Toyota Corolla 2002 Operating instructions

2004 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Aug. 2, 2004 01--040802--00
FOREWORD
This supplement has been prepared to provide information covering general service repairs for COROLLA
which underwent changes in August, 2004.
Applicable models: NDE 120 series
For the service specifications and repair procedures of the above model other than those listed in the supple-
ment, refer to the following manuals.
Manual Name Pub. No.
SCOROLLA Repair Manual RM925E
SCOROLLA Repair Manual Supplement (Jan., 2002) RM939E
SCOROLLA Repair Manual Supplement (Jan., 2003) RM1028E
SCOROLLA Repair Manual Supplement (May, 2004) RM1106E
S1ND--TV Engine Repair Manual RM1118E
SC53, C53A Manual Transaxle Repair Manual RM1117E
SCOROLLA Electrical Wiring Diagram Supplement (Aug., 2004) EWD626E
SCOROLLA New Car Featurer Supplement (May, 2004) NCF266E
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
TOYOTA MOTOR CORPORATION
CAUTION
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that non--specialized or uncertified technicians perform repair or service only using this manu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer’s vehicle.
In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow
the instruction shown below.
SMust read this manual thoroughly. It is especially important to have a good understanding of
all the contents written in the PRECAUTION of ”INTRODUCTION” section.
SThe service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools spe-
cified and recommended. If using non--specified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customer’s vehicle before starting the operation.
SIf part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
SIt is important to note that this manual contains various ”Cautions” and ”Notices” that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.
BACK TO SUB INDEX TO MODEL INDEX
TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

INTRODUCTION
PREPARATION
SERVICE SPECIFICATIONS
DIAGNOSTICS
ENGINE CONTROL SYSTEM
FUEL
EMISSION CONTROL
INTAKE
ENGINE MECHANICAL
EXHAUST
COOLING
LUBRICATION
STARTING & CHARGING
DRIVE SHAFT / PROPELLER SHAFT
BRAKE
MANUAL TRANSMISSION/TRANSAXLE
CLUTCH
HEATER & AIR CONDITIONER
INSTRUMENT PANEL/METER
ALPHABETICAL INDEX
1
2
3
5
10
11
12
13
14
15
16
17
19
30
32
41
42
55
71
MAIN INDEX
BACK TO FOREWORD &SUB INDEX TO MODEL INDEX
TOYOTA COROLLA REPAIR MANUAL SUPP 1129E
REPAIR MANUAL SUPPLEMENT 1129E
TOYOTA COROLLA

INTRODUCTION
HOW TO USE THIS MANUAL 01--1.............
GENERAL INFORMATION 01--1/2..................
IDENTIFICATION INFORMATION 01--3..........
VEHICLE IDENTIFICATION
AND SERIAL NUMBERS 01--3..................
REPAIR INSTRUCTION 01--4..................
PRECAUTION 01--4/18.............................
VEHICLE LIFT
AND SUPPORTLOCATIONS 01--19/20..............
HOW TO TROUBLESHOOT
ECU CONTROLLED SYSTEMS 01--21.........
GENERAL INFORMATION 01--21..................
HOW TO PROCEED WITH
TROUBLESHOOTING 01--22/31....................
ELECTRONIC CIRCUIT
INSPECTION PROCEDURE 01--32/36...............
TERMS 01--37.................................
ABBREVIATIONS USED IN MANUAL 01--37/41.........
GLOSSARYOFSAE AND TOYOTATERMS 01--42/44..
BACK TO MAIN INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

010XJ--02
N17080
Filler Cap
Float
Reservoir Tank
zGrommet
Clip
Slotted Spring Pin
: Specified torque
zNon--reusable part
Cylinder
Piston
Push Rod
Washer
Snap Ring
Boot
zGasket
Lock Nut
Clevis Pin
Clevis
N∙m(kgf∙cm, ft∙lbf)
12 (120, 9)
15 (155, 11)
--INTRODUCTION HOW TO USE THIS MANUAL
01--1
COROLLA Supplement (RM1129E)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is written in accordance with SAE J2008.
(1) Diagnosis
(2) Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting
(3) Final Inspection
(b) This manual explains (1) (see ”Diagnostics” section) and (2). (3) is omitted.
(c) The following procedures are omitted from this manual. However, these procedures must be per-
formed.
(1) Using a jack or lift to perform operations
(2) Cleaning a removed part
(3) Performing a visual check
2. INDEX
(a) An alphabetical INDEX section is provided at the end of the manual as a reference to help you find
the item to be repaired.
3. PREPARATION
(a) Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending
on the repair procedure. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the ”Preparation” section of this manual.
4. REPAIR PROCEDURES
(a) A component illustration is placed under the title where necessary.
(b) Non--reusable parts, grease application areas, precoated parts and torque specifications are noted
in the component illustrations.
Example:
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

Illustration:
what to do and where
Component part No.
Explanation text: how to perform task
Task heading: what you will be doing
Set part No.
INSTALL FRONT AXLE HUB BEARING
D32545
01--2
--INTRODUCTION HOW TO USE THIS MANUAL
COROLLA Supplement (RM1129E)
(c) Torque specifications, grease application areas and non--reusable parts are emphasized in the proce-
dures.
NOTICE:
There are cases where such information can only be explained by using an illustration. In these
cases, all the information such as torque, oil, etc. are described in the illustration.
(d) Only items with key points are described in the text. What to do and other details are placed in illustra-
tions next to the text. Both the text and illustrations are accompanied by standard values and notices.
(e) Illustrations of similar vehicle models are sometimes used. In those cases, minor details may be differ-
ent from the actual vehicle.
(f) Procedures are presented in a step--by--step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The explanation text tells how to perform the task. It also has information such as specifications
and warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
headings are easy to read and the text below the task heading provides detailed information. Important spec-
ifications and warnings are always written in bold type.
5. SERVICE SPECIFICATIONS
(a) SPECIFICATIONS are presented in bold--faced text throughout the manual. The specifications are
also found in the ”Service Specifications” section for quick reference.
6. TERMS DEFINITION
CAUTION Possibility of injury to you or other people.
NOTICE Possibility of damage to components being repaired.
HINT Provides additional information to help you perform repairs.
7. SI UNIT
(a) The units used in this manual comply with the SI UNIT (International System of Units) standard. Units
from the metric system and the English system are also provided.
Example:
Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf)
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

010XK--02
D33475
AB
D33476
CB
E
A
D
--INTRODUCTION IDENTIFICATION INFORMATION
01--3
COROLLA Supplement (RM1129E)
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND SERIAL NUMBERS
1. VEHICLE IDENTIFICATION NUMBER
(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: 1CD--FTV, 1ND--TV
B: 2ZZ--GE, 3ZZ--FE, 4ZZ--FE
C: C50, C53, C53A, C64, C150
D: E351, E357
E: A246E
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

010XL--02
B84157
1
2
3
4
56
01--4
--INTRODUCTION REPAIR INSTRUCTION
COROLLA Supplement (RM1129E)
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
1Attire SAlways wear a clean uniform.
SHat and safety shoes must be worn.
2Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation.
3Safe operation
SWhen working with 2 or more persons, be sure to check safety for one another.
SWhen working with the engine running, make sure to provide ventilation for exhaust fumes in the
workshop.
SIf working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety
equipment and take extra care not to injure yourself or others.
SWhen jacking up the vehicle, be sure to support the specified location with a safety stand.
SWhen lifting up the vehicle, use appropriate safety equipment.
4Preparation of tools and
measuring gauge Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement.
5
Removal and installation,
disassembly and assem-
bly operations
SDiagnose with a thorough understanding of proper procedures and of the reported problem.
SBefore removing the parts, check the general condition of the assembly and for deformation and damage.
SWhen the assembly is complicated, take notes. For example, note the total number of electrical connections,
bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions.
Temporarily mark hoses and their fittings if needed.
SClean and wash the removed parts if necessary and assemble them after a thorough check.
6Removed parts
SPlace the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the
new parts.
SFor non--reusable parts such as gaskets, O--rings, and self--locking nuts, replace them with new ones as
instructed in this manual.
SRetain the removed parts for customer inspection, if requested.
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

Z11554
Seal Lock Adhesive
--INTRODUCTION REPAIR INSTRUCTION
01--5
COROLLA Supplement (RM1129E)
(b) JACKING UP AND SUPPORTING VEHICLE
(1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the
vehicle at the proper locations (see page 01--19).
(c) PRECOATED PARTS
(1) Precoated parts are bolts and nuts that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
moved in any way, it must be recoated with the spe-
cified adhesive.
(3) When reusing a precoated part, clean off the old
adhesive and dry the part with compressed air.
Then apply new seal lock adhesive appropriate to
that part.
(4) Some seal lock agents harden slowly. You may
have to wait for the seal lock agent to harden.
(d) GASKETS
(1) When necessary, use a sealer on gaskets to prevent leaks.
(e) BOLTS, NUTS AND SCREWS
(1) Carefully follow all the specifications for tightening torques. Always use a torque wrench.
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

V35007
D25628
V35008
Illustration Symbol Part Name Abbreviation
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSIBLE LINK
CIRCUIT BREAKER
FUSE
M--FUSE
H--FUSE
FL
CB
01--6
--INTRODUCTION REPAIR INSTRUCTION
COROLLA Supplement (RM1129E)
(f) FUSES
(1) When inspecting a fuse, check that the wire of the
fuse is not broken.
(2) When replacing fuses, be sure that the new fuse
has the correct amperage rating. Do not exceed the
rating or use one with a lower rating.
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

D25786
Shape (Example) Removal/Installation
Clip Remover
Pliers
Screwdriver
Scraper
Protective Tape
Clip
Protective Tape
Remove clips from front or rear using clip remover
or pliers.
Remove fasteners with a clip remover or screwdriver.
Remove clips with a wide scraper to prevent
panel damage.
--INTRODUCTION REPAIR INSTRUCTION
01--7
COROLLA Supplement (RM1129E)
(g) CLIPS
(1) The removal and installation methods of typical clips used for vehicle body parts are shown in
the table below.
HINT:
If clips are damaged during a procedure, always replace the damaged clip with a new clip.
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

D32182
Shape (Example) Removal/Installation
Removal Installation
Removal Installation
Removal Installation
Screwdriver
Screwdriver
Screwdriver
Clip Remover
Clip Remover
Clip Remover
Push
Push
Push
Small Clip Remover
Remove rivet by pushing the center pin through and prying
out the rivet shell.
Remove rivet by unscrewing the center pin and prying out
the rivet shell.
Remove rivet by prying out the pin and then prying out the
rivet shell.
01--8
--INTRODUCTION REPAIR INSTRUCTION
COROLLA Supplement (RM1129E)
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

D31750
INCORRECT CORRECT
D25064
L1 L2L1 L2L1 L2L1 L2
D02612
L2L1 L2L1 L2L1 L2L1
D01201
--INTRODUCTION REPAIR INSTRUCTION
01--9
COROLLA Supplement (RM1129E)
(h) REMOVAL AND INSTALLATION OF VACUUM HOSES
(1) To disconnect a vacuum hose, pull and twist from
the end of the hose. Do not pull from the middle of
the hose as this may cause damage.
(2) When disconnecting vacuum hoses, use tags to
identify where they should be reconnected.
(3) After completing any hose related repairs, double
check that the vacuum hoses are properly con-
nected. The label under the hood shows the proper
layout.
(4) When using a vacuum gauge, never force the hose
onto a connector that is too large. If a hose has been
stretched, it may leak air. Use a step--down adapter
if necessary.
(i) TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
(1) Use the formula below to calculate special torque
values for situations where SST or an extension tool
is combined with the torque wrench.
Formula: T’ = T x L2/(L1 + L2)
T’ Reading of torque wrench {N⋅m(kgf⋅cm,ft⋅lbf)}
TTorque {N⋅m(kgf⋅cm,ft⋅lbf)}
L1 Length of SST or extension tool {cm (in.)}
L2 Length of torque wrench {cm (in.)}
NOTICE:
If an extension tool or SST is combined with a torque
wrench and the wrench is tightened to the torque specifica-
tion in this manual, the actual torque will be excessive and
parts will be damaged.
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

01--10
--INTRODUCTION REPAIR INSTRUCTION
COROLLA Supplement (RM1129E)
2. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEATBELTPRETENSIONER
The COROLLA is equipped with aSupplemental Restraint System (SRS).
CAUTION:
Failure to carry out the service operations in the correct sequence could cause the SRS to unexpect-
edly deploy during servicing and lead to serious injury.
Furthermore, if amistake is made when servicing the SRS, it is possible that the SRS may fail to oper-
ate properly.Before servicing (including removal or installation of parts, inspection or replacement),
be sure to read the following section carefully.
(a) GENERAL NOTICE
(1) As the malfunction symptoms of the SRS are difficult to confirm, the Diagnostic Trouble Codes
(DTCs) become the most important source of information when troubleshooting. When trouble-
shooting the SRS, always check the DTCs before disconnecting the battery
(see Pub. No.RM925, page 05--942).
(2) Work must be started at least 90 seconds after the ignition switch is turned OFF and the negative
(--)terminal, cable is disconnected from the battery.
(The SRS is equipped with aback--up power source. If work is started within 90 seconds after
turning the ignition switch OFF and disconnecting the cable from the negative (--)battery termi-
nal, the SRS may deploy).
When the disconnecting the cable from the negative (--)battery terminal, clock and audio system
memory is erased. Before starting work, make anote of the settings of each memory system.
When work is finished, reset the clock and audio systems as before.
CAUTION:
Never use abackup power source (battery or other) to avoid erasing system memory.The backup
power source may inadvertently power the SRS and cause it to deploy.
(3) In minor collisions where the SRS does not deploy,the horn button assembly (see Pub. No.
RM925E, page 60--14),front passenger airbag assembly (see Pub. No. RM925E, page 60--27),
front seat airbag assembly (see Pub. No. RM925E, page 60--32),curtain shield airbag assembly
(see Pub. No. RM1028E, page 60--24) and seat belt pretensioner should be inspected before
further use of the vehicle.
(4) Never use SRS parts from another vehicle. When replacing parts, use new parts.
(5) Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the
sensor during repairs.
(6) Never disassemble and attempt to repair the airbag sensor assemblies, horn button assembly,
front passenger airbag assembly,curtain shield airbag assembly,front seat airbag assembly or
seat belt pretensioner.
(7) Replace the airbag sensor assemblies, horn button assembly,front passenger airbag assembly,
curtain shield airbag assembly or front seat airbag assembly or instrument panel lower airbag
assembly if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects
in the case, bracket or connector are present.
(8) Donot directly expose the airbag sensor assemblies, horn button assembly,front airbag assem-
bly,front seat airbag assembly,curtain shield airbag assembly or seat belt pretensioner to hot
air or flames.
(9) Use avoltmeter/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting electri-
cal circuits.
(10) Information labels are attached to the SRS components. Follow the instructions on the labels.
(11) After work on the SRS is completed, check the SRS warning lamp
(see Pub. No. RM925E, page 05--947).
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

D30401
Mark
D25096
CORRECT INCORRECT
Z13950
NEVER USE ANOHMMETER ON ANAIRBAG OR PRETENSIONER
--INTRODUCTION REPAIR INSTRUCTION
01--11
COROLLA Supplement (RM1129E)
(b) SPIRAL CABLE (in Combination Switch)
(1) The steering wheel must be fitted correctly to the
steering column with the spiral cable at the neutral
position, otherwise cable disconnection and other
problems may occur.
See Pub. No. RM925E, page 60--22 for information
about correct installation of the steering wheel.
(c) HORN BUTTONASSEMBLY (with Airbag)
(1) When removing the horn button or handling anew horn button, it should be placed with the pad
surface facing up. See the illustration below.
Placing the horn button with the pad surface facing down may lead to aserious accident if the
airbag accidently inflates. Also, do not place anything on top of the horn button.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
could cause serious injury.
(3) Grease or detergents of any kind should not be applied to the steering wheel pad.
(4) Store the horn button in an area where the ambient temperature is below 93˚C(200˚F), the hu-
midity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(4 pins). These connectors contain shorting springs. This feature reduces the possibility of the
airbag deploying due to currents entering the squib wiring.
(6) When disposing of the vehicle or the horn button by itself, the airbag should be inflated using
SST before disposal (see Pub. No. RM925E, page 60--14).Activate in asafe place away from
electrical noise.
Example:
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

D27522
CORRECT INCORRECT
Z13951
NEVER USE ANOHMMETER ON ANAIRBAG OR PRETENSIONER
01--12
--INTRODUCTION REPAIR INSTRUCTION
COROLLA Supplement (RM1129E)
(d) FRONT PASSENGER AIRBAG ASSEMBLY
(1) Always place aremoved or new airbag assembly with the airbag inflation direction facing up.
Placing the airbag assembly with the airbag inflation direction facing down could cause aserious
accident if the airbag inflates.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
could cause serious injury.
(3) Grease or detergents of any kind should not be applied to the airbag assembly.
(4) Store the airbag assembly in an area where the ambient temperature is below 93˚C(200˚F),
the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(4 pins). These connectors contain shorting springs. This feature reduces the possibility of the
airbag deploying due to currents entering the squib wiring.
(6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed
using SST before disposal (see Pub. No. RM925E, page 60--27).
Activate in a safe place away from electrical noise.
Example:
(e) CURTAIN SHIELD AIRBAG ASSEMBLY
(1) Always place the removed or new airbag assembly in a clear plastic bag, and keep it in a safe
place.
NOTICE:
The plastic bag is not reuseable.
CAUTION:
Never disassemble the curtain shield airbag assembly.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
could cause serious injury.
(3) Grease or detergents of any kind should not be applied to the airbag assembly.
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

D31641
CORRECT
Clear Plastic Bag
INCORRECT
Z13951
NEVER USE ANOHMMETER ON ANAIRBAG OR PRETENSIONER
--INTRODUCTION REPAIR INSTRUCTION
01--13
COROLLA Supplement (RM1129E)
(4) Store the airbag assembly in an area where the ambient temperature is below 93˚C(200˚F),
the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(2 pins). These connectors contain shorting springs. This feature reduces the possibility of the
airbag deploying due to currents entering the squib wiring.
(6) When disposing of avehicle or the airbag assembly unit by itself, the airbag should be deployed
using SST before disposal (see Pub. No. RM925E, page 60--24).
Activate in asafe place away from electrical noise.
Example:
(f) FRONT SEATAIRBAG ASSEMBLY
(1) Always place aremoved or new airbag assembly with the airbag inflation direction facing up.
Placing the airbag assembly with the airbag inflation direction facing down could cause aserious
accident if the airbag deploys.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
could cause serious injury.
(3) Grease or detergents of any kind should not be applied to the airbag assembly.
(4) Store the airbag assembly in an area where the ambient temperature is below 93˚C(200˚F),
the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(2 pins). These connectors contain shorting springs. This feature reduces the possibility of the
airbag deploying due to currents entering the squib wiring.
(6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed
using SST before disposal (See Pub. No. RM925E, page 60--32).
Activate in a safe place away from electrical noise.
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

D30924
NEVER USE ANOHMMETER ON ANAIRBAG OR PRETENSIONER
Z13951
NEVER USE ANOHMMETER ON ANAIRBAG OR PRETENSIONER
D30370
NEVER USE ANOHMMETER ON ANAIRBAG OR PRETENSIONER
01--14
--INTRODUCTION REPAIR INSTRUCTION
COROLLA Supplement (RM1129E)
Example:
(g) SEATBELTPRETENSIONER
(1) Never measure the resistance of the seat belt pretensioner. This may cause the seat belt preten-
sioner to activate, which could cause serious injury.
(2) Never disassemble the seat belt pretensioner.
(3) Never install the seat belt pretensioner on another vehicle.
(4) Store the seat belt pretensioner in an area where the ambient temperature is below 80˚C
(176˚F), the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(2 pins). These connectors contain shorting springs. This feature reduces the possibility of the
seat belt pretensioner deploying due to currents entering the squib wiring.
(6) When disposing of a vehicle or the seat belt pretensioner unit by itself, the seat belt pretensioner
should be activated before disposal (see Pub. No. RM925E, page 61--4).Activate in asafe place
away from electrical noise.
(7) As the seat belt pretensioner is hot after being activated, allow some time for it to cool down suffi-
ciently before disposal. Never apply water to try to cool down the seat belt pretensioner.
(8) Grease, detergents, oil or water should not be applied to the front seat outer belt.
Example:
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

D33608
Cable
Negative (--)
Battery
Terminal
D31751
INCORRECT
--INTRODUCTION REPAIR INSTRUCTION
01--15
COROLLA Supplement (RM1129E)
(h) AIRBAG SENSOR ASSEMBLY
(1) Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has
deployed.
(2) The connectors to the airbag sensor assembly should be connected or disconnected with the
sensor mounted on the floor. If the connectors are connected or disconnected while the airbag
sensor assembly is not mounted on the floor, the SRS may activate.
(3) Work must be started at least 90 seconds after the ignition switch is turned OFF and the cable
from the negative (--) battery terminal is disconnected, even if only loosening the set bolts of the
airbag sensor assembly.
(i) WIRE HARNESS AND CONNECTOR
(1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All the con-
nectors in the system are a standard yellow color. If the SRS wire harness becomes discon-
nected or the connector becomes broken, repair or replace it.
3. ELECTRONIC CONTROL
(a) REMOVAL AND INSTALLATION OF BATTERY CABLE
(1) Before performing electronic work, disconnect
cable from the negative (--) battery terminal to pre-
vent component and wire damage caused by acci-
dental short circuits.
(2) When disconnecting the terminal cable, turn the
ignition switch and headlamp dimmer switch OFF
and loosen the terminal nut completely. Perform
these operations without twisting or prying the ter-
minal. Remove the battery cable from the battery
terminal.
(3) Clock settings, radio settings, audio system
memory, DTCs and other data are erased when the
battery cable is disconnected. Write down any nec-
essary data before disconnecting the battery cable.
(b) HANDLING OF ELECTRONIC PARTS
(1) Do not open the cover or case of the ECU unless
absolutely necessary. If the IC terminals are
touched, the IC may be rendered inoperative by
static electricity.
(2) Do not pull the wires when disconnecting electronic
connectors. Pull the connector itself.
(3) Be careful not to drop electronic components, such
as sensors or relays. If they are dropped on a hard
surface, they should be replaced.
(4) When cleaning the engine with steam, protect the
electronic components, air filter and emission--re-
lated components from water.
(5) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

D01563
D25081
Spring Type Clamp
Clamp Track
D20025
01--16
--INTRODUCTION REPAIR INSTRUCTION
COROLLA Supplement (RM1129E)
(6) When measuring the resistance of a wire connector,
insert the tester probe carefully to prevent terminals
from bending.
4. REMOVAL AND INSTALLATION OF FUEL SYSTEM PARTS
(a) PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Work in a location with good air ventilation that does not have welders, grinders, drills, electric
motors, stoves, or any other ignition sources.
(2) Never work in a pit or near a pit as vaporized fuel will collect in those places.
(b) REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Prepare a fire extinguisher before starting operation.
(2) To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, and
do not spray the surrounding area with water. Be careful when performing work in this area, as
the work surface will become slippery. Do not clean up gasoline spills with water, as this may
cause the gasoline to spread, and possibly create a fire hazard.
(3) Avoid using electric motors, working lights and other electric equipment that can cause sparks
or high temperatures.
(4) Avoid using iron hammers as they may create sparks.
(5) Dispose of fuel--contaminated cloth separately using a fire resistant container.
5. REMOVAL AND INSTALLATION OF ENGINE INTAKE
PARTS
(a) If any metal particles enter inlet pass, this may damage
the engine.
(b) When removing and installing inlet system parts, cover
the openings of the removed parts and engine openings.
Use gummed tape or other suitable materials.
(c) When installing inlet system parts, check that no metal
particles have entered the engine or the installed part.
6. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the clamp position so
that it can be reinstalled in the same position.
(b) Replace any deformed or dented clamps with new ones.
(c) When reusing a hose, attach the clamp on the clamp track
portion of the hose.
(d) For a spring type clamp, you may want to spread the tabs
slightly after installation by pushing in the direction of the
arrow marks as shown in the illustration.
7. FOR VEHICLES EQUIPPED WITH MOBILE COMMU-
NICATION SYSTEMS
(a) Install the antenna as far away from the ECU and sensors
of the vehicle electronic systems as possible.
(b) Install an antenna feeder at least 20 cm (7.87 in.) away
from ECUs and sensors of the vehicle electronic systems.
For details about ECU and sensor locations, refer to the
section of the applicable component.
(c) Keep the antenna and feeder separate from other wirings
as much as possible. This will prevent signals from the
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E

B87729
TRC OFF Indicator Lamp
TRC Cut Switch
B84144
SLIP Indicator
A82779
DLC3
1314 15161211109
12345678
TS
CG
--INTRODUCTION REPAIR INSTRUCTION
01--17
COROLLA Supplement (RM1129E)
communication equipment from affecting vehicle equip-
ment and vice--versa.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install any high--powered mobile communication
system.
8. FOR VEHICLES EQUIPPED WITH TRACTION CON-
TROL (TRC) SYSTEM
When testing with a 2--wheel drum tester such as a speedome-
ter tester, a combination tester of the speedometer and brake,
a chassis dynamometer, or when jacking up the front wheels
and driving the wheels, always turn the TRC system OFF via the
TRC cut (TRC OFF) switch before testing.
NOTICE:
TRC system OFF condition can be confirmed by the TRC
OFF warning indicator in the combination meter.
(a) Confirm that the TRC system is OFF.
(1) Press the TRC cut (TRC OFF) switch to turn off the
TRC system.
(2) Check that the TRC OFF indicator illuminates.
HINT:
The SLIP indicator should always operate right after the engine
is restarted.
(3) Begin testing.
(4) Press the TRC cut (TRC OFF) switch to turn on the
TRC system and check that the TRC OFF indicator
turns off.
HINT:
The SLIP indicator lamp blinks when the TRC system is operat-
ing.
(5) Be sure to follow the instructions for work prepara-
tion and final confirmation of proper operation of the
VSC system.
9. FOR VEHICLES EQUIPPED WITH VEHICLE STABIL-
ITY CONTROL (VSC) SYSTEM
(a) NOTICES WHEN USING DRUM TESTER
(1) Before beginning testing, disable the Vehicle Stabil-
ity Control (VSC) system. To disable the VSC, turn
the ignition switch OFF and connect SST to termi-
nals TS and CG of the DLC3.
SST 09843--18040
NOTICE:
SConfirm that the VSC warning lamp blinks.
SThe VSC system will be reset when the engine is re-
started.
SFor safety, secure the vehicle with restraint chains
while using a wheel dynamometer.
BACK TO CHAPTER INDEX TO MODEL INDEX
To Alphabetical Index
To Sub Index TOYOTA COROLLA REPAIR MANUAL SUPP 1129E