Toyota 2001-2004 Corolla User manual

Toyota Corolla
Manual de taller
2001-2004

COMPONENTES
DEL ARBOL DE LEVAS

140OI–01
A64044
Engine Under Cover RH
Clip
Fan and Generator V Belt
Cylinder Head Cover No. 2
Clip
Engine Mounting Insulator RH
N·m (kgf·cm, ft·lbf) : Specified torque
52 (530, 38)
52 (530, 38)
7.0 (71, 62 in.⋅lbf)
–ENGINE MECHANICAL CAMSHAFT
14–93
1103
2004 COROLLA (RM1037U)
CAMSHAFT
COMPONENTS

A64043
Ventilation Hose No. 2
Clamp Bracket
Ventilation Hose
Ignition Coil Assy
Engine Wire
Clamp Bracket
Clamp Bracket
Gasket
Cylinder Head Cover
Sub–assy
Seal Washer
N·m (kgf·cm, ft·lbf) : Specified torque
9.0 (92, 80 in.⋅lbf)
9.0 (92, 80 in.⋅lbf)
9.0 (92, 80 in.⋅lbf)
9.0 (92, 80 in.⋅lbf)
11 (112, 8)
11 (112, 8)
11 (112, 8)
11 (112, 8)
14–94
–ENGINE MECHANICAL CAMSHAFT
2004 COROLLA (RM1037U)

A64006
V–ribbed Belt
Tensioner Assy
Camshaft Bearing Cap No. 1
Camshaft Timing Gear
or Sprocket
Camshaft Timing Gear Assy
Chain Tensioner
Assy No. 1
Camshaft
Camshaft No. 2
Camshaft Bearing Cap No. 3
69 (704, 51)
29 (296, 21)
9.0 (92, 80 in.⋅lbf)
23 (235, 17)
54 (551, 40)
54 (551, 40)
13 (133, 10)
N·m (kgf·cm, ft·lbf) : Specified torque
Timing Chain Sub–assy
–ENGINE MECHANICAL CAMSHAFT
14–95
2004 COROLLA (RM1037U)

140OJ–01
A65077
A60622
A01045
A64005
14–96
–ENGINE MECHANICAL CAMSHAFT
2004 COROLLA (RM1037U)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER RH
2. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 screw, 3 clips and engine under cover.
3. 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.
4. REMOVE ENGINE MOUNTING INSULATOR
SUB–ASSY RH
(a) Remove the PS oil pump reservoir and put it aside.
(b) Place a wooden block between the jack and engine, and
set the jack, then remove the 4 bolts, the 2 nuts and en-
gine mounting insulator RH.
REEMPLAZO
1. QUITAR EL MOTOR BAJO CUBIERTA RH

A64021
A64022
A64023
A65078
A64058
–ENGINE MECHANICAL CAMSHAFT
14–97
1107
2004 COROLLA (RM1037U)
5. DISCONNECT ENGINE WIRE
(a) Remove the 5 clamps from the 5 clamp brackets.
(b) Disconnect the 4 ignition coil connectors.
(c) Remove the bolt and nut installing the engine wire.
6. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils.
7. DISCONNECT VENTILATION HOSE
(a) Disconnect the ventilation hose from the cylinder head
cover.
8. DISCONNECT VENTILATION HOSE NO.2
(a) Disconnect the ventilation hose from the cylinder head
cover.

A64856
A62185
Mark Mark
Mark
Timing Chain
Cover Surface
Groove
A11858
A62186
Paint Mark
14–98
–ENGINE MECHANICAL CAMSHAFT
2004 COROLLA (RM1037U)
9. REMOVE CYLINDER HEAD COVER SUB–ASSY
(a) Remove the 9 bolts, 2 seal washers, 2 nuts, 3 clamp
brackets and cylinder head cover.
10. 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.
11. 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.
12. REMOVE CAMSHAFT
NOTICE:
Be sure not to revolve the crankshaft without the chain ten-
sioner.
(a) Set the No. 1 cylinder to the TDC/compression.
(b) Place match marks on the timing chain and camshaft tim-
ing sprockets.

A62178
Push
A62187
Fix
Tighten
A62188
24 5 3 1
A32124
A62189
2 4 31
–ENGINE MECHANICAL CAMSHAFT
14–99
2004 COROLLA (RM1037U)
(c) Remove the 2 nuts and chain tensioner.
(d) Fix the camshaft with a wrench and so on, then loosen
the camshaft timing gear set bolt.
NOTICE:
Be careful not to damage the valve lifter.
(e) Loosen the camshaft bearing cap bolts on No. 2 camshaft
in the order as shown in the illustration in several
passes,and remove the caps.
(f) Remove the camshaft timing gear as shown in the illustra-
tion.
(g) Loosen the camshaft bearing cap bolts on camshaft in the
order as shown in the illustration in several passes,and
remove the caps.

A32125
A32556
A62190
Advance
Side Path
Retard Side
Path
Open
Close
RubberVinyl Tape
Open
Close
A62191
Advanced
Side Path
Retard
Side Path
14–100
–ENGINE MECHANICAL CAMSHAFT
2004 COROLLA (RM1037U)
(h) Remove the camshaft with holding the timing chain.
(i) Tie the timing chain with a string as shown in the illustra-
tion.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
13. INSPECT CAMSHAFT TIMING GEAR ASSY
(a) Check the lock of camshaft timing gear.
(1) Grip the camshaft with a vice, and confirm the cam-
shaft timing gear is locked.
NOTICE:
Be careful not to damage the camshaft.
(b) Release lock pin.
(1) Cover 4 oil paths of cam journal with vinyl tape as
shown in the illustration.
HINT:
Two advance side paths are provided in the groove of the cam-
shaft. Plug one of the path with a rubber piece.
(2) Break through the tapes of the advance side path
and the retard side path on the opposite side of the
groove.
(3) Put air pressure into two broken paths (the advance
side path and the retard side path) with about 150
kPa {1.5 kgf⋅cm}.
CAUTION:
Cover the pathes with shop rag to avoid oil splashing.

A62192
Hold Pressure
Decompress
Advanced
Side Path
Retard
Side Path
A62190
Advance
Side Path
Retard Side
Path
Open
Close
RubberVinyl Tape
Open
Close
–ENGINE MECHANICAL CAMSHAFT
14–101
2004 COROLLA (RM1037U)
(4) Confirm if the camshaft timing gear assembly re-
volves in the timing advance direction when weak-
ening the air pressure of the timing retard path.
HINT:
The lock pin is released, and camshaft timing gear, revolves in
the advance direction.
(5) When the camshaft timing gear comes to the most
advanced position, take out the air pressure of the
timing retard side path, and then, take out that of
timing advance side path.
CAUTION:
Camshaft timing assembly gear occasionally shifts to the
retard side abruptly, if the air compression of the advanced
side path is released before retard side path. It often
causes the breakage of the lock pin.
(c) Check smooth revolution
(1) Revolve the camshaft timing gear assembly within
the movable range except for the most retarded
position several times, and check the smooth revo-
lution.
CAUTION:
Be sure to perform this check by hand, instead of air pres-
sure.
(d) Check the lock in the most retarded position.
(1) Confirm that the camshaft timing gear assembly is
locked at the most retarded position.
14. REMOVE CAMSHAFT TIMING GEAR ASSY
(a) Grip the camshaft with a vice, and confirm that it the gear
locked.
CAUTION:
Be careful not to damage the camshaft.
(b) Cover 4 oil paths of cam journal with vinyl tape as shown
in the illustration.
HINT:
Two advance side paths are provided in the groove of the cam-
shaft. Plug one of the path with a rubber piece.
(c) Break through the tapes of the advance side path and the
retard side path on the opposite side of the groove.

A62191
Advanced
Side Path
Retard
Side Path
A62192
Hold Pressure
Decompress
Advanced
Side Path
Retard
Side Path
A62193
Straight Pin
Fringe Bolt
A62194
Straight Pin
Key Groove
14–102
–ENGINE MECHANICAL CAMSHAFT
2004 COROLLA (RM1037U)
(d) Put air pressure into two broken paths (the advance side
path and the retard side path) with about 150 kPa {1.5
kgf⋅cm}.
CAUTION:
Cover the pathes with shop rag to avoid oil splashing.
(e) Confirm if the camshaft timing gear assembly revolves in
the timing advance direction when weakening the air
pressure of the timing retard path.
HINT:
The lock pin is released, and camshaft timing gear revolves in
the advance direction.
(f) When the camshaft timing gear comes to the most ad-
vanced position, take out the air pressure of the timing re-
tard side path, and then, takeout that of timing advance
side path.
CAUTION:
Camshaft timing gear assembly occasionally shifts to the
retard side abruptly, if the air compression of the advanced
side path is released before retard side paths. It often
causes the breakage of the lock pin.
(g) Remove the fringe bolt of camshaft timing gear assembly.
NOTICE:
Be sure not to remove the other 4 bolts.
In case of reusing the camshaft timing gear, release
the strait pin locking first, and then install the gear.
15. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear assembly and the camshaft
together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc-
tion (as shown in the illustration) with pushing it lightly
against the camshaft. Push further at the position where
the pin gets into the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right angle).
(c) Check that there is no clearance between the gear’s
fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 N⋅m (551 kgf⋅cm 40 ft⋅lbf)

A62195
Painted Link
Timing Mark
A62196
4 123
A62197
Painted Link
Timing Mark
A32124
–ENGINE MECHANICAL CAMSHAFT
14–103
2004 COROLLA (RM1037U)
(e) Check that the camshaft timing gear assembly can move
to the retard angle side (the right angle), and is locked at
the most retarded position.
16. INSTALL CAMSHAFT
(a) 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 gear.
(b) 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)
(c) 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 gear.
(d) Tighten the camshaft timing gear set bolt temporarily.

A62198
3124
5
6
7
A62187
Fix
Tighten
A62185
Mark Mark
Mark
Timing Chain
Cover Surface
Groove
A62177
Raise
Push
Hook
Pin
14–104
–ENGINE MECHANICAL CAMSHAFT
2004 COROLLA (RM1037U)
(e) 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)
(f) Install the bearing cap No. 1.
Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf)
(g) Fix the camshaft with a wrench 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.
(h) 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.
(i) Install chain tensioner.
(1) Check the O–ring is clean, and set the hook as
shown in the illustration.

A62178
Push
A62180
Disconnect
Hook
Pin Turn
A62181
Plunger
Turn
Push
A11858
–ENGINE MECHANICAL CAMSHAFT
14–105
2004 COROLLA (RM1037U)
(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.
(3) Turn the crankshaft counter clockwise, and discon-
nect the plunger knock pin from the hook.
(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.
17. ADJUST VALVE CLEARANCE (See page 14–5)
18. INSTALL V–RIBBED BELT TENSIONER ASSY
(a) Install the V–ribbed belt tensioner with the nut and bolt.
Torque:
Nut 29 N⋅m (296 kgf⋅cm, 21 ft⋅lbf)
Bolt 69 N⋅m (704 kgf⋅cm, 51 ft⋅lbf)

A62182
Seal Packing
A65687
AA
A
A
A
A
A
A
BB
A
A64023
A64022
14–106
–ENGINE MECHANICAL CAMSHAFT
2004 COROLLA (RM1037U)
19. 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.
(c) Install the cylinder head cover and 3 cable brackets with
the 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)
20. 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)
21. INSTALL ENGINE WIRE
(a) Install the engine wire with the bolt and nut.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)

A64005
A65077
–ENGINE MECHANICAL CAMSHAFT
14–107
1117
2004 COROLLA (RM1037U)
22. INSTALL ENGINE MOUNTING INSULATOR
SUB–ASSY RH
(a) Install engine mounting insulator with the 4 bolts and 2
nuts.
Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf)
23. 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)
24. CHECK ENGINE OIL LEAK

140OG–01
A64042
Engine Under Cover RH
Fan and Generator V Belt
Vane Pump Assy
Generator Assy
Terminal Cap
No. 1
Cylinder Head Cover No. 2
Clip
Engine Mounting Insulator RH
N·m (kgf·cm, ft·lbf) : Specified torque
Clip
54 (551, 40)
25 (255, 18)
37 (377, 27)
7.0 (71, 62 in.⋅lbf)
52 (530, 38)
52 (530, 38)
9.8 (100, 7)
–ENGINE MECHANICAL CHAIN SUB–ASSY
14–79
2004 COROLLA (RM1037U)
CHAIN SUB–ASSY
COMPONENTS

A64043
Ventilation Hose No. 2
Clamp Bracket
Ventilation Hose
Ignition Coil Assy
Engine Wire
Clamp Bracket
Clamp Bracket
Gasket
Cylinder Head Cover
Sub–assy
Seal Washer
N·m (kgf·cm, ft·lbf) : Specified torque
9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf)
9.0 (92, 80 in.⋅lbf)
9.0 (92, 80 in.⋅lbf)
11 (112, 8)
11 (112, 8)
11 (112, 8)
11 (112, 8)
14–80
–ENGINE MECHANICAL CHAIN SUB–ASSY
1090
2004 COROLLA (RM1037U)

A60625
Crankshaft Pulley
V–ribbed Belt
Tensioner Assy
Water Pump Assy
Transverse Engine
Engine Mounting Bracket
Crank Position Sensor
Chain Tensioner Assy No. 1
Timing Chain or
Belt Cover Sub–assy
Oil Seal
Crankshaft Position Sensor
Plate No. 1
Chain Sub–assy
Chain Tensioner Slipper
Crankshaft timing Sprocket
O–ring
Non–reusable part
N·m (kgf·cm, ft·lbf) : Specified torque
47 (479, 35)
29 (296, 21)
69 (704, 51)
138 (1,047, 102)
13 (133, 10)
9.0 (92, 80 in.⋅lbf)
9.0 (92, 80 in.⋅lbf)
19 (194, 14)
9.0 (92, 80 in.⋅lbf1) (L=20)
11 (112, 8) (L=35)
13 (133, 10) (M6)
19 (194, 14) (M8)
9.5 (97, 84 in.⋅lbf)
–ENGINE MECHANICAL CHAIN SUB–ASSY
14–81
2004 COROLLA (RM1037U)