)

1.8 seconds (OFF)

73–17

2004 COROLLA (RM1037U)

1809Author!: Date!:

Page 46

73–18

–THEFT DETERRENT & DOOR LOCK TOYOTA VEHICLE INTRUSION PROTECTION

SYSTEM

3. PASSIVE ARMING MODE

! This mode can be switched according to the specified method (See step 4). ! Initially set mode (when shipped from factory) is the active mode (No passive mode).

Disarmed State (A)

Perform the following and the system will go to ”Disarmed state (B)”: " Insert and remove the key from the ignition key cylinder, and then open and close the driver’s door.

Disarmed State (B)

Perform any of the followings and the system will return to ”Disarmed state (A)”:

" Push the unlock switch on the transmitter. " Put the key in the lock cylinder on the driver’s

or passenger’s door and turn it towards unlock.

" Insert the key in the ignition key cylinder. " Reconnect the battery terminal.

Arming Preparation State

Perform the following and the system will return to ”Disarmed state (B)”: " Open either of the closed doors or luggage compartment door.

Perform the following and the system will go to ”Arming preparation state”: " Close all doors and luggage compartment door.

Perform the following and the system will go to ”Armed state”: " Allow 30 seconds to elapse with all doors and luggage compartment door closed.

2004 COROLLA (RM1037U)

Continued from next page

Continued to next page

1810Author!: Date!:

Page 47

–THEFT DETERRENT & DOOR LOCK TOYOTA VEHICLE INTRUSION PROTECTION

SYSTEM

Continued from previous pageContinued to previous page

Armed State

73–19

Perform any of the followings and the system will return to ”Disarmed state (A)”:

" Push the unlock switch on the transmitter. " Put the key in the lock cylinder on the driver’s

or passenger’s door and turn it towards unlock. " Insert the key into the ignition key cylinder and turn the ignition ON.

Alarm Sounding State

Perform any of the followings and the system will go to ”Alarm sounding state”: " Open either of the closed doors and allow the entry delay time*1 to pass.

" Open the closed luggage compartment door. " Reconnect the battery terminal. " Turn the ignition ON without using the key.

*1: See the ”Entry delay function”

on the next page

Perform any of the followings and the system will return to ”Disarmed state (A)”:

" Push the unlock switch on the transmitter. " Put the key in the lock cylinder on the driver’s

or passenger’s door and turn it towards unlock. " Insert the key into the ignition key cylinder and turn the ignition ON.

Perform the following and the system will return to ”Armed state”: " The alarm sounding time (60 sec.) has elapsed.

2004 COROLLA (RM1037U)

1811Author!: Date!:

Page 48

73–20

–THEFT DETERRENT & DOOR LOCK TOYOTA VEHICLE INTRUSION PROTECTION

SYSTEM

Entry delay function:

HINT: In the armed state, if either closed door is opened, entry delay time will start. If the transferring condition (Armed state → Disarmed state) is satisfied during this entry delay time, the system will transfer to the disarmed state. However if the condition is not satisfied, the system will judge it to be a theft, and then the system will transfer to the alarm sounding state.

Door

Open

Indicator

OFF

Alarming output

OFF

Entry delay time

System condition

(0, 14, 30 sec.)

Armed state Alarm sounding

state

HINT: The entry delay time can be selected among 0, 14, 30 seconds by the customizing function.

Indicator light output:

Condition Indicator light

Disarmed state OFF

Arming preparation state ON

Armed state (Entry delay time) BLINK (ON)

Alarm sounding state ON

HINT: Blinking frequency:

0.2 seconds (ON)

1.8 seconds (OFF)

Transfer to the active mode:

HINT: In each state of the passive mode, when the transferring condition to the active mode (disarmed state of active mode → arming preparation state of active mode) is satisfied, the system will transfer to each state of the active mode. In this case, the active mode will continue until the system transfers to the disarmed state.

State of Passive Mode Before Transfer State of Active Mode After Transfer

Disarmed state Arming preparation state

Arming preparation state Arming preparation state (continuing for 30 sec.)

Armed state

Armed state (During entry delay time)

Alarm sounding state

(After alarming time has elapsed, the system will transfer to the armed state)

After alarming time has elapsed, the system will transfer to the armed state

2004 COROLLA (RM1037U)

1812Author!: Date!:

Page 49

4. CHANGING METHOD OF PASSIVE MODE (ON or OFF)

–THEFT DETERRENT & DOOR LOCK TOYOTA VEHICLE INTRUSION PROTECTION

SYSTEM

73–21

Within 5 sec.

Within 40 sec.

2 sec.

" No key in the ignition key cylinder " Driver’s door opened " All doors unlocked

Insert and remove the key from the ignition key cylinder 3 times.

Close the driver’s door.

Lock and unlock all doors 3 times by the key or remote control.

Open and close the driver’s door.

Lock and unlock the driver’s door lock knob 3 times.

Open the driver’s door.

( = Vehicle initial condition)

Input to the vehicle

Output from the vehicle

Within 20 sec.

2 sec.

The system starts forced door lock once (answer back).

Unlock the driver’s door lock knob.

Close and open the driver’s door 3 to 5

Close and open the driver’s door 2 times

times

Lock and unlock the driver’s door lock

Lock and unlock the driver’s door lock knob.

knob.

* 0 sec.

The system starts forced door lock once (answer back).

PASSIVE MODE OFF

The system starts forced door lock once (answer back).

PASSIVE MODE ON

HINT:

" Initial mode is PASSIVE MODE OFF. " If there is a different signal in the middle of changing, it is invalid.

*: Entry delay time

4 times 5 times3 times

* 14 sec. * 30 sec.

2004 COROLLA (RM1037U)

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73–22

–THEFT DETERRENT & DOOR LOCK TOYOTA VEHICLE INTRUSION PROTECTION

SYSTEM

5. FORCED DOOR LOCK CONTROL

(a) Forced door lock is a control that prevents intrusion into vehicles. When a door is unlocked (when an

alarm starts), instantaneously forced door lock will be executed. (1) Condition to execute forced door lock:

Detecting any or all of the following conditions activates forced door lock.

! Theft deterrent system is in the alarm sounding state of the active mode. ! No key is in the ignition key cylinder. ! Any of the front doors is unlocked. ! Since the previous forced door lock, 0.38 seconds or more have elapsed.

(2) Conditions to stop forced door lock:

Detecting any of the following conditions stops forced door lock.

! All doors are locked. ! The alarm has finished. ! The key is inserted into the key cylinder.

Glass Breakage Sensor ECU

Volume

B59188

6. OPERATE GLASS BREAKAGE SENSOR

(a) If the glass breakage sensor detects the glass is broken

(at 1st time), the sensor will issue an alarm for 20 seconds (pre–alarming). If the glass breakage sensor detects the glass is broken further more (at 2nd time), the sensor will issue an alarm for 60 seconds.

(b) The sensitivity of the glass breakage sensor can be ad-

justed by the volume switch in the glass breakage sensor

ECU. HINT: Because the glass breakage sensor has a high sensitivity, it might issue a wrong alarm if it is adjusted in the volume of high sensitive.

2004 COROLLA (RM1037U)

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Page 51

01–4

–INTRODUCTION IDENTIFICATION INFORMATION

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION AND SERIAL NUMBERS

1. VEHICLE IDENTIFICATION NUMBER

D27356

D27359

(a) The vehicle identification number is stamped on the ve-

hicle identification number plate and certification label, as

shown in the illustration.

A: Vehicle Identification Number Plate

B: Certification Label

2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL

NUMBER

(a) The engine serial number is stamped on the cylinder

block of the engine, and the transaxle serial number is

stamped on the housing, as shown in the illustration.

A: 1ZZ–FE

B: C59

C: A245E

01031–06

2004 COROLLA (RM1037U)

7Author!: Date!:

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02–58

VEHICLE CONTROL SYSTEM

PREPARATION

Recomended Tools

–PREPARATION VEHICLE CONTROL SYSTEM

021CP–01

09082–00040

TOYOTA Electrical Tester IGNITION OR STARTER SWITCH

ASSY

2004 COROLLA (RM1037U)

103Author!: Date!:

Page 53

51–8

–POWER STEERING VANE PUMP ASSY

OVERHAUL

NOTICE:

! When using a vise, do not over tighten. ! When installing, coat the parts indicated by the arrows with power steering fluid

(See page 51–7).

1. REMOVE FRONT WHEEL RH

2. DRAIN POWER STEERING FLUID

3. REMOVE ENGINE UNDER COVER RH

4. REMOVE FAN AND GENERATOR V BELT

5. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1

(a) Remove the clip and disconnect the oil reservoir to pump hose No.1.

6. DISCONNECT PRESSURE FEED TUBE ASSY

SST

(a) Using SST, disconnect the pressure feed tube assy.

SST 09023–38400 (b) Remove the bolt and disconnect the pressure feed tube

clamp.

5107W–01

F42474

7. REMOVE VANE PUMP ASSY

(a) Disconnect the oil pressure switch connector. (b) Remove the 2 bolts, nuts and vane pump assy.

C80321

8. REMOVE VANE PUMP BRACKET REAR

(a) Remove the bolt and vane pump bracket rear.

9. FIX VANE PUMP ASSY

(a) Using SST, hold the vane pump assy in a vise.

SST 09630–00014 (09631–00132)

2004 COROLLA (RM1037U)

SST

F42477

1543Author!: Date!:

Page 54

51–9

–POWER STEERING VAN E PUM P ASS Y

10. REMOVE POWER STEERING SUCTION PORT UNION

(a) Remove the bolt and power steering suction port union. (b) Remove the O–ring from the power steering suction port union.

11. REMOVE FLOW CONTROL VALVE

(a) Remove the pressure port union. (b) Remove the O–ring from the pressure port union. (c) Remove the flow control valve and flow control valve compression spring.

12. REMOVE POWER STEERING OIL PRESSURE SWITCH NOTICE: Be careful so that oil pressure switch is not dropped or strongly damaged, however if it is damaged replace it with a new one.

13. REMOVE VANE PUMP HOUSING REAR

(a) Remove the 4 bolts and vane pump housing rear from the vane pump housing front. (b) Remove the O–ring from the vane pump housing front.

14. REMOVE W/PULLEY SHAFT SUB–ASSY

(a) Using a screwdriver, remove the snap ring from the w/ pulley shaft sub–assy. (b) Remove the w/ pulley shaft sub–assy.

15. REMOVE VANE PUMP ROTOR

(a) Remove the 10 vane plates. (b) Remove the vane pump rotor.

16. REMOVE VANE PUMP CAM RING

C65368

C65369

17. REMOVE VANE PUMP SIDE PLATE FRONT

(a) Remove the side plate from the pump housing front. (b) Remove the O–ring from the side plate front.

2004 COROLLA (RM1037U)

1544Author!: Date!:

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51–10

Vane Pump Shaft

SST

Bushing

Front Housing

–POWER STEERING VAN E PUM P ASS Y

18. REMOVE VANE PUMP HOUSING OIL SEAL

(a) Using SST and a hammer, remove the vane pump hous-

ing oil seal.

SST 09631–10030

NOTICE: Be careful not to damage the pump housing.

F42143

19. INSPECT OIL CLEARANCE

(a) Using a micrometer and a caliper gauge, measure the oil

seal clearance.

Standard clearance:

0.021 – 0.043 mm (0.0008 – 0.0017 in.)

Maximum clearance: 0.07 mm (0.0028 in.)

If it is more than the maximum, replace the vane pump assy.

F09875

Height

Length

Thickness

Feeler Gauge

20. INSPECT VANE PUMP ROTOR AND VANE PLATES

(a) Using a micrometer, measure the height, thickness and

length of the vane plates.

Minimum height: 7.6 mm (0.299 in.)

Minimum thickness: 1.405 mm (0.0553 in.)

Minimum length: 11.993 mm (0.4722 in.)

N00372

(b) Using a feeler gauge, measure the clearance between a

side face of the vane pump rotor groove and vane plate.

Maximum clearance: 0.03 mm (0.0012 in.)

If it is more than the maximum, replace the vane pump assy.

R10282

21. INSPECT FLOW CONTROL VALVE

(a) Coat the flow control valve with power steering fluid and

check that it falls smoothly into the flow control valve hole

by its own weight.

2004 COROLLA (RM1037U)

F41493

1545Author!: Date!:

Page 56

Compressed Air

F41491 F41622

Vernier Calipers

51–11

–POWER STEERING VAN E PUM P ASS Y

(b) Check the flow control valve for leakage. Close one of the

holes and apply compressed air of 392 – 490 kPa (4 – 5

kgf⋅cm

, 57 – 71 psi) into the opposite side hole, and con-

firm that air does not come out from the end holes. If necessary, replace the vane pump assy.

22. INSPECT FLOW CONTROL VALVE COMPRESSION

SPRING

(a) Using vernier calipers, measure the free length of the

spring.

Minimum free length: 36.9 mm (1.453 in.)

If it is not within the specification, replace the vane pump assy.

R08702

23. INSPECT PRESSURE PORT UNION

(a) If the union seat in the pressure port union is remarkably damaged and it may cause fluid leakage,

replace the vane pump assy.

24. INSTALL VANE PUMP HOUSING OIL SEAL

(a) Coat a new vane pump housing oil seal lip with power

SST

steering fluid. (b) Using SST and a press, install a new vane pump housing

oil seal.

SST 09950–60010 (09951–00280), 09950–70010

(09951–07100)

NOTICE:

Oil Seal

F08480

Make sure that the vane pump housing oil seal is installed facing in the correct direction.

25. INSTALL W/PULLEY SHAFT SUB–ASSY

Power Steering Fluid

(a) Coat inside bushing surface of the vane pump housing

front with power steering fluid. (b) Gradually insert the vane pump shaft.

NOTICE: Do not damage the vane pump housing oil seal lip in the vane pump housing front.

2004 COROLLA (RM1037U)

F40339

1546Author!: Date!:

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51–12

–POWER STEERING VAN E PUM P ASS Y

26. INSTALL VANE PUMP SIDE PLATE FRONT

(a) Coat a new O–ring with power steering fluid and install

it to the vane pump housing front.

C65369

(b) Coat a new O–ring with power steering fluid and install it

to the side plate front.

Inscribed Mark

C65368

of the vane pump housing front, and install the vane pump

side plate front.

NOTICE: Make sure that the side plate front is installed facing in the correct direction.

F08482

27. INSTALL VANE PUMP CAM RING

(a) Align the dent of the cam ring with that of the side plate

front, and install the cam ring with the inscribed mark fac-

ing outward.

F08483

Inscribed Mark

2004 COROLLA (RM1037U)

Round End

F08484

28. INSTALL VANE PUMP ROTOR

(a) Install the vane pump rotor with the inscribed mark facing

outward. (b) Coat 10 vane plates with power steering fluid. (c) Install the vane plates with the round end facing outward.

1547Author!: Date!:

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51–13

–POWER STEERING VANE PUMP ASSY

(d) Using a snap ring expander, install a new snap ring to the

w/ pulley shaft sub–assy.

F40343

29. INSTALL VANE PUMP HOUSING REAR

(a) Coat a new O–ring with power steering fluid and install it to the pump housing rear. (b) Align the straight pin of the vane pump housing rear with the dents of the vane pump cam ring, vane

pump side plate front and vane pump housing front, and install the vane pump housing rear with the 4 bolts.

Torque: 22 N⋅m (220 kgf⋅cm, 16 ft⋅lbf)

30. INSPECT PRELOAD

(a) Check that the pump rotates smoothly without abnormal

noise. (b) Temporarily install the service bolt.

Recommended service bolt:

Thread diameter: 10 mm (0.3937 in.)

Thread pitch: 1.25 mm (0.0492 in.)

Bolt length: 50 mm (1.9685 in.)

C53369

Rotating torque:

0.27 N⋅m (2.8 kgf⋅cm, 2.4 ft⋅lbf) or less

31. INSTALL POWER STEERING OIL PRESSURE SWITCH

(a) Coat a new O–ring with power steering fluid and install it to the power steering oil pressure switch. (b) Install the power steering oil pressure switch to the vane pump assy.

Torque: 21 N⋅m (210 kgf⋅cm, 15 ft⋅lbf)

32. INSTALL FLOW CONTROL VALVE

(a) Coat the flow control valve compression spring and flow

control valve with power steering fluid. (b) Install the flow control valve compression spring and flow

control valve. (c) Coat a new O–ring with power steering fluid and install it

to the pressure port union. (d) Install the pressure port union.

F42475

Torque: 69 N⋅m (700 kgf⋅cm, 51 ft⋅lbf)

2004 COROLLA (RM1037U)

1548Author!: Date!:

Page 59

51–14

–POWER STEERING VAN E PUM P ASS Y

33. INSTALL POWER STEERING SUCTION PORT UNION

(a) Coat a new O–ring with power steering fluid, and install it to the power steering suction port union. (b) Install the power steering suction port union with the bolt.

Torque: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf)

34. INSTALL VANE PUMP ASSY

(a) Install the vane pump assy with the 2 bolts and nuts.

Torque: 37 N⋅m (380 kgf⋅cm, 27 ft⋅lbf)

(b) Connect the oil pressure switch connector.

NOTICE: Be careful that the oil does not adhere to the connector.

C80321

35. INSTALL VANE PUMP BRACKET REAR

(a) Install the vane pimp bracket rear with the bolt.

Torque: 37 N⋅m (380 kgf⋅cm, 27 ft⋅lbf)

SST

36. CONNECT PRESSURE FEED TUBE ASSY

(a) Using SST, connect the pressure feed tube assy.

Fulcrum Length

SST 09023–38400

Torque: 41 N⋅m (420 kgf⋅cm, 30 ft⋅lbf)

HINT:

! Use a torque wrench with a fulcrum length of 345 mm

(13.58 in.).

! This torque value is effective when SST is parallel to a

F13579

torque wrench. (b) Connect the pressure feed tube clamp with the bolt.

Torque: 7.8 N⋅m (80 kgf⋅cm, 69 ft⋅lbf)

37. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1

(a) Connect the oil reservoir to pump hose No.1 with the clip.

38. INSTALL FAN AND GENERATOR V BELT

39. INSTALL FRONT WHEEL RH Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)

40. ADD POWER STEERING FLUID

41. BLEED POWER STEERING FLUID(See page 51–3)

42. INSPECT FLUID LEAK

43. INSTALL ENGINE UNDER COVER RH

2004 COROLLA (RM1037U)

1549Author!: Date!:

Page 60

VANE PUMP ASSY

COMPONENTS

51–7

–POWER STEERING VAN E PUM P ASS Y

5107V–01

Pressure Port Union

69 (700, 51)

O–Ring!

Flow Control Valve

Suction Port Union

37 (380, 27)

Vane Pump Shaft with Vane Pump Pulley

12 (120, 9)

O–Ring!

Front Housing

Oil Seal!

Rear Housing

Snap Ring!

Vane Pump Rotor

Spring

22 (220, 16)

Oil Pressure Switch

21 (210, 15)

Vane Pump Bracket Rear

O–Ring!

N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque

Non–reusable part!

Power steering fluid

2004 COROLLA (RM1037U)

Side Plate

O–Ring!

× 10

22 (220, 16)

Vane P l ate

Cam Ring

F42473

1542Author!: Date!:

Page 61

VALVE CLEARANCE

ADJUSTMENT

14–5

–ENGINE MECHANICAL VALVE CLEARANCE

140OE–01

1. REMOVE CYLINDER HEAD COVER NO.2

(a) Remove the 2 nuts, 2 clips and cylinder head cover.

A65077

2. DISCONNECT ENGINE WIRE

(a) Remove the 5 clamps from the 5 clamp brackets.

A64021

A64022

(b) Disconnect the 4 ignition coil connectors.

3. REMOVE IGNITION COIL ASSY

(a) Remove the 4 bolts and 4 ignition coils.

2004 COROLLA (RM1037U)

A64023

1015Author!: Date!:

Page 62

14–6

–ENGINE MECHANICAL VALVE CLEARANCE

4. DISCONNECT VENTILATION HOSE

(a) Disconnect the ventilation hose from the cylinder head

cover.

A65078

5. DISCONNECT VENTILATION HOSE NO.2

(a) Disconnect the ventilation hose from the cylinder head

cover.

A64058

6. REMOVE CYLINDER HEAD COVER SUB–ASSY

(a) Remove the 9 bolts, 2 seal washers, 2 nuts, 3 clamp

A64856

7. REMOVE ENGINE UNDER COVER RH

brackets and cylinder head cover.

2004 COROLLA (RM1037U)

1016Author!: Date!:

Page 63

Mark

Timing Chain Cover Surface

14–7

–ENGINE MECHANICAL VALVE CLEARANCE

8. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Turn the crankshaft pulley, and align its groove with timing

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 marks as above.

Groove

A62185

A01131

A01132

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):

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.

(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.)

Exhaust 0.25 – 0.35 mm (0.0098 – 0.0138 in.)

2004 COROLLA (RM1037U)

1017Author!: Date!:

Page 64

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 INS ULATOR

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

A11858

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.

Paint Mark

2004 COROLLA (RM1037U)

13. ADJUST VALVE CLEARANCE NOTICE: Be sure not to revolve the crankshaft without the chain tensioner.

(a) Set the No. 1 cylinder to the TDC/compression. (b) Place match marks on the timing chain and camshaft tim-

ing sprockets.

A62186

1018Author!: Date!:

Page 65

Tighten

Push

Fix

14–9

–ENGINE MECHANICAL VALVE CLEARANCE

A62178

(d) Fix the camshaft with a spanner and so on, then loosen

the camshaft timing gear set bolt.

NOTICE: Be careful not to damage the valve lifter.

24 5 3 1

A62187

(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

2431

2004 COROLLA (RM1037U)

(g) Loosen the camshaft bearing cap bolts on camshaft in

the orde r as sh own in th e illustra ti o n in seve ra l

passes,and remove the caps.

A62189

1019Author!: Date!:

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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 cover.

A32556

A01082

(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

Valve clearance:

Intake A = B + (C – 0.20 mm (0.0079 in.)

Exhaust A = B + (C – 0.30 mm (0.0118 in.)

HINT:

" Select a new lifter with a thickness as close as possible

to the calculated values.

" 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.).

Timing Mark

2004 COROLLA (RM1037U)

Painted Link

A62195

(m) As shown in the illustration, install the timing chain on the

camshaft timing gear, with the painted links aligned with

the timing marks on the camshaft timing sprocket.

1020Author!: Date!:

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–ENGINE MECHANICAL VALVE CLEARANCE

14–11

4123

Painted Link

Timing Mark

(n) Examine the front marks and numbers and tighten the

bolts in the order shown in the illustration.

Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf)

A62196

(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.

A62197

(p) Tighten the camshaft timing gear set bolt temporarily.

Tighten

3124

Fix

A32124

(q) Examine the front marks and numbers and tighten the

bolts in the order shown in the illustration.

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)

A62198

(s) Fix the camshaft with a spanner and so on, then tighten

the camshaft timing gear set bolt.

Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) NOTICE: Be careful not damage the valve lifter.

A62187

2004 COROLLA (RM1037U)

1021Author!: Date!:

Page 68

14–12

Mark

Timing Chain Cover Surface

–ENGINE MECHANICAL VALVE CLEARANCE

(t) Check the match marks on the timing chain and camshaft

timing sprockets, and then the alignment of the pulley

groove with timing mark of the chain cover as shown in the

illustration.

Raise

Push

Groove

Push

A62185

(u) Install chain tensioner.

(1) Check the O–ring is clean, and set the hook as

shown in the illustration.

Hook

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 hook release the plunger.

Disconnect

Hook

Pin Turn

2004 COROLLA (RM1037U)

A62178

(3) Turn the crankshaft counterclockwise, and discon-

nect the plunger knock pin from the hook.

A62180

1022Author!: Date!:

Page 69

Plunger

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.

Push

Turn

A62181

14. INSTALL V–RIBBED BELT TENSIONER ASSY

(a) Install the V–ribbed belt tensioner with the nut and bolt.

Torque: 29 N⋅m (296 kgf⋅cm, 21 ft⋅lbf) for Nut 69 N⋅m (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)

Seal Packing

A64005

A62182

16. INSTALL CYLINDER HEAD COVER SUB–ASSY

(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:

" Remove any oil from the contact surface. " Install the cylinder head cover within 3 minutes after

applying seal packing.

" Do not put into engine oil 2 hours after installing.

2004 COROLLA (RM1037U)

1023Author!: Date!:

Page 70

14–14

–ENGINE MECHANICAL VALVE CLEARANCE

9 bolts, 2 seal washers and 2 nuts. Uniformly tighten the bolts and nuts, in the several passes.

Torque: A 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf) B 9.0 N⋅m (92 kgf⋅cm, 80 in⋅lbf)

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

2004 COROLLA (RM1037U)

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

1024Author!: Date!:

Page 71

20. CHECK ENGINE OIL LEAK

14–15

–ENGINE MECHANICAL VALVE CLEARANCE

2004 COROLLA (RM1037U)

1025Author!: Date!:

Page 72

05–682

–DIAGNOSTICS POWER DOOR LOCK CONTROL SYSTEM

057TJ–01

KEY CONFINEMENT PREVENTION FUNCTION DOES NOT WORK

PROPERLY (UNLOCK WARNING SWITCH CIRCUIT)

CIRCUIT DESCRIPTION

The unlock warning switch turns on when the key is inserted in the ignition key cylinder and the door courtesy switch turns on when the driver’s door is opened, and the integration relay monitors both switches conditions. According to these switches conditions, the integration relay controls the door locking operation not to lock the doors while both switches are on, in order to prevent the key from being confined.

WIRING DIAGRAM

Instrument Panel J/B

D4 Front Door Courtesy Lamp Switch Assy (Driver’s Side)

U1 Un–lock Warning Switch Assy

W–B

J6 J/C

L–B

Center J/B

4A 4A

R–W

L–B

I11 Integration Relay

DCTY

KSW

2004 COROLLA (RM1037U)

*1: w/ Door Lock Control

B59535

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Page 73

–DIAGNOSTICS POWER DOOR LOCK CONTROL SYSTEM

INSPECTION PROCEDURE

1INSPECT UN–LOCK WARNING SWITCH ASSY

05–683

Un–lock Warning Switch Assy

Free

Push

B51903

2CHECK WIRE HARNESS

(UN–LOCK WARNING SWITCH ⇔ INSTRUMENT PANEL J/B)

Un–lock Warning Switch Assy (Wire Harness Side)

(a) Remove the un–lock warning switch assy. (b) Inspect the un–lock warning switch assy continuity, as

shown in the illustration and table.

Standard:

Terminal No. Condition Specified condition

U1–1 ⇔ U1–2

Free No continuity

Push Continuity

NG REPLACE UN–LOCK WARNING SWITCH ASSY

(a) Disconnect the un–lock warning switch assy and instru-

ment panel J/B connectors.

(b) Check the continuity between the terminals of the un–lock

warning switch assy and instrument panel J/B connectors, as shown in the illustration and table.

Standard (Check for open):

Symbols (Terminal No.)

(Un–lock warning switch ⇔ Instrument panel J/B)

(U1–2) ⇔ KSW (IJ–8)

(U1–1) ⇔ Body ground

Specified condition

Continuity

Instrument Panel J/B (Wire Harness Side)

2004 COROLLA (RM1037U)

B59536

NG REPAIR OR REPLACE WIRE HARNESS AND

CONNECTOR

848Author!: Date!:

Page 74

05–684

–DIAGNOSTICS POWER DOOR LOCK CONTROL SYSTEM

3INSPECT FRONT DOOR COURTESY LAMP SWITCH ASSY (DRIVER’S SIDE)

Front Door Courtesy Lamp Switch Assy (Driver’s Side)

Free

Push

4CHECK WIRE HARNESS

(FRONT DOOR COURTESY LAMP SWITCH ASSY [DRIVER’S SIDE] ⇔ INSTRUMENT PANEL J/B)

Front Door Courtesy Lamp Switch Assy [Driver’s Side] (Wire Harness Side)

B58556

(a) Remove the courtesy lamp switch. (b) Inspect the courtesy lamp switch continuity, as shown in

the illustration and table.

Standard:

Terminal No. Condition Specified condition

D4–1 ⇔ Body ground

Free Continuity

Push No continuity

NG REPLACE FRONT DOOR COURTESY LAMP

SWITCH ASSY

(a) Disconnect the courtesy lamp switch and instrument pan-

el J/B connectors.

(b) Check the continuity between the terminals of the courte-

sy lamp switch and instrument panel J/B connectors, as shown in the illustration and table.

Standard (Check for open):

Symbols (Terminal No.)

(Courtesy lamp switch ⇔ Instrument panel J/B)

(D4–1) ⇔ DCTY (ID–1) Continuity

Specified condition

Instrument Panel J/B (Wire Harness Side)

REPLACE INTEGRATION RELAY

B59537

NG REPAIR OR REPLACE WIRE HARNESS AND

CONNECTOR

2004 COROLLA (RM1037U)

849Author!: Date!:

Page 75

99–4

–MAINTENANCE UNDER HOOD

UNDER HOOD

9900X–13

GENERAL MAINTENANCE

1. GENERAL NOTES

! Maintenance requirements vary depending on the country. ! Check the maintenance schedule in the owner’s manual supplement. ! Following the maintenance schedule is mandatory. ! Determine the appropriate time to service the vehicle using either miles driven or time (month) elapsed,

whichever reaches the specification first.

! Maintain similar intervals between periodic maintenance unless noted. ! Failng to check each vehicle part could lead to poor engine performance and increase exhaust emis-

sions.

2. WINDSHIELD WASHER FLUID

(a) Check that there is sufficient fluid in the tank.

3. ENGINE COOLANT LEVEL

(a) Check that the coolant level is between the ”FULL” and ”LOW” lines on the see–through reservoir.

4. RADIATOR AND HOSES

(a) Check that the front of the radiator is clean and free of leaves, dirt and bugs. (b) Check the hoses for cracks, kinks, rotting loose connections.

5. BATTERY ELECTROLYTE LEVEL

(a) By rocking the vehicle, check that the electrolyte level of all the battery cells is between the upper and

lower lines on the case.

6. BRAKE FLUID LEVEL

(a) Check that the brake fluid levels are near the upper level line on the see–through reservoirs.

7. ENGINE DRIVE BELT

(a) Check the drive belt for fraying, cracks, wear and oiliness.

8. ENGINE OIL LEVEL

(a) Check if the level of engine oil is between ”F” and ”L” on the dipstick with the engine turned off.

9. POWER STEERING FLUID LEVEL

(a) Check the level on the dipstick. (b) The level should be in the ”HOT” or ”COLD” range depending on the fluid temperature.

10. AUTOMATIC TRANSMISSION FLUID LEVEL

(a) Park the vehicle on a level surface. (b) With the engine idling and the parking brake applied, shift the selector into all the positions from ”P”

to ”L”. Then shift to the ”P” position.

the fluid level is in the ”HOT” range.

(d) Perform this check with the fluid at the normal driving temperature:70 to 80°C (158 to 176°F). HINT: After extended driving under harsh conditions (high speeds, hot weather, heavy traffic or pulling a trailer), let the engine cool down for approximately 30 minutes before checking the fluid level.

11. EXHAUST SYSTEM

(a) Check for unusual exhaust sounds or abnormal exhaust fumes. Locate the cause and correct it.

2004 COROLLA (RM1037U)

1892Author!: Date!:

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05–740

–DIAGNOSTICS TOYOTA VEHICLE INTRUSION PROTECTION

SYSTEM

057SA–01

TVIP ECU COMMUNICATION CIRCUIT

CIRCUIT DESCRIPTION

The wireless receiver receives a SET/UNSET signal for the TVIP system and sends the signal to the TVIP ECU via the integration relay.

WIRING DIAGRAM

I11 Integration Relay

TVIP ECU

T3 IRSG

I24326

TVSS

INSPECTION PROCEDURE

1CHECK TVIP ECU

(a) Check that the operation of the TVIP function is normal. HINT: With this inspection, the TVIP ECU CPU can be diagnosed if it works normally or not.

NG CHECK AND REPLACE TVIP ECU

(See page 01–30)

B59563

2004 COROLLA (RM1037U)

905Author!: Date!:

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–DIAGNOSTICS TOYOTA VEHICLE INTRUSION PROTECTION

SYSTEM

2CHECK WIRE HARNESS (TVIP ECU ⇔ INTEGRATION RELAY)

(a) Disconnect the TVIP ECU and integration relay connec-

TVIP ECU (Wire Harness Side)

Integration Relay

I11

(Wire Harness Side)

IRSG (28)

tors.

(b) Check the continuity between the terminal of the TVIP

ECU connector and integration relay connectors, as shown in the illustration and table.

Standard:

Symbols (Terminal No.)

(TVIP ECU ⇔ Integration relay)

IRSG (T3–28) ⇔ TVSS (I11–26) Continuity

05–741

Specified condition

TVSS (26)

B59601

NG REPAIR OR REPLACE WIRE HARNESS AND

CONNECTOR

CHECK AND REPLACE TVIP ECU (See page 01–30)

2004 COROLLA (RM1037U)

906Author!: Date!:

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05–343

–DIAGNOSTICS ABS WITH EBD SYSTEM (April, 2003)

057UQ–03

Ts Terminal Circuit

CIRCUIT DESCRIPTION

The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the DTC check. Connecting terminals Ts and CG of the DLC3 starts the check.

WIRING DIAGRAM

Skid Control ECU

D1 DLC3

with Actuator

W–B

11 IA6

Center J/B

21 4B

W–B

J6 J/C

10 S1

F42891

2004 COROLLA (RM1037U)

508Author!: Date!:

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05–344

–DIAGNOSTICS ABS WITH EBD SYSTEM (April, 2003)

INSPECTION PROCEDURE

1 INSPECT DLC3 TERMINAL VOLTAGE(Ts TERMINAL)

DLC3

(a) Turn the ignition switch to ON. (b) Measure voltage between terminals Ts and CG of DLC3.

OK: Voltage: 10 – 14 V

C52361

OK Go to step 3

2CHECK HARNESS AND CONNECTOR(DLC3 – BODY GROUND)

(a) Check for open and short circuit in harness and connector between terminal CG of the DLC3 and body

ground (See page 01–30).

NG REPAIR OR REPLACE HARNESS OR

CONNECTOR

3CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU – DLC3)

(a) Check for open and short circuit in harness and connector between terminal Ts of the DLC3 and skid

control ECU (See page 01–30).

NG REPAIR OR REPLACE HARNESS OR

CONNECTOR

CHECK AND REPLACE BRAKE ACTUATOR ASSY (See page 05–306)

2004 COROLLA (RM1037U)

509Author!: Date!:

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05–596

–DIAGNOSTICS AUDIO SYSTEM (April, 2003)

HOW TO PROCEED WITH TROUBLESHOOTING

1VEHICLE BROUGHT TO WORKSHOP

2CUSTOMER PROBLEM ANALYSIS (SEE PAGE 05–598)

3CHECK AND CLEAR DTC (SEE PAGE 05–599)

4PROBLEM SYMPTOM CONFIRMATION

SYMPTOM OCCURS (GO TO STEP 6)

055ZY–05

SYMPTOM DOES NOT OCCUR (GO TO STEP 5)

5SYMPTOM SIMULATION (SEE PAGE 01–20)

6DTC CHECK (SEE PAGE 05–599)

MALFUNCTION CODE (GO TO STEP 7)

NORMAL CODE (GO TO STEP 8)

7DTC CHART (SEE PAGE 05–605)

GO TO STEP 9

8PROBLEM SYMPTOMS TABLE (SEE PAGE 05–609)

9CIRCUIT INSPECTION (SEE PAGE 05–610 – 05–637)

2004 COROLLA (RM1037U)

761Author!: Date!:

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10 CONFIRMATION TEST

END

05–597

–DIAGNOSTICS AUDIO SYSTEM (April, 2003)

2004 COROLLA (RM1037U)

762Author!: Date!:

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05–670

–DIAGNOSTICS POWER DOOR LOCK CONTROL SYSTEM

POWER DOOR LOCK CONTROL SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING

1VEHICLE BROUGHT IN

2CUSTOMER PROBLEM ANALYSIS CHECK AND SYMPTOM CHECK

(See page 05–671)

3PROBLEM SYMPTOMS TABLE (See page 05–676)

(a) Without applicable symptoms, proceed to ”A” (b) With applicable symptoms, proceed to ”B”

BGO TO STEP 5

057TD–01

4 PERFORM TROUBLESHOOTING IN THE FOLLOWING METHOD, DEPENDING ON

MALFUNCTION SYMPTOM

(a) Terminals of ECU (See page 05–673) (b) Inspection (See page 73–3) (c) On–vehicle inspection (See page 73–1)

5ADJUSTMENT, REPAIR OR REPLACEMENT

END

2004 COROLLA (RM1037U)

835Author!: Date!:

Page 83

05–294

–DIAGNOSTICS ABS WITH EBD SYSTEM (April, 2003)

ABS WITH EBD SYSTEM (April, 2003)

HOW TO PROCEED WITH TROUBLESHOOTING

1 Vehicle Brought to Workshop

2 Customer Problem Analysis (See page 05–296)

3 Check and Clear DTCs and Freeze Frame Data (See page 05–297)

4 Problem Symptom Confirmation

057U7–04

Symptom does not occur: Go to step 5

Symptom occurs: Go to step 6

5 Symptom Simulation (See page 01–30)

6 DTC Check (See page 05–297)

There is no output: Go to step 7

There is output: Go to step 8

7 Problem Symptoms Table (See page 05–307)

Check for fluid leakage and Go to step 10

8 DTC Chart (See page 05–303)

9 Circuit Inspection (See page 05–308 – 05–343)

HINT: When 2 or more DTC’s are recorded, and the problem is not identified, perform circuit inspection of the other DTC’s.

2004 COROLLA (RM1037U)

459Author!: Date!:

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05–295

–DIAGNOSTICS ABS WITH EBD SYSTEM (April, 2003)

10 Identification of Problem

11 Repair

12 Comfirmation Test

End

HINT: Step 3, 6, 9, 12: Diagnostic steps permitting the use of the hand–held tester. Fail safe function: When a failure occurs in the ABS system, the ABS warning light is lit and the ABS operation is prohibited. In addition to this, when the failure which disables the EBD operation occurs, the brake warning light is lit as well and the EBD operation is prohibited.

2004 COROLLA (RM1037U)

460Author!: Date!:

Page 85

05–638

–DIAGNOSTICS COMBINATION METER

COMBINATION METER

HOW TO PROCEED WITH TROUBLESHOOTING

1 Vehicle Brought to Workshop

2 Customer Problem Analysis (See page 05–639)

3 Problem Symptom Confirmation (See page 05–647)

4 Circuit Inspection (See page 05–648 – 05–668)

057KA–02

5 Repair or Replace

6 Confirmation Test

7 End

2004 COROLLA (RM1037U)

803Author!: Date!:

Page 86

05–346

–DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC

TRANSAXLE [ECT] (April, 2003)

HOW TO PROCEED WITH TROUBLESHOOTING

The hand–held tester can be used at step 3, 4, 6, 9.

1 Vehicle Brought to Workshop

2 Customer Problem Analysis (See page 05–349)

3 Connect the OBD II scan tool or hand–held tester to DLC3

4 Check and Clear DTC and Freeze Frame Data (See page 05–353)

0527H–17

5 Visual Inspection

6 Setting the Check Mode Diagnosis (See page 05–354)

7 Problem Symptom Confirmation (See page 05–356)

Symptom does not occur: Go to step 8

Symptom occur: Go to step 9

8 Symptom Simulation (See page 01–20)

9 DTC Check (See page 05–353)

2004 COROLLA (RM1037U)

DTC is not output: Go to step 10

DTC is output: Go to step 18

511Author!: Date!:

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–DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC

TRANSAXLE [ECT] (April, 2003)

10 Basic Inspection (See page 40–2, 40–6 and 40–44)

NG Go to step 20

11 Mechanical System Test (See page 05–358)

NG Go to step 17

12 Hydraulic Test (See page 05–360)

NG Go to step 17

05–347

13 Manual Shifting Test (See page 05–361)

NG Go to step 15

14 Problem Symptoms Table Chapter 1 (See page 05–374)

NG Go to step 19

15 Problem Symptoms Table Chapter 2 (See page 05–374)

NG Go to step 17

16 Problem Symptoms Table Chapter 3 (See page 05–374)

17 Part Inspection

18 DTC Chart (See page 05–372)

2004 COROLLA (RM1037U)

Go to step 20

512Author!: Date!:

Page 88

05–348

19 Circuit Inspection

20 Identification of Problem

21 Repair

22 Confirmation Test

End

–DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC

TRANSAXLE [ECT] (April, 2003)

2004 COROLLA (RM1037U)

513Author!: Date!:

Page 89

05–700

–DIAGNOSTICS TOYOTA VEHICLE INTRUSION PROTECTION

SYSTEM

TOYOTA VEHICLE INTRUSION PROTECTION SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING

Troubleshoot in accordance with the procedure on the following pages.

1VEHICLE BROUGHT TO WORKSHOP

2CUSTOMER PROBLEM ANALYSIS CHECK AND SYMPTOM CHECK

(See page 05–701)

(a) Without applicable symptoms, proceed to ”A”. (b) With applicable symptoms, proceed to ”B”.

B Go to step 4

3 SYMPTOM SIMULATION

057RT–01

4PROBLEM SYMPTOMS TABLE (See page 05–707)

(a) Without applicable symptoms, proceed to ”A”. (b) With applicable symptoms, proceed to ”B”.

B Go to step 5

5CIRCUIT INSPECTION AND PART INSPECTION (See page 05–707)

6 PERFORM TROUBLESHOOTING IN THE FOLLOWING METHOD, DEPENDING ON

MALFUNCTION SYMPTOM

(a) Terminals of ECU (Seepage 05–703) (b) On–vehicle inspection (Seepage 73–14)

7ADJUSTMENT, REPAIR OR REPLACEMENT

8 CONFIRMATION TEST

END

2004 COROLLA (RM1037U)

865Author!: Date!:

Page 90

05–685

–DIAGNOSTICS WIRELESS DOOR LOCK CONTROL SYSTEM

WIRELESS DOOR LOCK CONTROL SYSTEM

05DUB–01

HOW TO PROCEED WITH TROUBLESHOOTING

HINT:

! Troubleshooting of the wireless door lock control system is based on the premise that the power door

lock system is operating normally. Therefore, before troubleshooting the wireless door lock control system, first make certain that the the power door lock system is operating normally.

! Use this procedure to troubleshoot the wireless door lock control system.

1VEHICLE BROUGHT TO WORKSHOP

2CUSTOMER PROBLEM ANALYSIS CHECK AND SYMPTOM CHECK

(See page 05–686)

3PROBLEM SYMPTOMS TABLE (See page 05–691)

(a) If the fault is not listed on the problem symptoms table, proceed to A. (b) If the fault is listed on the problem symptoms table, proceed to B.

B Go to step 5

4OVERALL ANALYSIS AND TROUBLESHOOTING

(a) Terminals of ECU (See page 05–688) (b) On–vehicle inspection (See page 73–8)

5ADJUST, REPAIR OR REPLACE

6 CONFIRMATION TEST

END

2004 COROLLA (RM1037U)

850Author!: Date!:

Page 91

–DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM (April, 2003)

SUPPLEMENTAL RESTRAINT SYSTEM (Apr., 2003)

HOW TO PROCEED WITH TROUBLESHOOTING

The hand–held tester can be used at step 4, 6, 8 and 9.

1VEHICLE BROUGHT TO WORKSHOP

2CUSTOMER PROBLEM ANALYSIS (See page 05–423)

3 WARNING LIGHT CHECK (See page 05–424)

4 THE DTCs CHECK (Present and Past DTCs) (See page 05–424)

05–421

05256–15

DTCs IS OUTPUT (INCLUDING NORMAL SYSTEM CODE): Go to step 5

DTCs IS NOT OUTPUT: PROBLEM SYMPTOMS TABLE (See page 05–436)

5 THE DTCs CHART (See page 05–430)

6 CIRCUIT INSPECTION (See page 05–437 to 05–579)

TROUBLE CODE IS OUTPUT: Go to step 7

NORMAL SYSTEM CODE IS OUTPUT: Go to step 11

7 REPAIR

8CLEAR THE DTCs (Present and Past DTCs) (See page 05–424)

2004 COROLLA (RM1037U)

586Author!: Date!:

Page 92

05–422

–DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM (April, 2003)

9 THE DTCs CHECK (Present and Past DTCs) (See page 05–424)

DTCs IS NOT OUTPUT: Go to step 10

DTCs IS OUTPUT: Go to step 5

10 SYMPTOM SIMULATION (See page 01–20)

WARNING LIGHT REMAINS OFF: Go to step 11

WARNING LIGHT IS ON: Go to step 5

11 CONFIRMATION TEST

END

2004 COROLLA (RM1037U)

587Author!: Date!:

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05–742

–DIAGNOSTICS CRUISE CONTROL SYSTEM (April, 2003)

CRUISE CONTROL SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING

1VEHICLE BROUGHT TO WORKSHOP

2CUSTOMER PROBLEM ANALYSIS (See page 05–744)

3 CHECK AND CLEAR DTC (See page 05–745)

4PROBLEM SYMPTOM CONFIRMATION

0526X–05

SYMPTOM DOES NOT OCCUR (GO TO STEP 5)

SYMPTOM OCCUR (GO TO STEP 6)

5 SYMPTOM SIMULATION (See page 01–20)

6 DTC CHECK (See page 05–745)

MALFUNCTION CODE (GO TO STEP 7)

NORMAL CODE (GO TO STEP 8)

7 DTC CHART (See page 05–750)

GO TO STEP 9

8PROBLEM SYMPTOMS TABLE (See page 05–754)

2004 COROLLA (RM1037U)

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–DIAGNOSTICS CRUISE CONTROL SYSTEM (April, 2003)

9CIRCUIT INSPECTION (See page 05–755 – 05–788)

10 IDENTIFICATION OF PROBLEM

11 PARTS INSPECTION

12 REPAIR

13 CONFIRMATION TEST

05–743

END

2004 COROLLA (RM1037U)

908Author!: Date!:

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73–11

–THEFT DETERRENT & DOOR LOCK DOOR CONTROL TRANSMITTER

DOOR CONTROL TRANSMITTER

730B3–03

REGISTRATION

1. REGISTRATION OF RECOGNITION CODE

HINT:

! The add mode is used to retain the already registered codes while registering a new recognition code.

This mode is used when adding a transmitter. If the number of the registered codes exceeds 4, the previously registered code will be correspondingly erased in order, starting from the first registered code.

! The rewrite mode is used to erase all the previously registered codes and register only new recognition

codes. This mode is used when exchanging the transmitter or the door control receiver for new one.

! The prohibition mode is used to erase all the registered codes and cancel the wireless door lock func-

tion. Use this mode when the transmitter is lost.

! The confirmation mode is to confirm how many recognition codes have already been registered before

an additional registration of a recognition code.

! All the following registration procedures must be performed in order continuously.

(a) The vehicle should be in the following conditions.

(1) The key is not inserted in the ignition key cylinder. (2) Driver’s door is OPENED. (The other doors are CLOSED) (3) Driver’s door is UNLOCKED.

(b) Perform the following operations to select the desired mode.

(1) Insert and remove the key from the ignition switch twice within 5 seconds. (2) After the above operations, close and open the driver door twice within 40 seconds. Then insert

the key into the ignition key cylinder and remove it.

(3) After the above operations, close and open the driver door twice within 40 seconds. Then insert

the key into the ignition key cylinder and close the door.

(4) Turn the ignition switch from LOCK to ON and back to LOCK at approximately 1 second interval

1 to 5 times to select a mode (see the table below). Then remove the key from the ignition key cylinder.

Number of ON–LOCK operation of ignition switch:

Add Mode

ON–LOCK operation: 1 time

LOCK

Rewrite Mode

ON–LOCK operation: 2 times

T1 T1

LOCK

T1: Approx. 1 sec.

2004 COROLLA (RM1037U)

Confirmation Mode

ON–LOCK operation: 3 times

LOCK

Prohibition Mode

ON–LOCK operation: 5 times

LOCK

T1 T1

B58899

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73–12

–THEFT DETERRENT & DOOR LOCK DOOR CONTROL TRANSMITTER

NOTICE: If the number of the ON–LOCK operation of the ignition switch is 0, 4 or 6 or more, there will be no response (power door lock and unlock operation) to inform which mode has been selected.

(5) After selecting a mode, the integration relay automatically performs the power door

LOCK–UNLOCK operation within 3 seconds to inform the selected mode (see the table below).

HINT:

! In the confirmation mode, when the operation is performed twice, it directs that 2 types of recognition

codes have been registered.

! In the confirmation mode, If the number of the registration code is 0, the LOCK–UNLOCK operation

is automatically performed 5 times.

! If the prohibition mode or confirmation mode is selected, registration procedure is completed.

Response of selected mode (Power door lock operation):

Confirmation ModeAdd Mode

LOCK

UNLOCK

LOCK

UNLOCK

T1: Approx. 1 sec. T2: Approx. 2 sec.

1st time

T2 T2

LOCK

UNLOCK

Prohibition ModeRewrite Mode

T1 T1 T1 T1

LOCK

UNLOCK

2nd time

(1) Within 40 seconds after the add mode or the rewrite mode has been selected, press the LOCK

and UNLOCK switches on the transmitter switch simultaneously for 1.0 – 1.5 seconds. Within 3 seconds after the previous operation, press either one of the switches for more than 1.0 seconds.

(2) Within 3 seconds after the transmitter switch has been turned OFF, the LOCK–UNLOCK opera-

tion will be automatically performed once if the registration of the recognition code of the transmitter is completed correctly.

In case the LOCK–UNLOCK operation is performed twice, the registra-

tion of recognition code has failed. Perform the registration procedure from the beginning once again.

B50827

2004 COROLLA (RM1037U)

1804Author!: Date!:

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–THEFT DETERRENT & DOOR LOCK DOOR CONTROL TRANSMITTER

Response for registration completion:

LOCK–UNLOCK Occurs Once LOCK–UNLOCK Occurs Twice

Registration of recognition code has

Registration of recognition code has failed.

been completed.

T1 T1 T1

LOCKLOCK

UNLOCK UNLOCK

73–13

T1: Approx. 1 sec.

(3) If the multiple transmitter to be registered, repeat step (c) within 40 seconds after the previous

registration.

HINT:

! 4 types of recognition codes can be registered at one time. ! If even one of the following conditions is satisfied, the registration mode will finish.

! 40 seconds have elapsed while an input of each mode is ready. ! Any of the doors is opened ! The key plate is inserted in the ignition key cylinder. ! 4 types of recognition codes are registered at once.

B58900

2004 COROLLA (RM1037U)

1805Author!: Date!:

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73–10

–THEFT DETERRENT & DOOR LOCK TRANSMITTER BATTERY

TRANSMITTER BATTERY

730B2–01

REPLACEMENT

1. REPLACE TRANSMITTER BATTERY NOTICE: Special caution should be taken for handling each component as they are precision electronic components.

(a) Using a screwdriver, pry out the transmitter case.

NOTICE: Do not forcibly pry out the case.

HINT: Tape the screwdriver tip before use.

Tape

B59380

B59371

(b) Remove the battery (lithium battery).

NOTICE:

! Do not push the terminals with your finger. ! Prying up the battery (lithium battery) to forcibly re-

move it will cause deformation of the terminals.

! Do not touch the battery with wet hands. Water may

cause unexpected rust.

! Do not touch or move any components inside the

transmitter as it may interfere with proper operation.

2. INSTALL TRANSMITTER BATTERY

(a) Install a new battery (lithium battery) with the positive (+)

side up, as shown in the illustration.

NOTICE:

! Be sure that the positive side and the negative side of

the transmitter battery are matched–up correctly.

! Be careful not to bend the electrode of the transmitter

battery insertion.

! Be careful that dust or oil does not adhere to the trans-

mitter case.

(b) Install the case securely.

2004 COROLLA (RM1037U)

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Page 99

–DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC

TRANSAXLE [ECT] (April, 2003)

05–379

05DU3–01

DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT

MALFUNCTION (PRNDL INPUT)

DTC P0850 PARK/NEUTRAL SWITCH INPUT CIRCUIT

CIRCUIT DESCRIPTION

The park/neutral position switch detects the shift lever position and sends signals to the ECM.

DTC No. DTC Detecting Condition Trouble Area

P0705

P0850

MONITOR DESCRIPTION

The park/neutral position switch detects the gearshift position and sends a signal to the ECM. For security, the park/neutral position switch detects the gearshift position so that engine can be started only when the vehicle is in P or N shift position. When the park/neutral position switch sends more than one signal at a time from switch positions P, R, N, 2, or L the ECM interprets this as a fault in the switch. The ECM will turn on the MIL.

2 or more switches are ON simultaneously for P, R, N, 2 and L

positions (2–trip detection logic)

Park/neutral position switch remains ON (P, N position) during

driving under conditions (a) and (b) for 30 sec. (2–trip detection

logic)

(a) Vehicle speed: 70 km/h (44 mph) or more (b) Engine speed: 1,500 – 2,500 rpm

! Open or short in park/neutral position switch circuit

! Park/neutral position switch

! ECM

MONITOR STRATEGY

P0705

Related DTCs P0705

Required sensors/Components Park/neutral position switch

Frequency of operation Continuous

Duration 0.5 sec.

MIL operation 2 driving cycles

Sequence of operation None

P0850

Related DTCs P0850 Park/neutral position switch/Verify switch cycling

Required sensors/Components Park/neutral position switch

Frequency of operation Continuous

Duration 30 sec.

MIL operation 2 driving cycles

Sequence of operation None

Shift lever position select switch/Verify switch input

2004 COROLLA (RM1037U)

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–DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC

TRANSAXLE [ECT] (April, 2003)

TYPICAL ENABLING CONDITION

P0705

Item

The monitor will run whenever the following DTCs are not present.

The typical enabling condition is not available.

Minimum Maximum

Specification

See page 05–369

–

P0805

Item

The monitor will run whenever the following DTCs are not present.

Vehicle speed 70 km/h (43 mph) or more –

Engine speed 1,500 rpm or more 2,700 rpm or less

Intake air amount per revolution 0.43 g/rev. or more –

Minimum Maximum

Specification

See page 05–369

TYPICAL MALFUNCTION THRESHOLDS

P0705

Detection criteria Threshold

Number of the following signal input at the same time. 2 or more

Park/neutral position switch ON

L shift position switch ON

2 shift position switch ON

R shift position switch ON

P0850

Detection criteria Threshold

PNP signal ON

COMPONENT OPERATING RANGE

Parameter Standard value

Park/neutral position switch The park/neutral position switch sends only one signal to the ECM.

2004 COROLLA (RM1037U)

545Author!: Date!:

Toyota Corolla 2004 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual