Toyota Corolla 2004 User Manual

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.

2004 COROLLA (RM1037U)

462Author!: Date!:

05–298

–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)

2004 COROLLA (RM1037U)

463Author!: Date!:

–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”.

2004 COROLLA (RM1037U)

464Author!: Date!:

05–300

–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.

2004 COROLLA (RM1037U)

465Author!: Date!:

05–301

–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.

2004 COROLLA (RM1037U)

466Author!: Date!:

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.

2004 COROLLA (RM1037U)

467Author!: Date!:

–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.

2004 COROLLA (RM1037U)

I32452

1611Author!: Date!:

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

1612Author!: Date!:

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)

2004 COROLLA (RM1037U)

I31967

1613Author!: Date!:

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)

2004 COROLLA (RM1037U)

1614Author!: Date!:

55–39

–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.

2004 COROLLA (RM1037U)

1609Author!: Date!:

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

1610Author!: Date!:

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.

2004 COROLLA (RM1037U)

1799Author!: Date!:

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.

2004 COROLLA (RM1037U)

1800Author!: Date!:

–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.

2004 COROLLA (RM1037U)

1801Author!: Date!:

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.

2004 COROLLA (RM1037U)

1710Author!: Date!:

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

2004 COROLLA (RM1037U)

1706Author!: Date!:

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.

2004 COROLLA (RM1037U)

1707Author!: Date!:

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!:

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!:

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!:

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!:

–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!:

–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!:

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!:

–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!:

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!:

–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!:

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!:

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!:

+ 425 hidden pages

Toyota Corolla 2004 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual