Toyota Corolla L4 1587cc 1.

6L DOHC (4A-FE) 1

TOYOTA COROLLA
4A-FE Engine L4 1.6 lts. DOHC
Repair Manual

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Vehicle: Application and ID
VIN Information

Engine Identification
Engine VIN Code I.D. [1] ............................................................................................................................................................................................ 1

Engine Displacement ...................................................................................................................................................................... 1.6 Liter (98 cu.in.)

Engine Configuration ....................................................................................................................................................................................... Inline 4

Engine Designation ............................................................................................................................................................................................. 4A-FE

Fuel System [2] ........................................................................................................................................................................................................ MFI

Ignition System ........................................................................................................................................................... Nippondenso Electronic Ignition

Computer System [3] ........................................................................................................................................................................................... TCCS

REMARKS:
[1] VIN Position #4
[2] Multi-port Fuel Injection
[3] Toyota Computer Control System

VIN Label Location

To determine the correct part number needed, it may be necessary to know the production date, model number, and engine number.

The production date, engine number and all model information can be found on the identification label located as noted below.
^ On Passenger Cars, the I.D. Label is located on the inside of the driver's door.
^ On trucks, Vans and Land Cruisers, the Label is located on the lower part of the driver's door pillar

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Vehicle: Application and ID
Abbreviations
ABS Anti-Lock Brake System
ALR Automatic Locking Retractor
A/T Automatic Transaxle
ATF Automatic Transmission Fluid
BDC Bottom Dead Center
BTDC Before Top Dead Center
Calif. California
CB Circuit Breaker

CRS Child Restraint System

DP Dash Pot
ECU Electronic Control Unit

ELR Emergency Locking Retractor

ESA Electronic Spark Advance
FIPG Formed in Place Gasket
FL Fusible Link

Fr Front
IG Ignition
IN Intake (Manifold, Valve)
J/B Junction Block
LED Light Emitting Diode

LH Left-Hand
LSPV Load Sensing Proportioning Valve
Max Maximum
Min. Minimum
MP Multipurpose
M/T Manual Transaxle
OD Overdrive
O/D Overdrive
0/S Oversize
PCV Positive Crankcase Ventilation

PKB Parking Brake

PS Power Steering

RH Right-Hand
Rr Rear
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
STD Standard
SW Switch

TOC Top Dead Center

TEMP. Temperature
T/M Transmission
TMC Toyota Motor Corporation
TMM Toyota Motor Manufacturing U.S.A., Inc.
U/S Undersize
VCV Vacuum Control Valve
VSV Vacuum Switching Valve

VTV Vacuum Transmitting Valve

w/ With
w/o Without

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 4
Vehicle: Application and ID
SAE J-1930 Information
This glossary lists all SAE - J193O terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their Toyota
equivalents.

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Engine: Application and ID
ENGINE............................................................................................................................................................................................ 1.6L (1587cc) 4 cyl

ENGINE DESIGNATION.................................................................................................................................................................................... 4A-FE

FUEL SYSTEM...................................................................................................................................................................... Multi-Point Fuel Injection

IGNITION SYSTEM................................................................................................................................................... Nippondenso Electronic Ignition

COMPUTER SYSTEM................................................................................................................................ Toyota Computer Control System (TCCS)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 8
Engine: Service and Repair
Removal

Part 1 Of 3

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Part 2 Of 3

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Part 3 Of 3

1. Remove battery and tray.

2. Remove hood.
3. Remove engine under covers.
4. Drain engine coolant.
5. Drain engine oil.
6. Drain transaxle oil.
7. Disconnect accelerator cable from accelerator bracket.
8. Disconnect throttle cable from accelerator bracket.
9. Remove radiator with cooling fan. See Cooling System.
10. Remove air cleaner assembly:
a. Disconnect the intake air temperature (IAT) sensor connector from the air cleaner cap.
b. Loosen the air cleaner hose clamp bolt.
c. Disconnect the air cleaner cap clips.

d. Remove the air cleaner cap with the air cleaner hose.
e. Remove the air cleaner filter element.
f. Disconnect the harness clamp from the boss, and remove the 3 bolts and air cleaner case.

11. Remove coolant reservoir tank tray. Remove the 2 bolts and tray.
12. Remove washer tank:

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a. Remove the washer tank mounting bolt.

b. Disconnect the connector and hose, and remove the washer tank.
13. Remove cruise control actuator as follows:
a. Remove the actuator cover.
b. Disconnect the cable from the actuator.
c. Disconnect the actuator connector.

d. Remove the 3 bolts, and disconnect the actuator with the bracket.

14. Disconnect hoses and connector:

a. Disconnect the following vacuum hoses from intake chamber:
(1) MAP hose from gas filter.
(2) Brake booster vacuum hose.
(3) A/C vacuum hose from actuator.
b. Disconnect the air hose from the air pipe.
c. Disconnect the A/C actuator connector.
15. Disconnect wires and connectors.

a. RH Fender apron side than disconnect the following wire and connectors:
(1) Ground strap connector.
(2) MAP sensor connector.
(3) A/C pressure switch.
(4) Engine wire from fender apron.

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b. LH Fender apron side than disconnect the following wire and connectors:
(1) DLC 1 connector.
(2) Connect from fender apron.
(3) Ground strap from fender apron.
c. Remove the 2 bolts and engine relay box.

d. Disconnect the 4 connectors from the engine relay box.

16. Remove charcoal canister:

a. Disconnect the hose from the charcoal canister.
b. Remove the charcoal canister from the bracket.

17. Disconnect the 2 heater hoses from the water inlet housing.

18. Disconnect fuel inlet hose.

CAUTION: Catch leaking fuel in a container.

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19. Disconnect fuel return hose.

CAUTION: Catch leaking fuel in a container.

20. Remove clutch release cylinder without disconnecting pipe. Remove the 3 bolts, release cylinder and tube from the transaxle. M/T only.

21. Disconnect transaxle control cable(s) from transaxle.

22. Disconnect engine wire from cabin:
a. Remove the LH front door scuff plate.
b. Remove the lower finish panel.
c. Remove the RH front door scuff plate.
d. Remove the lower panel with glove compartment door.
e. Remove the radio.
f. Remove the center cluster finish panel.
g. Remove the rear console box.
h. Remove the shift lever knob. M/T only.
i. Remove the shifting hole bezel. A/T only.
j. Remove the finish lower center panel.
k. Remove the floor carpet bracket.
l. Disconnect the following connectors:
(1) 3 ECM connectors.
(2) Cowl wire connector.

m. Pull out the engine wire from the cowl panel.

23. Remove A/C compressor without disconnecting hoses:
a. Disconnect the A/C compressor connector.
b. Remove the drive belt.

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c. Remove the 4 bolts, and disconnect the A/C compressor.

NOTE: Put aside the compressor, and suspend it securely from the radiator support.

24. Remove PS pump without disconnecting hoses:

a. Remove the PS drive belt.
b. Remove the 2 bolts, and disconnect the PS pump from the engine.

NOTE: Put aside the pump and suspend it to the cowl with a string.

25. Remove front exhaust pipe:

a. Disconnect the oxygen sensor connector.
b. Remove the 2 bolts holding the front exhaust pipe to the mounting bracket.
c. Remove the 2 bolts and support bracket holding the front exhaust pipe to the TWC.
d. Using a 14 mm deep socket wrench, remove the 2 nuts.
e. Remove the front exhaust pipe and 2 gaskets.
26. Remove drive shafts. See Transmission and Drivetrain.
27. Disconnect engine mounting center member:

a. Remove the through-bolt holding the rear mounting insulator to the mounting bracket.

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b. Remove the 2 hole covers.

c. Remove the 5 bolts, 4 nuts and center member.

NOTE: Removing the above bolts and nuts will loosen the center member, but will not free it completely. Allow the center member to
remain suspended.

28. Remove the through-bolt and nut holding the mounting insulator to the mounting bracket.
29. Remove engine and transaxle assembly from vehicle:

a. Install a engine hanger No.1 in the correct direction. Torque: 27 Nm (20 ft. lbs.).
b. Attach the engine chain hoist to the engine hangers.
c. Remove the 3 bolts, ground wire and actuator bracket.

d. Remove the screw, bolt and bracket.

e. Remove the bolt and damper.

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f. Remove the 4 bolts, 2 nuts and RH mounting insulator.

g. Remove the 2 bolts and mounting stay.

h. Remove the 3 bolts, through bolt and LH mounting insulator.

i. Remove the 3 bolts and LH mounting bracket.

j. Lift the engine out of the vehicle slowly and carefully.

CAUTION: Make sure the engine is clear of all wiring, hoses and cables. Be careful not to hit the power steering gear housing and throttle
position sensor.

k. Place the engine and transaxle assembly onto the stand.

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30. Remove the 2 bolts and mounting bracket.

31. Remove the 3 bolts (Except 3 A/T) or 2 bolts (3 A/T) and mounting bracket.
32. Remove starter. See Starting and Charging.
33. Separate engine and transaxle. See Transmission and Drivetrain.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 18
Engine: Service and Repair
Installation
1. Assemble engine and transaxle. See Transmission and Drivetrain.
2. Install starter. See Starting and Charging.

3. Install rear engine mounting bracket. Tighten the 2 bolts (3 A/T) or 3 bolts (Except 3A/T) holding the mounting bracket to the transaxle.
Torque to 77 Nm (57 ft. lbs.).

4. Install front engine mounting bracket. Tighten the 2 bolts holding the mounting bracket to the transaxle. Torque to 77 Nm (57 ft. lbs.).
5. Install engine and transaxle assembly in vehicle as follows:
a. Attach the engine sling device to the engine hangers.

b. Lower the engine into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH mounting.

CAUTION: Be careful not to hit the power steering gear housing and throttle position sensor.

c. Keep the engine level, and align RH and LH mountings with the body bracket.

d. Install the LH mounting bracket with the 3 bolts. Torque to 52 Nm (38 ft. lbs.).
e. Attach the RH mounting insulator to the body, and temporarily install the 3 bolts.
f. Attach the RH mounting insulator the mounting bracket, and temporarily install the bolt and 2 nuts.
g. Attach the LH mounting insulator to the body, and temporarily install the through bolt.

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h. Attach the Lid mounting insulator to the mounting bracket, and install the 3 bolts. Torque to 56 Nm (41 ft. lbs.).
i. Tighten the through bolt holding the LH mounting insulator to the body. Torque to 87 Nm (64 ft. lbs.).

j. Install the mounting stay with the 2 bolts. Torque to 21 Nm (15 ft. lbs.).

k. Tighten the 4 bolts and 2 nuts holding the RH mounting insulator to the body and mounting bracket. Torque to:
A: 64 Nm (47 ft. lbs.).
B: 52 Nm (38 ft. lbs.).
C: 25 Nm (19 ft. lbs.).
l. Install the A/C damper with the bolt.
m. Install the A/C bracket with the bolt and screw.
n. Install the cruise control actuator bracket and ground wire with the 3 bolts.
o. Remove the engine chain hoist from the engine.
p. Remove the bolt and engine hanger No. 1.
6. Connect engine mounting center member as follows:

a. Temporarily install the center member to the body with the 5 bolts and 4 nuts.

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b. Tighten the through-bolt holding the rear engine mounting insulator to the rear mounting bracket. Torque to 87 Nm (64 ft. lbs.).

c. Tighten the 5 bolts and 4 nuts holding the center member to the body. Torque to:
- Bolt A: 61 Nm (45 ft. lbs.).
- Bolt B: 64 Nm (47 ft. lbs.).
- Bolt C: 48 Nm (35 ft. lbs.).
- Nut: 57 Nm (42 ft. lbs.).
d. Install the 2 hole covers.

7. Install front engine mounting insulator. Tighten the through bolt and nut holding the mounting insulator to the mounting bracket. Torque to
87 Nm (64 ft. lbs.).
8. Install drive shafts. See Transmission and Drivetrain.
9. Install front exhaust pipe as follows:
a. Place 2 new gaskets to the front and rear of the front exhaust pipe.
b. Using a 14 mm deep socket wrench, install the front exhaust pipe with 2 new nuts. Torque to 62 Nm (46 ft. lbs.).
c. Install the 2 bolts and support bracket holding the front exhaust pipe to the exhaust manifold. Torque to 43 Nm (32 ft. lbs.).
d. Install the 2 bolts holding the front exhaust pipe bracket to the mounting bracket. Torque to 19 Nm (14 ft. lbs.).
e. Connect the oxygen sensor connector.

10. Install Power Steering (PS) pump as follows:

a. Install the PS pump with the 2 bolts. Torque to 39 Nm (23 ft. lbs.).
b. Install the drive belt.

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11. Install A/C compressor as follows:

a. Install the compressor with the 3 bolts. Torque to 25 Nm (18 ft. lbs.).
b. Install the drive belt.
c. Connect the A/C compressor connector.
12. Connect engine wire to cabin as follows:
a. Push in the engine wire through the cowl panel.
b. Connect the following connectors:
(1) 3 ECM connectors.
(2) Cowl wire connector.
c. Install the floor carpet bracket.
d. Install the finish lower center panel.
e. A/T: Install the shifting hole bezel.
f. M/T: Install the shift lever knob.
g. Install the rear console box.
h. Install the center cluster finish panel.
i. Install the radio.
j. Install the lower panel with glove compartment door.
k. Install the RH front door scuff plate.
l. Install the lower finish panel.
m. Install the LH front door scuff plate.
13. Connect transaxle control cable(s) to transaxle
14. Install clutch release cylinder. Install the release cylinder and tube with the 3 bolts. M/T only.

15. Connect fuel return hose.

16. Connect fuel inlet hose. Torque to 29 Nm (22 ft. lbs.).
17. Connect heater hoses. Connect the 2 heater hoses to the water inlet housing.
18. Install charcoal canister as follows:
a. Connect the hose to charcoal canister.
b. Install the charcoal canister to the bracket.
19. Connect wires and connectors as follows:
a. Connect the 4 connectors to the engine relay box.
b. Install the engine relay box with the 2 bolts.

c. LH Fender apron side connect the following wire and connectors:

(1) DLC1 connector.
(2) Connector from fender apron.
(3) Ground strap from fender apron.

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d. RH fender apron side connect the following wire and connectors:

(1) Ground strap connector.
(2) Manifold Absolute Pressure (MAP) connector.
(3) A/C pressure switch.
(4) Engine wire from fender apron.

20. Connect hoses and connector as follows:

a. Connect the A/C actuator connector.
b. Connect the air hoses to the air pipe.
c. Connect the following vacuum hoses to the intake chamber:
(1) MAP hose to gas filter.
(2) Brake booster vacuum hose.
(3) A/C vacuum hose from actuator.

21. Install cruise control actuator as follows:

a. Install the actuator and bracket with the 3 bolts.
b. Connect the actuator connector.
c. Connect the cruise control actuator cable to the actuator.
d. Install the actuator cover.
22. Install washer tank as follows:
a. Connect the connector and vinyl hose to the washer tank.
b. Install the washer tank with the bolt.
23. Install coolant reservoir tank stay. Install the stay with the bolts.
24. Install air cleaner assembly as follows:
a. Install the air cleaner case with the 3 bolts.
b. Connect the harness clamp to the boss of the case.
c. Install the air cleaner filter element.
d. Connect the air cleaner hose, and install the air cleaner cap with the 4 clips.
e. Tighten the air cleaner hose clamp bolt.
f. Connect the Intake Air Temperature (IAT) sensor connector to the air cleaner cap.
25. Install radiator with cooling fan. See Cooling System.
26. Connect throttle cable, and adjust it. A/T only.
27. Install accelerator cable, and adjust it.
28. Fill radiator with engine coolant.
29. Fill with engine oil.
30. Fill with transaxle oil.

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31. Start engine and check for leaks.
32. Perform engine adjustment.
33. Install engine under covers.
34. Install hood. See Body and Frame.
35. Perform road test. Check for abnormal noises, shock slippage, correct shift points and smooth operation.
36. Recheck engine coolant and oil levels.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 24
Lifter / Lash Adjuster: Service and Repair

1. REMOVE VALVE LIFTERS AND SHIMS

HINT: Arrange the valve lifters and shims in correct order.

. INSPECT VALVE LIFTERS AND LIFTER BORES

(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Lifter bore diameter: 28.005 - 28.026 mm (1.1026 - 1.1034 in.)

(b) Using a micrometer, measure the lifter diameter.

Lifter diameter: 27.975 - 27.985 mm (1.1014 - 1.1018 in.)

3. INSTALL VALVE LIFTERS AND SHIMS

(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.

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Cylinder Block Assembly: Service and Repair
CYLINDER BLOCK
COMPONENTS

REMOVAL OF ENGINE (4A-FE)

1. REMOVE BATTERY AND HOOD
2. REMOVE RH AND LH ENGINE UNDER COVERS
3. DRAIN ENGINE OIL
4. DRAIN ENGINE COOLANT
5. DRAIN GEAR OIL (M/T) OR FLUID (A/T)
6. REMOVE RADIATOR WITH COOLING FAN
7. DISCONNECT ACCELERATOR WIRE FROM BRACKET
8. (A/T) DISCONNECT THROTTLE CABLE FROM BRACKET
9. (w/ CRUISE CONTROL) REMOVE CRUISE CONTROL ACTUATOR

10. REMOVE AIR CLEANER ASSEMBLY

(a) Disconnect the vacuum hose from the charcoal canister.

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(b) Disconnect the air intake temp. sensor connector from the air cleaner cap.
(c) Disconnect the air hose from the air pipe.
(d) Loosen the air cleaner hose clamp bolt.
(e) Disconnect the air cleaner cap clips.
(f) Remove the air cleaner cap with air cleaner hose.
(g) Remove the air cleaner filter element.

(h) Disconnect the harness clamp from the boss, and remove the three bolts and air cleaner case.
(i) Remove the two bolts and air cleaner support bracket.
11. REMOVE WASHER TANK

12. DISCONNECT FOLLOWING HOSES:

(a) Disconnect the following vacuum hoses from the intake chamber:
(1) Vacuum sensor hose from gas filter
(2) Brake booster vacuum hose
(3) (with A/C), Two A/C vacuum hoses from actuator
(b) (w/PS and/or with A/C) Disconnect the air hose from the air pipe.
(c) Disconnect the fuel return hose from the air pipe.
13. DISCONNECT ENGINE WIRE
(a) Remove the three nuts, No.2 junction block and No.5 relay block.
(b) Disconnect the following connectors:
- Ground strap connector and bolt
- Check connector
- Vacuum sensor connector
- (with A/C) A/C wire connector
(c) Remove the front and rear console boxes.

(d) Remove the center cover in front of the console box.

(e) Disconnect the four connectors from the cowl wire and ECU.

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(f) Pull out the engine wire from the cowl panel.

14. DISCONNECT HEATER WATER HOSES

(a) Disconnect the heater hose from the water inlet housing.
(b) Disconnect the hose from the water inlet pipe.

15. DISCONNECT INLET FUEL HOSE FROM FUEL FILTER

16. DISCONNECT FUEL RETURN HOSE FROM AIR PIPE

17. (w/PS) DISCONNECT PS PUMP

(a) Loosen the adjusting bolt, pivot bolt, and remove the drive belt.
(b) Remove the adjusting bolt, pivot bolt and PS pump.
(c) Suspend the PS pump.

18. (with A/C) DISCONNECT A/C COMPRESSOR

(a) Loosen the adjusting bolt and remove the drive belt.
(b) Remove the four compressor mounting bolts.

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(c) Move the compressor aside and suspend it.

19. DISCONNECT SPEEDOMETER CABLE FROM TRANSAXLE

20. (M/T) REMOVE CLUTCH RELEASE CYLINDER WITHOUT DISCONNECTING PIPE AND HOSE.

21. (M/T) DISCONNECT CONTROL CABLES

(a) Remove the two clips, washers and retainers.
(b) Disconnect the control cables from the shift outer lever and select outer lever.

22. (A/T) DISCONNECT CONTROL CABLE

(a) Remove the clip and retainer.
(b) Disconnect the control cable from the shift lever.
23. RAISE VEHICLE

NOTICE: Be sure the vehicle is securely supported.

24. (4WD) DISCONNECT OIL COOLER HOSES

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25. REMOVE FRONT EXHAUST PIPE

(a) Disconnect the oxygen sensor connector.
(b) Remove the two bolts and disconnect pipe from the catalytic converter.
(c) Remove the two nuts and exhaust pipe.
26. DISCONNECT DRIVE SHAFTS FROM TRANSAXLE
27. (4WD) DISCONNECT PROPELLER SHAFT

28. DISCONNECT FRONT, CENTER (2WD) AND REAR MOUNTINGS FROM CENTER MEMBER
(a) Remove the two hole covers.
(b) Remove the six bolts (2WD) or two bolts and two nuts (4WD) from each mounting.

(c) Remove the front mounting bolt and mounting.

(d) Remove the rear mounting bolt and mounting.

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29. (4WD) REMOVE FRONT SUSPENSION CROSSMEMBER

Remove the eight bolts from the front suspension crossmember.

30. REMOVE ENGINE MOUNTING CENTER MEMBER

Remove the five bolts (2WD) or four bolts (4WD), insulators and member.

31. REMOVE ENGINE WITH TRANSAXLE FROM VEHICLE

(a) Attach the engine chain hoist to the lifting bracket on the engine.

HINT: Hang the engine wires and hoses on the chain

.

(b) Remove the three bolts and mounting stay.

(c) Remove the bolt, two nuts, through bolt and RH mounting.

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(d) Remove the two bolts and mounting stay.

(e) Remove the three bolts and disconnect the LH mounting bracket from the transaxle bracket.

(f) Lift the engine out of the vehicle slowly and carefully. Clear the LH mounting while lowering the transaxle.

NOTICE: Be careful not to hit the power steering gear housing and throttle position sensor.

(g) Make sure the engine is clear of all wiring, hoses and cables.
(h) Place the engine with the transaxle onto the stand.
32. DISCONNECT FOLLOWING CONNECTORS:
(a) Back-up lamp switch connector (M/T)
(b) Neutral start switch connector (A/T)
33. REMOVE HOLE PLUG FROM REAR END PLATE
34. (A/T) REMOVE SIX TORQUE CONVERTER MOUNTING BOLTS
35. REMOVE STARTER
36. REMOVE TRANSAXLE FROM ENGINE

INSTALLATION OF ENGINE (4A-FE)

1. INSTALL TRANSAXLE TO ENGINE

2. INSTALL STARTER
3. (A/T) INSTALL SIX TORQUE CONVERTER MOUNTING BOLTS
4. INSTALL HOLE PLUG TO REAR END PLATE
5. CONNECT FOLLOWING CONNECTORS:
- Back-up lamp switch (M/T) Neutral start switch (A/T)

6. INSTALL ENGINE WITH TRANSAXLE TO VEHICLE

(a) Attach the engine hoist chain to the lifting bracket on the engine.

HINT: Hang the engine wires and hoses on the chain.

(b) Lower the engine into the engine compartment.

- Tilt the transaxle downward, lower the engine and clear the left mounting.

NOTICE: Be careful not to hit the power steering gear housing and throttle position sensor.
(c) Keep the engine level, and align each mounting with the bracket.

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(d) Install the RH mounting insulator to the engine mounting bracket with the two nuts and bolt.
Torque:
Bolt 650 kg-cm (47 ft-lb, 64 N.m)
Nut 530 kg-cm (38 ft-lb, 52 N.m)
(e) Align the RH mounting insulator with the body bracket and temporarily install the mounting through bolt and nut.
Torque: 890 kg-cm (64 ft-lb, 87 N.m)

(f) Align the LH mounting insulator bracket with the transaxle case bracket. Temporarily install the three bracket bolts.
Torque: 490 kg-cm (35 ft-lb, 48 N.m)

(g) Install the RH mounting stay with the three bolts.

Torque: 430 kg-cm (31 ft-lb, 42 N.m)
(h) Install the LH mounting stay with the two bolts.
Torque: 210 kg-cm (15 ft-lb, 21 N.m)
(i) Remove the hoist chain from the engine.
7. RAISE VEHICLE

NOTICE: Be sure the vehicle is securely supported.

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8. INSTALL ENGINE MOUNTING CENTER MEMBER

(a) Install and torque the rear mounting bolt.
Torque: 890 kg-cm (94 ft-lb, 87 N.m)

(b) Install and torque the front mounting bolt.

(c) Install the engine mounting member with the five bolts. Torque the bolts.
Torque: 620 kg-cm (45 ft-lb, 61 N.m)

9. (4WD) INSTALL FRONT SUSPENSION CROSSMEMBER

Install the suspension crossmember with the eight bolts.
Torque:
(Front lower arm bolt) 2,100 kg-cm (152 ft-lb, 206 N.m)
(Rear bolt) 1,300 kg-cm (94 ft-lb, 127 N.m)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 34

10. INSTALL FRONT, CENTER (2WD) AND REAR MOUNTINGS ONTO MEMBER
(a) Temporarily install the front and rear mountings and bolts.
(b) Align each bolt hole at the brackets with the member. Install and torque the bolts and nuts.
Torque: Front 490 kg-cm (35 ft-lb, 48 N.m)
Center (2WD) 530 kg-cm (38 ft-lb, 52 N.m)
Rear (2WD) 530 kg-cm (38 ft-lb, 52 N.m)
Rear (4WD) 580 kg-cm (42 ft-lb, 57 N.m)
(c) Install the two hole covers.
(d) Shake the engine several times to make sure that there is no load on the front and rear (All only) mounting insulators.

NOTICE:
On M/T, check that the insulator space is equal all the way around.
On A/T, check that the space above and below the insulator is equal.

HINT: On new insulators, the lower space is wider than the upper space On M/T, it does not matter if the insulator ribs (4 places) are broken.

11. (4WD) CONNECT PROPELLER SHAFT

12. CONNECT DRIVE SHAFTS TO TRANSAXLE

13. INSTALL FRONT EXHAUST PIPE

(a) Install both sets of new gaskets and the front pipe.
(b) Connect the exhaust pipe to the manifold. Install and torque two new nuts.
Torque: 630 kg-cm (46 ft-lb 62 N.m)
(c) Install the two bolts to the catalytic converter and bracket.
(d) Connect the oxygen sensor connector.
14. (4WD) CONNECT OIL COOLER HOSES
15. LOWER VEHICLE

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 35

16. CONNECT CONTROL CABLES

(a) Connect the control cables to the shift outer lever and select lever.
(b) Install the retainers, washers and clips.

17. (A/T) CONNECT CONTROL CABLE

(a) Connect the control cable to the shift lever.
(b) Install the retainer and clip.

18. (M/T) INSTALL CLUTCH RELEASE CYLINDER

(a) Install the release cylinder with the two bolts.
(b) Connect the bracket to the transaxle.
(c) Install the clip to the clutch pipe bracket.
19. CONNECT SPEEDOMETER CABLE TO TRANSAXLE

20. (with A/C) INSTALL A/C COMPRESSOR

Install the four compressor mounting bolts.
Torque: 250 kg-cm (18 ft-lb, 25 N.m)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 36

21. (w/PS) INSTALL PS PUMP

(a) Connect the PS pump with pivot bolt and adjusting bolts.
(b) Install the drive belt. Torque the bolts.
Torque: 400 kg-cm (29 ft-lb, 39 N.m)
22. ADJUST DRIVE BELT

23. CONNECT FUEL RETURN HOSE TO AIR PIPE

24. CONNECT INLET HOSE TO FUEL FILTER Torque: 300 kg-cm (22 ft-lb, 29 N.m)

25. CONNECT HEATER WATER HOSES

(a) Connect the heater hose to the water inlet pipe.
(b) Connect the heater hose to the water inlet housing.
26. CONNECT ENGINE WIRE
(a) Push in the engine wire through the cowl panel.
(b) Connect the four connectors to the cowl wire and ECU.
(c) Install the center cover in front of the console box.
(d) Install rear and front console boxes.

(e) Connect the following connectors:

- Ground strap connector and bolt
- Check connector
- Vacuum sensor connector A/C wire connector
(f) Install the No.2 junction block and No.5 relay block with the three nuts.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 37

27. CONNECT FOLLOWING HOSES:

(a) Connect the fuel return hose to the air pipe.
(b) (w/PS and/or with A/C), Connect the air hoses to the air pipe.
(c) Connect the following vacuum hoses to the intake chamber:
(1) Vacuum sensor hose to gas filter
(2) Brake booster vacuum hose
(3) (with A/C Two A/C vacuum hoses to actuator
28. INSTALL WASHER TANK

29. INSTALL AIR CLEANER ASSEMBLY

(a) Install the air cleaner support bracket with the two bolts.
(b) Install the air cleaner case with the three bolts.
(c) Connect the harness clamp to the boss of the case.
(d) Install the air cleaner filter element.
(e) Connect the air cleaner hose, and install the air cleaner cap with the four clips.
(f} Tighten the air cleaner hose clamp bolt.
(g) Connect the air hose to the air pipe.
(h) Connect the air intake temp. sensor connector to the air cleaner cap.
(i) Connect the vacuum hose to the charcoal canister.
30. (w/CRUISE CONTROL) INSTALL CRUISE CONTROL ACTUATOR
31. (A/T) CONNECT THROTTLE CABLE TO BRACKET
32. CONNECT ACCELERATOR WIRE TO BRACKET
33. INSTALL RADIATOR WITH COOLING FAN
34. (M/T) REFILL MANUAL TRANSAXLE AND TRANSFER WITH GEAR OIL
2WD C50/52 API GL-4 or GL-5 SAE 75W-90 2.7 qt. U.S.
4WD E55/57F5 API GL-5 SAE 75W-90, 80W-90 or 80W 5.3 U.S. qt.
35. (A/T) REFILL AUTOMATIC TRANSAXLE AND TRANSFER WITH FLUID
2WD/4WD DEXRON II 5.8 qt, Differential 1.5 qt.
36. REFILL WITH COOLANT
Close the radiator and engine drain cock and fill with coolant.
Total capacity (w/Heater):
M/T (Ex. AE92L - ACMXKK) liters (5.9 US qts, 4.9 Imp. qts)
M/T (AE92L - ACMXKK) 6.2 liters (6.2 US qts, 5.5 Imp. qts)
A/T 6.1 liters (6.4 US qts 5.4 Imp. qts)
37. REFILL WITH ENGINE OIL
Oil Grade: API grade SG
Capacity: Dry fill 3.7 liters (3.9 US qts, 3.3 Imp. qts)
Drain and refill (w/o Oil filter change) 3.0 liters (3.2 US qts, 2.6 Imp. qts)
Drain and refill (w/Oil filter change) 3.2 liters (3.4 US qts, 2.8 Imp. qts)
8. INSTALL BATTERY
39. START ENGINE AND CHECK FOR LEAKS
Warm up engine and inspect leakage.
40. RECHECK COOLANT AND ENGINE OIL LEVEL
41. INSTALL RH AND LH ENGINE UNDER COVERS
42. INSTALL HOOD

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 38
Connecting Rod: Service and Repair

Fig. 22 Piston & Connecting Rod Assembly

Pistons are available in standard and oversize of .050 inch. If piston bore is not within specifications, Service and Repair piston and/or cylinder
block. When assembling piston onto connecting rod, ensure mark on top of piston and mark on connecting rod are on same side, Fig. 22. When
installing piston and connecting rod assembly, ensure mark on top of piston is facing toward front of engine.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 39
Cylinder Head Assembly: Service and Repair
California

Accessory Removal

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 40

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 41

1. Disconnect negative battery cable.

Caution: You must wait at least 90 seconds after disconnecting the negative battery terminal before beginning work.

2. Drain engine coolant. Remove RH lower engine cover.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 42

3. Disconnect accelerator cable from bracket.

4. On A/T equipped vehicles, disconnect throttle cable from bracket.
5. Disconnect the IAT sensor connector from the air cleaner cap.

6. Loosen the air cleaner hose clamp bolt.

7. Disconnect the air cleaner cap clips.
8. Remove the air cleaner cap with the air cleaner hose.
9. Remove generator and distributor.
10. Disconnect the sub-oxygen sensor connector.

11. Remove the 2 bolts and support bracket holding the front exhaust pipe to the mounting bracket.
12. Remove the 2 bolts and support bracket holding the front exhaust pipe to the catalytic converter.
13. Using a 14mm deep socket, remove the 2 nuts, the front exhaust pipe and 2 gaskets.

14. Remove the main oxygen sensor connector and the 4 bolts and the upper heat shield.

15. Remove the 2 bolts and manifold stay.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 43

16. Remove the 5 nuts, exhaust manifold and gasket.

17. Remove the 3 bolts and lower heat shield from the exhaust manifold.

18. Remove the 4 nuts and 2 catalytic converter heat shields.

19. Remove the 2 bolts, 2 nuts, catalytic converter and gasket.

20. Disconnect the radiator inlet hose from the water outlet.

21. Remove the 2 bolts and water outlet.

22. Disconnect the ECT sensor connector, ECT switch connector, and the IAC valve connector.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 44

23. Disconnect the hoses as shown above:

1) Radiator outlet hose

2) Water bypass hoses
3) Heater water hoses
4) 2 EVAP TVV vacuum hoses

24. Remove the bolt, 2 nuts, the water inlet, and the inlet housing assembly.

25. Remove the nut and engine hanger.

26. Disconnect the ground strap connector and the map connector.
27. On A/C equipped vehicles, disconnect the A/C pressure switch.

28. Disconnect the wire harness from the RH fender apron.

29. Disconnect the map sensor hose from the gas filter.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 45
30. Disconnect the brake booster vacuum hose.
31. On A/C equipped vehicles, disconnect the vacuum hoses from the actuator and the actuator connector.
32. On P/S equipped vehicles, disconnect the air hose from the air pipe.
33. Disconnect the EGR VSV connector and EGR gas temperature sensor connector. Disconnect the vacuum hose from the EGR valve and
remove the EGR VSV.

34. Disconnect the engine harness clamp.

35. Remove the 3 bolts and manifold stay.

36. Disconnect the fuel return hose from the pressure regulator.
37. Disconnect the air hose from the air pipe.

38. Remove the bolt, nut, and air pipe.

39. Disconnect the 2 vacuum hoses from the throttle body. Remove the 2 bolts, 2 nuts, EGR valve, vacuum modulator, vacuum hose assembly
and gaskets.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 46

40. Remove the 2 bolts and accelerator bracket.

41. Disconnect the throttle position sensor connector.

42. Remove the 2 bolts, 2 nuts, throttle body, and gasket.

43. Remove the fuel inlet hose clamp bolt.

44. Remove the bolt, air intake chamber stay, and gasket.

45. Disconnect the 2 PCV hoses from the cylinder head cover.
46. Disconnect the vacuum hose from the pressure regulator.

47. Using a 6mm hexagon wrench, remove the 3 bolts.

48. Remove the 2 nuts, air intake chamber and gasket.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 47

49. Disconnect the union bolt, 2 gaskets, and fuel inlet hose.
50. Disconnect the fuel injector electrical connectors.

51. Remove the 2 bolts and fuel rail together with the 4 injectors.

Caution: Be careful not to drop the injectors when removing the fuel rail.

52. Remove the insulators and spacers from the cylinder head, remove the injectors from the fuel rail and remove the O-rings and grommets from
the injectors.

53. Disconnect the Compressor wire on A/C equipped vehicles and remove the oil pressure switch connector.
54. Remove the bolts, wire harness cover and disconnect the wire harness from the valve cover.

55. Disconnect the knock sensor and ECT sender. Remove the bolt and disconnect the engine ground strap.

56. Remove the 3 nuts and disconnect the wire harness.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 48

57. Remove the 7 mount bolts, ground strap, 2 nuts and intake manifold and gasket.
58. Remove the RH engine mount.

Cylinder Head Removal

1. Remove the 4 cap nuts, seal washers, valve cover, gasket, and spark plugs.

2. Remove the 6 bolts, and the No.3 and No.2 timing belt covers.

3. Turn the crankshaft pulley and align it's groove with the timing mark "0" of the No.1 timing belt cover.
4. Make sure that the hole of the cam timing pulley is aligned with the timing mark of the bearing cap. If not, turn the crank 1 complete
revolution.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 49

5. Remove the timing belt from the cam pulley. If re-using the belt, mark it at this time as shown.

6. Remove the plug from the No.1 timing belt cover.

7. Loosen the idler pulley mounting bolt and push the idler pulley towards the left as far as it will go, temporarily tighten it.

NOTE:Keep belt area clean from foreign objects, water, oil or other substances. Support the belt so that the meshing of the crank timing pulley and
timing belt do not shift.

8. Hold the hexagonal head wrench portion of the cam with a wrench and remove the bolt and pulley.

9. Remove the engine hanger and generator bracket.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 50

10. Remove the dipstick, remove the mount bolt and pull out the dipstick guide. Remove the O-ring from the dipstick guide.

11. Remove the 2 nuts and water inlet from the water inlet hose.

12. Set exhaust cam so the knock pin is slightly above the top of the cylinder head.

Caution: Keep camshaft level while removing, otherwise it may crack the cylinder head.

13. Remove the 2 bolts and the front bearing cap.

14. Secure the intake cam sub-gear to the main gear with a service bolt as shown. Recommended service bolt is 6mm thread diameter, 1.0mm
thread pitch, and 16-20mm (0.63-0.79 in.) length.

15. Remove the 8 bearing cap bolts in several passes in the sequence shown above, remove the 4 bearing caps and the camshafts.

Caution: Do not pry on or attempt to force the camshaft with a tool or other object.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 51

16. Set the exhaust cam so the knock pin is located slightly counterclockwise from the vertical axis of the cam as shown.

17. Remove the 2 bolts, front bearing cap and oil seal.

18. Remove the 8 bearing cap bolts in several passes in the sequence shown above, remove the 4 bearing cap bolts and camshaft.

19. Using SST 09205-16010, loosen and remove the cylinder head bolts in several passes in the sequence as shown above.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 52

20. Lift the cylinder head from the dowels on the block and place the head on wooden blocks.

Note: If the cylinder head is difficult to lift off, pry with a screwdriver between the head and the block saliences. Do not damage the head or block
mating surfaces when removing the head.

Cylinder Head Installation

1. Place the new head gasket in position on the block as shown.

2. Carefully place the cylinder head in place on the gasket.
3. Apply a light coat of engine oil to the threads and underneath the heads of the head bolts at this time.

Caution: If any head bolt is broken or deformed in any way replace with a new one.

4. Using SST 09205-16010, install and tighten the 10 head bolts in several passes in the sequence shown above. Starting torque is 29 Nm (22
ft.lbs).
5. The bolts are of 2 different lengths. Length A is 90mm (3.54 in.) and goes to the intake manifold side. Length B is 108mm (4.25 in.) and goes
to the exhaust manifold side.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 53

6. Mark the front of the head bolts with paint as shown.

7. Torque the head bolts 90° in the same order as shown. Again torque the head bolts and additional 90° and make sure the paint marks now all
point towards the rear of the engine.

Caution: Be careful to keep camshafts level while installing so as not to crack the cylinder head and/or seize the camshaft.

8. Apply MP grease to the thrust portion of the camshaft.

9. Place the exhaust cam so the knock pin is located slightly counterclockwise from the vertical axis as shown.

10. Remove any old packing material and apply new seal packing, part no. 08826-00080, to the cylinder head as shown.

11. Install the bearing caps in their proper locations as shown above.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 54

12. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Install and tighten the 10 cap bolts in the order
shown, in several passes. Final torque is 13 Nm (9 ft.lbs).

13. Apply MP grease to the new oil seal lip.

14. Using SST 09223-46011, tap the oil seal in with the lip facing as shown above.

15. set the exhaust cam so that the knock pin is slightly above the top of the cylinder head as shown above.
16. Apply MP grease to the thrust portion of the intake camshaft.

17. Engage the intake cam gear to the exhaust cam gear by matching the assembly installation mark on each gear as shown.

Caution: As shown, there are also timing (TDC) marks on the cam gears, do NOT use these marks to line the cam up with.

18. Roll down the intake cam onto the bearing journals while engaging the gears with each other.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 55

19. Install the bearing caps in their proper location as shown above.
20. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

21. Install and tighten the 8 bearing cap bolts in the order shown above in several passes. Final torque is 13 Nm (9 ft.lbs).

22. Remove the service bolt.

23. Install the No.1 bearing cap with the arrow mark facing forward.

Note: If the No.1 bearing cap does not fit properly, push the cam gear backwards.

24. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
25. Install and alternately tighten the bolts to a final torque of 13 Nm (9 ft.lbs).

26. Turn the exhaust cam clockwise, and set it with the knock pin facing upward as shown above.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 56

27. Check that the timing marks of the cam gears are aligned as shown.
28. Check and adjust valve clearance as necessary.

29. Connect the water inlet to the water inlet hose, install the 2 nuts and torque to 15 Nm (11 ft.lbs).

30. Push in the oil dipstick guide after coating the new O-ring with a small amount of engine oil.

31. Install the mount bolt, insert the oil dipstick and torque the mount bolt to 9 Nm (82 in.lbs).

32. Install the generator bracket and torque the 3 bolts to 26 Nm (20 ft.lbs).

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 57

33. Align the cam knock pin with the knock pin groove of the pulley and slide the pulley on.
34. Temporarily install the timing pulley bolt. Hold the hex portion of the cam with a wrench and torque the cam pulley bolt to 59 Nm (43 ft.lbs).

35. Line up the marks made on the timing belt and the cam sprocket as shown.

36. Loosen the idler pulley bolt a 1/2 turn.

37. Turn the crank pulley, clockwise only, 2 full revolutions from TDC to TDC.

38. Check that the crank and cam pulleys line up with there respective marks as shown, if they do not, remove the belt and reinstall.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 58

39. Torque the idler pulley bolt to 37 Nm (27 ft.lbs).

40. Check that timing belt deflection is 5 - 6 mm (0.20 - 0.24 in.) as shown. Adjust idler pulley as necessary to match spec.

41. Install the No.2 and No.3 timing belt covers, torque to 7.4 Nm (65 in.lbs). Install spark plugs, torque to 18 Nm (13 ft.lbs).

42. Remove any old packing material and apply new seal packing, part No. 08826-00080, to the circular plug as shown.

43. Install the semi-circular plug to the cylinder head.

44. Remove any old packing material from the valve cover and cylinder head.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 59

45. Apply seal packing, part No. 08826-00080, to the cylinder head as shown above.
46. Install new gasket to the valve cover.

47. Install the valve cover with the seal washers and cap nuts. Torque to 5.9 Nm (52 in.lbs).

NOTE: When using a new cylinder head, spark plug tubes must be installed.

Installing Spark Plug Tubes

(a) Mark the standard position away from the edge, onto the spark plug tube.
Standard protrusion: 46.8 - 47.6 mm (1.843 - 1.874 inch)

(b) Apply adhesive to the spark plug tube hole of the cylinder head.
Sealant: Part No. 08833 - 00070, Adhesive 1324, THREE BOND 1324 or equivalent.

(c) Using a press, press in a new spark plug tube until there is 46.8 - 47.6 mm (1.843 - 1.874 inch) protruding from the camshaft bearing
cap installation surface of the cylinder head.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 60

CAUTION: Avoid pressing a new spark plug tube in too far by measuring the amount of protrusion while pressing.

Accessory Installation
1. Install RH engine mount.

2. Using a new gasket, install the intake manifold and ground strap. Torque the bolts and nuts in several passes to 19 Nm (14 ft.lbs).

3. Connect the wire harness, install the ground strap and connect the knock sensor and ECT sender connectors.

4. Connect the wire harness to the valve cover and install the harness cover with the 2 mount bolts.
5. Connect the oil pressure switch and, on A/C equipped vehicles, the A/C compressor connector.

6. Apply a light coat of gas to the new O-ring and install the new O-rings and new grommets to the injectors.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 61

7. While turning the injector side to side, install it to the fuel rail. Install all 4 injectors in this manner. Position the injector connectors upwards.

8. Place 4 new insulators and the 2 spacers in position on the intake manifold.

9. Place the 4 injectors and the fuel rail in position on the intake manifold and temporarily install the 2 mount bolts in place.

10. Check that the injectors rotate smoothly. If not, check O-rings for improper installation, replace as necessary and reinstall the injectors.
Position the injector connectors upward.

11. Torque the mount bolts to 15 Nm (11 ft.lbs). Connect the injector electrical connectors.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 62

12. Install the 2 new gaskets, inlet pipe and union bolt to the fuel rail, torque union bolt to 29 Nm (22 ft.lbs).

13. Using a new gasket, install the air intake chamber and torque the mount nuts to 19 Nm (14 ft.lbs). Torque the 6mm hex bolts to 19 Nm (14
ft.lbs). Connect the vacuum line to the fuel pressure regulator.

14. Connect the 2 PCV hoses to the valve cover.

15. Using a new gasket, install the air intake chamber stay and torque the mount bolt to 28 Nm (21 ft.lbs). Install the fuel inlet hose clamp bolt.

16. Install a new gasket with the protrusion facing down as shown above.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 63

17. Install the throttle body and torque the mount bolts and nuts in the sequence shown to 22 Nm (16 ft.lbs). Connect the throttle position sensor
connector.

18. Install the accelerator bracket.

19. Using new gaskets, install the EGR valve, vacuum modulator, and vacuum hose assembly.
20. Connect the 2 vacuum hoses to the throttle body.

21. Install the air pipe and connect the fuel return hose to the pressure regulator and the air hose to the air pipe.

22. Install the intake manifold stay and torque the 12mm bolts to 19 Nm (14 ft.lbs) and the 14mm bolts to 39 Nm (29 ft.lbs).

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 64

23. Install wiring harness clamp.

24. Install the EGR VSV and connect the vacuum hose to the EGR valve.
25. Connect the EGR VSV connector and EGR gas temperature sensor connector.

26. On A/C equipped vehicles, connect the A/C actuator connector and, on P/S equipped vehicles, connect the air hoses to the air pipe.
27. Connect the following hoses to the intake chamber:

^ MAP hose to gas filter

^ Brake booster vacuum hose to gas filter
^ On A/C equipped vehicles, A/C vacuum hose from actuator

28. Connect wire harness from RH apron.

29. On A/C equipped vehicles, connect A/C pressure switch.
30. Connect MAP sensor connector and ground strap connector.

31. Install engine hanger and torque to 28 Nm (21 ft.lbs).

32. Using a razor blade, remove any remaining packing material from the water inlet housing gasket surfaces.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 65

33. Apply seal packing, part No. 08826-00100, as shown above.

Note: Do not use an excessive amount of seal packing, parts must be assembled within 15 minutes of application of seal packing.

34. Install the water inlet, torque bolt and nuts to 20 Nm (14 ft.lbs).

35. Connect the radiator outlet hose (1), water bypass hose (2), heather hoses (3), and the two EVAP TVV vacuum hoses (4).
36. Connect the ECT sensor connector, ECT switch connector, and the IAC valve connector.
37. Using a razor blade, remove any remaining seal packing from the water outlet housing gasket surfaces.

38. Apply seal packing, part No. 08826-00100, to the water outlet housing groove as shown above.

39. Install the water outlet and torque the bolts to 15 Nm (11 ft.lbs).

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 66

40. Install a new gasket and the catalytic converter. Torque the 2 bolts and 2 nuts to 28 Nm (22 ft.lbs).

41. Install the 2 catalytic convert heat shields.

42. Install the lower heat shield to the exhaust manifold.

43. Install a new gasket and the exhaust manifold. Torque the bolts in several passes to 34 Nm (25 ft.lbs).

44. Install the manifold stay and alternately torque the bolts to 39 Nm (29 ft.lbs).

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 67

45. Install the upper heat shield.

46. Place the 2 new gaskets to the front and rear of the front exhaust pipe. Install the front exhaust pipe and torque to 62 Nm (46 ft.lbs).
47. Install the support bracket and torque to 43 Nm (32 ft.lbs).
48. Install the 2 bolts holding the front exhaust pipe bracket to the mounting bracket and torque to 19 Nm (14 ft.lbs).
49. Connect the sub-oxygen sensor connector.
50. Install distributor and generator.

51. Connect the air cleaner hose and install the air cleaner cap.
52. Tighten the air cleaner hose clamp and connect the IAT sensor connector.

53. Connect the vacuum hose to the charcoal canister.

54. On cruise control equipped vehicles, connect the cruise control actuator cable.

55. On A/T equipped vehicles, connect the throttle cable.

56. Connect the accelerator cable.
57. Refill engine with coolant and connect negative battery cable.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 68
58. Start the engine, warm to normal operating temperature and check for leaks.
59. Install RH engine lower cover.
60. Check and adjust ignition timing as necessary.
61. Road test vehicle and top off coolant and oil as necessary after engine cools down.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 69
Cylinder Head Assembly: Service and Repair
Except California

Accessory Removal

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 70

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1. Disconnect negative battery cable.

Caution: You must wait at least 90 seconds after disconnecting the negative battery terminal before beginning work.

2. Drain engine coolant. Remove RH lower engine cover.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 72

3. Disconnect accelerator cable from bracket.

4. On A/T equipped vehicles, disconnect throttle cable from bracket.
5. Disconnect the IAT sensor connector from the air cleaner cap.

6. Loosen the air cleaner hose clamp bolt.

7. Disconnect the air cleaner cap clips.
8. Remove the air cleaner cap with the air cleaner hose.
9. Remove generator and distributor.
10. Disconnect the oxygen sensor connector.

11. Remove the 2 bolts and support bracket holding the front exhaust pipe to the mounting bracket.
12. Remove the 2 bolts and support bracket holding the front exhaust pipe to the exhaust manifold.
13. Using a 14mm deep socket, remove the 2 nuts, the front exhaust pipe and 2 gaskets.

14. Remove the 5 bolts and the upper heat shield.

15. Remove the 3 bolts and manifold stay.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 73

16. Remove the 5 nuts, exhaust manifold and gasket.

17. Remove the 3 bolts and lower heat shield from the exhaust manifold.
18. Disconnect the radiator inlet hose from the water outlet.

19. Remove the 2 bolts and water outlet.

20. Disconnect the ECT sensor connector, ECT switch connector, and the IAC valve connector.

21. Disconnect the hoses as shown above:

1) Radiator outlet hose

2) Water bypass hoses
3) 2 EVAP TVV vacuum hoses

22. Remove the bolt, 2 nuts, the water inlet, and the inlet housing assembly.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 74

23. Remove the nut and engine hanger.

24. Disconnect the ground strap connector and the map connector.
25. On A/C equipped vehicles, disconnect the A/C pressure switch.

26. Disconnect the wire harness from the RH fender apron.

27. Disconnect the map sensor hose from the gas filter.
28. Disconnect the brake booster vacuum hose.
29. On A/C equipped vehicles, disconnect the vacuum hoses from the actuator and the actuator connector.
30. On P/S equipped vehicles, disconnect the air hose from the air pipe.

31. Disconnect the engine wire clamp.

32. Remove the 3 bolts and manifold stay.

33. Disconnect the fuel return hose from the pressure regulator.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 75
34. Disconnect the air hose from the air pipe.

35. Remove the bolt, nut, and air pipe.

36. Remove the 2 bolts and accelerator bracket.

37. Disconnect the throttle position sensor connector.

38. Remove the 2 bolts, 2 nuts, throttle body, and gasket.

39. Remove the fuel inlet hose clamp bolt.

40. Remove the bolt, air intake chamber stay, and gasket.

41. Disconnect the 2 PCV hoses from the cylinder head cover.
42. Disconnect the vacuum hose from the pressure regulator.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 76

43. Using a 6mm hexagon wrench, remove the 3 bolts.

44. Remove the 2 nuts, air intake chamber and gasket.

45. Disconnect the union bolt, 2 gaskets, and fuel inlet hose.
46. Disconnect the fuel injector electrical connectors.

47. Remove the 2 bolts and fuel rail together with the 4 injectors.

Caution: Be careful not to drop the injectors when removing the fuel rail.

48. Remove the insulators and spacers from the cylinder head, remove the injectors from the fuel rail and remove the O-rings and grommets from
the injectors.

49. Disconnect the Compressor wire on A/C equipped vehicles and remove the oil pressure switch connector.
50. Remove the bolts, engine wire cover and disconnect the engine wire from the valve cover.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 77

51. Disconnect the knock sensor and ECT sender. Remove the bolt and disconnect the engine wire ground strap.

52. Remove the 3 nuts and disconnect the engine wire.

53. Remove the 7 mount bolts, ground strap, 2 nuts and intake manifold and gasket.
54. Remove the RH engine mount.

Cylinder Head Removal

1. Remove the 4 cap nuts, seal washers, valve cover, gasket, and spark plugs.

2. Remove the 6 bolts, and the No.3 and No.2 timing belt covers.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 78

3. Turn the crankshaft pulley and align it's groove with the timing mark "0" of the No.1 timing belt cover.
4. Make sure that the hole of the cam timing pulley is aligned with the timing mark of the bearing cap. If not, turn the crank 1 complete
revolution.

5. Remove the timing belt from the cam pulley. If re-using the belt, mark it at this time as shown.

6. Remove the plug from the No.1 timing belt cover.

7. Loosen the idler pulley mounting bolt and push the idler pulley towards the left as far as it will go, temporarily tighten it.

NOTE:Keep belt area clean from foreign objects, water, oil or other substances. Support the belt so that the meshing of the crank timing pulley and
timing belt do not shift.

8. Hold the hexagonal head wrench portion of the cam with a wrench and remove the bolt and pulley.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 79

9. Remove the engine hanger and generator bracket.

10. Remove the dipstick, remove the mount bolt and pull out the dipstick guide. Remove the O-ring from the dipstick guide.

11. Remove the 2 nuts and water inlet from the water inlet hose.

12. Set exhaust cam so the knock pin is slightly above the top of the cylinder head.

Caution: Keep camshaft level while removing, otherwise it may crack the cylinder head.

13. Remove the 2 bolts and the front bearing cap.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 80

14. Secure the intake cam sub-gear to the main gear with a service bolt as shown. Recommended service bolt is 6mm thread diameter, 1.0mm
thread pitch, and 16-20mm (0.63-0.79 in.) length.

15. Remove the 8 bearing cap bolts in several passes in the sequence shown above, remove the 4 bearing caps and the camshafts.

Caution: Do not pry on or attempt to force the camshaft with a tool or other object.

16. Set the exhaust cam so the knock pin is located slightly counterclockwise from the vertical axis of the cam as shown.

17. Remove the 2 bolts, front bearing cap and oil seal.

18. Remove the 8 bearing cap bolts in several passes in the sequence shown above, remove the 4 bearing cap bolts and camshaft.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 81

19. Using SST 09205-16010, loosen and remove the cylinder head bolts in several passes in the sequence as shown above.

20. Lift the cylinder head from the dowels on the block and place the head on wooden blocks.

Note: If the cylinder head is difficult to lift off, pry with a screwdriver between the head and the block saliences. Do not damage the head or block
mating surfaces when removing the head.

Cylinder Head Installation

1. Place the new head gasket in position on the block as shown.

2. Carefully place the cylinder head in place on the gasket.
3. Apply a light coat of engine oil to the threads and underneath the heads of the head bolts at this time.

Caution: If any head bolt is broken or deformed in any way replace with a new one.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 82

4. Using SST 09205-16010, install and tighten the 10 head bolts in several passes in the sequence shown above. Starting torque is 29 Nm (22
ft.lbs).
5. The bolts are of 2 different lengths. Length A is 90mm (3.54 in.) and goes to the intake manifold side. Length B is 108mm (4.25 in.) and goes
to the exhaust manifold side.

6. Mark the front of the head bolts with paint as shown.

7. Torque the head bolts 90° in the same order as shown. Again torque the head bolts and additional 90° and make sure the paint marks now all
point towards the rear of the engine.

Caution: Be careful to keep camshafts level while installing so as not to crack the cylinder head and/or seize the camshaft.

8. Apply MP grease to the thrust portion of the camshaft.

9. Place the exhaust cam so the knock pin is located slightly counterclockwise from the vertical axis as shown.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 83

10. Remove any old packing material and apply new seal packing, part no. 08826-00080, to the cylinder head as shown.

11. Install the bearing caps in their proper locations as shown above.

12. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Install and tighten the 10 cap bolts in the order
shown, in several passes. Final torque is 13 Nm (9 ft.lbs).

13. Apply MP grease to the new oil seal lip.

14. Using SST 09223-46011, tap the oil seal in with the lip facing as shown above.

15. set the exhaust cam so that the knock pin is slightly above the top of the cylinder head as shown above.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 84
16. Apply MP grease to the thrust portion of the intake camshaft.

17. Engage the intake cam gear to the exhaust cam gear by matching the assembly installation mark on each gear as shown.

Caution: As shown, there are also timing (TDC) marks on the cam gears, do NOT use these marks to line the cam up with.

18. Roll down the intake cam onto the bearing journals while engaging the gears with each other.

19. Install the bearing caps in their proper location as shown above.
20. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

21. Install and tighten the 8 bearing cap bolts in the order shown above in several passes. Final torque is 13 Nm (9 ft.lbs).

22. Remove the service bolt.

23. Install the No.1 bearing cap with the arrow mark facing forward.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 85

Note: If the No.1 bearing cap does not fit properly, push the cam gear backwards.

24. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
25. Install and alternately tighten the bolts to a final torque of 13 Nm (9 ft.lbs).

26. Turn the exhaust cam clockwise, and set it with the knock pin facing upward as shown above.

27. Check that the timing marks of the cam gears are aligned as shown.
28. Check and adjust valve clearance as necessary.

29. Connect the water inlet to the water inlet hose, install the 2 nuts and torque to 15 Nm (11 ft.lbs).

30. Push in the oil dipstick guide after coating the new O-ring with a small amount of engine oil.

31. Install the mount bolt, insert the oil dipstick and torque the mount bolt to 9 Nm (82 in.lbs).

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 86

32. Install the generator bracket and torque the 3 bolts to 26 Nm (20 ft.lbs).

33. Align the cam knock pin with the knock pin groove of the pulley and slide the pulley on.
34. Temporarily install the timing pulley bolt. Hold the hex portion of the cam with a wrench and torque the cam pulley bolt to 59 Nm (43 ft.lbs).

35. Line up the marks made on the timing belt and the cam sprocket as shown.

36. Loosen the idler pulley bolt a 1/2 turn.

37. Turn the crank pulley, clockwise only, 2 full revolutions from TDC to TDC.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 87

38. Check that the crank and cam pulleys line up with there respective marks as shown, if they do not, remove the belt and reinstall.

39. Torque the idler pulley bolt to 37 Nm (27 ft.lbs).

40. Check that timing belt deflection is 5 - 6 mm (0.20 - 0.24 in.) as shown. Adjust idler pulley as necessary to match spec.

41. Install the No.2 and No.3 timing belt covers, torque to 7.4 Nm (65 in.lbs). Install spark plugs, torque to 18 Nm (13 ft.lbs).

42. Remove any old packing material and apply new seal packing, part No. 08826-00080, to the circular plug as shown.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 88

43. Install the semi-circular plug to the cylinder head.

44. Remove any old packing material from the valve cover and cylinder head.

45. Apply seal packing, part No. 08826-00080, to the cylinder head as shown above.
46. Install new gasket to the valve cover.

47. Install the valve cover with the seal washers and cap nuts. Torque to 5.9 Nm (52 in.lbs).

NOTE: When using a new cylinder head, spark plug tubes must be installed.

Installing Spark Plug Tubes

(a) Mark the standard position away from the edge, onto the spark plug tube.
Standard protrusion: 46.8 - 47.6 mm (1.843 - 1.874 inch)

(b) Apply adhesive to the spark plug tube hole of the cylinder head.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 89
Sealant: Part No. 08833 - 00070, Adhesive 1324, THREE BOND 1324 or equivalent.

(c) Using a press, press in a new spark plug tube until there is 46.8 - 47.6 mm (1.843 - 1.874 inch) protruding from the camshaft bearing
cap installation surface of the cylinder head.

CAUTION: Avoid pressing a new spark plug tube in too far by measuring the amount of protrusion while pressing.

Accessory Installation
1. Install RH engine mount.

2. Using a new gasket, install the intake manifold and ground strap. Torque the bolts and nuts in several passes to 19 Nm (14 ft.lbs).

3. Connect the wire harness, install the ground strap and connect the knock sensor and ECT sender connectors.

4. Connect the wire harness to the valve cover and install the harness cover with the 2 mount bolts.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 90
5. Connect the oil pressure switch and, on A/C equipped vehicles, the A/C compressor connector.

6. Apply a light coat of gas to the new O-ring and install the new O-rings and new grommets to the injectors.

7. While turning the injector side to side, install it to the fuel rail. Install all 4 injectors in this manner. Position the injector connectors upwards.

8. Place 4 new insulators and the 2 spacers in position on the intake manifold.

9. Place the 4 injectors and the fuel rail in position on the intake manifold and temporarily install the 2 mount bolts in place.

10. Check that the injectors rotate smoothly. If not, check O-rings for improper installation, replace as necessary and reinstall the injectors.
Position the injector connectors upward.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 91

11. Torque the mount bolts to 15 Nm (11 ft.lbs). Connect the injector electrical connectors.

12. Install the 2 new gaskets, inlet pipe and union bolt to the fuel rail, torque union bolt to 29 Nm (22 ft.lbs).

13. Using a new gasket, install the air intake chamber and torque the mount nuts to 19 Nm (14 ft.lbs). Torque the 6mm hex bolts to 19 Nm (14
ft.lbs). Connect the vacuum line to the fuel pressure regulator.

14. Connect the 2 PCV hoses to the valve cover.

15. Using a new gasket, install the air intake chamber stay and torque the mount bolt to 28 Nm (21 ft.lbs). Install the fuel inlet hose clamp bolt.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 92

16. Install a new gasket with the protrusion facing down as shown above.

17. Install the throttle body and torque the mount bolts and nuts in the sequence shown to 22 Nm (16 ft.lbs). Connect the throttle position sensor
connector.

18. Install the accelerator bracket.

19. Install the air pipe and connect the fuel return hose to the pressure regulator and the air hose to the air pipe.

20. Install the intake manifold stay and torque the 12mm bolts to 19 Nm (14 ft.lbs) and the 14mm bolts to 39 Nm (29 ft.lbs).

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 93

21. Install wiring harness clamp.

22. On A/C equipped vehicles, connect the A/C actuator connector and, on P/S equipped vehicles, connect the air hoses to the air pipe.
23. Connect the following hoses to the intake chamber:

^ MAP hose to gas filter

^ Brake booster vacuum hose to gas filter
^ On A/C equipped vehicles, A/C vacuum hose from actuator

24. Connect wire harness from RH apron.

25. On A/C equipped vehicles, connect A/C pressure switch.
26. Connect MAP sensor connector and ground strap connector.

27. Install engine hanger and torque to 28 Nm (21 ft.lbs).

28. Using a razor blade, remove any remaining packing material from the water inlet housing gasket surfaces.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 94

29. Apply seal packing, part No. 08826-00100, as shown above.

Note: Do not use an excessive amount of seal packing, parts must be assembled within 15 minutes of application of seal packing.

30. Install the water inlet, torque bolt and nuts to 20 Nm (14 ft.lbs).

31. Connect the radiator outlet hose (1), water bypass hose (2), heater hoses (3), and the two EVAP TVV vacuum hoses (4).
32. Connect the ECT sensor connector, ECT switch connector, and the IAC valve connector.
33. Using a razor blade, remove any remaining seal packing from the water outlet housing gasket surfaces.

34. Apply seal packing, part No. 08826-00100, to the water outlet housing groove as shown above.

35. Install the water outlet and torque the bolts to 15 Nm (11 ft.lbs).

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 95

36. Install the lower heat shield on the exhaust manifold.

37. Install the exhaust manifold with the new gasket and torque the mount bolts in several passes to 34 Nm (25 ft.lbs).

38. Install the manifold stay, alternately torque the bolts to 39 Nm (29 ft.lbs).

39. Install the upper heat shield.

40. Place the 2 new gaskets to the front and rear of the front exhaust pipe. Install the front exhaust pipe and torque to 62 Nm (46 ft.lbs).
41. Install the support bracket and torque to 43 Nm (32 ft.lbs).
42. Install the 2 bolts holding the front exhaust pipe bracket to the mounting bracket and torque to 19 Nm (14 ft.lbs).
43. Connect the oxygen sensor connector.
44. Install distributor and generator.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 96

45. Connect the air cleaner hose and install the air cleaner cap.
46. Tighten the air cleaner hose clamp and connect the IAT sensor connector.

47. Connect the vacuum hose to the charcoal canister.

48. On cruise control equipped vehicles, connect the cruise control actuator cable.

49. On A/T equipped vehicles, connect the throttle cable.

50. Connect the accelerator cable.
51. Refill engine with coolant and connect negative battery cable.
52. Start the engine, warm to normal operating temperature and check for leaks.
53. Install RH engine lower cover.
54. Check and adjust ignition timing as necessary.
55. Road test vehicle and top off coolant and oil as necessary after engine cools down.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 97
Valve Clearance: Adjustments

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 98

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

HINT: Inspect and adjust the valve clearance when the engine is cold.

1. REMOVE CYLINDER HEAD COVER

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 99

(a) Disconnect the following wires and clamps:

(1) Alternator connector
(2) Alternator wire
(3) Oil pressure switch connector
(4) Two wire clamps

(b) Remove the two bolts and wire harness protector.

(c) Disconnect the wire harness from the cylinder head cover.

(d) Disconnect the high - tension cords at the rubber boot. Do not pull on the high-tension cords.

NOTICE: Pulling on or bending the cords may damage the conductor inside.

(e) Disconnect the PCV hoses from the cylinder head cover.

(f) Remove the four cap nuts, seal washers, cylinder head cover and gasket.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 100

2. SET NO.1 CYLINDER TO TDC/COMPRESSION

(a) Turn the crankshaft pulley and align its groove with the timing mark "0" of the No.1 timing belt cover.

(b) Check that the hole of the camshaft timing pulley is aligned with the timing mark of the bearing cap. If not, turn the crankshaft one
revolution (360°).

3. INSPECT VALVE CLEARANCE

(a) Check only the valves indicated.

- Using a thickness gauge, measure the clearance between the valve lifter and camshaft.
- Record the out - of - specification valve clearance measurements. They will be used later to determine the required replacement
adjusting shim.

Valve clearance (Cold):

Intake: 0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust: 0.25 - 0.35 mm (0.010 - 0.014 in.)

(b) Turn the crankshaft pulley one revolution (3600) and align the its groove with timing mark "0" of the No.1 timing belt cover.

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(c) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a))

4. ADJUST INTAKE VALVE CLEARANCE

A. Remove intake camshaft

NOTICE: Since the thrust clearance of the camshaft is small. the camshaft must be kept level while it is being removed. If the camshaft is
not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged. causing the camshaft to seize or break. To
avoid this. the following steps should be carried out.

(a) Turn the crankshaft pulley so that the hole in the sub-gear (which sets the sub-gear to the camshaft drive gear) comes up.

HINT: The above state allows the No.1 and No.3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.

(b) Remove the two bolts and No.1 bearing cap.

(c) Secure the intake camshaft sub-gear to the drive gear with a service bolt.

Recommended service bolt:

Thread diameter: 6 mm
Thread pitch: 1.0 mm
Bolt length: 16 - 20 mm (0.63 - 0.79 in.)

HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above
operation.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 102

(d) Uniformly loosen and remove the eight bearing cap bolts in several passes, in the sequence shown.
(e) Remove the four bearing caps and camshaft.

HINT: If the camshaft is not being lifted out straight and level, reinstall the No.3 bearing cap with the two bolts. Then alternately
loosen and remove the bearing cap bolts with the camshaft gear pulled up

NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object.

B. Remove adjusting shim

Remove the adjusting shim with a small screwdriver.

C. Determine the replacement adjusting shim size by following Formula or Charts:

(a) Using a micrometer, measure the thickness of the removed shim.

(b) Calculate the thickness of a new shim so that the valve clearance comes within specified value.

T: Thickness of removed shim

A: Measured valve clearance
N: Thickness of new shim

Intake: N = T + (A - 0.20 mm (0.008 in.))

(c) Select a new shim with a thickness as close as possible to the calculated value.

HINT: Shims are available in 16 sized in increments of 0.05 mm (0.0020 in.), from 2.55 mm (1.0039 in.) to 3.30 mm (0.1299 in.).

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 103

D. Install new adjusting shim

Place a new adjusting shim on the valve lifter.

E. Install intake camshaft

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft
is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged. causing the camshaft to seize or
break. To avoid this, the following steps should be carried out.

(a) Turn the crankshaft pulley, set the intake camshaft so the knock pin is slightly above the top of the cylinder head.

(b) Apply MP grease to the thrust portion of the camshaft.

(c) Engage the intake camshaft gear to the exhaust camshaft gear by matching the assembly installation mark on each gear.

NOTICE: There are also timing marks (for TDC) on each gear as shown in the illustration. Do not use these marks.

(d) Roll down the intake camshaft onto the bearing journals while engaging gears with each other.

HINT: The above angle allows the No.1 and No.3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.

(e) Install the four bearing caps in their proper locations.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 104

(f) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(g) Install and uniformly tighten the eight bearing cap bolts in several passes, in the sequence shown.
Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)

(h) Remove the service bolt.

(i) Install the No.1 bearing cap with the arrow mark facing forward.

NOTICE: If the No.1 bearing cap does not fit properly, push the camshaft gear backwards by prying apart the cylinder head and
camshaft gear with a screwdriver.

(j) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
(k) Install and alternately tighten the two bearing cap bolts in several passes.
Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)

F. Recheck valve clearance

5. ADJUST EXHAUST VALVE CLEARANCE

A. Remove adjusting shim

(a) Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve upward.
(b) Position the notch of the valve lifter facing the front of the vehicle.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 105

(c) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A).
SST: 09248-55020 (09248-05011, 09248-05021)

HINT:
- Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration.
- When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it shallowly from the
intake side, at a slight angle.

- The shape of the cam makes it difficult to insert SST (B), from the intake side to the No.3 rear. For this shim, it is best approached
from the exhaust side instead.

(d) Remove the adjusting shim with a small screwdriver and magnetic finger.

B. Determine replacement adjusting shim size by following Formula or Charts:

(a) Using a micrometer, measure the thickness of the removed shim.

(b) Calculate the thickness of a new shim so that the valve clearance comes within specified value.

T: Thickness of removed shim

A: Measured valve clearance
N: Thickness of new shim

Exhaust: N = T + (A - 0.30 mm (0.012 in.))

(c) Select a new shim with a thickness as close as possible to the calculated value.

HINT: Shims are available in 16 sizes, in increments of 0.05 mm (0.0020 in.), from 2.55 mm (1.0039 in.) to 3.30 mm (0.1299 in.).

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 106

C. Install new adjusting shim

(a) Place a new adjusting shim on the valve lifter.

(b) Using SST (A), press down the valve lifter and remove SST (B).
SST: 09248-55020 (09248-05011. 09248-05021)

D. Recheck valve clearance

6. INSTALL CYLINDER HEAD COVER

(a) Remove any old packing (FIPG) material.

(b) Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
(c) Install the gasket to the cylinder head cover.

(d) Install the cylinder head cover with the four seal washers and cap nuts.
Torque. 5.9 N.m (60 kgf.cm, 52 in.lbf)

(e) Connect the PCV hoses to the cylinder head cover.

(f) Connect the four high-tension cords to the spark plugs.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 107

(g) Install the engine wire harness and protector with the two bolts.
(h) Connect the following wires and clamps:

(1) Alternator connector

(2) Alternator wire
(3) Oil pressure switch connector
(4) Two wire clamps

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 108
Fuel Pressure Release: Service and Repair
FUEL PRESSURE RELEASE
- Disconnect the cable from the negative (-) terminal of the battery.

CAUTION: Work must be started after approx. 90 seconds or longer from the time the ignition switch is turned to the "LOCK" position and
the negative terminal cable is disconnected from the battery.

- Put a suitable container or shop towel under the cold start injector pipe.

Union Bolt

- Slowly the union bolt for the fuel inlet hose from the delivery pipe.

Torque: 29 N.m (300 kgf.cm, 22 ft.lbs)

- When fuel pressure is released, re-tighten union bolt.

- Wipe off any splattered gasoline.
- Reconnect the battery negative (-) cable.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 109
Drive Belt: Service and Repair
A/C
DRIVE BELT REMOVAL

1. Remove Washer Reserve Tank

2. Remove Alternator Drive Belt

3. Loosen Idle Pulley Lock Nut

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

4. Loosen Adjusting Bolt And Remove Drive Belt

DRIVE BELT INSTALLATION

Installation is in the reverse order of removal.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 110
Drive Belt: Service and Repair
Alternator

GENERATOR INSTALLATION
1. INSTALL GENERATOR
(a) Mount generator on the generator bracket with the pivot bolt. nut and adjusting lock bolt. Do not tighten the bolts yet.
(b) Connect the generator connector.
(c) Connect the generator wire with the nut.

2. INSTALL DRIVE BELT

(a) Install the drive belt.
(b) Using a belt tension gauge, measure the drive belt tension.
Belt tension gauge: Nippondenso BTG-20 (95506-00020) Borrough: No. BT-33-73F
Drive belt tension:
New Belt =175 ± 5 lbf,
Used belt =115 ± 20. lbf
(c) Tighten the pivot and adjusting lock bolt.

HINT:

- "New belt" refers to a belt which has been used less than 5 minutes on a running engine.
- "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.
- After installing a belt, check that it fits properly in the ribbed grooves.
- Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.
- After installing a new belt. run the engine for about 5 minutes and recheck the belt tension.
3. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
4. PERFORM ON-VEHICLE INSPECTION

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 111
Oil Pressure Warning Lamp/Indicator: Testing and Inspection
1. Disconnect connector from warning switch and ground terminal on wire harness side connector.
2. Turn ignition switch to On position, then check warning light illuminates. If not, test bulb.
3. Ensure there is continuity between terminal and ground with engine stopped.
4. Ensure there is no continuity between terminal and ground with engine running.
5. Oil pressure should be as follows:
a. On Avalon, Previa, Supra and 1994-96 Camry, over 4.3 psi.
b. On Paseo models, over 2.8 psi.
c. On Celica models, over 2.9 psi.
d On RAV4 models, over 3.6 psi.
e. On MR2, Tacoma, Tercel, T100, 1993 Camry and Corolla models, over 7.1 psi.
6. On 4Runner, Pickup and Land Cruiser models, disconnect connector from sender gauge.
7. On all models, turn ignition switch to On position, then check receiver gauge needle indicates Low.
8. Ground terminal on wire harness side connector through a 3.4W test bulb.
9. Turn ignition switch to On position, then check bulb illuminates and receiver gauge needle moves to high side.
10. On 4Runner and Pickup models, measure resistance between terminals A and B. Resistance should be about 25.0 ohms. If not as specified,
replace receiver gauge.
11. On 1993 Land Cruiser models, measure resistance between terminals. Resistance should be 22.0-28.0 ohms. If not as specified, replace
receiver gauge.
12. On 1994-96 Land Cruiser models, measure resistance between terminals. Resistance should be 40.0-48.0 ohms. If not as specified, replace
receiver gauge.
13. If resistance is not as specified, replace sender gauge.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 112
Oil Pump: Testing and Inspection
COMPONENTS FOR DISASSEMBLY AND ASSEMBLY

OIL PUMP DISASSEMBLY

1. REMOVE RELIEF VALVE

(a) Using snap ring pliers, remove the snap ring.

(b) Remove the retainer, spring and relief valve.

2. REMOVE DRIVE AND DRIVEN ROTORS

Remove the 5 screws, pump body cover, O-ring. the drive and driven rotors.

OIL PUMP INSPECTION

1. INSPECT RELIEF VALVE

Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it doesn't, replace the relief valve.
If necessary, replace the oil pump assembly.

2. INSPECT DRIVE AND DRIVEN ROTORS

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A. Inspect rotor body clearance

Using a thickness gauge, measure the clearance between the driven rotor and body.

Standard body clearance: 0.080 - 0.180 mm (0.0031 - 0.0071 in.)

Maximum body clearance: 0.20 mm (0.0079 in.)

If the body clearance is greater than maximum, re place the rotors as a set.
If necessary, replace the oil pump assembly.

B. Inspect rotor tip clearance

Using a thickness gauge, measure the clearance between the drive and driven rotor tips.

Standard tip clearance: 0.025 - 0.085 mm (0.0010 - 0.0033 in.)

Maximum tip clearance: 0.35 mm (0.0138 in.)

If the tip clearance is greater than maximum1 replace the rotors as a set.

C. Inspect rotor side clearance

Using a thickness gauge and precision straight edge, measure the clearance between the rotors and precision straight edge.

Standard side clearance: 0.025 - 0.085 mm (0.0010 - 0.0033 in.)

Maximum side clearance: 0.10 mm (0.0039 in.)

If the side clearance is greater than maximum, replace the rotors as a set.
If necessary, replace the oil pump assembly.

3. REPLACE FRONT CRANKSHAFT OIL SEAL

OIL PUMP ASSEMBLY

1. INSTALL DRIVE AND DRIVEN ROTORS

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(a) Place the drive and driven rotors into pump body with the marks facing the pump body cover side.

(b) Install the oil pump body cover with the 5 screws. Torque: 10 N.m (105 kgf.cm, 8 ft.lbf)

2. INSTALL RELIEF VALVE

(a) Insert the relief valve. spring and retainer into the oil pump body hole.
(b) Using snap ring pliers, install the snap ring.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 115
Oil Pump: Service and Repair
COMPONENTS FOR OIL PUMP REMOVAL AND INSTALLATION

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OIL PUMP REMOVAL

HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned.

1. REMOVE HOOD
2. DRAIN ENGINE OIL
3. REMOVE ENGINE UNDER COVERS
4. REMOVE TIMING BELT

HINT: When removing the RH engine mounting, attach the engine hoist chain to the lifting bracket on the engine and lift the engine slightly.

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5. REMOVE IDLER PULLEY AND TENSION SPRING

Remove the bolt. pulley and tension spring.

6. REMOVE CRANKSHAFT TIMING PULLEY

If the pulley cannot be removed by hand, use 2 screwdrivers.
HINT: Position shop rags as shown to prevent damage.

7. REMOVE OIL DIPSTICK GUIDE AND DIPSTICK

(a) 7A-FE: Disconnect the crankshaft position sensor connector from the dipstick guide.
(b) Remove the mounting bolt and pull out the dipstick guide and gauge.
(c) Remove the O-ring from the dipstick guide.

8. REMOVE FRONT EXHAUST PIPE

(a) Disconnect the oxygen sensor connector.
(b) Remove the 2 bolts holding the front exhaust pipe to the mounting bracket.
(c) Remove the 2 bolts and support bracket holding the front exhaust pipe to the TWC.

(d) Using a 14 mm deep socket wrench, remove the 2 nuts.

(e) Remove the front exhaust pipe and 2 gaskets.

9. 4A-FE: REMOVE STIFFENER PLATE

(a) Remove the 5 set bolts.
(b) Remove the stiffener plate.

10. REMOVE OIL PAN

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 118

(a) 4A-FE: Remove the 19 bolts, 2 nuts and oil pan.

(b) 7A-FE: Remove the 13 bolts, 2 nuts and No.2 oil pan.

(c) Insert the blade of SST between the cylinder block and oil pan, and cut off applied sealer and remove the oil pan.
SST 09032-00100

NOTICE:
^ Do not use SST for the oil pump body side end rear oil seal retainer.
^ Be careful not to damage the oil pan flange.

11. 7A-FE: REMOVE OIL PAN BAFFLE PLATE

Remove 2 bolts, 2 nuts and baffle plate.

12. REMOVE OIL STRAINER

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 119

(a) 4A-FE: Remove the 2 bolts, 2 nuts, oil strainer and gasket.

(b) 7A-FE: Remove the 3 nuts, oil strainer and gasket.

13. 7A-FE: REMOVE NO.1 OIL PAN

(a) Remove the 3 transaxle mounting bolts from the engine rear end plate side.

(b) Remove the 6 bolts.

(c) Using 5 mm hexagon wrench, remove the 14 bolts and No.1 oil pan.

(d) Remove the No.1 oil pan by prying the portions between the cylinder block and No.1 oil pan with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and No.1 oil pan.

14. REMOVE OIL PUMP

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 120

(a) 7A-FE: Remove the bolt and crankshaft position sensor.

(b) Remove the 7 bolts.

(c) Using a plastic-faced hammer. remove the oil pump by carefully tapping the oil pump body.
(d) Remove the gasket.

OIL PUMP INSTALLATION

1. INSTALL OIL PUMP
(a) Place a new gasket on the cylinder block.

(b) Engage the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft. and slide the oil pump.

(c) Install the oil pump with the 7 bolts.

Torque: 21 N.m (218 kgf.cm. 16 ft.lbf)
Bolt length:
Long bolt: 35 mm (1.38 in.)
Other bolt: 25 mm (0.98 in.)

(d) 7A-FE: Install the crankshaft position sensor with the bolt.

2. 7A-FE: INSTALL NO.1 OIL PAN

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and cylinder block.
^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
^ Thoroughly clean all components to remove all the loose material.
^ Using a non-residue solvent. clean both sealing surfaces.

NOTICE: Do not use a solvent which will affect the painted surfaces.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 121

(b) Apply seal packing to the oil pan as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
^ Install a nozzle that has been cut to a 3 - 5 mm (0.12- 0.20 in.) opening.
^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.

(c) Using a 5 mm hexagon wrench, install the No.1 oil pan with new 14 bolts. Torque the bolts.
Torque: 16 N.m (165 kgf.cm. 12 ft.lbf) for Bolt A
(d) Install the 6 bolts. Torque the bolts.
Torque: 7.8 N.m (80 kgf.cm. 69 in..lbf) for Bolt B
(e) Install and torque the 3 transaxle mounting bolts to the engine rear end plate side.
Torque: 23 N.m (230 kgf.cm, 17 ft.lbf)

3. INSTALL OIL STRAINER

(a) 4A-FE: Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.
Torque: 9.3 N.m (95 kgf.cm. 82 in.lbf)

(b) 7A-FE: Install a new gasket and the oil strainer with the 3 nuts.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)

4. 7A-FE: INSTALL OIL PAN BAFFLE PLATE

Install the baffle plate with the 2 bolts and nuts.
Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)

5. INSTALL OIL PAN (4A-FE)/NO.2 OIL PAN (7A- FE)

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and cylinder block.
^ Using a razor blade and gasket scraper. remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
^ Thoroughly clean all components to remove all the loose material.
^ Using a non-residue solvent. clean both sealing surfaces.

NOTICE: Do not use a solvent which will affect the painted surfaces.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 122

(b) Apply seal packing to the oil pan as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

^ Install a nozzle that has been cut to a 3 - 5 mm (0.12- 0.20 in.) opening.
^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.

(c) 4A-FE: Install the oil pan with the 19 bolts and 2 nuts.
Torque: 4.9 N.m (50 kgf.cm. 43 in.lbf)

(d) 7A-FE: Install the No.2 oil pan with the 1 3 bolts and 2 nuts.
Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf)

6. 4A-FE: INSTALL STIFFENER PLATE

(a) Temporarily tighten the No.1 bolt.

(b) Torque the 5 bolts on the stiffener plate in the order shown.
Torque: 23 N.m (230 kgf.cm. 17 ft.lbf)

7. INSTALL FRONT EXHAUST PIPE

(a) Place 2 new gaskets to the front and rear of the front exhaust pipe.
(b) Using a 14 mm deep socket wrench. install the front exhaust pipe with 2 new nuts.
Torque: 62 N.m (630 kgf.cm. 46 ft.lbf)
(c) Install the 2 bolts and support bracket holding the front exhaust pipe to the TWC.
Torque: 43 N.m (440 kgf.cm, 32 ft.lbf)
(d) Install the 2 bolts holding the front exhaust pipe bracket to the mounting bracket.
Torque: 19 N.m (195 kgf.cm, 14 ft.lbf)
(e) Connect the oxygen sensor connector.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 123

8. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK

(a) Install a new O-ring to the dipstick guide.
(b) Apply small amount of engine oil to the O-ring.
(c) Push in the dipstick guide together with the dipstick, and install them with the bolt.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
(d) 7A-FE: Connect the crankshaft position sensor connector to the dipstick guide.

9. INSTALL CRANKSHAFT TIMING PULLEY

(a) Align the timing pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley, facing the flange side inward.

10. TEMPORARILY INSTALL IDLER PULLEY AND TENSION SPRING

(a) Install the idler pulley with the bolt. Do not tighten the bolt yet.
(b) Install the tension spring.
(c) Push the pulley toward the left as far as it will go and tighten the bolt.

11. INSTALL TIMING BELT

12. FILL WITH ENGINE OIL
13. START ENGINE AND CHECK FOR OIL LEAKS
14. RECHECK ENGINE OIL LEVEL
15. INSTALL ENGINE UNDER COVERS
16. INSTALL HOOD

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 124
Timing Components: Testing and Inspection
TIMING BELT INSPECTION

NOTICE:
- Replace every 60,000 miles.
- Do not bend. twist or turn the timing belt inside out.
- Do not allow the timing belt to come into contact with oil, water or steam.
- Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.

If there are any defects found, check the following points:

1. Premature parting.
- Check the proper installation.
- Check the timing cover gasket for damage and proper installation.

2. If the belt teeth are cracked or damaged, check to see if either camshaft or water pump is locked.

3. If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock.

4. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 125

5. If there is noticeable wear on the belt teeth, check the timing cover for damage, correct gasket installation, and for foreign material on the
pulley teeth.

If necessary, replace the timing belt.

IDLER PULLEY INSPECTION

1. Check that the idler pulley turns smoothly. If necessary, replace the idler pulley.

TENSION SPRING INSPECTION

1. Measure the free length of tension spring.

Free length: 35.3 mm (1.390 in.)

If the free length is not as specified, replace the tension spring.

2. Measure the tension of the tension spring at the specified installed length.

Installed tension: 58 N (13.0 lbf) at 50.5 mm (1.988 in.)

If the installed tension is not as specified, replace the tension spring.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 126
Timing Belt: Service and Repair
Timing Belt Removal

TIMING BELT REMOVAL

1. Disconnect cable from negative terminal of battery.

CAUTION: Turn the ignition switch to "LOCK". Disconnect the negative terminal from the battery. Wait at least 90 seconds before
proceeding with work.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 127

2. Remove washer tank.

(a) Remove the washer tank mounting bolt.
(b) Disconnect the connector and hose, remove the washer tank.

3. On vehicles with cruise control system, remove cruise control actuator.

(a) Remove the actuator cover.

(b) Disconnect the actuator connector.

(c) Remove the three bolts and disconnect the actuator with the bracket.

4. Remove RH front wheel.

5. Remove RH engine under cover.
6. Loosen water pump pulley bolts and remove alternator drive belt.

(a) Stretch the belt tight and loosen the water pump pulley bolts.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 128

(b) Loosen the pivot bolt and adjusting lock bolt.

(c) Loosen the adjusting bolt, and remove the drive belt.

7. On vehicles with A/C, remove A/C compressor without disconnecting hoses.

(a) Loosen the idler pulley mounting bolt A.

(b) Loosen the adjusting bolt B and remove the drive belt

(c) Disconnect the A/C compressor connector.

(d) Remove the four compressor mounting bolts.
(e) Move the compressor aside and suspend it.

8. On vehicles with A/C, remove A/C compressor mounting bracket.

Remove the four bolts and A/C compressor mounting bracket.

9. On vehicles with PS, remove PS pump drive belt.

(a) Loosen the pivot and lock bolts.
(b) Swing PS pump toward the engine and remove the drive belt.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 129

10. Disconnect engine wire.

(a) Disconnect the following connectors and wire:
- Alternator connector
- Alternator wire
- Oil pressure switch connector
(b) Remove the two bolts with the engine wire cover, and disconnect the engine wire from cylinder head cover.

11. Remove spark plugs.

(a) Disconnect the high - tension cords at the rubber boot. DO NOT pull on the cords.

NOTICE: Pulling on or bending the cords may damage the conductor inside.

(b) Using a 16mm plug wrench, remove the spark plug.

12. Remove cylinder head cover.

(a) Disconnect the PCV hoses from the cylinder head cover.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 130

(b) Remove the four cap nuts, seal washers, and cylinder head cover with the gasket.

13. Set No.1 cylinder at TDC/Compression.

(a) Turn the crankshaft pulley and align its groove with the No.1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are loose. If not, turn the crankshaft pulley one complete revolution (360°).

14. Disconnect connector from ground wire on RH fender apron.

15. Remove RH engine mounting insulator.

(a) Set the jack to the engine.

HINT: Place a wooden block between the jack and engine.

(b) On vehicles with A/C, remove the nut and bracket.

(c) Remove the five bolts, two nuts and RH mounting.

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16. Remove water pump pulley.

17. Remove crankshaft pulley.

(a) Using SST 09213-14010 and 09330-00021 to hold the crankshaft pulley. remove the pulley bolt.

(b) Using SST 09213-31021. remove the pulley.

18. Remove timing belt covers.

Remove the nine bolts, and timing belt covers.

19. Remove timing belt guide.

20. Remove timing belt and idler pulley.

HINT: (When re-using timing belt)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 132
Draw a direction arrow on the timing belt (in the direction of engine revolution), and place matchmarks on the timing belt and crankshaft
timing pulley.

(a) Remove the bolt, idler pulley and tension spring.

(b) Remove the timing belt.

21. Remove crankshaft timing pulley.

22. Remove camshaft timing pulley.

Hold the hexagonal head wrench portion of the camshaft with a wrench, and remove the bolt and timing pulley.

NOTICE: Be careful not to damage the cylinder head with the wrench

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 133
Timing Belt: Service and Repair
Timing Belt Installation

TIMING BELT INSTALLATION

1. Install camshaft timing pulley.

(a) Align the camshaft knock pin with the knock pin groove of the pulley. and slide on the pulley.
(b) Temporarily install the timing pulley bolt.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 134

(c) Hold the hexagonal wrench head portion of the camshaft with a wrench and tighten the timing pulley bolt.

Torque: 59 N.m (600 kgf.cm 43 ft.lbf)

(d) Turn the hexagonal wrench head portion of the camshaft and align the hole of the camshaft timing pulley with the timing mark of the
bearing cap.

2. Install crankshaft timing pulley.

(a) Align the pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley facing the flange side inward.
(c) Using the crankshaft pulley bolt, turn the crankshaft and align the timing marks of the crankshaft timing pulley and oil pump body.

3. Temporarily install idler pulley and tension spring.

(a) Install the idler pulley with the bolt. Do not tighten the bolt yet.
(b) Install the tension spring.
(c) Push the pulley toward the left as far as it will go and tighten the bolt.

4. Install timing belt.

NOTICE: The engine should be cold.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 135

HINT: If reusing the timing belt, align the points marked during removal and install the belt with the arrow pointing in the direction of
engine revolution.

5. Check valve timing and timing belt tension.

(a) Loosen the timing belt idler pulley mounting bolt.

(b) Temporarily install the crank pulley bolt and turn the crankshaft two revolutions from TDC to TDC.

HINT: Always turn the crankshaft clockwise.

(c) Check the valve timing.

Check that each pulley aligns with the marks as shown in the illustration.

(d) Tighten the timing belt idler pulley mounting bolt.

Torque: 37 N.m (375 kgf.cm. 27 ft.lbf)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 136

(e) Remove the temporarily installed crank pulley bolt.

(Reference)
(a) Measure the timing belt deflection as shown in the illustration.

Timing belt deflection: 5 - 6 mm (0.20 - 0.24 in.) et 20 N (2 kgf, 4.4 lbf)

(b) If the measured value is not within standard readjust with the idler pulley.

6. Install timing belt guide.

Install the guide, facing the cup side outward.

7. Install timing belt covers.

(a) Install the timing belt cover with the three bolts.
(b) Install the No.2 and No.3 timing belt covers with the six bolts.

Torque: 7.4 N.m (75 kgf.cm, 65 in.lbf)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 137

8. Install crankshaft pulley.

(a) Align the pulley set key with the key groove of the pulley and slide on the pulley.
(b) Temporarily install the pulley bolt.
(c) Using SST 09213-14010 and 09330-00021, install the pulley bolt.

Torque: 118 N.m (1,200 kgf.cm 87 ft.lbf)

9. Temporarily install water pump pulley.

10. Install RH engine mounting insulator.

(a) Tighten the two nuts and bolt holding the RH mounting insulator to the mounting bracket.

Bolt Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)

Nut Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)

(b) Tighten the four bolts holding the RH mounting insulator to the body.

Bolt A Torque: 25 N.m (260 kgf.cm, 19 ft.lbf)

Bolt B Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)

(c) On vehicles with A/C, install the bracket with bolt.

11. Connect ground connector to ground wire on RH fender apron.

12. Install cylinder head cover.

(a) Apply seal packing as shown in the illustration.

Seal packing: Part no.08826-00080 or equivalent

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 138

HINT: Clean the indicated portions by removing the original sealant before recoating.

(b) Install the gasket to the cylinder head cover.

(c) Install the cylinder head cover with the four seal washers and cap nuts.

(d) Install the PCV hoses to cylinder head cover.

13. Install spark plugs.

(a) using a 16 mm plug wrench, install the spark plug.

Torque: 18 N.m (180 kgf.cm, 13 ft.lbf)

(b) Connect the high-tension cords to spark plugs.

14. Connect engine wire.

(a) Connect the engine wire to the cylinder head cover, and install the two bolts with the engine wire cover.
(b) Connect the following connectors and wire:
- Alternator connector
- Alternator wire
- Oil pressure switch connector

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 139

15. On vehicles with PS, install and adjust PS drive belt.

Install the drive belt with the pivot and adjusting bolts.

Drive belt tension:

New belt 125 ± 25 lbf
Used belt 80 ± 20 lbf

16. On vehicles with A/C, install A/C compressor mounting bracket with the four bolts.

Torque: 47 N.m (480 kgf.cm. 35 ft.lbf)

17. On vehicles with A/C, install A/C compressor.

(a) Install the A/C compressor with the four bolts.

Torque: 25 N.m (250 kgf.cm. 18 ft.lbf)

(b) Connect the A/C compressor connector.

18. On vehicles with A/C, install and adjust A/C drive belt.
Install the drive belt with the idler pulley nut and adjusting bolt B.

Drive belt tension:

New belt 130 ± 10 lbf
Used belt 75 ± 15 lbf

19. Install and adjust alternator drive belt.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 140

(a) Install the drive belt with the pivot adjusting bolt and lock bolt.

Drive belt tension:

New belt 175 ± 5 lbf
Used belt 115 ± 20 lbf

(b) Tighten the four water pump pulley bolts.

Torque: 9.3 N.m (95 kgf.cm, 7 in.lbf)

20. Install RH engine under cover.

21. Install RH front wheel.

22. On vehicles with Cruise control, install cruise control actuator.

(a) Install the actuator and bracket with the three bolts.
(b) Connect the actuator connector.
(c) Install the actuator cover.

23. Install washer tank.

(a) Connect the connector and vinyl hose to the washer tank
(b) Install the washer lank with the bolt

24. Connect cable to negative terminal of battery.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 141
Timing Belt Idler Pulley: Testing and Inspection
IDLER PULLEY INSPECTION

1. Check that the idler pulley turns smoothly. If necessary, replace the idler pulley.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 142
Timing Belt Tensioner: Testing and Inspection
TENSION SPRING INSPECTION

1. Measure the free length of tension spring.

Free length: 35.3 mm (1.390 in.)

If the free length is not as specified, replace the tension spring.

2. Measure the tension of the tension spring at the specified installed length.

Installed tension: 58 N (13.0 lbf) at 50.5 mm (1.988 in.)

If the installed tension is not as specified, replace the tension spring.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 143
Timing Component Alignment Marks: Locations

CAUTION: Incorrect removal or installation of the timing belt can result in damage to internal engine components.

For complete Timing Belt Removal and Installation information: See: Timing Belt/Service and Repair

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 144
Water Pump: Service and Repair
COMPONENTS FOR REMOVAL AND INSTALLATION

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 145

REMOVAL
1. Drain engine coolant.

2. Remove RH engine mounting insulator.

3. Remove No. 2 and No. 3 timing belt covers.

4. Remove front engine mounting insulator as follows:

a. Remove the hole cover.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 146
b. Remove the 2 bolts from the mounting.
c. Remove the nut, through-bolt and front engine mounting insulator.
5. Remove electric cooling fan.
6. Disconnect engine wire remove the bolt and 2 nuts, and disconnect the engine wire.
7. Remove water pump as follows:

a. Disconnect the crankshaft position sensor connector from the dipstick guide.
b. Remove the mounting bolt and pull out the dipstick guide and gauge.
c. Disconnect the water temperature sender gauge connector.
d. Remove the 2 nuts and No.2 water inlet from the water inlet hose.

e. Remove the 3 bolts and water pump.

CAUTION: Be careful not to get coolant on the timing belt.

INSTALLATION
1. Install water pump as follows:

a. Place a new O-ring on the block.

b. Install the pump with the 3 bolts. Torque the bolts to 14 Nm (10 ft. lbs.).
c. Connect the inlet hose to the water pump, and install the water inlet No.2 to the cylinder head with the 2 nuts. Torque to 14.5 Nm (11 ft.
lbs.).
d. Connect the water temperature sender gauge connector.
2. Install oil dipstick guide and dipstick as follows:

a. Install a new O-ring on the oil dipstick guide.

b. Apply small amount of engine oil to the O-ring.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 147
c. Push in the oil dipstick guide with the O-ring.
d. Install the mounting bolt. Torque to 9.3 Nm (82 inch lbs.).
e. Connect the crankshaft position sensor connector to the dipstick guide.
3. Connect engine wire. Connect the engine wire with the bolt and 2 nuts.
4. Install electric cooling fan.
5. Install front engine mounting insulator.
a. Install the front engine mounting insulator, through-bolt and nut. Torque to 87 Nm (64 ft. lbs.).
b. Install the 2 bolts to the mounting. Torque to 64 Nm (47 ft. lbs.).
c. Install the hole cover.
6. Install No. 2 and No. 3 timing belt covers.
7. Install RH engine mounting insulator.
8. Fill radiator with engine coolant.
9. Start engine and check for leaks.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 148
Cooling System: Description and Operation

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 149

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 150
Cooling System: Testing and Inspection
Cooling System Pressure Check
1. With engine off and radiator cool, remove radiator cap and place suitable pressure tester to the radiator.
2. Pump it to 17.1 psi and check that the pressure does not drop.
3. If the pressure drops, check for leaks from hoses, radiator, or water pump. If no external leaks are found, check the heater core, engine block,
and intake manifold.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 151
Cooling System: Testing and Inspection
Diagnosis and Symptoms
1. If coolant temperature is low (below 181°F), proceed as follows:
a. Turn ignition switch on and check that cooling fan does not operate. If fan runs, check for faulty fan relay and/or temperature switch.
Check too for separated electrical connectors or severed wire between relay and temperature switch.
b. Disconnect temperature switch wire, then check that fan rotates. If fan does not run, check fan relay, fan motor, ignition relay and
temperature switch.
c. Connect temperature switch wire.
2. If coolant temperature is high (above 199°F), proceed as follows:
a. Raise engine temperature to at least 200°F, then confirm that fan rotates.
b. If fan does not rotate, replace temperature switch.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 152
Radiator Cooling Fan Motor Relay: Testing and Inspection
1. Check fan motor relay, located in engine compartment relay box, as follows:
a. Using an ohmmeter, check relay continuity. If in either case continuity is absent, replace relay. Check for continuity first between
terminals 1 and 2, then between terminals 3 and 4, Fig. 10.

Fig. 10 Cooling Fan Motor Relay Inspection.

b. Apply battery voltage across terminals 1 and 2, then confirm that continuity is not present between terminals 3 and 4. If continuity is
found, replace relay.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 153

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 154
Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection

Fig. 8 Main Relay Connector.

Fig. 1 Checking Cooling Fan Motor Relay

Fig. 3 Checking Fan Motor

1. Using an ohmmeter, check temperature switch continuity. Continuity should be present when water temperature is below 181°F and absent
when water temperature is above 199°F.
2. Inspect main relay, located in engine compartment relay box as follows:
a. Using an ohmmeter, check that continuity exists between terminals 1 and 2, Fig. 8, and 3 and 5. Confirm that continuity is not present
between terminals 3 and 4. If relay does not perform , replace relay.
b. Apply battery voltage across terminals 1 and 2, then ensure continuity exists between terminals 3 and 4 and no continuity exists between
terminals 3 and 5.
c. If relay does not perform as outlined in step e above, replace relay.
3. Check fan motor relay, located in engine compartment relay box, as follows:
a. Using an ohmmeter, check relay continuity. If in either case continuity is absent, replace relay. Check for continuity first between
terminals 1 and 2, then between terminals 3 and 4, Fig. 1.
b. Apply battery voltage across terminals 1 and 2, then confirm that continuity is not present between terminals 3 and 4. If continuity is
found, replace relay.
4. Connect an ammeter and battery to fan motor connector, Fig. 3. Ensure that fan rotates smoothly and that current is 5.8-7.4 amps.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 155
Coolant Temperature Sensor/Switch (For Computer): Description and Operation

Engine Coolant Temperature Sensor

PURPOSE
The engine coolant temperature sensor measures engine temperature by sensing water temperature. The ECM uses this information for
determining the proper air/fuel mixture for all conditions.

LOCATION
The sensor is threaded into the cylinder head near the distributor.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 156

Heater Control Valve On Firewall

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 157
Heater Control Valve: Service and Repair
WATER VALVE REMOVAL

1. Drain Engine Coolant From Radiator

REMOVAL HINT: It is not necessary to drain out all the coolant.

2. Disconnect Water Valve Control Cable

INSTALLATION HINT: For installing control cable, refer to "A/C Control cables adjustment" See: Heating and Air Conditioning/Control
Assembly/Adjustments

3. Disconnect Water Hoses From Heater Radiator Pipe And Water Valve

4. Remove Water Valve

Remove the bolt and water valve.

INSTALLATION HINT:
- Push the water hose onto the heater radiator pipe as far as the ridge on the pipe.

- Install the hose clip in a position, as shown in the illustration.

WATER VALVE INSTALLATION

Installation is in the reverse order of removal.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 158
Heater Core: Service and Repair

Fig. 10 A/C System Components.

1. Disconnect battery ground cable, then discharge system refrigerant.

2. Disconnect refrigerant lines from cooling unit Fig. 10, capping all openings.

3. Remove grommets from inlet and outlet fittings.

4. Drain cooling system.

5. Disconnect heater hoses at fire wall.

6. Remove glove compartment and lower instrument panel cover.

7. Disconnect electrical connectors at pressure switch and A/C harness.

8. Remove heating unit and cooling unit retaining bolts and nuts.

9. Remove heating and cooling units as an assembly.

10. Remove large sectional clamp retaining heating unit to cooling unit.

11. Separate upper and lower heater unit case.

12. Remove heater core.

13. Reverse removal procedures to install.

14. Evacuate and recharge A/C system, check for leaks.

15. Refill cooling system with new antifreeze.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 159
Temperature Gauge: Testing and Inspection

Fig. 75 Temperature Gauge Terminal Locations

1. Disconnect connector from sender gauge.

2. Turn ignition switch ON, then check receiver gauge needle indicates COOL.
3. Ground terminal on wire harness side connector through a 3.4W test bulb.
4. Turn ignition switch ON, then check bulb lights up and receiver gauge needle moves toward hot side.
5. If operation is as specified, replace sender gauge, then recheck system.
6. If operation is not as specified, measure receiver gauge resistance between terminals A, B and C.
7. On models with tachometer, resistance should be as follows:
a. A-B: about 176.0 ohms.
b. A-C: about 54.0 ohms.
c. B-C: about 230.0 ohms.
8. On models less tachometer, resistance should be as follows:
a. A-B: about 230.0 ohms.
b. A-C: about 54.0 ohms.
c. B-C: about 176.0 ohms.
9. If resistance is not as specified, replace receiver gauge.
10. Measure sender resistance between terminal and ground. Resistance should be 160-314 ohms at 122°F and 17-30 ohms at 248°F.
11. If resistance is not as specified, replace sender gauge.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 160
Radiator: Service and Repair

Fig. 32 Radiator Replacement

1. Drain engine coolant into suitable container.

2. Disconnect cooling fan electrical connector, Fig. 18.
3. Disconnect radiator hoses.
4. Disconnect coolant reservoir hose.
5. On models with automatic transaxle, disconnect oil cooler hoses.
6. Remove radiator supports, radiator and electric cooling fan.
7. Remove electric cooling fan from radiator.
8. Reverse procedure to install.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 161

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 162
Thermostat: Testing and Inspection

NOTE: The thermostat is numbered with the valve opening temperature.

1. Immerse the thermostat in water and gradually heat the water.

2. Check the valve opening temperature. Valve opening temperature: 80-84°C (176-183°F). If the valve opening temperature is not as specified,
replace the thermostat.

3. Check the valve lift. Valve lift: 8 mm (0.31 inch) or more at 95°C (203°F). If the valve lift is not as specified, replace the thermostat.
4. Check that the valve is fully closed when the thermostat is at low temperatures [below 40°C (104°F)]. If not closed, replace the thermostat.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 163
Thermostat: Service and Repair

CAUTION: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat,
even if the engine tends to overheat.

REMOVAL
1. Drain engine coolant

2. Disconnect Engine Coolant Temperature (ECT) switch connector.

3. Remove water inlet and thermostat as follows:

a. Remove the 2 nuts and water inlet from the water inlet housing.
b. Remove the thermostat.
c. Remove the gasket from the thermostat.

INSTALLATION
1. Place thermostat in water inlet housing as follows:

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 164

a. Install a new gasket onto the thermostat.

b. Align the thermostat jiggle valve with the upper side of the stud bolt, and insert the thermostat in the water inlet housing.

NOTE: The jiggle valve may be set within 10° of either side of the prescribed position.

2. Install water inlet. Install the water inlet with the 2 nuts. Torque to 9.3 Nm (82 inch lbs.).
3. Connect ECT switch connector.
4. Fill radiator with engine coolant.
5. Start engine and check for leaks.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 165

Under-hood Components

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 166

Component Layout

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 167
Three Way Catalytic Converter: Description and Operation
Federal Models

Exhaust System Layout

PURPOSE
The three way catalytic converter simultaneously removes up to 90% of all three major pollutants, (HC, CO, and oxides of nitrogen). A
complete catalytic reaction depends on the fuel mixture staying within a very narrow range + 1% of 14.7:1 which can only be achieved with a
properly functioning oxygen sensor system.

CONSTRUCTION
The catalytic converter consists of a metal housing, a ceramic grid substrate, and a catalytic coating of platinum and rhodium. The active
metal content is about 2 grams of platinum/rhodium.

OPERATION
As the exhaust gasses containing HC and CO pass through the converter in the presence of oxygen, the platinum catalyst starts the oxidation
(burning) process. The HC and CO then unite with oxygen to form water vapor and carbon dioxide. This oxidation process has no effect on
the NOx emissions.

To reduce the oxides of nitrogen (NOx), a separate reaction is necessary called "reduction." A reduction reaction is the removal of oxygen
from a material. In Three Way Catalyst type converters, rhodium is used as a catalyst to break down oxides of nitrogen into nitrogen and
oxygen. The effective conversion of pollutants begins at about 250°C (480°F).

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 168
Three Way Catalytic Converter: Description and Operation
California Models

Exhaust System Layout

PURPOSE
Two three way catalytic converters simultaneously remove up to 90% of all three major pollutants, (HC, CO, and oxides of nitrogen). A
complete catalytic reaction depends on the fuel mixture staying within a very narrow range + 1% of 14.7:1 which can only be achieved with a
properly functioning oxygen sensor system. Two converters are used, a warm-up converter (WU TWC) and a main converter (TWC).

CONSTRUCTION
Each catalytic converter consists of a metal housing, a ceramic grid substrate, and a catalytic coating of platinum and rhodium. The active
metal content is about 2 grams of platinum/rhodium.

OPERATION
As the exhaust gasses containing HC and CO pass through the converter in the presence of oxygen, the platinum catalyst starts the oxidation
(burning) process. The HC and CO then unite with oxygen to form water vapor and carbon dioxide. This oxidation process has no effect on
the NOx emissions.

To reduce the oxides of nitrogen (NOx), a separate reaction is necessary called "reduction." A reduction reaction is the removal of oxygen
from a material. In Three Way Catalyst type converters, rhodium is used as a catalyst to break down oxides of nitrogen into nitrogen and
oxygen. The effective conversion of pollutants begins at about 250°C (480°F).

Due to distance from the combustion chamber, the WU TWC reaches operating temperature much faster than the main TWC. The early
operation of the WU TWC causes faster operation of the O2 sensors and the main TWC.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 169
Three Way Catalytic Converter: Service and Repair
California Models

Main Converter

Three-way Catalytic Converter

1. Jack up vehicle.
2. Ensure the catalytic converter is cool.
3. Remove the four bolts and nuts holding the pipes to the converter.
4. Remove the converter and two gaskets.
5. Place new two gaskets on the front and rear pipes.
6. Install the converter with the bolts and nuts.
Torque Value: 32 ft.lb (43 Nm)

Warm-Up Converter (Wu TWC)

Front Pipe Removal

REMOVAL
1. Disconnect negative battery terminal.
2. Disconnect sub-oxygen sensor electrical connector.
3. Remove support bracket.
4. Using a 14mm deep socket, remove two nuts securing the front pipe to the warm-up converter.
5. Remove remaining front pipe bolts and remove pipe.

Converter Brace

6. Remove bolts and converter brace.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 170

Converter Removal

7. Remove converter and gasket.

Heatshield Attachment

8. Remove securing nuts and remove heat shield.

Gasket Installation

INSTALLATION
1. Install converter using a new gasket and new nuts.

Torque to: 22 ft.lb (29 Nm)

Manifold Support

2. Install manifold support.

Torque to: 29 ft.lb (39 Nm)

3. Reverse remainder of procedure to complete.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 171
Three Way Catalytic Converter: Service and Repair
Federal Models

Three-way Catalytic Converter

1. Jack up vehicle.
2. Ensure the catalytic converter is cool.
3. Remove the four bolts and nuts holding the pipes to the converter.
4. Remove the converter and two gaskets.
5. Place new two gaskets on the front and rear pipes.
6. Install the converter with the bolts and nuts.
Torque Value: 32 ft.lb (43 Nm)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 172
Ignition System: Description and Operation
PURPOSE
To produce a spark that will ignite the air/fuel mixture within an engine's cylinders, ignition systems generate high voltage and direct it to
spark plugs at each cylinder. Voltage must be high enough to jump the spark plug gap under compression and it must be supplied at the
correct time under a wide range of operating conditions.

DESCRIPTION
This vehicle uses an ECM controlled electronic ignition system. Components include:

1. Ignition coil.
2. Distributor with integral crank and cam angle sensors.
3. Igniter.
4. Distributor cap and high tension wiring for distributing high voltage to the spark plugs.

CRANK AND CAM ANGLE SENSORS

The crank and cam angle sensors provide the ECM with signals regarding engine rpm and #1 cylinder TDC (camshaft position). Together
with other inputs, the ECM calculates ignition timing over the range of vehicle operating conditions. For additional information on these
sensors, refer to COMPUTERS AND CONTROL SYSTEMS.

IGNITER
An ECM controlled igniter is used as a switch to regulate current flow through the coil primary circuit. Each time current flow is interrupted,
high voltage is induced to fire the spark plugs. Except for the initial setting, timing is determined by the ECM.

SECONDARY IGNITION COMPONENTS

A distributor cap, rotor and high tension wires are used to direct high voltage from the coil to each spark plug at the appropriate time as
calculated by the ECM.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 173

Flow Of Diagnosis - Ignition

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 174
Firing Order: Specifications

FIRING ORDER: 1 3 4 2

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 175
Ignition Timing: Adjustments

Checking Ignition Timing

1. Place transmission in neutral position.

2. Start engine and allow to achieve normal operating temperature.
3. Connect suitable jumper wire or Toyota SST #09843-18020 across data link connector 1 terminals E1 and TE1.
4. Connect timing light and inspect timing.

Timing 10° BTDC at idle

Setting Ignition Timing

5. If timing is not as specified, loosen distributor hold-down bolts and turn to adjust.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 176
Timing Marks and Indicators: Locations

Ignition Timing Marks

ECM BY-PASSED

Advance Ignition Timing Marks

ECM CONTROLLED

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 177
Camshaft Position Sensor: Description and Operation
PURPOSE
The camshaft angle sensor produces an output pulse to the ECM 1 time per distributor rotation. The ECM uses this signal to determine TDC
position for #1 cylinder.

LOCATION
The sensor is mounted inside the distributor.

CONSTRUCTION
The sensor is made up of a pick-up coil and a rotor with 1 tooth. The tooth coresponds to #1 cylinder TDC.

OPERATION
Whenever the engine is rotating, a sine-wave signal is returned to the ECM. As engine speed increases the frequency of the signal increases
as well. When coupled with the signal of the engine rpm sensor, exact piston position can be determined by the ECM.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 178
Engine RPM Sensor (NE signal): Testing and Inspection
Code 12 - G, NE Signal Circuit (No. 1)

Code Description

- The IIA (Distributor) in the Engine Control System contains two pickup coils (G and NE). The G pickup signals inform the ECM of the
standard crankshaft angle.

- The NE pickup signals inform the ECM of the crankshaft angle and the engine speed.

Diagnostic Chart

Circuit Diagram

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 179

Inspection Procedure

Oscilloscope Diagnosis

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 180
Engine RPM Sensor (NE signal): Testing and Inspection
Code 13 - G, NE Signal Circuit (No. 2)

Code Description

- This code indicates that a momentary interruption of the G, NE signal from the IIA (Distributor) to the ECM has occurred, but that it is
returned to normal. Note that although this problem may not necessarily appear at the time of inspection, it cannot be ignored because this
diagnostic trouble code is output, indicating that there is or was a malfunction in the G, NE signal circuit; this "malfunction" is usually a
loose connector.

- The IIA connector and the NE terminal of the ECM connector must therefore be checked for the following:

^ Loose connectors
^ Dirty connector terminals
^ Loose connector terminals

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 181
Distributor: Description and Operation

Ignition Circuit

PURPOSE
The distributor is used to direct high voltage to the appropriate spark plug. The unit also houses the cam position and engine speed (crank
angle) sensors, ignition coil and igniter.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 182
Distributor: Service and Repair
REMOVAL:

Ignition Wire Removal

1. Remove spark plug wires from spark plugs.

2. Disconnect distributor primary wire connector.
3. Remove distributor hold down bolts.

Distributor Removal And Installation

4. Remove distributor from cylinder head.

INSTALLATION:

TDC Timing Marks

1. Rotate the crankshaft clockwise to TDC. Position the slit of the exhaust camshaft.

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Distributor O-ring Installation

2. Apply a light coat of engine oil to the distributor O-ring prior to installation.

Distributor Drive Alignment

3. Align the protrusion on the housing with groove of the coupling side.

Distributor Removal And Installation

4. Install the distributor and align the protrusion of the flange with the nut of the valve cover.

Distributor Hold Down Bolts

5. Lightly tighten the distributor hold down bolts.

6. Reconnect the distributor primary wire connector, distributor cap, and spark plug wires.
7. Adjust ignition timing. Refer to ADJUSTMENT PROCEDURES.

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Ignition Cable: Testing and Inspection

Plug Wire Removal

Disconnect High-tension Cords From Spark Plugs

- Disconnect the high-tension cords at the rubber boot.

NOTICE:Pulling on or bending the cords may damage the conductor inside.

Remove IIA (Distributor) Cap Without Disconnecting High-tension Cords

Checking Wire Resistance

Inspect High-tension Cord Resistance

- Using an ohmmeter, measure the resistance without disconnecting the IIA cap.

Maximum resistance: 25 k ohms per cord

- If the resistance is greater than maximum, check the terminals.

- If necessary, replace the high-tension cord and/ or IIA cap.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 185
Ignition Coil: Testing and Inspection

Inspect Primary Coil Resistance

- Using an ohmmeter, measure the resistance between positive (+) and negative (-) terminals.

Primary coil resistance (Cold): 1.1 - 1.7 ohms

- If the resistance is not as specified, replace the ignition coil.

Inspect Secondary Coil Resistance

- Using an ohmmeter, measure the resistance between the positive (+) and high-tension terminals.

Secondary coil resistance (Cold): 9 - 15 k ohms

- If the resistance is not as specified, replace the ignition coil.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 186
Ignition Coil: Service and Repair

Distributor, Exploded View

REMOVAL:

1. Remove distributor from vehicle. Refer to DISTRIBUTOR in this section.

2. Remove the distributor cap from the distributor.
3. Remove the ignition rotor, and dust cover.

Ignition Coil Primary Wire Installation

4. Disconnect the wires from the terminals of the ignition coil.

Ignition Coil Removal

5. Remove the four retaining screws. Remove ignition coil and dust proof packing.

INSTALLATION:

1. Reinstall coil and packing. Tighten coil retaining screws evenly.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 187

CAUTION: Do not use impact or air tools on ignition coil retaining screws.

Ignition Coil Primary Wire Installation

2. Reconnect the wires to the terminals of the ignition coil.

Ignition Coil Wires

NOTE: Ensure the wires are properly inserted into their grooves, located on the side of the ignition coil. Ensure that the wires don't contact the
signal rotor or distributor housing.

3. Install the ignition rotor, dust cover, and distributor cap.

4. Install distributor in vehicle. Refer to DISTRIBUTOR in this section.

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Igniter: Description and Operation
PURPOSE
The igniter electronically fires the ignition coil in response to the ECM signal. Computers generally produce low amperage signals as outputs,
much lower than necessary to fire the coil.

LOCATION
Mounted near the ignition coil.

CONSTRUCTION
The igniter consists of a power transistor and circuitry to provide a tachometer output.

OPERATION
The igniter is essentially an electronic relay. It receives a "trigger" from the ECM and responds by turning a higher amperage current to the
ignition coil on and off. Each time a spark is produced an ignition confirmation (IGF) signal is sent to the ECM.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 189
Igniter: Service and Repair

Distributor, Exploded View

REMOVAL:

1. Remove distributor from vehicle. Refer to DISTRIBUTOR in this section.

2. Remove the distributor cap from the distributor.
3. Remove the ignition rotor, and dust covers.

Ignition Coil Primary Wire Installation

4. Disconnect the wires from the terminals of the ignition coil.

Ignition Coil Removal

5. Remove the four retaining screws. Remove ignition coil and dust proof packing.

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Igniter Wires

6. Remove the three screws and disconnect the three wires from the terminals of the igniter assembly.

Igniter Assembly Removal And Installation

7. Remove the two igniter retaining screws, remove the igniter assembly from the distributor housing.
8. To install reverse removal procedures.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 191
Pick-Up Coil: Testing and Inspection

Checking Air Gap

Inspect Air Gap

- Using a thickness gauge, measure the gap between the signal rotor and pickup coil projection.

Air gap: 0.2 - 0.4 mm (0.008 - 0.016 in.)

- If the air gap is not as specified, replace the distributor housing assembly.

Pick Up Coil Resistance

Inspect Signal Generator (pickup Coil) Resistance

- Using an ohmmeter, measure the resistance between the terminals as follows:

Terminals Resistance (Cold)

G+ G- 185 - 275 ohms
NE+ NE- 370 - 550 ohms

- If the resistance is not as specified, replace the distributor housing assembly.

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Ignition Switch: Service and Repair
1. On models equipped with airbags, disarm airbag system as outlined under Technician Safety Information.
2. On models less airbags, disconnect battery ground cable.
3. On models with coded audio anti-theft systems, remove steering wheel, if necessary, steering column garnish, if equipped, upper and
lower covers.
4. Disconnect electrical connectors from ignition switch.

5. Turn ignition key to ACC position. Push down the stop pin with a screwdriver and pull out ignition key cylinder.
6. Reverse procedure to install. If audio system was disabled, activate as outlined under Technician Safety Information. On models with air
bag system, rearm airbag system as outlined under Technician Safety Information.

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Spark Plug: Service and Repair

Ignition Wire Removal

1. Remove ignition wires from spark plugs.

2. Using a properly sized spark plug socket, remove spark plugs from cylinder head.
3. Using a suitable gapping tool, adjust spark plug gap.

Spark Plug Gap: 0.031 in (0.8 mm)

4. Apply a light coat of anti-seize compound to threads of spark plugs.

5. Using a properly sized spark plug socket, install spark plugs.

Torque Value: 13 ft.lb (18 Nm)

6. Reconnect spark plug wires to the appropriate spark plug. Ensure proper firing order.

Firing Order: 1-3-4-2

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 194
Steering: Symptom Related Diagnostic Procedures
Hard Steering
1. Improperly inflated tires.
2. Insufficient front end lubrication.
3. Excessive caster.
4. Worn steering system joints.
5. Worn lower arm ball joints.
6. Steering column binding.
7. Steering gear out of adjustment or faulty.
8. Improperly adjusted power steering belt.
9. Low reservoir fluid level.
10. Faulty power steering unit.

Poor Return
1. Improperly inflated tires.
2. Insufficient front end lubrication.
3. Incorrect wheel alignment.
4. Steering column binding.
5. Steering gear out of adjustment or faulty.

Excessive Play
1. Worn front wheel bearing.
2. Worn main shaft yoke or intermediate shaft yoke.
3. Worn lower ball joints.
4. Worn steering system joints.
5. Steering gear out of adjustment or faulty.

Abnormal Noise
1. Loose steering linkage.
2. Worn steering system joints.
3. Steering gear out of adjustment or faulty.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 195
Steering: Component Tests and General Diagnostics

Fluid Level
1. Place vehicle on a level surface.
2. With engine running at 1000 RPM or less, turn steering wheel from stop to stop several times.
3. Ensure fluid temperature is 176°F. If not repeat step 2.
4. Check fluid for foaming condition. Fluid foaming condition is usually caused by air trapped in system or low fluid level.
5. Check and adjust fluid level as needed.

Fluid Pressure
1. Using suitable tool, disconnect power steering pressure line from power steering pump.
2. Connect gauge side of pressure gauge to power steering pump side and valve side to pressure line.
3. Bleed power steering system.
4. Start engine, turn steering wheel from lock to lock three or four times.
5. Ensure proper fluid level.
6. Allow fluid temperature to reach at least 176°F.
7. Start engine and allow to idle.
8. Close pressure valve and observe valve reading. Do not keep valve closed for more then 10 seconds. Do not allow fluid temperature to
become too high.
9. Open valve fully.
10. Check and record pressure reading at 1000 RPM and 3000 RPM, less then 71 psi difference should be indicated from 1000 RPM to 3000
RPM. If difference is higher than indicated, repair or replace power steering pump flow control valve.
11. Ensure valve is fully open with engine at idle, check pressure with steering wheel at full lock. Do not maintain full lock position for more
than 10 seconds. Do not allow fluid temperature to become too high.

12. If pressure is below specifications, internal gear housing leak is indicated and must be repaired or replaced.
13. Center steering wheel and allow engine to idle.
14. Using suitable spring scale, measure steering effort in both directions. If steering effort is above specifications, repair power steering unit.

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Power Steering Bleeding: Service and Repair

Fig. 1 Bleeding Power Steering System

1. Ensure fluid in reservoir tank is at proper level.

2. With engine speed below 1000 RPM, turn steering wheel from stop to stop three or four times, keeping at full stop position for two to three
seconds.
3. Ensure fluid is not foamy or cloudy.
4. Measure fluid lever with engine running then stop engine and measure fluid level again, Fig. 1. Maximum rise of of fluid is .20 inch.
5. If a problem is found, proceed as follows:
a. Disconnect return hose from reservoir tank and drain fluid.
b. Fill reservoir tank with fresh fluid.
c. With return hose placed into a suitable container, start engine and run at 1000 RPM. After 1 or 2 seconds, fluid will begin to discharge
from the return hose. Stop engine immediately at this time. Ensure that some fluid remains in the reservoir tank.
d. Repeat steps b and c four or five times until there is no more air in fluid.
e. Connect return hose and correct fluid level.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 197
Power Steering Pump: Service and Repair
Removal and Installation

Fig. 10 Power Steering Pump Removal.

1. Refer to Fig. 10 when replacing power steering pump, noting the following:
a. Disconnect and connect pressure line using power steering hose nut wrench set tool No. 09631-22020, or equivalent.
b. Bleed power steering system after installation.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 198
Power Steering Pump: Service and Repair
Disassembly and Assembly

Fig. 26 Exploded View Of Power Steering Pump.

Disassemble
1. Position power steering pump in suitable soft-jawed vise.
2. Using suitable tool, remove pump pulley.
3. Remove air control valve, Fig. 26.
4. Remove reservoir tank, bracket and O-ring.
5. Remove pressure port union and O-ring, then remove flow control valve and spring.
6. Remove rear housing snap ring, then using suitable plastic hammer, tap out rear housing, wave washer and O-ring.
7. Using suitable plastic hammer, tap out shaft end, rear side plate and O-ring.
8. Remove pump shaft, cam ring and vane plates.
9. Using suitable screwdriver, remove pump shaft snap ring, remove rotor and front plate from pump shaft.
10. Remove front plate O-rings, then using suitable pin punch and hammer, drive out straight pin.

Inspection
1. Using suitable micrometer and calipers, measure oil clearance between shaft and bushing, .0028 inch or less should be indicated, if not
replace entire power steering pump.
2. Using suitable micrometer, measure height, thickness and length of vane plates. Minimum height should be .339 inch, thickness, .055 inch
and length
.5902 inch.
3. Using suitable feeler gauge, measure clearance between rotor groove and vane plate, maximum indicated should be 0.014 inch.
4. If measurements are not as indicated in steps 2 and 3, replace vane plate and/ or rotor with one having the same mark stamped on cam ring.
5. Coat flow control valve with power steering fluid, ensuring it falls smoothly into valve hole.
6. Close one flow control valve hole, then apply compressed air (57-71 psi) to opposite side, ensuring air does not come out end holes.

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7. If inspections are not as indicated in steps 6 and 7, replace flow control valve with one having same letter as on front housing.
8. Using suitable scale, measure flow control spring free length. Length should be 1.28-1.34 inches.
9. If required, replace oil seal as follows:
a. Using suitable screwdriver, pry out oil seal.
b. Using suitable socket and hammer, drive in new oil seal.

Assemble
1. Coat all sliding surfaces with power steering fluid.
2. Using suitable plastic hammer, drive short straight pin to front plate.
3. Install O-rings to front plate, then install front plate, rotor and snap ring to pump shaft.
4. Coat oil seal lip with MP grease, install long straight pin to front housing, align front plate hole and straight pin, then using suitable plastic
hammer, tap in pump shaft. Do not damage oil seal and O-rings.
5. Align cam ring holes with straight pins, then install cam ring with inscribed marks facing outward.
6. Install vane plates with round end facing outward.
7. Install side plate O-ring, then align side plate holes with pins and install side plate.
8. Install rear housing wave washer, O-ring, then using suitable plastic hammer, tap in rear housing, install snap ring.
9. Ensure pump shaft rotates smoothly without abnormal noise.
10. Temporarily install pulley nut and check rotating torque, 2.2 or less should be indicated.
11. Install spring, flow control valve, O-ring and pressure port union, tighten to specifications.
12. Install reservoir tank O-ring, tank and bracket, tighten to specifications.
13. Install air control valve.
14. Install woodruff key to power steering pulley shaft, then install pulley and nut, tighten to specifications.

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Steering Column: Service and Repair
With Tilt Column

Fig. 13 Exploded View Of Steering Column.

On models with air bags and/or anti-theft system, disarm systems as outlined under Technician Safety Information.

For steering column service, refer to Fig. 13.

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Steering Column: Service and Repair
Without Tilt Column

Fig. 12 Exploded View Of Steering Column.

On models with air bags and/or anti-theft system, disarm systems as outlined under Technician Safety Information.

For steering column service, refer to Fig.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 202
Air Bag(s) Arming and Disarming: Service and Repair
CAUTION:

* Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected
from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-)
terminal cable of the battery, the SRS may be deployed.)
* When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before
starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as before
and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle.
* Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs.
* Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or
flames.

AIR BAG SYSTEM DISARMING

The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90
seconds after the ignition is turned Off and the battery has been disconnected.
Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the
vehicle.
1. Turn ignition to Lock, then disconnect battery ground cable.
2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures.

AIR BAG SYSTEM ARMING

1. Ensure ignition is in Lock position.
2. Connect battery ground cable.
3. Wait at least 10 seconds before turning ignition from Lock position.
4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately 6 seconds. If lamp remains lit, an SRS
condition is indicated. Refer to Diagnosis and Testing.

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Steering Gear: Service and Repair
With Manual Steering

Inspection
1. Check rack teeth and back for wear or damage.
2. Ensure rack runout does not exceed .012 inch (.3 mm).
3. Inspect pinion bearings.

Disassembly/Assembly

Fig. 4 Rack & Pinion Manual Steering Gear Assembly.

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Fig. 5 Rack & Pinion Manual Steering Gear Assembly.

1. Clamp steering gear housing in soft jawed vise, Figs. 4 and 5..
2. Remove tie rod ends after making alignment marks.
3. Remove clips, clamps and rack boots.
4. Unstake claw washers and remove rack ends using suitable tools. Mark left and right ends and remove claw washers.
5. Using suitable tool, remove locknut and rack guide spring cap.
6. Remove rack guide spring, rack guide with spacer, then dust cover.
7. Using suitable tool, remove locknut and pinion bearing adjusting screw.
8. Pull rack fully from housing side and align pinion with notched portion of rack. Remove pinion and upper bearing as an assembly.
9. Remove rack from pinion side without turning it.
10. Reverse procedure to assemble, noting the following:
a. If necessary, replace pinion upper bearing using suitable tools.
b. If necessary, replace lower pinion bearing by heating rack housing to over 176°F and using a plastic hammer to tap housing and free
bearing. Then reheat rack housing to over 176°F and using a suitable tool, install new lower bearing, noting correct bearing direction.
c. If necessary, replace rack bushing using suitable tools. Ensure tube hole is not blocked with grease. Press new bushing in until edge.

Rack & Pinion Manual Steering Gear

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 205

Fig. 5 Rack & Pinion Manual Steering Gear Assembly.

Disassembly
1. Clamp steering gear housing in soft jawed vise, Fig. 5.
2. Remove tie rod ends after making alignment marks.
3. Remove clips, clamps and rack boots.
4. Unstake claw washers and remove rack ends using suitable tools. Mark left and right ends and remove claw washers.
5. Using suitable tool, remove locknut and rack guide spring cap.
6. Remove rack guide spring, rack guide with spacer, then dust cover.
7. Using suitable tool, remove locknut and pinion bearing adjusting screw.
8. Pull rack fully from housing side and align pinion with notched portion of rack. Remove pinion and upper bearing as an assembly.
9. Remove rack from pinion side without turning it.

Inspection & Assembly

1. Check rack teeth and back for wear or damage.
2. Ensure rack runout does not exceed .012 inch (.3mm).
3. Inspect pinion bearings, Fig. 5.
4. If necessary, replace pinion bearing as follows:
a. Remove upper bearing using suitable tool.
b. Install new upper bearing using suitable tool.
5. If necessary, replace lower pinion bearing as follows:
a. Heat rack housing to over 176°F (80°C).
b. Using plastic hammer, tap housing to free bearing.
c. Reheat rack housing to over 176°F (80°C).
d. Using suitable tool, install new lower bearing taking care to note correct bearing direction.
6. If necessary, replace rack bushing as follows:
a. Using suitable tool, remove rack bushing.
b. Ensure tube hole is not blocked with grease.
c. Install new rack bushing using suitable tool. Press new bushing in until edge surface of rack tube is even with surface of service tool.
7. If necessary, replace pinion oil seal as follows:
a. Using suitable tools, remove pinion oil seal.
b. Using service tools used above, drive new pinion seal in so it protrudes .020 inch (.5mm). During remaining assembly, coat all friction
surfaces with molybdenum disulfide lithium based grease.
8. Install rack into housing from pinion side. Position notched portion of rack so that pinion can be positioned inside.
9. Line up cutout portion of rack with pinion and install pinion making sure that pinion end is securely positioned in lower bearing.
10. Apply liquid sealer to threads of pinion bearing adjusting screw. Install screw using tool 09612-24012 or equivalent.
11. Line up cutout portion or rack with pinion.
12. Using service tool used previously, tighten pinion bearing adjusting screw so pinion turning torque is 3.2 inch lbs.
13. Loosen pinion bearing adjusting screw until pinion turning torque is 1.3-2.2 inch lbs.
14. Apply liquid sealer to pinion bearing adjusting screw locknut and install locknut. Using suitable tools, tighten locknut to specifications.
Recheck pinion preload and adjust, if necessary.
15. Install rack guide with spacer and spring.
16. Apply liquid sealer to guide spring cap threads
17. Mesh rack with pinion and install rack guide spring cap using suitable tool or equivalent.
18. Count total number of pinion rotations possible and return pinion half that amount to position pinion in neutral position.
19. Adjust total preload as follows:
a. Torque rack guide spring cap to 18 ft. lbs.
b. Return rack guide spring cap 25°.

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c. Measure total preload within on rotation from neutral position in both directions. Preload should be 6.9-11.3 inch lbs.
d. If preload is insufficient, retorque guide spring cap and return slightly less than 12°.
e. If preload is excessive, return rack guide spring cap slightly.
20. Apply liquid sealer on locknut thread and rear housing surface. Install locknut and torque to specifications
21. Recheck total preload. Adjust, if necessary.
22. Install dust cover.
23. Install claw washers and rack ends. Tighten rack end to specifications, using suitable tool, then stake claw washer.
24. Install rack boots taking care not to damage or twist boots. Note difference between right and left boots.
25. Install clamps and clips with open ends facing outward to avoid damage to boots.
26. Install tie rod ends so marks are aligned. Adjust toe-in and torque locknuts to specifications.

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Steering Gear: Service and Repair
With Power Steering

Removal and Installation

Fig. 7 Steering Gear Removal.

Fig. 8 Steering Wheel Mounting.

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Fig. 9 Steering Gear Installation.

Refer to Fig. 7 when replacing power steering gear, noting the following:
1. On models with audio coded anti-theft system, obtain three digit anti-theft code.
2. On all models, disconnect universal joint as follows:
a. Position front wheels facing straight ahead.
b. Using seat belt of driver's seat, fix steering wheel so that it does not turn, Fig. 8.
c. Place alignment marks on universal joint and control valve shaft.
d. Loosen upper universal joint bolt and remove lower universal joint bolt, then disconnect universal joint.
3. Disconnect tie rod ends using ball joint puller tool No. 09628-62011, or equivalent.
4. Disconnect and connect pressure and return tubes using power steering hose nut wrench set tool No. 09631-22020, or equivalent.
5. Slide gear assembly to righthand side to remove.
6. When connecting universal joint, set gear housing so that it matches dimensions shown in Fig. 9, with gear housing at center point.
7. Align marks made during removal and connect universal joint.

Toyota Type

Fig. 10 Exploded View Of Power Steering Gear. Corolla w/Toyota Gear

Disassemble

1. Using tool 09631-22020 or equivalent, remove pressure lines, Fig. 10.

2. Mount steering gear housing in soft jawed vise.
3. Remove tie rod ends.
4. Using screwdriver, loosen staked part of clamp and remove clamps. Remove clips and rack boots.
5. Remove rack ends and claw washers.
6. Remove dust cover.
7. Remove rack guide spring cap using tool 09612-24012 or equivalent.
8. Remove rack guide spring and rack guide.

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9. Remove rack housing cap.
10. Using tool 09616-00010 or equivalent, remove self-locking nut.
11. Place alignment marks on control valve housing and rack housing. Remove 2 bolts and pull out valve and housing as an assembly.
12. Using hammer and chisel, loosen staked part of claw washer.
13. Using tool 09631-16010, or equivalent, remove stopper nut and claw washer.
14. Place alignment marks on housing and tube.
15. Using hammer and chisel, loosen staked portion of locknut. Using tool 09617-16010 or equivalent, turn set nut to separate housing and
cylinder.
16. Using plastic hammer, knock out rack, end stop and wave washer.
17. Pull control valve out of housing.

Inspection & Assemble

During assembly, coat all moving parts, bearings, and bushings with molybdenum disulfide lithium base grease, and all O-rings and Teflon rings
with power steering fluid.
1. Check back surface of rack and teeth for wear or damage.
2. Ensure rack runout does not exceed .012 inch (.3 mm).
3. Using suitable micrometer and cylinder gauge, measure shaft O.D. and bushing I.D., shaft O.D. should be 1.0925 inch and bushing I.D.
should be 1.1102 inch.
4. If necessary, replace control valve, bearing, and oil seal as follows:
a. Remove snap ring and oil seal.
b. Using suitable tools and a press, remove bearing.
c. Using suitable tool, press in new bearing.
d. Using socket and press, install new oil seal.
e. Using snap ring pliers, install snap ring.
5. If necessary, replace pinion bearing as follows:
a. Using suitable tool, remove bearing.
b. Using same tool and hammer, install new bearing.
c. Tighten rack housing cap to snug down bearing.
d. Remove rack housing cap.
6. If necessary, replace housing oil seal as follows:
a. Using suitable tool, remove oil seal.
b. Using suitable tool, install new oil seal.
7. If necessary, replace cylinder end stop oil seal as follows:
a. Using suitable tool, remove oil seal.
b. Using suitable tool and hammer, install new oil seal.
8. If necessary, replace Teflon ring and O-ring as follows:
a. Remove Teflon ring and O-ring.
b. Install new O-ring.
c. Using fingers only, stretch new Teflon ring just enough to install into groove of rack.
d. Using fingers, smooth Teflon ring down so it fits tightly in groove.
9. Mount tool 09631-16020 on end of rack.
10. Coat tool with power steering fluid.
11. Insert rack into cylinder.
12. Remove tool.
13. Install new O-ring on end stop.
14. Push end stop into cylinder.
15. Assemble rack housing and cylinder as follows:
a. Mount housing in vise.
b. Install pin and new O-ring on housing.
c. Align marks on housing and cylinder.
d. Assemble housing, cylinder, and new set nut.
e. Using suitable tool, tighten set nut to specifications.
f. Using hammer and chisel, stake nut.
16. Install cylinder end stop nut with new claw washer.
17. Using suitable tool, tighten stop nut to specifications.
18. Stake claw washer.
19. Push control valve into housing.
20. Place new O-ring on control valve assembly, align marks on valve housing and rack housing, and install valve. Tighten bolts to
specifications.
21. Install new self-locking nut and tighten to specifications using suitable tool.
22. Apply liquid sealer to threads of new rack housing cap and install and tighten cap to specifications. Stake housing cap.
23. Install rack guide and spring.
24. Apply liquid sealer to spring cap threads and temporarily install spring cap.
25. Using suitable tool, tighten rack guide spring cap to specifications.
26. Using same tool, turn rack guide spring cap back 12°. Turn control valve shaft right and left, once or twice.
27. Using suitable tools and torque wrench, loosen rack guide spring cap until preload is 6.9-11.3 inch lbs.
28. Apply liquid sealer to spring cap threads.
29. Using suitable tool, install and tighten locknut to specifications.
30. Recheck total preload, adjust if necessary.

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31. Install rack ends.
32. Install dust cover.
33. Ensure rack hole is not clogged with grease and install rack boots, clamps, and clips.
34. Install tie rods and tighten locknuts to specifications.
35. Place new O-rings on pressure lines and install right and left turn pressure lines. Using suitable tool, tighten fittings to specifications.

Koyo Type

Fig. 9 Exploded View Of Power Steering Gear. Corolla w/Koyo Gear

Disassemble

1. Remove right and left turn pressure lines, Fig. 9.

2. Mount steering gear housing in soft jawed vise.
3. Remove tie rod ends.
4. Remove clips, clamps and rack boots.
5. Remove rack ends and claw washers.
6. Using suitable tool, remove rack guide spring cap locknut.
7. Using suitable tool, remove rack guide spring cap.
8. Remove rack guide spring, rack guide, and seat.
9. Remove dust cover.
10. Remove rack housing cap.
11. Using suitable tool, remove self-locking nut. Remove lower bearing and spacer.
12. Using suitable snap ring pliers, remove snap ring.
13. Using suitable tool, remove control valve with upper bearing and oil seal. Do not attempt to tap control valve out, since damage to valve
will result.

14. Using snap ring pliers, remove snap ring. Remove cylinder end stop and spacer.
15. Temporarily install rack end and tie rod on rack. The following step will damage the cylinder oil seal. Seal will require replacement.

16. Pull rack out with oil seal.

17. Remove cylinder oil seal with spacer using suitable tools.

Inspection & Assembly

During assembly, coat all moving parts, bearings, and bushings with molybdenum disulfide lithium base grease, and all O-rings and Teflon rings
with power steering fluid.
1. Check back surface of rack or teeth for wear or damage.
2. Ensure rack runout does not exceed .012 inch (.3mm).
3. If necessary, replace bushing and oil seal as follows:
a. Using service tool 09612-65014, or equivalent, remove bushing.
b. Using suitable brass bar, remove oil seal.
c. Coat oil seal lip with power steering fluid.
d. Using 24mm socket and extension, tap oil seal into housing.
e. Using suitable tool 09515-21010, 24mm socket, and extension, carefully press bushing in to depth of 2.736 inch (69.5mm). If bushing is

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pressed in too far, deformation of the housing will result. If bushing is not pressed in far enough, interference with the control valve will
result. Therefore, a press should be used to ensure proper installation. Temporarily install control valve to check that it turns properly.
4. If necessary, replace Teflon ring and O-ring as follows:
a. Remove Teflon ring and O-ring.
b. Install new O-ring.
c. Expand new Teflon ring with fingers taking care not to over stretch ring.
d. Position ring into piston ring groove of rack.
e. Snug down Teflon ring with fingers so it fits tightly in groove.
5. Install new spacer in cylinder.
6. Using suitable tools, install new oil seal. Position seal onto service tool with closed side away from shoulder on tool.
7. Mount service tool on rack. If tool can not be inserted smoothly, remove any burrs on rack with fine emery cloth.
8. Coat service tool with power steering fluid and insert rack into cylinder.
9. Remove service tool.
10. Install oil seal, spacer and cylinder end stop as follows:
a. Mount service tool on opposite end of rack.
b. Coat service tool with power steering fluid.
c. Install oil seal on rack.
d. Remove service tool.
e. Using suitable tool, tap in oil seal, spacer and end stop into cylinder.
f. Using snap ring pliers, install snap ring.
11. Check seal tightness as follows:
a. Install suitable tool to fluid fittings on cylinder housing.
b. Apply 15.75 inches Hg. (400mm Hg) of vacuum for about 30 seconds.
c. Ensure there is no drop in vacuum for approximately 30 seconds.
12. Place control valve in housing.
13. Using suitable tool, install upper bearing with press.
14. Install oil seal and snap ring, using suitable tool.
15. Install dust cover.
16. Install spacer, lower bearing, and self-locking nut on control valve shaft. Tighten nut to specifications.
17. Apply liquid seal to threads of new housing cap. Install and tighten cap to specifications. Using hammer and chisel, stake housing cap.
18. Install rack guide seat, rack guide, and spring.
19. Apply liquid sealer to threads of spring cap.
20. Using suitable tool, temporarily install spring cap.
21. Adjust total preload as follows:
a. Using suitable tool, tighten rack guide spring cap to specifications.
b. Turn rack guide spring cap back 12°.
c. Turn control valve shaft right and left a few times. Then, using suitable tools, and suitable torque wrench, loosen rack guide spring cap
until preload is 7.8-10.4 inch lbs.
22. Apply liquid sealer to threads of spring cap.
23. Using suitable tools, install and tighten locknut to specifications.
24. Recheck preload, and adjust if necessary.
25. Install claw washer, and rack end. Tighten rack end to specifications.
26. Stake claw washer.
27. Ensure rack hole is not clogged with grease. Install rack boots, clamps, and clips. Make sure that open ends of clips face outward to avoid
damage to boots.
28. Install tie rod ends onto rack ends and align marks. After adjusting toe-in, tighten locknut to specifications.
29. Install right and left turn pressure lines. Using tool 09633-00020 or equivalent, tighten nuts to specifications.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 212
Steering Wheel: Service and Repair

Spiral Cable Alignment.

1. Disconnect battery ground cable.

2. Remove trim cover from center of steering wheel.
3. Place alignment marks on steering wheel and mainshaft for assembly reference.
4. Remove nut attaching steering wheel to steering shaft.
5. Using a suitable puller, remove steering wheel. On some models, a steering wheel puller may not be necessary.
6. Reverse procedure to install.
7. On models with audio coded anti-theft system, obtain three digit anti-theft code.
8. On all models, position front wheels straight ahead.
9. Remove No. 2 and 3 steering wheel pad covers, then loosen steering wheel pad Torx screws until screw circumference groove catches on
screw case.
10. Carefully pull steering wheel pad rearward, then disconnect air bag electrical connector. Do not pull air bag wiring harness.
11. Store air bag assembly with upper surface of pad facing upward.
12. Disconnect steering wheel electrical connector, then remove set nut.
13. Place installation alignment marks on steering wheel and main shaft.
14. Using suitable steering wheel puller, remove steering wheel.
15. Reverse procedure to install, noting the following:
16. If spiral cable was removed, ensure front wheels are straight ahead, then turn spiral cable counterclockwise by hand until becomes harder to
turn cable, then rotate cable clockwise three turn to align red mark, Fig. 4.
17. Torque steering wheel attaching bolt to 26 ft. lb..
18. Torque steering wheel pad attaching Torx screws to 78 inch lbs. Reset audio anti-theft system, if equipped, as outlined under Technician
Safety Information.

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Fuel Delivery and Air Induction: Description and Operation
GENERAL DESCRIPTION

The fuel injection system delivers a precise amount of highly atomized fuel to the intake system to ensure optimum performance and emissions
compliance.

The Fuel System consists of three major sub-systems:

^ The fuel storage system,
^ Fuel injector with the supporting fuel injection control system, and
^ The fuel delivery and return system.

FUEL STORAGE

The fuel storage system consists of a fuel tank, fill pipe and filler cap.
FUEL INJECTION AND CONTROL

The injector is a solenoid operated valve designed to deliver fuel in an appropriate spray pattern to promote total fuel atomization in the intake air
stream

The fuel injection control system consists of the ECM (Electronic Control Module) and all of the engine and operating condition sensors. Using the
information from the sensors to determine the proper fuel amount and delivery time, the ECM varies the injector "ON" time to adjust the amount of
fuel delivered during each individual firing cycle.

For a more detailed description of the fuel injection system operation, refer to COMPUTERS AND CONTROL SYSTEMS.

FUEL DELIVERY AND RETURN

The fuel delivery system delivers fuel at a pressure and quantity high enough to allow the fuel regulator to maintain a constant fuel pressure in the
fuel delivery rail (in reference to the intake manifold pressure) under all driving conditions. A check valve in the fuel pump holds pressure in the
system after engine shutdown to prevent vapor lock and to ensure adequate pressure is available during warm engine re-start conditions.

The fuel delivery components consist of fuel supply lines, a high pressure fuel pump (mounted in the fuel tank), a fuel filter assembly and a fuel
pressure regulator.

The fuel return system recovers excess fuel vented by the fuel pressure regulator (mounted on the fuel rail) and returns it to the fuel tank. The fuel
return line is low pressure and returns directly to the fuel tank. The fuel return system consist of lines and couplings

FUEL VAPOR RECOVERY

The fuel vapor recovery system provides a route for the recovery of fuel vapors (from the fuel tank) either for storage in the charcoal canister, or for
evacuation through the purge control system. The vapor recovery system also consists of lines and couplings. These components function as
evaporative emissions control devices and are therefore covered in detail in EMISSION CONTROL DEVICES.

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Flow Of Diagnosis - Fuel

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Troubleshooting Chart

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Fuel Pressure: Testing and Inspection
- Check that the battery voltage is above 12 volts.
- Disconnect the cable from the negative (-) terminal of the battery.

CAUTION:Work must be started after approx. 90 seconds or longer from the time the ignition switch is turned to the "LOCK" position and
the negative terminal cable is disconnected from the battery.

Union Bolt

- Remove the union bolt and two gaskets, and disconnect the fuel inlet hose from the delivery pipe.

HINT:
^ Put a suitable container or shop towel under the cold start injector pipe.
^ Slowly loosen the union bolt.

Gauge Installation

- Install the fuel inlet hose and pressure gauge to the delivery pipe with three new gaskets and union bolt.

Torque: 29 N.m (300 kgf.cm, 22 ft.lbs)

- Wipe off any splattered gasoline.

Jumper Installation

- Using a jumper wire, connect terminals + B and FP of the check connector.

- Reconnect the battery negative (-) cable.
- Turn the ignition switch ON.

- Measure the fuel pressure.

Fuel pressure:
265 - 304 kPa (2.7 - 3.1 kgf/cm2, 38 - 44 psi)

- If pressure is high, replace the fuel pressure regulator.

- If pressure is low, check the following parts:

^ Fuel hoses and connections

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 217
^ Fuel pump
^ Fuel filter
^ Fuel pressure regulator

- Remove jumper wire.

Checking Fuel Pressure - No Vacuum To Regulator

- Start the engine.

- Disconnect the vacuum sensing hose from the fuel pressure regulator.
- Measure the fuel pressure at idle.

Fuel pressure:
265 - 304 kPa (2.7 - 3.1 kgf/cm2, 38 - 44 psi)

Checking Fuel Pressure - Vacuum To Regulator

- Reconnect the vacuum sensing hose to the fuel pressure regulator, and plug the hose end.
- Measure the fuel pressure at idle.

Fuel pressure:
206 - 255 kPa (2.1 - 2.6 kgflcm2, 31 - 37 psi)

- If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator.
- Stop the engine. Check that the fuel pressure remains 147 kPa (1.5 kgf/cm2, 21 psi) or more for 5 minutes after the engine is turned off.
- If pressure is not as specified, check the fuel pump, pressure regulator and/or injector.
- After checking fuel pressure, disconnect the battery negative (-) cable and carefully remove gauge to prevent gasoline from splashing.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 218
Idle Speed: Adjustments

Connecting Tachometer

NOTE: Idle speed is not adjustable, but may be checked. If correct idle speed cannot be achieved, refer to COMPUTERS AND CONTROL
SYSTEMS.

1. Place transmission in neutral position.

2. Start engine and allow to reach normal operating temperature.
3. Turn off all electrical accessories.
4. Connect tachometer to IG- terminal of data link connector as shown.

Idle speed: 700 +/- 50 rpm

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 219
Fuel Injector: Description and Operation

Fuel Injector

PURPOSE
The fuel injector sprays highly atomized fuel into the intake system to promote complete combustion of the air/fuel mixture.

LOCATION
Injectors are located around the outer edge of the intake manifold, near the cylinder head mating surface.

CONSTRUCTION
The injector is constructed of a metal housing which contains a magnetic solenoid operated pintle. The injector inlet houses a fine mesh
screen to filter out foreign particles. Top and bottom o-rings seal the outside of the injector to the intake manifold and fuel rail.

OPERATION
When the engine is cranking or running, constant voltage is supplied to the positive side of the solenoid valve from the fuel injection relay.
The ECM grounds the negative side of the solenoid valve, completing the electrical circuit, which energizes the magnetic winding. The
magnetic field raises the injector pintle. When the pintle is raised, pressurized fuel sprays through a metered orifice into the intake system.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 220
Fuel Injector: Testing and Inspection
Circuit Test
- The injectors are provided to the intake manifold. They inject fuel into the cylinders based on the signals from the engine control module.

Oscilloscope Diagnosis

Diagnostic Chart

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 221

Circuit Diagram

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 222

Inspection Procedure; Step 1 - 2

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 223

Inspection Procedure; Step 3 - 4

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Fuel Injector: Testing and Inspection
Component Test

Checking Injector Operation

Inspect Injector Operation

- Check operation sound from each injector.
- With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine rpm.

Checking Injector Operation

- If you have no sound scope, you can check the injector transmission operation with your finger.
- If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the engine ECU.

Inspect Injector Resistance

- Disconnect the injector connector.
- Using an ohmmeter, measure the resistance between the terminals.

Resistance: Approx. 13.8 ohms

- If the resistance is not as specified, replace the injector.

- Reconnect the injector connector.

Hose Connection

Inspect Injector Injection

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 225

Keep injector clear of sparks during the test.

CAUTION:

- Disconnect the fuel hose from the fuel filter outlet.

- Connect union and hose to the fuel filter outlet with two new gaskets and the union bolt.

Torque: 29 N.m (300 kgf.cm, 22 ft.lbs)

HINT: Use the vehicle's fuel filter.

Hose Connection

- Remove the pressure regulator from the delivery pipe, and connect the fuel return hose to the pressure regulator.
- Install a new 0-ring to the pressure regulator.
- Connect the hose to the pressure regulator with union and the two bolts.

Torque: 9.3 N.m (95 kgf.cm, 82 in.lbs)

- Install the grommet and a new 0-ring to the injector.

Hose Connection

- Connect union and hose to the injector, and hold the injector and union with clamp.
- Put the injector into the graduated cylinder.

HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out.

Jumper Installation

- Using a jumper, connect terminals +B and FP of the check connector.

- Reconnect the battery negative (-) cable.
- Turn the ignition switch ON.

NOTICE:Do not start the engine.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 226

Checking Injector Volume

- Connect wire to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder.
- Test each injector two or three times.

Volume:
40 - 50 cm3 (2.4 - 3.1 Cu in.) per 15 sec.

Difference between each injector:

5 cm3 (0.3 Cu in.) or less

- If the injection volume is not as specified, replace the injector.

Inspect Leakage
- Disconnect wire from the battery and check the fuel leakage from the injector.

Fuel drop:
One drop or less per minute

- Disconnect the battery negative (-) cable.

- Remove jumper wire.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 227
Fuel Injector: Service and Repair
Removal

Preparation
- Disconnect negative battery terminal.
- Disconnect IAT sensor electrical connector at air cleaner.
- Remove air cleaner cover and intake air tube.

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Throttle Cable Removal

Throttle Body Removal

- Remove cables from throttle body.
- Unbolt and remove cable bracket.

- Remove EGR vacuum hoses.

- Remove EVAP hoses.
- Disconnect TPS electrical connector.
- Disconnect IAC electrical connector.

Throttle Body Removal

- Unbolt and remove throttle body.

- Remove throttle body gasket.

Air Chamber Removal

- Remove air pipe and fuel hose clamp.
- Remove engine hanger and intake manifold support.

EGR Pipe Removal

- CA only - Remove EGR valve, modulator and pipe.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 229

- Disconnect vacuum hose from fuel pressure regulator.

- Remove PCV and hose.

- Remove air chamber cover and gasket.

Fuel Rail Removal

- Disconnect fuel injector electrical connectors.

Fuel Line Removal

- Remove fuel inlet line from fuel rail.

- Disconnect fuel return line from pressure regulator.

Injector Installation

- Unbolt fuel rail.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 230
- Remove fuel rail and injectors.
- Pull injectors from fuel rail.
- Remove spacers and insulators from intake manifold.
- Remove o-rings and grommets from injectors

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 231
Fuel Injector: Service and Repair
Installation

Preparation
- Using gasoline as a lubricant, install new o-rings and grommets to injectors.
- Push injectors into fuels rail.

- Install spacers and new insulators on intake manifold.

- Place injectors and fuel rail on manifold and install bolts finger tight.

- Check that injectors rotate freely in their bores.

- Point all electrical connectors up.
- Tighten fuel rail mounting bolts.

Torque value - 11 ft.lb (15 Nm)

- Reverse remainder of procedure to install, use new gaskets and note the following torque values:

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 232

Air intake chamber - 14 ft.lb (19 Nm)

EGR valve - 9 ft.lb (13 Nm)
Throttle body - 16 ft.lb (22 Nm)
Throttle cable bracket - 8 ft.lb (11 Nm)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 233
Fuel Pressure Regulator: Description and Operation

Fuel Pressure Regulator

PURPOSE
The fuel pressure regulator maintains fuel rail pressure at 31 - 37 psi (206 - 255 kPa) above manifold pressure.

LOCATION
Mounted on the fuel rail.

OPERATION
Manifold pressure is delivered to the regulator through a vacuum line. As the vacuum drops under load, fuel pressure is increased to
compensate for the additional fuel demands.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 234
Fuel Pressure Regulator: Service and Repair

Fuel Pressure Regulator

1. Remove pressure regulator vacuum hose.

2. Remove fuel return line.

Pressure Regulator Attachment

3. Remove mounting bolts and remove regulator.

O-Ring Installation

4. Replace O-ring before reinstallation.

5. Lubricate O-ring with gasoline and rotate back and forth while inserting in fuel rail.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 235
Pressure Regulator Attachment

6. When regulator is completely inserted in fuel rail, torque retaining screws to 82 in.lbs. (9.3 Nm).
7. Reverse remainder of procedure to complete.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 236
Fuel Pump: Description and Operation

Fuel Pump

PURPOSE
The fuel pump is used to provide a constant supply of high pressure fuel to the injectors.

LOCATION
Mounted in the fuel tank.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 237
Fuel Pump: Testing and Inspection

Jumper Installation

QUICK CHECK
- Check that the battery voltage is above 12 volts.
- Disconnect the cable from the negative (-) terminal of the battery.

CAUTION:Work must be started after approx. 90 seconds or longer from the time the ignition switch is turned to the "LOCK" position and
the negative (-) terminal cable is disconnected from the battery.

- Using a jumper wire, connect terminals + B and FP of the check connector.

- Turn the ignition switch ON.

NOTICE: Do not start the engine.

Checking For Fuel Pressure

- Check that there is pressure in the hose from the fuel filter.

HINT: At this time, you will hear fuel return noise.

- Remove jumper wire.

FUEL PUMP INSPECTION

- Check that the battery voltage is above 12 volts.
- Disconnect the cable from the negative (-) terminal of the battery.

CAUTION:Work must be started after approx. 90 seconds or longer from the time the ignition switch is turned to the "LOCK" position and
the negative (-) terminal cable is disconnected from the battery.

- Remove rear seat cushion.

Fuel Pump Cover

- Remove floor service hole cove. Remove the four screws and service hole cover.
- Disconnect fuel pump & sender gauge connector.

Inspect Fuel Pump Resistance

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 238

Fuel Pump Resistance Check

- Using an ohmmeter, measure the resistance between the terminals 4 and 5.

Resistance (Cold):
0.2 - 3.0 0

- If the resistance is not as specified, replace the fuel pump.

Inspect Fuel Pump Operation

Fuel Pump Operation Check

- Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel
pump operates. If operation is not as specified, replace the fuel pump.

NOTE
^ These tests must be performed quickly (within 10 seconds) to prevent the coil from burning out.
^ Keep the fuel pump as far away from the battery as possible.
^ Always perform switching at the battery side.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 239
Fuel Pump: Service and Repair
1. Disconnect negative battery terminal.
2. Remove rear seat cushion.

Fuel Pump Removal

3. Disconnect fuel pump and gauge sender electrical connector.

4. Remove retaining bolts and remove service cover.

Fuel Lines

5. Remove fuel supply line with a suitable wrench or Toyota SST #09631-22020.
6. Remove fuel return line.

Pump Cover Removal

7. Remove 8 retaining bolts.

Fuel Pump Removal

8. Lift pump bracket assembly from tank.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 240

Fuel Pump Disassembly

9. Pull lower end of fuel pump out of pump bracket.

10. Disconnect fuel pump electrical connector.
11. Disconnect fuel outlet line.
12. Remove fuel pump.

Filter Removal

13. Using a small screwdriver, remove filter retaining clip.

14. Remove filter.
15. Reverse procedure to install, replacing all gaskets.

Torque pump bracket bolts to: 34 in.lbs (3.9 Nm).

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 241
Circuit Opening Relay: Locations

Engine Compartment Components

Engine Compartment Components

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Engine Compartment Components

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 243
Circuit Opening Relay: Description and Operation

Circuit Opening Relay Schematic

PURPOSE
The circuit opening relay provides power to the fuel pump.

LOCATION
Located behind the center console, next to the cruise control ECM.

CONSTRUCTION
The relay consists of a single set of contacts controlled by two separate coils.

OPERATION
One coil is energized when the key is turned to the start position. The relay contacts close and power is supplied to the fuel pump for starting.
Once the ECM begins to receive pulses from the engine rpm sensor it grounds the other coil which continues to hold the contacts closed after
the key is released to the run position.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 244
Circuit Opening Relay: Testing and Inspection

Circuit Opening Relay Inspection - Checking Continuity

Inspect Relay Continuity

- Using an ohmmeter, check that there is continuity between terminals STA and E1.
- Check that there is continuity between terminals +B and FC.
- Check that there is no continuity between terminals +B and FP.
- If continuity is not as specified, replace the relay.

Circuit Opening Relay Inspection - Checking Operation

Inspect Relay Operation

- Apply battery voltage across terminals STA and E1.
- Using an ohmmeter, check that there is continuity between terminals +B and FP.
- If operation is not as specified, replace the relay.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 245
Air Control Valve: Description and Operation

Throttle Body Components

PURPOSE
The idle air control valve (IAC) is used to maintain proper idle speeds during varying conditions.

LOCATION
Mounted to the right side of the intake plenum.

CONSTRUCTION
The valve is a duty-cycle operated air control valve.

OPERATION
The IAC receives a continuous signal the ECM. By varying the ON/OFF time ratio of the signal, the ECM is able to control the size of the air
passage through the valve. Air passing through the valve bypasses the throttle causing an increase in idle speed.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 246
Air Control Valve: Testing and Inspection

IAC Operation

- The rotary solenoid type IAC valve is provided on the intake air chamber and intake air bypassing the throttle valve is directed to the IAC
valve through a passage.

- In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed.

- The ECM operated only the AC valve to perform idle-up and provide feedback for the target idling speed, but in the 4A-FE engine of the
Corolla, a VSV for idle-up control is also added (for air conditioning).

Diagnostic Chart

Circuit Diagram

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 247

Inspection Procedure; Step 1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 248

Inspection Procedure; Step 2 - 3

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 249
Idle Up Control Valve: Description and Operation

A/C Idle-Up Valve

PURPOSE
The A/C idle-up VSV opens a throttle valve bypass line to maintain idle quality during A/C operation.

LOCATION
The VSV is mounted to the firewall in the engine compartment.

OPERATION
The solenoid is located in-line with a throttle valve bypass hose. When energized by the ECM, air is allowed past the throttle valve, raising
the idle speed.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 250
EFI Main Relay: Description and Operation

Main Relay Circuit Schematic

PURPOSE
The main relay provides power to the ECM.

LOCATION
The relay is located in the relay box on the left side of the engine compartment.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 251
EFI Main Relay: Testing and Inspection
Back-Up Power Source
Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is off for use by the diagnostic trouble code
memory and air-fuel ratio adaptive control value memory, etc.

Diagnostic Chart

Circuit Diagram

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 252

Inspection Procedure

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 253
EFI Main Relay: Testing and Inspection
EFI Main Relay

EFI Main Relay Inspection - Checking Continuity

Inspect Relay Continuity

- Using an ohmmeter, check that there is continuity between terminals 1 and 2.
- Check that there is no continuity between terminals 3 and 5.
- If continuity is not as specified, replace the relay.

EFI Main Relay Inspection - Checking Operation

Inspect Relay Operation

- Apply battery voltage across terminals 1 and 2.
- Using an ohmmeter, check that there is continuity between terminals 3 and 5
- If operation is not as specified, replace the relay.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 254
Throttle Position Sensor: Description and Operation

Throttle Body Components

PURPOSE
The throttle position sensor detects throttle angle and idle position of the throttle plate.

LOCATION
The sensor is mounted on the throttle body.

CONSTRUCTION
The sensor contains a potentiometer and an idle switch.

OPERATION
Whenever the throttle is opened, a varied resistance signal is reported to the ECM. When the throttle is returned to the idle position, the idle
switch portion of the sensor is closed.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 255
Throttle Position Sensor: Adjustments

TPS Adjustment

1. Remove throttle body, refer to FUEL SUPPLY AND AIR INDUCTION.

2. Loosen TPS mounting screws.

TPS Adjustment

3. Connect ohmmeter across TPS terminals IDL and E2.

4. California only: Apply vacuum to throttle opener diaphragm.
5. Insert a 0.028 in. (0.70 mm) feeler gauge between throttle stop screw and stop lever.

TPS Adjustment

6. Gradually turn TPS until ohmmeter reading changes.

7. Tighten TPS screws.
8. Reinstall throttle body.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 256
Throttle Body: Description and Operation

Throttle Body

PURPOSE
The throttle body controls air flow into the engine. Mounting is also provided for the throttle position sensor and throttle opener.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 257
Throttle Body: Testing and Inspection

Checking Throttle Movement

- Check that the throttle linkage moves smoothly.

Checking Vacuum Passages

- Check the vacuum at each port.

^ Start the engine.
^ Check the vacuum with your finger.

Port Vacuum Conditions

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 258
Engine Control Module: Diagrams

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 259

ECM Terminal Identification

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 260
Engine Control Module: Service and Repair
Removal

1. Disconnect negative battery cable.

2. Remove the floor mat bracket.

3. Disconnect the three connectors from the ECM.
4. Remove the ECM.

Installation

1. Insert the ECM into the mount bracket as shown above.

2. Connect the three connectors to the ECM.

3. Install the floor mat bracket.

4. Reconnect the negative battery cable.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 261
A/C Signal: Testing and Inspection
- Designed for improved driveablity, this circuit cuts off A/C in the presence of one of the following conditions:

^ Engine starting
^ Immediately following A/C switch engagement
^ Take off
^ Accelerating from under 40 km/h (25 mph) and under 2,800 rpm

Diagnostic Chart

Circuit Diagram

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 262

Inspection Procedure

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 263
Intake Air Temperature Sensor: Description and Operation

Intake Air Temperature Sensor

PURPOSE
The intake air temperature sensor determines the temperature of the air entering the engine. The ECM uses the sensor data to compensate for
changes in air density because of temperature changes.

LOCATION
The sensor is mounted to the air cleaner box on the left side of the engine compartment.

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Under-hood Components

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 265
EGR Vacuum Modulator: Testing and Inspection

Fig. 15 EGR Vacuum Modulator Filter

EGR System Testing

1. Check the filters in the top cap of the EGR vacuum modulator for contamination and damage. Fig. 15
2. Using compressed air, clean the filters and reinstall.
3. Disconnect the vacuum hoses from ports P, Q and R of the EGR vacuum modulator.
4. Block ports P and R with your finger.
5. Blow air into port Q and check that air passes through to the air filter side without resistance. Fig. 82
6. Start the engine and raise speed to 2,500 rpm.

EGR System Testing

7. Repeat steps No. 4 and 5 above. Check that there is strong resistance to air flow on air filter side. Fig. 83
8. If a problem is found, replace the EGR vacuum modulator.
9. Reconnect the vacuum hoses to their proper locations.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 266
Malfunction Indicator Lamp: Description and Operation

"CHECK" ENGINE LAMP Or Malfunction Indicator Light Location

PURPOSE
The malfunction indicator light notifies the vehicle operator that an ECM related problem has occurred. The light is also used to extract
trouble codes from the ECM.

LOCATION
The light is part of the instrument cluster.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 267
Manifold Pressure/Vacuum Sensor: Description and Operation

MAP Sensor Circuit

PURPOSE
The manifold absolute pressure sensor sends a voltage signal to the ECM based manifold pressure (vacuum). The ECM uses this reference to
determine engine load.

LOCATION
The sensor is mounted to the right side of the firewall, near the wiper motor.

CONSTRUCTION
The sensor consists of a solid state pressure sensor connected to an external vacuum nipple.

OPERATION
A 5 volt supply is fed to the sensor whenever the ignition is turned on. As pressures (vacuum) are detected, a signal (approx. 1 - 4 volts) is
returned to the ECM. The vacuum to signal ratio is constant, making very precise measurement possible.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 268
Oxygen Sensor: Description and Operation
Non-California Models

Oxygen Sensor Operation

PURPOSE
The oxygen sensor measure the oxygen content in the exhaust and sends a voltage signal to the ECM.

LOCATION
The oxygen sensor is mounted in the exhaust pipe, just below the exhaust manifold.

CONSTRUCTION
The sensor consists of a steel housing, sensor tip and its protective sleeve. The sensor tip itself is made from a platinum covered
zirconium-oxide pipe.

OPERATION

This sensor produces a measureable voltage by comparing the amount of oxygen in the exhaust gas with the amount in the ambient air.

The sensor operates only within a certain temperature range of approx. 545 - 1530°F (285 - 850°C).

The exhaust gases reach the outer surface of the oxygen sensor tip via the openings in the protective sleeve. Ambient air reaches the sensor's
inner surface via channels. The differance in oxygen content produces a voltage read by the ECM.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 269
Oxygen Sensor: Description and Operation
California Models

Oxygen Sensor Operation

PURPOSE
Two oxygen sensors, a main and a sub, measure the oxygen content in the exhaust and send a voltage signal to the ECM.

Under-hood Components

LOCATION
The oxygen sensors are mounted in the exhaust pipe, before and after the warm-up catalyst.

CONSTRUCTION
Each sensor consists of a steel housing, sensor tip and its protective sleeve. The sensor tip itself is made from a platinum covered
zirconium-oxide pipe.

OPERATION

This sensor produces a measureable voltage by comparing the amount of oxygen in the exhaust gas with the amount in the ambient air.

The sensor operates only within a certain temperature range of approx. 545 - 1530°F (285 - 850°C).

The exhaust gases reach the outer surface of the oxygen sensor tip via the openings in the protective sleeve. Ambient air reaches the sensor's
inner surface via channels. The differance in oxygen content produces a voltage read by the ECM.

The sub-oxygen sensor functions primarily as a diagnostic aid for the catalyst. The ECM compares sensor outputs to determine if the catalyst
is functioning properly.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 270
Transmission Position Switch/Sensor: Testing and Inspection
- The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on the terminal NSW of the ECM is
grounded to body ground via the starter relay thus the terminal NSW voltage becomes 0V. When the shift lever is in the D, 2, L or R
position, the park/neutral position switch goes off, so the voltage of ECM terminal NSW becomes battery positive voltage, the voltage of the
ECM internal power source.

- If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control
(estimated control), etc.

- When the park/neutral position switch is off, code "51" is output in the test mode diagnosis. (This is not abnormal.)

Diagnostic Chart

Circuit Diagram

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Inspection Procedure

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 272
Vehicle: Specifications

Camshaft Position Sensor

Resistance Value
G+ - G- ................................................................................................................................................................................................ 185 - 275 ohms
NE+ - G- ............................................................................................................................................................................................. 370 - 550 ohms

System Specifications
Maximum Output Amps .............................................................................................................................................................................................. 80
Rotor Coil Resistance Ohms ...................................................................................................................................................................................... 2.9
Voltage Regulator Voltage ....................................................................................................................................................................................... [01]

[01] -- 13.9-15.1 volts at 77°F, 13.5-14.3 volts at 239°F.

Alternator
Maximum Output Amps .............................................................................................................................................................................................. 80
Rotor Coil Resistance Ohms ...................................................................................................................................................................................... 2.9
Voltage Regulator Voltage ....................................................................................................................................................................................... [01]

[01] -- 13.9-15.1 volts at 77°F, 13.5-14.3 volts at 239°F.

Voltage Regulator
Maximum Output Amps .............................................................................................................................................................................................. 80
Rotor Coil Resistance Ohms ...................................................................................................................................................................................... 2.9
Voltage Regulator Voltage ....................................................................................................................................................................................... [01]

[01] -- 13.9-15.1 volts at 77°F, 13.5-14.3 volts at 239°F.

Condenser Fan
Current Draw ......................................................................................................................................................................................... 7.4 Amp max.

Coolant Temperature Sensor/Switch (For Computer)

Resistance value:
-4°F (-20°C) ......................................................................................................................................................................................... 10 - 20 kohms
32°F (0°C) ................................................................................................................................................................................................ 4 - 7 kohms
68°F (20°C) .............................................................................................................................................................................................. 3 - 4 kohms
104°F (40°C) ...................................................................................................................................................................................... 0.9 - 1.3 kohms
140°F (60°C) ...................................................................................................................................................................................... 0.4 - 0.7 kohms
176°F (80°C) ...................................................................................................................................................................................... 0.2 - 0.4 kohms

EGR Control Solenoid

Resistance ................................................................................................................................................................................................... 37 - 44 ohms

EGR Temperature Sensor

Resistance value:
112°F (50°C) ........................................................................................................................................................................................ 64 - 97 kohms
212°F (100°C) ...................................................................................................................................................................................... 11 - 16 kohms
302°F (150°C) ......................................................................................................................................................................................... 2 - 4 kohms

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ECM Terminal Resistance

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 274

Fuel Injector
Resistance ......................................................................................................................................................................................... Approx. 13.8 ohms

Fuel Pump
Resistance value ....................................................................................................................................................................................... 0.2 - 3.0 ohms

Idle Up Control Valve

Resistance ................................................................................................................................................................................................... 30 - 34 ohms

Ignition Cable
Resistance Value ................................................................................................................................................................................ 25 K ohm (MAX)

Ignition Coil
Resistance
Primary circuit ...................................................................................................................................................................................... 1.1 - 1.7 ohms
Secondary circuit ................................................................................................................................................................................... 9k - 15k ohms

Intake Air Temperature Sensor

Resistance value:

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 275
-4°F (-20°C) ......................................................................................................................................................................................... 10 - 20 kohms
32°F (0°C) ................................................................................................................................................................................................ 4 - 7 kohms
68°F (20°C) .............................................................................................................................................................................................. 3 - 4 kohms
104°F (40°C) ...................................................................................................................................................................................... 0.9 - 1.3 kohms
140°F (60°C) ...................................................................................................................................................................................... 0.4 - 0.7 kohms
176°F (80°C) ...................................................................................................................................................................................... 0.2 - 0.4 kohms

Overdrive Switch, A/T

Resistance
Switch OFF ................................................................................................................................................................................ 0 ohms (continuity)
Switch ON ................................................................................................................................................................................ infinite ohms (open)

Reduction Type Starter (1.0 KW Rating)

Brush Spring Tension, Ounces .............................................................................................................................................................................. 62-85
No Load Test
Amperes ...................................................................................................................................................................................................................... 90
Volts ......................................................................................................................................................................................................................... 11.5
RPM ........................................................................................................................................................................................................................ 3000

Reduction Type Starter (1.4 KW Rating)

Brush Spring Tension, Ounces .............................................................................................................................................................................. 62-85
No Load Test
Amperes ...................................................................................................................................................................................................................... 90
Volts ......................................................................................................................................................................................................................... 11.5
RPM ........................................................................................................................................................................................................................ 3500

Throttle Position Sensor

Resistance:
Lever at stop screw
VTA - E2 ...................................................................................................................................................................................... 0.2 - 0.6 k Ohms

Lever 0.016 in (0.40 mm) from stop screw

IDL - E2 ................................................................................................................................................................................. less than 2.4 k Ohms

Lever 0.035 in (0.90 mm) from stop screw

IDL - E2 ....................................................................................................................................................................................................... Infinite

Wide open throttle

VTA - E2 .................................................................................................................................................................................... 3.3 - 10.0 k Ohms
VC - E2 ......................................................................................................................................................................................... 4.0 - 8.5 k Ohms

Air Bag Systems

Component .......................................................................................................................................................................................... Torque/Ft. Lbs.

Center Air Bag Sensor .................................................................................................................................................................................................. 9

Front Air Bag Sensor .................................................................................................................................................................................................. 19
Steering Wheel Retaining Nut ..................................................................................................................................................................................... 26
Steering Wheel Side Torx Screws ....................................................................................................................................................................... 78 [01]

[01] -- Inch lbs.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 276

Service Data Part 1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 277

Service Data Part 2

Torque Specifications

System Specifications
Component .......................................................................................................................................................................................... Torque/Ft. Lbs.
Brake Line To Master Cylinder Union Nuts ............................................................................................................................................................... 11
Master Cylinder Bolts ................................................................................................................................................................................................... 9
Piston Stopper Bolt .................................................................................................................................................................................................... 6-7
Reservoir Set Screw .................................................................................................................................................................................... 13-15.5 [01]
Wheel Cylinder Bolts .................................................................................................................................................................................................... 7

[01] -- ............................................................................................................................................................................................................... Inch Lbs.

Bleeder Plug 74 in.lb

Bleeder Plug 74 in.lb

Flexible Hose 22 ft.lb

Caliper Bolt 18 ft.lb

Torque Plate 65 ft.lb

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 278
Union Nut 11 ft.lb

Standard Inside Diameter 7.874 in

Maximum Inside Diameter 7.913 in

Bleeder Plug 74 in.lb

Union Nut 11 ft.lb

Wheel Cylinder 7 ft.lb

Front Brake Pad Thickness Standard Thickness 0.472 in

Minimum Thickness 0.039 in

Brake Pedal Assy

Pedal Height, Inch ............................................................................................................................................................................................ 5.47-5.87
Pedal Freeplay, Inch ........................................................................................................................................................................................ 0.12-0.24

Front Brake Rotors Standard Thickness 0.866 in

Minimum Thickness 0.787 in

Maximum Runout 0.0020 in

Standard Lining Thickness 0.157 in

Minimum Lining Thickness 0.039 in

System Specifications
Brake Line To Master Cylinder Union Nuts ............................................................................................................................................................... 11
Master Cylinder Bolts ................................................................................................................................................................................................... 9
Piston Stopper Bolt .................................................................................................................................................................................................... 6-7
Reservoir Set Screw .................................................................................................................................................................................... 13-15.5 [01]
Wheel Cylinder Bolts .................................................................................................................................................................................................... 7

[01] -- Inch Lbs.

Union Nut 11 ft.lb

Wheel Cylinder 7 ft.lb

System Specifications
Component .......................................................................................................................................................................................... Torque/Ft. Lbs.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 279

Back-Up Lamp Switch ................................................................................................................................................................................................ 30

Bleeder Plug .................................................................................................................................................................................................................. 8
Bond Cable To Body ................................................................................................................................................................................................... 14
Clutch Accumulator .................................................................................................................................................................................................... 15
Clutch Cover ............................................................................................................................................................................................................... 14
Clutch Line Union ....................................................................................................................................................................................................... 11
Clutch Master Cylinder ................................................................................................................................................................................................. 9
Control Shaft Cover .................................................................................................................................................................................................... 14
Drain Plug ................................................................................................................................................................................................................... 29
Driveshaft To Side Gear Shaft .................................................................................................................................................................................... 27
Exhaust Pipe Clamp Bolt ............................................................................................................................................................................................ 14
Exhaust Pipe To Converter ......................................................................................................................................................................................... 32
Exhaust Pipe To Manifold .......................................................................................................................................................................................... 46
Filler Plug .................................................................................................................................................................................................................... 29
Front Bearing Retainer .................................................................................................................................................................................................. 8
Front Engine Mount .................................................................................................................................................................................................... 58
Lock Ball Assembly .................................................................................................................................................................................................... 29
Lower Ball Joint .......................................................................................................................................................................................................... 47
Master Cylinder Reservoir Tank ................................................................................................................................................................................. 18
Output Shaft Bearing Lock Plate .................................................................................................................................................................................. 8
Release Cylinder To Transaxle ..................................................................................................................................................................................... 9
Shift Fork To Set Bolt ................................................................................................................................................................................................. 12
Speedometer Driven Gear Lock Plate ........................................................................................................................................................................... 8
Transaxle Case Protector ............................................................................................................................................................................................... 9
Transaxle Case To Case Cover ................................................................................................................................................................................... 13
Transaxle Case To Transaxle Case ............................................................................................................................................................................. 22
Transaxle To Engine (8mm) ......................................................................................................................................................................................... 8
Transaxle To Engine (10mm) ..................................................................................................................................................................................... 17
Transaxle To Engine (10mm) ..................................................................................................................................................................................... 34
Transaxle To Engine (12mm) ..................................................................................................................................................................................... 47
Transaxle To Starter .................................................................................................................................................................................................... 29

Clutch Disc, M/T

Disc Rivet Head Depth:
Minimum ..................................................................................................................................................................................... 0.3 mm (0.012 inch)
Disc Runout:
Maximum ..................................................................................................................................................................................... 0.8 mm (0.031 inch)

Clutch Master Cylinder

SERVICE SPECIFICATIONS
Slotted Spring Pin Protrusion ....................................................................................................................................... 1.5-3.5mm (0.059-0.138 inch)

TORQUE SPECIFICATIONS
Master Cylinder:
Installation Nut .................................................................................................................................................................... 12 Nm (108 inch lbs.)

Clutch Pedal Assembly

Pedal Height:
From Asphalt Sheet ............................................................................................................................................. 138.4-148.4 mm (5.449-5.843 inch)
Pedal Freeplay ................................................................................................................................................................. 1.0-5.0 mm (0.039-0.197 inch)
Push Rod Play At Pedal Top ......................................................................................................................................... 5.0-15.0 mm (0.197-0.591 inch)
Clutch Release Point:
From Pedal Full Stroke End Position .............................................................................................................................. 25 mm (0.98 inch) Or More

Clutch Release Fork, M/T

Release Fork Support ......................................................................................................................................................................... 37 Nm (27 ft. lbs.)

Clutch Slave Cylinder

Release Cylinder:
Installation Bolt ......................................................................................................................................................................... 12 Nm (108 inch lbs.)
Bleeder Plug ................................................................................................................................................................................... 8.3 Nm (74 inch lbs.)

Hydraulic Hose, Clutch

Clutch Line Union .............................................................................................................................................................................. 15 Nm (11 ft. lbs.)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 280
Pressure Plate
SERVICE SPECIFICATIONS
Diaphragm Spring Finger Wear:
Maximum Depth .................................................................................................................................................................... 0.5 mm (0.020 inch)
Maximum Width .................................................................................................................................................................... 6.0 mm (0.236 inch)
Diaphragm Spring Tip Non-Alignment:
Maximum ............................................................................................................................................................................... 0.5 mm (0.020 inch)

TORQUE SPECIFICATIONS
Clutch Cover to Flywheel ............................................................................................................................................................... 19 Nm (14 ft. lbs.)
Flywheel Set Bolt ........................................................................................................................................................................... 78 Nm (58 ft. lbs.)

Distributor, Ignition
Air Gap ........................................................................................................................................................................... 0.2 - 0.4 mm (0.08 - 0.016 in.)

Torque value ........................................................................................................................................................................................ 14 ft.lb. (19 Nm)

System Specifications
Component .......................................................................................................................................................................................... Torque/Ft. Lbs.

Bearing Locknut See TSB DL001-98 3-6-98............................................................................................................................................................ 137

Brake Caliper To Steering Knuckle ............................................................................................................................................................................ 18
Driveshaft Locknut .................................................................................................................................................................................................... 159
Shock Absorber To Steering Knuckle ....................................................................................................................................................................... 105
Stabilizer Bar Link Nut ............................................................................................................................................................................................... 47
Steering Knuckle Attaching Nuts .............................................................................................................................................................................. 105
Steering Knuckle To Lower Arm ................................................................................................................................................................................ 83
Tie Rod To Steering Knuckle ...................................................................................................................................................................................... 36
Wheel Lug Nut ............................................................................................................................................................................................................ 76

[01] ........................................................................................................................... -With 13 inch wheel, 18 ft. lbs.; w/14 & 15 inch wheel, 29 ft. lbs.

Saginaw Type Boot & Clamp

Damper Position, Inch [01] .................................................................................................................................................................................... 14.14
Driveshaft Length, Inch [01]
Righthand ............................................................................................................................................................................................................... 33.75
Lefthand ................................................................................................................................................................................................................. 21.26

[01] -- ........................................................................................................................................................................................................ ± .20 inches.

Toyota Type Boot & Clamp

Damper Position, Inch [01] .................................................................................................................................................................................... 14.14
Driveshaft Length, Inch [01]
Righthand ............................................................................................................................................................................................................... 33.17
Lefthand ................................................................................................................................................................................................................... 20.8

[01] -- .......................................................................................................................................................................................................... ± .20 inches.

System Specifications
WU - Catalyst to exhaust manifold:
Torque value ....................................................................................................................................................................................... 22 ft.lb (29 Nm)

TWC to exhaust pipe:

Torque value ....................................................................................................................................................................................... 32 ft.lb (43 Nm)

EGR Valve
Torque value ........................................................................................................................................................................................... 9 ft.lb (13 Nm)

Thermal Vacuum Valve, EGR

Torque value ......................................................................................................................................................................................... 22 ft.lb (29 Nm)

General Engine Specifications

Fuel System ............................................................................................................................................................................. Multi-Port Fuel Injection
Bore & Stroke, Inches ................................................................................................................................................................................... 3.19 x 3.03
Compression Ratio ..................................................................................................................................................................................................... 9.5

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 281
Maximum Brake H.P. @ RPM ................................................................................................................................................................................. [02]
Maximum Torque Ft. Lbs. @ RPM ............................................................................................................................................................. 100 @ 4800
Normal Oil Pressure, psi ........................................................................................................................................................................................... [01]

[01] -- At idle, 4.3 psi or more; @ 3000 RPM, 36-71 psi.

[02] -- California, 100 @ 5800; Federal, 105 @ 5800.

Service Specifications

Service Specifications (1 Of 3)

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Service Specifications (2 Of 3)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 283

Service Specifications (3 Of 3)

Service Specifications
Torque Specifications

Torque Specifications (1 Of 3)

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Torque Specifications (2 Of 3)

Torque Specifications (3 Of 3)

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Torque Specifications

Intake Camshaft Bearing Cap Removal Sequence

Exhaust Camshaft Bearing Cap Removal Sequence

Exhaust Camshaft Bearing Cap Tightening Sequence

Intake Camshaft Bearing Cap Tightening Sequence

Camshaft Bearing Removal/Torque Sequence

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 286

Cylinder Head Bolt Removal Sequence

Cylinder Head Torque Sequence

Cylinder Head Removal/Torque Sequence

Main Bearing Cap Removal Sequence

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Main Bearing Cap Tightening Sequence

Main Bearing Cap Removal/Torque Sequence

Flywheel Tightening Sequence

Flywheel Torque Sequence

A/T Drive Plate Tightening Sequence

A/T Drive Plate Torque Sequence

System Specifications
Refer to Engine/Specifications/Mechanical.
See: Engine, Cooling and Exhaust/Engine/Specifications

Camshaft Pulley Bolt 43 ft.lb

Camshaft, Engine
Journal Dia. .................................................................................................................................................................................................. .9822-.9829
Max. Journal Runout ............................................................................................................................................................................................ 0.0016
Bearing Clearance ........................................................................................................................................................................................ .0014-.0028
Camshaft Endplay ..................................................................................................................................................................................................... [01]
Lifter Dia. ................................................................................................................................................................................................. 1.2191-1.2195
Lifter To Bore Clearance ............................................................................................................................................................................. .0009-.0023

[01] -- Intake, .0012-.0033 inch; exhaust, .0014-.0035 inch.

System Specifications
Refer to Engine/Specifications/Mechanical.
See: Engine, Cooling and Exhaust/Engine/Specifications
Connecting Rod Bearing
Refer to Engine/Specifications/Mechanical.
See: Engine, Cooling and Exhaust/Engine/Specifications
Connecting Rod, Engine
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See: Engine, Cooling and Exhaust Engine, Specifications, Torque Specifications

Crankshaft Main Bearing

Refer to Engine/Specifications/Mechanical.
See: Engine, Cooling and Exhaust/Engine/Specifications

Crankshaft Pulley Bolt 87 ft.lb

Piston Pin, Engine

Cylinder Head Torque Sequence

Cylinder Head Torque

Piston Ring, Engine

Piston Ring Specifications See: Engine, Cooling and Exhaust/Engine/Specifications/Service Specifications
Piston, Engine
Piston Specifications See: Engine, Cooling and Exhaust/Engine/Specifications/Service Specifications

System Specifications

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Cylinder Head Torque Sequence

Cylinder Head Torque Sequence

Tightening torque:
Step 1 ..... 29 Nm (22 ft lb)
Step 2 ..... Tighten additional 90°
Step 3 ..... Tighten additional 90°

Valve Cover
Torque ............................................................................................................................................................................................... 5.9 Nm (52 in.lbs).

Component specifications not listed above are found under Engine Specifications. See: Engine, Cooling and Exhaust/Engine/Specifications

Adjusting Shim Selection Chart

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Service Specifications
Valve clearance (Cold):
Intake .................................................................................................................................................................... 0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust ................................................................................................................................................................. 0.25 - 0.35 mm (0.010 - 0.014 in.)

Drive Belt
Belt .................................................................................................................................................................................................................. Air Cond.
New Lbs. ............................................................................................................................................................................................................ 140-180
Used Lbs. ............................................................................................................................................................................................................. 80-120

Belt .................................................................................................................................................................................................................. Alternator

New Lbs. ............................................................................................................................................................................................................ 140-180

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Used Lbs. ........................................................................................................................................................................................................... 110-150

Belt .......................................................................................................................................................................................................... Power Steering

New Lbs. ............................................................................................................................................................................................................ 100-150
Used Lbs. ............................................................................................................................................................................................................. 60-100

Oil Pump, Engine

Gear To Body Clearance .............................................................................................................................................................................. .0031-.0071
Tip Clearance ............................................................................................................................................................................................... .0010-.0033
Side Clearance ............................................................................................................................................................................................. .0010-.0033

Timing Belt Defletion 0.24 - 0.28 in at 4.4 lbf

Idler Pulley Bolt 27 ft.lb

Tensioner Spring Free Length 1.390 in

Installed Tension 13.0 lbf at 1.988 in

Exhaust Manifold
Exhaust Manifold X Cylinder Head
Torque ................................................................................................................................................................................................ 34 Nm (25 ft.lbs.)

Firing Order

FIRING ORDER: 1 3 4 2

Drive Plate to Crankshaft Bolts 47 ft.lb

Tighten the bolts in 2 or 3 passes in sequence shown.

Drive Plate to torque Converter 20 ft.lb

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Drive Plate runout (maximum) 0.0079 in

A/T Drive Plate Tightening Sequence

Flywheel to Crankshaft Bolts 58 ft.lb

Flywheel runout (maximum) 0.004 in Over limit, replace.

Flywheel Tightening Sequence

Tightening torque
Tightening torque

Tightening torque Fuel filter to body 4.9 Nm

Union bolt 29.5 Nm

Flare nut 30 Nm

System Specifications
Belt .................................................................................................................................................................................................................. Air Cond.
New Lbs. ............................................................................................................................................................................................................ 140-180
Used Lbs. ............................................................................................................................................................................................................. 80-120

Belt .................................................................................................................................................................................................................. Alternator

New Lbs. ............................................................................................................................................................................................................ 140-180
Used Lbs. ........................................................................................................................................................................................................... 110-150

Belt .......................................................................................................................................................................................................... Power Steering

New Lbs. ............................................................................................................................................................................................................ 100-150
Used Lbs. ............................................................................................................................................................................................................. 60-100

Compressor Clutch
Clutch Air Gap
0.014 - 0.026 inch

Standard clearance:
0.5 ± 0.15 mm (0.020 ± 0.0059 in.)

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Cooling Unit x Suction Tube 24 ft.lb

Cooling Unit x Liquid Tube 10 ft.lb

Controlled Idle Speed Specifications

Controlled Idle Speed Specifications

Idle Speed With Accesories Off 650 - 750 rpm

With A/C On With Magnetic Clutch Not Engaged approx. 650 rpm

With Magnetic Clutch Engaged approx. 900 rpm

Toyota base timing

Toyota base timing

Base timing 10 deg BTDC at 700+/-50 rpm

Maximum RPM, cooling fan and vacuum advance (if equipped)
OFF.

Torque Specifications

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Service Data Part 1

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Service Data Part 2

Type/torque
Type/torque

Recommended type ND K16R-U

NGK BKR5EYA

Tightening torque 14 ft.lb

Plug gap 0.031 in

Spark Plug Type, Gap and Torque

Gap ................................................................................................................................................................................................... 0.031 in (0.8 mm)

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Torque Value ...................................................................................................................................................................................... 13 ft.lb (18 Nm)

Reduction Type Starter (1.0 KW Rating)

Brush Spring Tension, Ounces .............................................................................................................................................................................. 62-85
No Load Test
Amperes ...................................................................................................................................................................................................................... 90
Volts ......................................................................................................................................................................................................................... 11.5
RPM ........................................................................................................................................................................................................................ 3000

Reduction Type Starter (1.4 KW Rating)

Brush Spring Tension, Ounces .............................................................................................................................................................................. 62-85
No Load Test
Amperes ...................................................................................................................................................................................................................... 90
Volts ......................................................................................................................................................................................................................... 11.5
RPM ........................................................................................................................................................................................................................ 3500

Tightening Specifications

Alignment
FRONT END ALIGNMENT
Caster Angle, Degrees .............................................................................................................................................................. Limits + 7/12 to +2 1/12
Desired .................................................................................................................................................................................................................. +1 1/3
Camber Angle, Degrees ............................................................................................................................................................ Limits -11/12 to + 7/12
Desired ....................................................................................................................................................................................................................... -1/6
Toe-In, Inch .............................................................................................................................................................................................................. 0.04
Toe-Out on Turns, Deg. ..................................................................................................................................................................................................
Outer Wheel ...................................................................................................................................................................................................... 39
Inner Wheel ....................................................................................................................................................................................................... 33
Steering Axis Inclination, Deg. ......................................................................................................................................................................... +12 7/12
Ball Joint Wear ......................................................................................................................................................................................................... [01]

[01] -- Refer to Ball Joint Inspection ..................................................................................................................... under Front Suspension & Steering.

Belt Tension
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Belt .................................................................................................................................................................................................................. Air Cond.

New Lbs. ............................................................................................................................................................................................................ 140-180
Used Lbs. ............................................................................................................................................................................................................. 80-120

Belt .................................................................................................................................................................................................................. Alternator

New Lbs. ............................................................................................................................................................................................................ 140-180
Used Lbs. ........................................................................................................................................................................................................... 110-150

Belt .......................................................................................................................................................................................................... Power Steering

New Lbs. ............................................................................................................................................................................................................ 100-150
Used Lbs. ............................................................................................................................................................................................................. 60-100

Tightening Specifications
COROLLA

Component .......................................................................................................................................................................................... Torque/Ft. Lbs.

Control Valve Self-Locking Nut ................................................................................................................................................................................. 18
Control Valve Shaft To Universal Joint ...................................................................................................................................................................... 26
Drive Pulley To Rotor Shaft ........................................................................................................................................................................................ 32
Gear Housing Bracket To Body .................................................................................................................................................................................. 43
Power Steering Pump Installation Bolt ....................................................................................................................................................................... 32
Pressure & Return Tube To Gear Housing ................................................................................................................................................................... 9
Pressure Port Union To Pump Housing ...................................................................................................................................................................... 51
Pressure Tube To Pressure Port Union ....................................................................................................................................................................... 40
Rack Guided Spring Cap Locknut .............................................................................................................................................................................. 43
Rack Housing Cap ....................................................................................................................................................................................................... 43
Rack To Rack End ...................................................................................................................................................................................................... 61
Reservoir Installation Bolt .......................................................................................................................................................................................... 30
Steering Main Shaft To Universal Joint ...................................................................................................................................................................... 26
Tie Rod End Locknut .................................................................................................................................................................................................. 41
Tie Rod End To Steering Knuckle .............................................................................................................................................................................. 36
Turn Pressure Tube Union Nut ..................................................................................................................................................................................... 9

Wheel Fastener
Lug Nut Torque .................................................................................................................................................................................. 76 ft. lb.(103 Nm)

Thermostat Housing, Engine Cooling

Bolts ................................................................................................................................................................................................ 14.5 Nm (11 ft. lbs.)

Thermostat, Engine Cooling

Valve Lift [1] ....................................................................................................................................................................................... 8 mm (0.31 inch)

[1] At 95° C (203° F)

Water Pump
Component .......................................................................................................................................................................................... Torque/Ft. Lbs.
Water Pump Bolts ......................................................................................................................................................................................................... 7

Compression Check
Compression Pressure at 250 rpm
Std. ............................................................................................................................................................................................... 191 psi (1,320 kPa)
Limit ................................................................................................................................................................................................ 142 psi (981 kPa)
Difference between cylinders .................................................................................................................................................. 14 psi (98 kPa) or less

Intake Manifold Vacuum

At Idle Speed .................................................................................................................................................................... 12.6 in.Hg (46 kPa) or less

System Specifications
Radiator Cap Relief Pressure ................................................................................................................................................................................ 13 lbs.

Relief Pressure
Relief Pressure

Radiator Cap Relief Pressure 10.7-14.9 psi

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Thermostat, Engine Cooling

Opening Temperature ................................................................................................................................................................... 80-84°C (176-183°F)

Oil Pressure Specifications

Oil Pressure Specifications

At idle more than 4.3 psi

At 3,000 rpm 36 - 71 psi

Engine at normal operating temperature

Oil Pump, Engine

Refer to Engine Lubrication; Specifications; Pressure, Vacuum and Temperature.
See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Specifications
Fuel Pressure
Fuel Pressure Specifications

With Fuel Pressure Regulator vacuum hose disconnected ................................................................................................... 265-304 kPa (38-44 psi)
With Fuel Pressure Regulator vacuum hose connected ....................................................................................................... 206-255 kPa (31-37 psi)
Steering
Maximum Oil Level Rise, Inch .................................................................................................................................................................................. 0.2
Minimum Oil Pressure, psi [01] ................................................................................................................................................................................ 853
Maximum Oil Pressure, psi [01] ............................................................................................................................................................................... 924
Steering Effort ..................................................................................................................................................................................................... 11 [02]

[01] -- SV models, 924 psi, VZV models, 1067 psi.

[02] -- Ft. lbs.

Capacity Manual Transmission Nippondenso radiator 5.8 qt (US)

Harrison radiator 6.6 qt (US)

Automatic Transmission Nippondenso Radiator 6.6 qt (US)

Harrison radiator 6.4 qt (US)

Coolant type Ethylene glycol

Differential Fluid - A/T

TYPE ................................................................................................................................................................................................................... AF
Tercel & Corolla w/3 speed; Camry 4-cyl; 1994 V-6

CAPACITY, Refill:
Corolla, Tercel .......................................................................................................................................................................... 1.4 liters 3.0 pints
Camry, 4-cyl ............................................................................................................................................................................. 1.6 liters 3.4 pints
V-6, 1994 ................................................................................................................................................................................. 1.0 liters 2.1 pints

Capacity with filter 3.5 qt (US)

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Fuel
Fuel Tank ........................................................................................................................................................................................... 13.2 gal (50 liters)

Fuel Tank 13.2 gal (US)

Refrigerant
Refrigerant Capacity ....................................................................................................................................................................................... 1.65 lbs.

Refrigerant Type ................................................................................................................................................................................................... R-12

Total Refrigerant Oil Amount ............................................................................................................................................................................ 4.1 oz.

Refrigerant Oil Type ............................................................................................................................................................................ Denso Oil 6 [1]

[1] Or Equivalent

Refrigerant Oil
Refrigerant Capacity ....................................................................................................................................................................................... 1.65 lbs.

Refrigerant Type ................................................................................................................................................................................................... R-12

Total Refrigerant Oil Amount ............................................................................................................................................................................ 4.1 oz.

Refrigerant Oil Type ............................................................................................................................................................................ Denso Oil 6 [1]

[1] Or Equivalent

Required Brake Fluid SAE DOT3

Clutch Fluid
Specified type ................................................................................................................................................. SAE J1703 or FMVSS No. 116 DOT 3

Do not use alcohol type anti-freeze or water without anti-freeze.

Specified Type Ethylene-glycol Based Anti-freeze/coolant

Toyota brand recommended.

Coolant Concentration 50% Anti-freeze / 50% Distilled Or Demineralized Water

Engine Oil
API Grade: SG multigrade or better and recommended viscosity SAE.

Use the chart below to determine SAE viscosity by temperature range anticipated before next oil change:

Temperature Range ....................................................................................................................................................................................... Viscosity

Above 0°F ........................................................................................................................................................................................................... 10W-30

Below 50°F ........................................................................................................................................................................................................... 5W-30

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Fuel
FUEL TYPE ............................................................................................................................................................ Above 91 RON Octane, Unleaded

Lubricant

Type ND-OIL 8

System Specifications
Lubricant Type
Power Steering ..................................................................................................................................................................................... Dexron II/IIE/III

Fluid type
Fluid type

Type Dextron II ATF

or equivalent.

Power Steering Pump

LUBRICATION

Lubricant Type
Power Steering ..................................................................................................................................................................................... Dexron II/IIE/III

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Vehicle: Locations

Component Locations: Body

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Component Locations: Engine Compartment

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Component Locations: Engine Compartment

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Component Locations: Instrument Panel

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Component Locations: Instrument Panel

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Relay Locations: Body

Relay Locations: Engine Compartment

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Relay Locations: Instrument Panel

Fig. 5

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Connector And Ground Locations: Body

Connector And Ground Locations: Engine Compartment

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Connector Locations: Instrument Panel

Connector Locations: Instrument Panel

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Connector And Ground Locations: Body

Connector And Ground Locations: Engine Compartment

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Ground Locations: Instrument Panel

Splice Locations: Engine Compartment

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Splice Locations: Instrument Panel

Splice Locations: Body

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Vehicle: Diagrams

Abbreviations

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Symbol Identification

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Symbol Identification

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Key To Wiring Diagrams

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Glossary Of Terms And Symbols

Glossary Of Terms And Symbols

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Wire Color Code Identification

Continuity and Resistance Check

Meter Types

1. Use a digital or analog multimeter with a minimum 10k ohm resistance.

2. Disconnect the battery or connector so there is no power between the check points.
3. Set the ohmmeter to the appropriate range.

Continuity And Resistance Check

4. Connect the two leads of the meter to each of the check points.

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Diode Check

5. If the circuit or component has diodes, reverse the leads and check again.
a. When contacting the negative lead to the diode's positive side and the positive lead to the negative side, there should be continuity.
b. When connecting the two leads in reverse, there should not be continuity.

Electronic Component Handling

STATIC DISCHARGE
^ Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin
area like the wrist.
^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components on the ECU circuit board.

TESTING
^ When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON"
as necessary.
^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform
measurements through pin.

CONTROL UNIT DAMAGE

^ Do not try to disassemble the control unit.
^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, ECU and
radio.
^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's.
^ Avoid getting water on any of the Fuel and Engine Control System Components.
^ Never apply battery power to a component unless directed to do so in a test procedure.

Electronic Component Replacement

1. Before servicing electronic components, disconnect the battery ground.

NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if ground cable is removed.

2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires.

Battery Precautions
CAUTION:
- Never use a booster/starter which has a voltage rating above 12 volts to start engine.
- Always ensure the battery is properly connected to the vehicle prior to attempting to start engine.
- Don't disconnect the battery when the engine is running.
- When charging a battery, be sure battery cables are disconnected.
- The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near battery.

Electrical Connections and Circuits

1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when
reinstalling.
2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test
procedure.
3. Do not use a self powered test lamp to check continuity.
4. Do not create any arcing to check the continuity of a circuit.

Electrostatic Discharge
ELECTROSTATIC DISCHARGE

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Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to
damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as
4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative
in nature.

There are several ways in which a person can become statically charged. The most common methods of charging are by friction and
induction.

CHARGING BY FRICTION
Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as
great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic
materials.

CHARGING BY INDUCTION
Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily
touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity.

PRECAUTIONS
Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling
and testing electronic components.

Proper Tools and Testing Procedures

DIGITAL VOLT/OHM METER
Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when testing an ECU or related components,
unless use of an analog meter is specified by a testing procedure. Analog meters have low internal impedance and cause circuit "loading" in
low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a DVOM is necessary to obtain
accurate measurements and avoid damaging low voltage ECU circuits and components.

TESTING PROCEDURES
Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless specified by a testing procedure. ECU's
provide a regulated constant low voltage source to some circuits, which may require a minimum resistance (impedance) to operate. Directly
grounding or applying battery power to these circuits could damage the ECU and cause a system failure.

Finding Short Circuits

Meter Types

1. Use a digital or analog multimeter with a minimum 10k ohm resistance.

2. Remove the blown fuse and disconnect all loads for that circuit.

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Finding A Short Circuit

3. Connect a test lamp in place of the fuse.

4. Establish conditions that turn the test lamp on.
EXAMPLE
a) Ignition SW ON
b) Ignition SW ON and SW 1 ON
c) Ignition SW, SW 1 and Relay ON (connect the relay)
5. Connect and disconnect the components or connectors in the circuit while watching the test light.
a) The test light will come on when the shorted circuit or component is connected.
b) The test light will go off when the circuit or component is disconnected

Voltage Check

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Meter Types

1. Use a digital or analog multimeter with a minimum 10k ohm resistance.

Voltage Check

2. Establish conditions in which voltage should be present at the check point.

EXAMPLE:
a) Ignition SW ON
b) Ignition SW and SW 1 ON
c) Ignition SW, SW1 and Relay ON (SW 2 OFF)

3. Set the volt meter set to the appropriate range for the circuit being tested.
4. Connect the negative lead to a good ground point or the negative battery terminal, and connect the positive lead to the connector or
component terminal.

NOTE: This test can be done with a test light if the circuit does not include sensitive electrical components, i.e. electrical control units.

Circuit Protection Devices

The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current
requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result

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of a pinched or cut wire or an internal device short circuit, such as an electronic module failure.
The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an
electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will
not necessarily prevent damage to the component.

CIRCUIT PROTECTION DEVICES

There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link.

CIRCUIT BREAKERS

A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or
other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic
types of circuit breakers used in GM vehicles: cycling and non-cycling.

Cycling Circuit Breaker

The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, it
will close again after a few seconds. If the cause of the high current is still present it will open again. It will continue to cycle open and closed until
the condition causing the high current is removed.

Non-Cycling Circuit Breaker

There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small
heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is
removed. The other type is solid state, known as an Electronic Circuit Breaker (EC13). This device has a Positive Temperature Coefficient. It
increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases,
therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the circuit is effectively open. The EC13 will not
reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or
two.

Fig. 1 Fuse Devices

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Fig. 2 Fuse Rating and Color

FUSES

The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a device that, by the melting of its element, opens an
electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a
circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color identification and ratings are shown in Fig. 2.
For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element.
If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These
fuses are located within the individual wiring harness and will appear to be an open circuit if blown.

Autofuse

The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often
used to protect the wiring assembly between the Fuse Block and the system components.

Maxifuse
The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is designed to protect cables, normally between the
Battery and Fuse Block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the
Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to
be a slower blowing fuse, with less chance of nuisance blows.

Minifuse

The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the
wiring assembly between a Fuse Block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to
be accomplished within the same amount of space as Autofuses.

Pacific Fuse Element

The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible link, the fuse element is designed to protect wiring

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from a direct short to ground. Though the element is easier to service and inspect than a fusible link, it has limited use and will be replaced by
Maxifuses in future vehicles.

Fig. 3 Good and Damaged Fusible Links

Fig. 6 Wire Size Conversion Table

Fusible Links

In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection
devices that will melt and create an open circuit, Fig. 3.

Not all fusible link open circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify
continuity.
Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link
is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to
protect a 5 sq.mm wire use a 2 sq.mm link, Fig. 6. Links are marked on the insulation with wire gage size because the heavy insulation makes the
link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link.
Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use
fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded
Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to
replace Hypalon(R) fusible links.

Determining characteristics of the types of fusible links:

- Hypalon(R) (limited use): only available in .35 sq.mm or smaller and its insulation is one color all the way through.
- SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation.
- Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the
insulation.
Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should
be cut 150-225 mm (approx 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx 9 in.).

CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload protection.

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Fig. 4 Single Wire Feed Fusible Link

Fig. 5 Double Wire Feed Fusible Link

To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and
use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use
Crimp and Seal splices whenever possible.
To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each
harness wire, Fig. 5.

Typical Electrical Repair

An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. A
short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse
to blow or a circuit breaker to open.

SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION

- Locate the damaged wire.
- Find and correct the cause of the wire insulation damage.
- For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (Refer to the splicing instructions
for copper or shielded cable for the correct splicing procedure).

Splicing Copper Wire Using Splice Clips

The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture
sealing.

Step 1: Open the Harness

If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from
sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire.

Step 2: Cut the Wire

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Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to
change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other
splices, harness branches or connectors.

Fig. 6 Wire Size Conversion Table

Step 3: Strip the Insulation

When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. See table, Fig. 6, for
the commercial (AWG) wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent
metric size. To find the correct wire size either find the wire on the schematic and convert the metric size to the AWG size, or use an AWG wire
gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is
removed. Be careful to avoid nicking or cutting any of the wires.

Fig. 8 Crimping the Splice Clip

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Fig. 9 Completing the Crimp

Step 4: Crimp the Wires

Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J
38125-A Terminal Repair Kit. Select the correct anvil on the crimper. On most crimpers your choice is limited to either a small or large anvil.
Overlap the stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then, center the splice clip under the stripped
wires and hold it in place.
^ Open the crimping tool to its full width and rest one handle on a firm flat surface.
^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip.
^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes, Fig. 8.
^ Before crimping the ends of the clip, be sure that:
- The wires extend beyond the clip in each direction.
- No strands of wire are cut loose, and
- No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of
the clip or you may damage or nick the wires, Fig. 9.

Step 5: Solder

Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10.

Follow the manufacturer's instruction for the solder equipment you are using.

Fig. 11 Proper First Taping

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Fig. 12 Proper Second Taping

Step 6: Tape the Splice

Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the
existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the nagged ends will tangle with the other wires in the
harness, Fig. 11.
If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape, Fig.
12.

Splicing Copper Wire Using Crimp and Seal Splice Sleeves

Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one to one splice. They are to be used
where there are special requirements such as moisture scaling.

Step 1: Open the Harness

If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from
sewing supply stores). The Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to
form a one to one splice.

Step 2: Cut the Wire

Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the
location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices,
harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage.

Fig. 6 Wire Size Conversion Table

Step 3: Strip the Insulation

If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire, see Fig. 6.

To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire
gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is
removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires.
Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section.

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Fig. 13 Hand Crimp Tool

Fig. 14 Seal Splice Sequence

Step 4: Select and Position the Splice Sleeve

Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded.
Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the
crimp falls midway between the end of the barrel and the stop.
The sleeve has a stop in the middle of the barrel to prevent the wire from going further, Fig. 14. Close the hand crimper handles slightly to hold the
splice sleeve firmly in the proper nest.

Step 5: Insert Wires into Splice Sleeve and Crimp

Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper tightly until the crimper handles open when
released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end
of the splice.

Step 6: Shrink the Insulation around the Splice

Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing
completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is
achieved, Fig. 14.

Splicing Twisted/Shielded Cable

Fig. 15 Twisted/Shielded Cable

Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this
construction is used between the ECM and the distributor. See Fig. 15 for a breakdown of twisted/shielded cable construction.

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Step 1: Remove Outer Jacket

Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape.

Step 2: Unwrap the Tape

Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made.

Fig. 16 The Untwisted Conductors

Step 3: Prepare the Splice

Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger
splices to avoid shorts, Fig. 16.

Fig. 17 The Re-assembled Cable

Step 4: Re-assemble the Cable

After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape.
Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig.
17.

Fig. 18 Proper Taping

Step 5: Tape the Cable

Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the jacket you removed to make the repair.

Repairing Connectors
The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general
groups: Push-to-Seat and Pull-to-Seat and Weather Pack.

^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced.

^ Use the proper Pick(s) or Tool(s) that apply to the terminal.

Figure 1 - Typical Push-To-Seat Connector

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Fig. 20 Typical Pull-to-Seat Connector and Terminal

PUSH-TO-SEAT AND PULL-TO-SEAT

Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The steps are illustrated with typical connectors. Your
connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply.

1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain connectors when mated.
2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal from backing out of the connector.

NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated.

3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector.
4. Separate the connector halves and back out seals.
5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position.
6. Locate the terminal lock tang in the connector canal.
7. Insert the proper size pick straight into the connector canal at the mating end of the connector.
8. Depress the locking tang to unseat the terminal.
Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector.
Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector.

NOTE: Never use force to remove a terminal from a connector.

9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR.

10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease.
11. Install any CPAs or TPAs, close any secondary locks and join connector halves.

Fig. 21 Typical Weather Pack Connector and Terminal

WEATHER PACK

Follow the steps below to repair Weather Pack(R) connectors, Fig. 21.
1. Separate the connector halves.
2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector.
3. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position.
4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder.
5. Gently pull on the lead to remove the terminal through the back of the connector.

NOTE: Never use force to remove a terminal from a connector.

6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR.
7. Reform the lock tang and reseat terminal in connector body.
8. Close secondary locks and join connector halves.

Terminal Repair

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Fig. 22 Terminal Repair

The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals, Fig. 22. Some terminals do not
require all steps shown. Skip those that don't apply. (Refer to GM Terminal Repair Kit J 38125-A for further information.)

1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals.
2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only).
3. Remove insulation.
4. Align seal with end of cable insulation (Weather Pack(R) terminals only).
5. Position strip (and seal for Weather Pack(R)) in terminal.
6. Hand crimp core wings.
7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)).
8. Solder all hand crimped terminals.

Alternator

Fig. 1 Exploded View Of Alternator. Less IC Regulator

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Fig. 2 Exploded View Of Alternator. 50 Amp

Fig. 3 Exploded View Of Alternator. 55 Amp

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Fig. 4 Exploded View Of Alternator. 60 & 70 Amp

Fig. 6 Exploded View Of Alternator. 80, 90 & 100 Amp

Refer to Figs. 1 through 4 and 6, for alternator exploded views.

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Magnetic Clutch

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Magnetic Clutch

Front Brake Components

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Timing Components

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TIMING COMPONENTS

CAMSHAFT/CRANKSHAFT ALIMENT SPECIFICATIONS

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Cooling Unit

Components

Starter Motor

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Fig. 1 Exploded View Of Reduction Type Starter

Fig. 2 Exploded View Of Starter

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Fig. 3 Exploded View Of Starter.

Fig. 4 Exploded View Of Starter. Celica, Camry & MR2 W/1.4 Or 1.6 Kilowatts

Fig. 5 Exploded View Of Starter. Celica, Camry & MR2 w/1.4 Kilowatts Compact Type

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Fig. 6 Exploded View Of Conventional Starter.

Fig. 7 Exploded View Of Planetary Starter. Paseo

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Connector Identification

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Connector Identification

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Junction Block No. 2 (Views)

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Junction Block No. 3 (View)

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Junction Block No. 1

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Junction Block No. 4

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Relay Block No. 5

Relay Block No. 6 (Canada)

Connector Identification

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Connector Identification

Fig. 28 Center Airbag Sensor Assembly Connector. Corolla

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System Diagram
CONNECTOR VIEWS

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 362

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 366

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 367

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Fig. 37 Connector Identification

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ECM Terminal Identification

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Junction Block No. 1 (Inner Circuit)

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Junction Block No. 2 (Inner Circuit)

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Junction Block No. 3 (Inner Circuit)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 405

Ground Points: BH, BI, And BJ

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 406

Ground Points: EA, EB, EC, IE, And IF

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 407

Ground Points: ID And IG

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 408

Ground Points: ID And IG

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 409

J/B No. 1 Inner Circuit

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 410

J/B No. 2 Inner Circuit

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 411

J/B No. 3 Inner Circuit

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 412

J/B No. 4 Inner Circuit

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 413

Fig. 10 SRS Wiring Circuit. Corolla

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 414

Supplemental Restraint System (Airbag)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 415

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 416

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 417

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 418

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 419

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 420

Fig. 34 Wiring Diagram. Corolla

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 421

Anti-Lock Brakes (ABS)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 422

Anti-Lock Brakes (ABS)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 423

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 424

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 425

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 426

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 114
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 427

Theft Deterrent And Door Locks

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 428

Theft Deterrent And Door Locks

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 429

Theft Deterrent And Door Locks

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 430

Theft Deterrent And Door Locks

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 431

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 432

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 433

Instrument Panel (Combination Meter)

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 121
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 434

Back-up Light

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 122
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 435

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 123
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 436

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 437

Instrument Panel (Combination Meter)

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 125
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 438

Instrument Panel (Combination Meter)

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 126
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 439

Stop Light

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 440

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 441

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 442

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 443

Instrument Panel (Combination Meter)

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 131
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 444

Charging System

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 445

Cigarette Lighter And Clock

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 446

Cigarette Lighter And Clock

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 134
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 447

Radiator Fan (Cooling Fan) And Air Conditioner

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 135
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 448

Radiator Fan (Cooling Fan) And Air Conditioner

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 136
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 449

Radiator Fan (Cooling Fan) And Air Conditioner

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 137
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 450

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 138
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 451

Instrument Panel (Combination Meter)

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 139
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 452

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 453

Instrument Panel (Combination Meter)

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 141
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 454

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 142
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 455

Interior Light

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 456

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 457

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 145
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 458

Cruise Control

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 146
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 459

Cruise Control

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 147
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 460

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 461

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 462

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 463

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 464

Back Door Lock

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 465

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 466

Theft Deterrent And Door Locks

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 467

Theft Deterrent And Door Locks

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 468

Theft Deterrent And Door Locks

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 156
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 469

Theft Deterrent And Door Locks

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 470

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 158
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 471

Door Locks (Without Theft Deterrent System)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 472

Door Locks (Without Theft Deterrent System)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 473

Unlock And Seat Belt Warning

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 474

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 475

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 476

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 477

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 478

Turn Signal And Hazard Warning Light

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 479

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 480

Headlight (With Daytime Running Lamps)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 481

Headlight (With Daytime Running Lamps)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 482

Headlight (With Daytime Running Lamps)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 483

Headlight (Without Daytime Running Lamps)

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 171
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 484

Light Auto Turn Off

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 485

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 173
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 486

Rear Window Defogger

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 174
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 487

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 488

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 489

Instrument Panel (Combination Meter)

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 177
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 490

Instrument Panel (Combination Meter)

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 178
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 491

vergaray.collantes@gmail.com
 179
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 492

Radiator Fan (Cooling Fan) And Air Conditioner

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 180
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 493

Radiator Fan (Cooling Fan) And Air Conditioner

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 181
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 494

Radiator Fan (Cooling Fan) And Air Conditioner

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 182
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 495

AC System Schematic

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 183
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 496

Instrument Panel (Combination Meter)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 497

Instrument Panel (Combination Meter)

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 185
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 498

Instrument Panel (Combination Meter)

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 186
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 499

Horn

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 500

Part 1 Of 3

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 501

Part 2 Of 3

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 502

Part 3 Of 3

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 503

vergaray.collantes@gmail.com
 191
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 504

Instrument Panel (Combination Meter)

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 192
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 505

Instrument Panel (Combination Meter)

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 193
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 506

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 194
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 507

vergaray.collantes@gmail.com
 195
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 508

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 196
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 509

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 197
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 510

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 198
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 511

Power Mirrors

vergaray.collantes@gmail.com
 199
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 512

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 200
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 513

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 201
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 514

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 202
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 515

vergaray.collantes@gmail.com
 203
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 516

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 204
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 517

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 205
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 518

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 206
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 519

Engine Management - (Part 1 Of 4)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 520

Engine Management - (Part 2 Of 4)

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 208
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 521

Engine Management - (Part 3 Of 4)

vergaray.collantes@gmail.com
 209
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 522

Engine Management - (Part 4 Of 4)

vergaray.collantes@gmail.com
 210
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 523

Engine Management - (Part 1 Of 4)

vergaray.collantes@gmail.com
 211
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 524

Engine Management - (Part 2 Of 4)

vergaray.collantes@gmail.com
 212
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 525

Engine Management - (Part 3 Of 4)

vergaray.collantes@gmail.com
 213
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 526

Engine Management - (Part 4 Of 4)

vergaray.collantes@gmail.com
 214
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 527

vergaray.collantes@gmail.com
 215
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 528

System Schematic

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 529

vergaray.collantes@gmail.com
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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 530

Radio And Player

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 218
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 531

Unlock And Seat Belt Warning

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 219
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 532

vergaray.collantes@gmail.com
 220
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 533

vergaray.collantes@gmail.com
 221
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 534

Starting System

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 222
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 535

Sunroof

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 223
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 536

vergaray.collantes@gmail.com
 224
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 537

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 225
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 538

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 226
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 539

Instrument Panel (Combination Meter)

vergaray.collantes@gmail.com
 227
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 540

Taillight And Illumination

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 228
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 541

Taillight And Illumination

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 229
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 542

Taillight And Illumination

vergaray.collantes@gmail.com
 230
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 543

Shift Interlock Circuit

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 231
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 544

vergaray.collantes@gmail.com
 232
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 545

Transmission Controls (Electronically Controlled)

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 233
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 546

Transmission Controls (Electronically Controlled)

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 234
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 547

Turn Signal And Hazard Warning Light

vergaray.collantes@gmail.com
 235
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 548

vergaray.collantes@gmail.com
 236
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 549

Power Window

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 237
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 550

Power Window

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 238
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 551

vergaray.collantes@gmail.com
 239
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 552

Front Wiper/Washer

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 240
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 553

Rear Wiper/Washer

Vacuum and Vapor Hose Routing

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 241
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 554

Component Layout

Under-hood Components

Vacuum and Vapor Hose Schematic

Vacuum Connection

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 242
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 555

Vacuum Connection

Vacuum and Vapor Hose Routing

Component Layout

Under-hood Components

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 243
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 556

Vacuum and Vapor Hose Schematic

Vacuum Connection

Vacuum Connection

Vacuum and Vapor Hose Routing

Component Layout

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 244
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 557

Under-hood Components

Vacuum and Vapor Hose Schematic

Vacuum Connection

Vacuum Connection

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 1
Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 558
Computers and Control Systems: Testing and Inspection

Flow Of Diagnosis

Verifying Customer Complaint

Complaint Verification
Whenever possible the technician should personally verify the complaint.
- Having experienced the malfunction, you will be less likely to attempt to repair a non-existent fault.

Malfunction Verification

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 559
Automotive control systems are easily misunderstood, leading to repairs that attempt to force a system to perform in a way it was never
intended to.
- Always compare system operation to normal system operation as described in either the owners manual or DESCRIPTION AND
OPERATION.
- When possible compare vehicle operation with that of a known good vehicle.

Previous Repairs
The vehicle repair history can provide explanations to unusual complaints which elude normal troubleshooting attempts. Incorrect
components or unapproved repairs can have subtle influences on seemingly unrelated systems.
- Always attempt to get the "whole story" from the customer.
- When possible check the system or component which was last repaired.

Checking the Basics

CHECKING THE BASICS
All troubleshooting must begin by "CHECKING THE BASICS". Certain basic faults can be undetectable by the self-diagnostic systems of
the fuel and ignition control units and in some cases can actually interfere with the self-checking and fault memory operation.

System fault codes are cleared whenever the control unit or the battery is disconnected. Therefore, all fault codes should be read prior to any
vehicle power interruption or troubleshooting.

Prior to any teardown, repair or component replacement, the following steps should always be considered.

BATTERY STATE OF CHARGE

Batteries in a state of partial discharge can have a dramatic effect on control units and related components.

POSITIVE BATTERY CABLE INTEGRITY

All B+ connections must be in perfect condition for trouble-free electronic system operation. Refer to ELECTRICAL AND
ELECTRONIC DIAGRAMS for B+ interconnects.

FUSE INTEGRITY
Fuses are employed to prevent possible damage to electrical components and wiring harnesses. The fuses and their connections must be
without dynamic resistance. Dynamic resistance can only be checked using the voltage drop method of testing.

NEGATIVE GROUND CONNECTIONS

As all electrical circuits complete a circle, all B- connections must also be checked and verified to be in perfect condition. A poor "common"
ground point will cause seemingly unrelated systems to influence one another. High current systems which encounter a poor "common"
ground can back feed through other electrical systems causing unusual operation and perhaps inexplicable component failure. As with the
B+ side of the electrical system, the ground side should be checked dynamically using the voltage drop technique.

POWER TRAIN CABLE ATTACHMENTS

Metal cables attached to the engine or transmission which appear overheated and/or discolored indicate the need to thoroughly test all ground
connections.

POWER SUPPLY RELAYS

The system relay as well as its' plug connection can be a source of intermittent operation which will not set a fault in control unit fault
memory.

CRANKSHAFT POSITION/SPEED SENSOR

Monolithic sensors should be checked statically and dynamically. Physical mounting and condition of the sensor must be assured.

HIGH TENSION COIL AND SECONDARY COMPONENTS WIRING

The secondary ignition system should be checked visibly as well as with a suitable engine analyzer and scope. All components should be
examined for tight connections and freedom from carbon tracking, moisture and corrosion.

FUEL DELIVERY
Fuel delivery must begin at once when cranking and the pressure in the fuel rails must be within specifications. Fuel pressure retention must
be maintained between the fuel pump outlet and the pressure regulator after engine shutdown.

SPARK PLUGS
If out of specification, spark plugs can significantly impair engine performance. Spark plug type, condition and gap must verified according
to specification.

AIR/FUEL RATIO
When troubleshooting idle quality or driveability complaints, it is necessary to consider the following:

^ Injector spray pattern quality

^ Presence of unmetered air leaks
^ Evaporative purge system

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^ Excessive engine oil dilution
^ Substandard fuel or unapproved additives
^ Carbon build-up

Check For Intermittent Problems

CHECK FOR MOMENTARY INTERRUPTION

As described in How to Display and Read Diagnostic Trouble Codes, abnormality detection ability in the test mode is increased compared to
that in the normal mode, so that when momentary interruptions or momentary shorts occur in the ECM signal circuits (G, NE, THW, THA, PIM,
VTA) shown in the table, the appropriate diagnostic trouble code is output.

Accordingly, when the diagnostic trouble codes shown in the table (13, 22, 24, 31, 41) are output during the diagnostic trouble code check, and
inspection of the appropriate circuits reveals no abnormality, perform the check for momentary interruption as described below.

By performing the check for momentary interruption, the place where momentary interruptions or momentary shorts are occurring due to poor
contacts can be isolated.

1. CLEAR DIAGNOSTIC TROUBLE CODES (Refer to How to Clear Diagnostic Trouble Codes)

2. SET TEST MODE (Refer to How to Display and Read Diagnostic Trouble Codes)

(a) With the ignition switch off, using SST, connect the terminals TE2 and E1 of the data link connector 1. SST 09843-18020
(b) Start the engine and check to see if the malfunction indicator lamp goes off.

3. PERFORM A SIMULATION TEST

Using the symptom simulation, apply vibration to and pull lightly on the wire harness, connector or terminals in the circuit indicated by the
malfunction code.

In this test, if the malfunction indicator lamp lights up, it indicates that the place where the wire harness, connector or terminals being pulled
or vibrated has faulty contact. Check that point for loose connections, dirt on the terminals, poor fit or other problems and repair as necessary.

NOTE: After cancelling out the diagnostic trouble code in memory and set the test mode, if the malfunction indicator lamp does not go off
after the engine is started, check thoroughly for faulty contact, etc., then try the check again. If the malfunction indicator lamp still
does not go off, check and replace ECM.

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Initial Inspection (Basic Inspection)

BASIC INSPECTION

When the normal code is displayed in the diagnostic trouble code check, troubleshooting should be performed in the order for all possible
circuits to be considered as the causes of the problems. In many cases, by carrying out the basic engine check shown in the following flow charts,
the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting.

Step 1

Step 2

Step 3

Step 4

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Step 5

Step 6

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Step 7

Step 8

System Description
DESCRIPTION OF SELF DIAGNOSIS

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 564

The ECM contains a built-in self-diagnosis system by which troubles with the engine signal network are detected and a malfunction indicator
lamp on the instrument panel lights up. By analyzing various signals as shown in the later table (Trouble Code Descriptions) the Electronic
Control Module (ECM) detects system malfunctions relating to the sensors or actuators.

In the normal mode, the self-diagnosis system monitors 13 (California specification vehicles) or 10 (Other than California specification vehicles)
items, indicated by code No. as shown in Trouble Code Descriptions. A malfunction indicator lamp informs the driver that a malfunction has
been detected. The lamp goes off automatically when the malfunction has been repaired. But the diagnostic trouble code(s) remains stored in the
ECM memory. The ECM stores the code(s) until it is cleared by removing the EFI fuse with the ignition switch off.

The diagnostic trouble code can be read by the number of blinks of the malfunction indicator lamp when TE1 and E1 terminals on the data link
connector 1 are connected. When 2 or more codes are indicated, the lowest number (code) will appear first.

In the test mode, 10 (California specification vehicles) or 7 (Other than California specification vehicles) items, indicated by code No. as shown
in Trouble Code Descriptions are monitored. If a malfunction is detected in any one of the systems indicated by code Nos. 13, 21, 22, 24, 25,
26, 27, 31, 41 and 71 (California specification vehicles) or 13, 21, 22, 24, 25, 31 and 41 (Other than California specification vehicles) the ECM
lights the malfunction indicator lamp to warn the technician that malfunction has been detected. In this case, TE2 and E1 terminals on the data
link connector 1 should be connected as shown in How to Display and Read Diagnostic Trouble Codes.

In the test mode even if the malfunction is corrected, the malfunction code is stored in the ECM memory even when the ignition switch is off
(except code Nos. 43 and 51). This also applies in the normal mode. The diagnostic mode (normal or test) and the output of the malfunction
indicator lamp can be selected by connecting the TE1, TE2 and E1 terminals on the data link connector 1 as shown in How to Display and Read
Diagnostic Trouble Codes.

A test mode function has been added to the functions of the self-diagnosis system of the normal mode for the purpose of detecting malfunctions
such as poor contact, which are difficult to detect in the normal mode. This function fills up the self diagnosis system. The test mode can be
implemented by the technician following the appropriate procedures of check terminal connection and operation described in How to Display
and Read Diagnostic Trouble Codes.
Fail Safe Operation
DESCRIPTION OF FAIL SAFE OPERATION

If any of the following codes is recorded, the ECM enters fail-safe mode.

Back-Up Function
DESCRIPTION OF BACK-UP FUNCTION

If there is trouble with the program in the ECM and the ignition signals (IGT) are not output from microcomputer, the ECM controls fuel
injection and ignition timing at predetermined levels as a back-up function to make it possible to continue to operate the vehicle.

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Furthermore, the injection duration is calculated from the starting signal (STA) and the throttle position signal (IDL). Also, the ignition timing is
fixed at the initial ignition timing, 5° BTDC, without relation to the engine speed.

NOTE: If the engine is controlled by the back-up function, the malfunction indicator lamp lights up to warn the driver of the malfunction but
the diagnostic trouble code is not output.
With Scan Tool
HOW TO DISPLAY AND READ DIAGNOSTIC TROUBLE CODES WITH A SCAN TOOL

Toyota does not provide a procedure to retrieve diagnostic trouble codes with a scan tool.
Without Scan Tool
HOW TO DISPLAY AND READ DIAGNOSTIC TROUBLE CODES WITHOUT SCAN TOOL

Normal Mode

1. Turn ignition switch on.

2. Using SST, connect terminals between TE1 and E1 of the data link connector 1. SST 09843-18020
3. Read the diagnostic trouble code from malfunction indicator lamp.

NOTE: If a diagnostic trouble code is not output, check the TE1 terminal circuit See: Component Tests and General Diagnostics/TE1, TE2
Terminal Circuit

- As an example, the blinking patterns for codes; normal, 12 and 31 are as shown in the illustrations below.

Normal

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 566

Code 12 and 31

4. Check the details of the malfunction using the Trouble Code Descriptions.
5. After completing the check, disconnect terminals TE1 and E1, and turn off the display.

NOTE: In the event of 2 or more malfunction codes, indication will begin from the smaller numbered code and continue in order to the
larger.

Test Mode

Compared to the normal mode, the test mode has high sensing ability to detect malfunctions.

It can also detect malfunctions in the starter signal circuit, the IDL contact signal of the throttle position sensor, air conditioning signal and
park/neutral position switch signal.

Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the test mode.

1. Initial conditions.

(a) Battery positive voltage 11 V or more.

(b) Throttle valve fully closed (throttle position sensor IDL points closed).
(c) Transmission in park/neutral position.
(d) Air conditioning switched off.

2. Turn ignition switch off.

3. Using SST, connect terminals TE2 and E1 of data link connector 1. SST 09843-18020

4. Turn ignition switch on.

NOTE:

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- To confirm that the test mode is operating, check that the malfunction indicator lamp flashes when the ignition switch is turned to ON.
- If the malfunction indicator lamp does not flash, refer to diagnostic chart for the TE2 terminal circuit See: Component Tests and General
Diagnostics/TE1, TE2 Terminal Circuit

5. Start the engine.

6. Simulate the conditions of the malfunction described by the customer.

7. After the road test, using SST, connect terminals TE1 and E1 of data link connector 1. SST 09843-18020
8. Read the diagnostic trouble code on malfunction indicator lamp on the combination meter.

9. After completing the check, disconnect terminals TE1, TE2 and E1, and turn off the display.

NOTE:
- The test mode will not start if terminals TE2 and E1 are connected after the ignition switch is turned on.
- When vehicle speed is 5 km/h (3 mph) or below, diagnostic trouble code "42" (Vehicle speed signal) is output, but this is not abnormal.
- When the engine is not cranked, diagnostic trouble code "43" (Starter signal) output, but this is not abnormal.
- When the automatic transaxle shift lever is in the "D", "2", "L" or "R" shift position, or when the air conditioning is on or when the
accelerator pedal is depressed, code "51" (Switch condition signal) is output, but this is not abnormal.

With Scan Tool

HOW TO CLEAR DIAGNOSTIC TROUBLE CODES WITH A SCAN TOOL

Toyota does not provide a procedure to clear diagnostic trouble codes with a scan tool.
Without Scan Tool
HOW TO CLEAR DIAGNOSTIC TROUBLE CODES WITHOUT A SCAN TOOL

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 568

1. After repair of the trouble areas, the diagnostic trouble code retained in the ECM memory must be cleared out by removing the EFI fuse
(15A) from J/B No.2 for 10 seconds or more, with the ignition switch OFF.

NOTE:
- Cancellation can also be done by removing the battery negative (-) terminal, but in this case, other memory systems (clock, etc.) will also
be cancelled out.
- If it is necessary to work on engine components requiring removal of the battery terminal, a check must first be made to see if a
diagnostic trouble code has been recorded.

2. After cancellation, road test the vehicle to check that a normal code is now read on the malfunction indicator lamp.

If the same diagnostic trouble code appears, it indicates that the trouble area has not been repaired thoroughly.
Antilock Brake System (ABS)
DIAGNOSTIC TROUBLE CODE CHART

HINT:
- Using SST 09843-18020, connect the terminals Tc and E1, and remove the short pin. If a malfunction code is displayed during the
diagnostic trouble code check, check the circuit listed for that code in the table.

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Trouble Code Descriptions

Diagnostic Trouble Code of Speed Sensor Check Function

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Type A Codes

Fig. 1 Type A Diagnostic Codes.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 571

Fig. 2 Type A Diagnostic Codes.

Fig. 3 Type A Diagnostic Codes.

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Fig. 4 Type A Diagnostic Codes.

Fig. 5 Type A Diagnostic Codes.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 573

Fig. 6 Type A Diagnostic Codes.

Fig. 7 Type A Diagnostic Codes.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 574

Fig. 8 Type A Diagnostic Codes.

1 On models except T100, proceed as follows:

a. Place ignition switch to On position.
b. Push set/coast switch to on and hold it there.
c. Place main switch in on position, then push set/coast switch to off.
d. Read diagnostic code by watching main switch indicator flash.
e. Refer to Figs. 1 through 8, for description of codes.
2 On T100 models, prodeed as follows:
a. Using tool No. 09843-18020, or equivalent, connect Data Link Connector (DLC) check terminals Tc and E1, Fig. 9.

Fig. 9 Data Link Connector.

b. Read trouble code on cruise main indicator lamp, Fig. 6.

c. After reading codes, disconnect terminals Tc and E1, then turn off display

Type B Codes

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 575

Fig. 10 Type B Diagnostic Codes.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 576

Fig. 11 Type B Diagnostic Codes.

Fig. 12 Type B Diagnostic Codes.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 577

Fig. 13 Type B Diagnostic Codes.

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Fig. 14 Type B Diagnostic Codes.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 579

Fig. 15 Type B Diagnostic Codes.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 580

Fig. 16 Type B Diagnostic Codes.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 581

Fig. 17 Type B Diagnostic Codes.

Fig. 18 Type B Diagnostic Codes.

1. Drive vehicle at a speed of less then 10 mph, then press set/coast switch three time in two seconds. Inspect system for codes with ignition
and main switches in on position. Loss of system power will cause codes to be cleared from computers memory.
2. On MR2, Paseo, Pickup, Tacoma, T100 and 4Runner, with vehicle stopped, with suitable jumper wire, connect check terminals 3 and 11
of data link connector (DLC).
3. On Land Cruiser and Previa models, with vehicle stopped, with suitable jumper wire, connect check terminals 3 and 15.
4. On all models, read the codes by watching the main switch indicator flash.
5. Refer to Figs. 10 through 18, for description of codes.

Engine Control System

TROUBLE CODE DESCRIPTIONS

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 582

NOTE: Parameters listed in the chart may not be exactly same as your reading due to type of the instruments or other factors.

If a malfunction code is displayed during the diagnostic trouble code check in test mode, check the circuit for that code listed in the tables below.

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PART 1 OF 4

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 585

PART 2 OF 4

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 586

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PART 3 OF 4

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PART 4 OF 4

1: "ON" displayed in the diagnosis mode column indicates that the malfunction indicator lamp is lighted up when a malfunction is detected.
"OFF" indicates that the "CHECK" does not light up during malfunction diagnosis, even if a malfunction is detected. "N.A." indicates that
the item is not included in malfunction diagnosis.
*2: "0" in the memory column indicates that a diagnostic trouble code is recorded in the ECM memory when a malfunction occurs. "X" indicates
that a diagnostic trouble code is not recorded in the ECM memory even if a malfunction occurs. Accordingly, output of diagnostic results in
normal or test mode is performed with the IG switch ON.
*3: Only for California specification vehicles.
*4: Only for automatic transaxle vehicles.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 589
*5: This indicates items for which "2 trip detection logic" is used. With this logic, when a logic malfunction is first detected, the malfunction is
temporarily stored in the ECM memory. If the same case is detected again during the second drive test, this second detection causes the
malfunction indicator lamp to light up. The 2 trip repeats the same mode a 2nd time. (However, the IG switch must be turned OFF between
the 1st trip and 2nd trip). In the Test Mode, the malfunction indicator lamp lights up the 1st trip a malfunction is detected.

DTC 11
DTC 11, 12 ABS Control (Solenoid) Relay Circuit

CIRCUIT DESCRIPTION
This relay supplies power to each ABS solenoid. After the ignition switch is turned on, if the initial check is OK, the relay goes on.

Fail safe function: If trouble occurs in the control (solenoid) relay circuit, the ECU cuts off current to the ABS control (solenoid) relay and
prohibits ABS control.

DIAGNOSTIC CHART

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 590

Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Step 2

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 592

Step 3

Step 4

DTC 12
DTC 11, 12 ABS Control (Solenoid) Relay Circuit

CIRCUIT DESCRIPTION
This relay supplies power to each ABS solenoid. After the ignition switch is turned on, if the initial check is OK, the relay goes on.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 593

Fail safe function: If trouble occurs in the control (solenoid) relay circuit, the ECU cuts off current to the ABS control (solenoid) relay and
prohibits ABS control.

DIAGNOSTIC CHART

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 594
Wiring Diagram

INSPECTION PROCEDURE

Step 1

Step 2

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 595

Step 3

Step 4

DTC 13
DTC 13, 14 ABS Control (Motor) Relay Circuit

CIRCUIT DESCRIPTION
The ABS control (motor) relay supplies power to the ABS pump motor. If the accumulator pressure drops, the ECU switches the control
(motor) relay ON and operates the ABS pump motor.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 596

Fail safe function: If trouble occurs in the control (motor) relay circuit, the ECU cuts off the current to the ABS control (solenoid) relay and
prohibits ABS control.

DIAGNOSTIC CHART

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 597

Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 598

Step 2

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 599

Step 3

Step 4

DTC 14
DTC 13, 14 ABS Control (Motor) Relay Circuit

CIRCUIT DESCRIPTION
The ABS control (motor) relay supplies power to the ABS pump motor. If the accumulator pressure drops, the ECU switches the control
(motor) relay ON and operates the ABS pump motor.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 600

Fail safe function: If trouble occurs in the control (motor) relay circuit, the ECU cuts off the current to the ABS control (solenoid) relay and
prohibits ABS control.

DIAGNOSTIC CHART

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 601

Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 602

Step 2

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 603

Step 3

Step 4

DTC 21
DTC 21, 22, 23, 24 ABS Actuator Solenoid Circuit

CIRCUIT DESCRIPTION
This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders, thus controlling the
turning of the wheels.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 604

Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the control (solenoid) relay and prohibits ABS
control.

DIAGNOSTIC CHART

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 605

Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 606

Step 2

DTC 22
DTC 21, 22, 23, 24 ABS Actuator Solenoid Circuit

CIRCUIT DESCRIPTION
This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders, thus controlling the
turning of the wheels.

Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the control (solenoid) relay and prohibits ABS
control.

DIAGNOSTIC CHART

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 607

Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 608

Step 2

DTC 23
DTC 21, 22, 23, 24 ABS Actuator Solenoid Circuit

CIRCUIT DESCRIPTION
This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders, thus controlling the
turning of the wheels.

Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the control (solenoid) relay and prohibits ABS
control.

DIAGNOSTIC CHART

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 609

Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 610

Step 2

DTC 24
DTC 21, 22, 23, 24 ABS Actuator Solenoid Circuit

CIRCUIT DESCRIPTION
This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders, thus controlling the
turning of the wheels.

Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the control (solenoid) relay and prohibits ABS
control.

DIAGNOSTIC CHART

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 611

Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 612

Step 2

DTC 31
DTC 31, 32, 33,34, 35, 36 Speed Sensor Circuit

CIRCUIT DESCRIPTION

The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used for control of the ABS system.
The front rotor and rear rotor have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed
sensor generates an AC voltage. Since the frequency of this AC voltage changes in proportion to the speed of the rotors (wheels), the
frequency is used by the ECU to detect the speed of each wheel.

HINT: DTC 31 is for the right front wheel speed sensor.

DTC 32 is for the left front wheel speed sensor.
DTC 33 is for the right rear wheel speed sensor.
DTC 34 is for the left rear wheel speed sensor.

Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits
ABS control.

DIAGNOSTIC CHART

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 613

Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Step 2

Step 3

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Step 4

DTC 32
DTC 31, 32, 33,34, 35, 36 Speed Sensor Circuit

CIRCUIT DESCRIPTION

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 616

The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used for control of the ABS system.
The front rotor and rear rotor have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed
sensor generates an AC voltage. Since the frequency of this AC voltage changes in proportion to the speed of the rotors (wheels), the
frequency is used by the ECU to detect the speed of each wheel.

HINT: DTC 31 is for the right front wheel speed sensor.

DTC 32 is for the left front wheel speed sensor.
DTC 33 is for the right rear wheel speed sensor.
DTC 34 is for the left rear wheel speed sensor.

Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits
ABS control.

DIAGNOSTIC CHART

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 617

Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Step 2

Step 3

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Step 4

DTC 33
DTC 31, 32, 33,34, 35, 36 Speed Sensor Circuit

CIRCUIT DESCRIPTION

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 620

The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used for control of the ABS system.
The front rotor and rear rotor have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed
sensor generates an AC voltage. Since the frequency of this AC voltage changes in proportion to the speed of the rotors (wheels), the
frequency is used by the ECU to detect the speed of each wheel.

HINT: DTC 31 is for the right front wheel speed sensor.

DTC 32 is for the left front wheel speed sensor.
DTC 33 is for the right rear wheel speed sensor.
DTC 34 is for the left rear wheel speed sensor.

Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits
ABS control.

DIAGNOSTIC CHART

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Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Step 2

Step 3

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Step 4

DTC 34
DTC 31, 32, 33,34, 35, 36 Speed Sensor Circuit

CIRCUIT DESCRIPTION

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 624

The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used for control of the ABS system.
The front rotor and rear rotor have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed
sensor generates an AC voltage. Since the frequency of this AC voltage changes in proportion to the speed of the rotors (wheels), the
frequency is used by the ECU to detect the speed of each wheel.

HINT: DTC 31 is for the right front wheel speed sensor.

DTC 32 is for the left front wheel speed sensor.
DTC 33 is for the right rear wheel speed sensor.
DTC 34 is for the left rear wheel speed sensor.

Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits
ABS control.

DIAGNOSTIC CHART

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Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Step 2

Step 3

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Step 4

DTC 35
DTC 31, 32, 33,34, 35, 36 Speed Sensor Circuit

CIRCUIT DESCRIPTION

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The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used for control of the ABS system.
The front rotor and rear rotor have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed
sensor generates an AC voltage. Since the frequency of this AC voltage changes in proportion to the speed of the rotors (wheels), the
frequency is used by the ECU to detect the speed of each wheel.

HINT: DTC 31 is for the right front wheel speed sensor.

DTC 32 is for the left front wheel speed sensor.
DTC 33 is for the right rear wheel speed sensor.
DTC 34 is for the left rear wheel speed sensor.

Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits
ABS control.

DIAGNOSTIC CHART

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Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Step 2

Step 3

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Step 4

DTC 36
DTC 31, 32, 33,34, 35, 36 Speed Sensor Circuit

CIRCUIT DESCRIPTION

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The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used for control of the ABS system.
The front rotor and rear rotor have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed
sensor generates an AC voltage. Since the frequency of this AC voltage changes in proportion to the speed of the rotors (wheels), the
frequency is used by the ECU to detect the speed of each wheel.

HINT: DTC 31 is for the right front wheel speed sensor.

DTC 32 is for the left front wheel speed sensor.
DTC 33 is for the right rear wheel speed sensor.
DTC 34 is for the left rear wheel speed sensor.

Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits
ABS control.

DIAGNOSTIC CHART

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Wiring Diagram

INSPECTION PROCEDURE

Step 1

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Step 2

Step 3

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Step 4

DTC 41
DTC 41 IG Power Source Circuit

CIRCUIT DESCRIPTION
This is the power source for the ECU and becomes power source for the CPU and actuators.

Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits

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ABS control.

DIAGNOSTIC CHART
First check battery voltage. If the voltage is not between 10 V and 14 V, check and repair the charging system.

Wiring Diagram

INSPECTION PROCEDURE

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Step 1

Step 2

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Step 3

DTC 51
DTC 51 ABS Pump Motor Lock

CIRCUIT DESCRIPTION

Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off the current to the control (solenoid) relay and prohibits ABS
control.

DIAGNOSTIC CHART
See inspection of ABS actuator.

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Wiring Diagram

DTC 12
CODE 12 - G, NE SIGNAL (NO. 1)

Circuit Description

The IIA (Distributor) in the Engine Control System contains two pickup coils (G and NE).
The G signals inform the ECM of the standard crankshaft angle.
The NE signals inform the ECM of the crankshaft angle and the engine speed.

Detecting Condition

Inspection Using Oscilloscope

- During cranking or idling, check between terminals G1 and G(-), NE(+) and NE(-) of engine control module.

NOTE: The correct waveforms appear as shown in the illustration.

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Diagnostic Chart

Wiring Diagram

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 641

Step 1

Step 2

Step 3

Inspection Procedure
DTC 13
CODE - 13 G, NE SIGNAL CIRCUIT (NO. 2)

Circuit Description

The IIA (Distributor) in the Engine Control System contains two pickup coils (G and NE).

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The G signals inform the ECM of the standard crankshaft angle.
The NE signals inform the ECM of the crankshaft angle and the engine speed.

Detecting Condition

Diagnostic Chart

This code indicates that a momentary interruption of the G, NE signal from the IIA to the ECM has occurred, but that it is returned to normal.
Note that although this problem may not necessarily appear at the time of inspection, it cannot be ignored because this diagnostic trouble
code is output, indicating that there is or was a malfunction in the G, NE signal circuit; this "malfunction" is usually a loose connector.

The IIA connector and the NE terminal of the ECM connector must therefore be checked for the following:
1. Loose connectors
2. Dirty connector terminals
3. Loose connector terminals

DTC 14
CODE - 14 IGNITION SIGNAL CIRCUIT

Circuit Description

The ECM determines the ignition timing, turns on Tr1 at a predetermined angle (degree CA) before the desired ignition timing and outputs an
ignition signal (IGT) "1" to the IIA (Distributor).

Since the width of the IGT signal is constant, the dwell angle control circuit in the IIA determines the time the control circuit starts primary
current flow to the ignition coil based on the engine speed and ignition timing one revolution ago, that is, the time the Tr2 turns on.

When it reaches the ignition timing, the ECM turns Tr1 off and outputs the IGT signal "0". This turns Tr2 off, interrupting the primary
current flow and generating a high voltage in the secondary coil which causes the spark plug to spark. Also, by the counter electromotive
force generated when the primary current is interrupted, the IIA sends an ignition confirmation signal (IGF) to the ECM. The ECM stops fuel
injection as a fail safe function when the IGF signal is not input to the ECM.

Detecting Condition

Inspection Using Oscilloscope

- During cranking or idling, check waveform between terminal IGT, IGF and E1 of engine control module.

NOTE: The correct waveform appears as shown in the illustration, with rectangle waves.

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Diagnostic Chart

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Wiring Diagram

Step 1

Step 2

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Step 3

Step 4

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Step 5

Step 6

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Step 7

Step 8

Inspection Procedure
DTC 21
CODE - 21 MAIN OXYGEN SENSOR CIRCUIT

Circuit Description

To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for
most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the
stoichiometric air-fuel ratio.

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The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air-fuel ratio. This
characteristic is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air-fuel
ratio.

When the air-fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the
LEAN condition (small electromotive force: 0 V).

When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio the oxygen concentration in the exhaust gas is reduced and the
oxygen sensor informs the ECM of the RICH condition (large electromotive force: 1V).

The ECM judges by the electromotive force from the oxygen sensor whether the air-fuel ratio is RICH or LEAN and controls the injection
time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to
perform accurate air-fuel ratio control.

Detecting Condition

*1 Refer to Trouble Code Descriptions, Note *5.

Trouble Code Detection Driving Pattern

Purpose of the driving pattern.

(a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded.
(b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected.

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(1) Disconnect the EFI fuse (15 A) for 10 sec. or more, with IG switch OFF. Initiate test mode (Connect terminal TE2 and E1 of data link
connector 1 with IG switch OFF).
(2) Start the engine and warm up with all ACC switch OFF.
(3) After the engine is warmed up, let it idle for 3 min.
(4) After performing the idling in step (3), perform gradual acceleration with in the range 1,300 ~ 1,700 rpm (centered around 1,500 rpm)
with the A/C switch ON and D position for A/T (5th for M/T).
(Take care that the engine speed does not fall below 1,200 rpm when shifting. Gradually depress the accelerator pedal and kept it.
Steady so that engine braking does not occur).
(5) Maintain the vehicle speed at 40 - 50 mph (64 - 80 km/h).
(6) Keep the vehicle running for 1 - 2 min. after starting acceleration.

NOTE: If a malfunction exists, the malfunction indicator lamp will light up after approx. 60 sec. from the start of acceleration.

CAUTION:If the conditions in this test are not strictly followed, detection of the malfunction will not be possible.

Inspection Using Oscilloscope

- With the engine racing (2,500 rpm) measure between terminals OX1 and E1 of engine control module.

NOTE: The correct waveform appears as shown in the illustration above, oscillating between approximately 0.1 V and 0.9 V.

If the oxygen sensor has deteriorated, the amplitude of the voltage will be reduced as shown.

Diagnostic Chart

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Wiring Diagram

DTC 22
CODE - 12 ENGINE COOLANT TEMP. SENSOR CIRCUIT

Circuit Description

The engine coolant temperature sensor senses the coolant temperature. A thermistor built into the sensor changes the resistance value
according to the coolant temperature.

The lower the coolant temperature, the greater the thermistor resistance value, and the higher the coolant temperature, the lower the
thermistor resistance value ( Fig. 1.).

The engine coolant temperature sensor is connected to the ECM (refer to wiring diagram). The 5 V power source voltage in the ECM is
applied to the engine coolant temperature sensor from the terminal THW via a resistor R. That is, the resistor R and the engine coolant
temperature sensor are connected in series.

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When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the coolant temperature, the
potential at the terminal THW also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during
cold engine operation. If the ECM records the diagnostic trouble code 22, it operates the fail safe function, keeping the coolant temperature at
a constant 80°C (176°F).

Detecting Condition

Diagnostic Chart

NOTE: If diagnostic trouble codes "22" (engine coolant temperature sensor circuit), "24" (intake air temperature sensor circuit), "31"
(manifold absolute pressure sensor circuit) and "41" (throttle position sensor circuit) are output simultaneously, E2 (sensor ground)
may be open.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 652

Wiring Diagram

Step 1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 653
Step 2

Step 3

Inspection Procedure

NOTE: If diagnostic trouble codes "22" (engine coolant temperature sensor circuit), "24" (intake air temperature sensor circuit), "31"
(manifold absolute pressure sensor circuit) and "41" (throttle position sensor circuit) are output simultaneously, E2 (sensor ground)
may be open.

DTC 24
CODE - 24 INTAKE AIR TEMP. CIRCUIT

Circuit Description

The intake air temp. sensor is built into the air cleaner cap and senses the intake air temperature. The structure of the sensor and connection to
the ECM is the same as the engine coolant temp sensor. (Refer to Code 22 Circuit Description)

Detecting Condition

Diagnostic Chart

NOTE: If diagnostic trouble codes "22" (engine coolant temperature sensor circuit), "24" (intake air temperature sensor circuit), "31"
(manifold absolute pressure sensor circuit) and "41" (throttle position sensor circuit) are output simultaneously, E2 (sensor ground)
may be open.

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Wiring Diagram

Step 1

Step 2

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Step 3

Inspection Procedure

DTC 25
CODE - 25 AIR-FUEL RATIO LEAN MALFUNCTION

Circuit Description

The main oxygen sensor is located in the exhaust manifold. It indirectly determines whether the fuel mixture is rich or lean by detecting the
concentration of oxygen present in the exhaust gas.

Detecting Condition

*1 Only for California specification vehicles.

*2 Refer to Trouble Code Descriptions, note *5

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Trouble Code Detection Driving Pattern

Purpose of the driving pattern.

(a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded.
(b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected.

NOTE: Before this test, check the feedback voltage for oxygen sensor. See: Component Tests and General Diagnostics

(1) Disconnect the EFI fuse (15 A) for 10 sec. or more, with IG switch OFF. Initiate test mode (Connect terminal TE2 and E1 of data link
connector 1 with IG switch OFF).
(2) Start engine and warm up.
(3) After the engine is warmed up, let it race at 2,500 rpm for 3 min.
(4) After performing the racing in step (3), perform idling for 1 min.

NOTE: If a malfunction exists, the malfunction indicator lamp will light up during step (4).

CAUTION:If the conditions in this test are not strictly followed, detection of the malfunction will not be possible.

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Diagnostic Chart

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Wiring Diagram

Step 1

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Step 2

Step 3

Step 4

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Step 5

Step 6

Step 7

Step 8

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Step 9

Inspection Procedure

DTC 26
CODE - 26 AIR-FUEL RATIO RICH MALFUNCTION

Circuit Description

The main oxygen sensor is located in the exhaust manifold. It indirectly determines whether the fuel mixture is rich or lean by detecting the
concentration of oxygen present in the exhaust gas.

Detecting Condition

*1 Only for California specification vehicles.

*2 Refer to Trouble Code Descriptions, note *5

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 662

Trouble Code Detection Driving Pattern

Purpose of the driving pattern.

(a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded.
(b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected.

NOTE: Before this test, check the feedback voltage for oxygen sensor. See: Component Tests and General Diagnostics

(1) Disconnect the EFI fuse (15 A) for 10 sec. or more, with IG switch OFF. Initiate test mode (Connect terminal TE2 and E1 of data link
connector 1 with IG switch OFF).
(2) Start engine and warm up.
(3) After the engine is warmed up, let it race at 2,500 rpm for 3 min.
(4) After performing the racing in step (3), perform idling for 1 min.

NOTE: If a malfunction exists, the malfunction indicator lamp will light up during step (4).

CAUTION:If the conditions in this test are not strictly followed, detection of the malfunction will not be possible.

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Diagnostic Chart

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 664

Wiring Diagram

Step 1

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Step 2

Step 3

Step 4

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Step 5

Step 6

Step 7

Step 8

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Step 9

Inspection Procedure

DTC 27
CODE - 27 SUB-OXYGEN SENSOR CIRCUIT (ONLY FOR CALIFORNIA SPEC.)

Circuit Description

The sub-oxygen sensor is installed on the exhaust pipe. Its construction and operation is the same as the main oxygen sensor.

To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for
most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the
stoichiometric air-fuel ratio.

The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air-fuel ratio. This
characteristic is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air-fuel
ratio.

When the air-fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the
LEAN condition (small electromotive force: 0 V).

When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio the oxygen concentration in the exhaust gas is reduced and the
oxygen sensor informs the ECM of the RICH condition (large electromotive force: 1V).

The ECM judges by the electromotive force from the oxygen sensor whether the air-fuel ratio is RICH or LEAN and controls the injection
time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to
perform accurate air-fuel ratio control.

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Detecting Condition

* Refer to Trouble Code Descriptions, note *5.

Trouble Code Detection Driving Pattern

Purpose of the driving pattern.

(a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded.
(b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected.

(1) Disconnect the EFI fuse (15 A) for 10 sec. or more, with IG switch OFF. Initiate test mode (Connect terminals TE2 and E1 of data
link connector 1 with IG switch OFF).
(2) start the engine and warm up, with all ACC switch OFF.
(3) After the engine is warmed up, let it drive at 50 - 55 mph (80 - 88 km/h) for 10 min. or more.
(4) After driving, stop at a safe place and perform idling for 2 min. or less.
(5) After performing the idling in step (4), perform acceleration to 60 mph (96 km/h) with the throttle valve fully open.

NOTE: If a malfunction exists, the malfunction indicator lamp will light up during step (5).

CAUTION:If the conditions in this test are not strictly followed, detection of the malfunction will not be possible.

Diagnostic Chart

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Wiring Diagram
DTC 31
CODE - 31 MANIFOLD ABSOLUTE PRESSURE SENSOR CIRCUIT

Circuit Description

By a built-in sensor unit, the manifold absolute pressure sensor detects the intake manifold pressure as a voltage. The ECM then determines
the basic injection duration and basic ignition advance angle based on this voltage.

Since the manifold absolute pressure sensor does not use the atmospheric pressure as a criterion, but senses the absolute pressure inside the
intake manifold (the pressure in proportion to the preset absolute vacuum 0), it is not influenced by fluctuations in the atmospheric, pressure
due to high altitude and other factors. This permits it to control the air- fuel ratio at the proper level under all conditions.

Detecting Condition

If the ECM records diagnostic trouble code "31", it operates the fail safe function, keeping the ignition timing and fuel injection volume
constant and making it possible to drive the vehicle.

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Diagnostic Chart

Wiring Diagram

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Step 1

Step 2

Step 3

Inspection Procedure

DTC 41
CODE - 41 THROTTLE POSITION SENSOR CIRCUIT

Circuit Description

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The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully
closed, the IDL contacts in the throttle position sensor are on, so the voltage at the terminal IDL of the ECM become O V. At this time, a
voltage of approximately 0.7 V is applied to the terminal VTA of the ECM.

When the throttle valve is opened, the IDL contacts go off and thus the power source voltage of approximately 12 V in the ECM is applied to
the terminal IDL of the ECM. The voltage applied to the terminal VTA of the ECM increases in proportion to the opening angle of the
throttle valve and becomes approximately 3.2 - 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions
from these signals input from the terminals VTA and IDL, and uses them as one of the conditions for deciding the air-fuel ratio correction,
power increase correction and fuel-cut control etc.

Detecting Condition

NOTE:
- When the connector for the throttle position sensor is disconnected, diagnostic trouble code 41 is not displayed. Diagnostic trouble code
41 is displayed only when there is an open or short in the VTA signal circuit of the throttle position sensor.

Diagnostic Chart

NOTE: If diagnostic trouble codes "22"(engine coolant temperature sensor circuit), "24" (intake air temperature sensor circuit), "31"
(manifold absolute pressure sensor circuit) and "41" (throttle position sensor circuit) are output simultaneously, F2 (sensor ground)
may be open.

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Wiring Diagram

Step 1

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Step 2

Step 3

Inspection Procedure

NOTE: If diagnostic trouble code "22" (engine coolant temperature sensor circuit), "24" (intake air temperature sensor circuit), "31"
(manifold absolute pressure sensor circuit) and "41" (throttle position sensor circuit) are output simultaneously, E2 (sensor ground)
may be open.

DTC 42
CODE - 42 VEHICLE SPEED SENSOR CIRCUIT

Circuit Description

The Vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via
the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the
combination meter, it is then transmitted to the engine control module. The ECM determines the vehicle speed based on the frequency of

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these pulse signals.

Detecting Condition

NOTE: In test mode, diagnostic trouble code 42 is output when vehicle speed is 5 km/h (3 mph) or below.

Diagnostic Chart

Wiring Diagram

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 676

Step 1

Step 2

Inspection Procedure

DTC 43
CODE - 43 STARTER SIGNAL CIRCUIT

Circuit Description

When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve
good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is
mainly used to increase the fuel injection volume for the starting injection control and after-start injection control.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 677
Detecting Condition

Diagnostic Chart

NOTE: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the matrix
chart of problem symptoms. See: Symptom Related Diagnostic Procedures

Wiring Diagram

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 678

Step 1

Step 2

Inspection Procedure

DTC 51
CODE - 51 SWITCH CONDITION SIGNAL CIRCUIT

Circuit Description

Park/Neutral Position Switch Signal-The ECM uses the signals from the park/neutral position switch to determine whether the transmission is
in park or neutral, or in some other gear.

Air Conditioning Switch Signal-The ECM uses the output from the air conditioning switch to determine whether or not the air conditioning is
operating so that it can increase the idling speed of the engine if necessary.

Throttle Position Sensor IDL Signal-The IDL contacts are mounted in the throttle position sensor, and detects the idle condition.

Detecting Condition

* Only vehicles with A/T.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 679

NOTE: In this circuit, diagnosis can only be made in the test mode.

Diagnostic Chart

Wiring Diagram

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Step 1

Step 2

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 681

Step 3

Step 4

Inspection Procedure

DTC 71
CODE - 71 EGR SYSTEM MALFUNCTION (ONLY FOR CALIFORNIA SPEC.)

Circuit Description

The EGR system recirculates exhaust gas, which is controlled to the proper quantity to suit the driving conditions, into the intake air mixture
to slow down combustion, reduce the combustion temperature and reduces NOx emissions. The amount of EGR is regulated by the EGR
vacuum modulator according to the engine load.

If even one of the following conditions is fulfilled, the VSV is turned OFF by a signal from the ECM. This results in atmospheric air acting
on the EGR valve, closing the EGR valve and shutting off the exhaust gas (EGR cut-off).

Under the following conditions, EGR is cut to maintain driveability.

- Engine coolant temp. below 47°C (11 7'F).

- During deceleration (throttle valve closed).
- Light engine load (amount of intake air very small).
- Engine speed over 4,400 rpm.
- Engine racing.

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Detecting Condition

* Refer to Trouble Code Descriptions, note *5.

Trouble Code Detection Driving Pattern

Purpose of the driving pattern.

(a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded.
(b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected.

(1) Disconnect the EFI fuse (15 A) for 10 sec. or more, with IG switch OFF. Initiate test mode (Connect terminals TE2 and E1 of data
link connector 1 with IG switch OFF).
(2) Start the engine and warm up.
(3) After the engine is warmed up, let it idle for 3 min.
(4) With the A/C ON and transmission in 5th gear (A/T in "D" position), drive at 55 - 60 mph (88 - 96 km/h) for 4 min. or less.

NOTE: If a malfunction exists, the malfunction indicator lamp will light up during step (4).

CAUTION:If the conditions in this test are not strictly followed, detection of the malfunction will not be possible.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 683

Diagnostic Chart

Wiring Diagram

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 684

Step 1

Step 2

Step 3

Step 4

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 685

Step 5

Step 6

Inspection Procedure

Fig. 60 Normal Diagnostic Code (Part 1 Of 2). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 686

Fig. 60 Normal Diagnostic Code (Part 2 Of 2). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 687

Fig. 61 Diagnostic Code 11 (Short In Squib Circuit Or Front Airbag Sensor Circuit, Part 1 Of 6). Corolla, Tercel & Paseo

Fig. 61 Diagnostic Code 11 (Short In Squib Circuit Or Front Airbag Sensor Circuit, Part 2 Of 6). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 688

Fig. 61 Diagnostic Code 11 (Short In Squib Circuit Or Front Airbag Sensor Circuit, Part 3 Of 6). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 689

Fig. 61 Diagnostic Code 11 (Short In Squib Circuit Or Front Airbag Sensor Circuit, Part 4 Of 6). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 690

Fig. 61 Diagnostic Code 11 (Short In Squib Circuit Or Front Airbag Sensor Circuit, Part 5 Of 6). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 691

Fig. 61 Diagnostic Code 11 (Short In Squib Circuit Or Front Airbag Sensor Circuit, Part 6 Of 6). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 692

Fig. 62 Diagnostic Code 12 (Short In Squib Circuit Or Front Airbag Sensor Circuit, Part 1 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 693

Fig. 62 Diagnostic Code 12 (Short In Squib Circuit Or Front Airbag Sensor Circuit, Part 2 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 694

Fig. 62 Diagnostic Code 12 (Short In Squib Circuit Or Front Airbag Sensor Circuit, Part 3 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 695

Fig. 62 Diagnostic Code 12 (Short In Squib Circuit Or Front Airbag Sensor Circuit, Part 4 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 696

Fig. 62 Diagnostic Code 12 (Short In Squib Circuit Or Front Airbag Sensor Circuit, Part 5 Of 5). Corolla, Tercel & Paseo

Fig. 63 Diagnostic Code 13 (Short In Squib Circuit Between D+ & D- , Part 1 Of 6). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 697

Fig. 63 Diagnostic Code 13 (Short In Squib Circuit Between D+ & D- , Part 2 Of 6). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 698

Fig. 63 Diagnostic Code 13 (Short In Squib Circuit Between D+ & D- , Part 3 Of 6). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 699

Fig. 63 Diagnostic Code 13 (Short In Squib Circuit Between D+ & D- , Part 4 Of 6). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 700

Fig. 63 Diagnostic Code 13 (Short In Squib Circuit Between D+ & D- , Part 5 Of 6). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 701

Fig. 63 Diagnostic Code 13 (Short In Squib Circuit Between D+ & D- , Part 6 Of 6). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 702

Fig. 64 Diagnostic Code 14 (Open In Squib Circuit, Part 1 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 703

Fig. 64 Diagnostic Code 14 (Open In Squib Circuit, Part 2 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 704

Fig. 64 Diagnostic Code 14 (Open In Squib Circuit, Part 3 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 705

Fig. 64 Diagnostic Code 14 (Open In Squib Circuit, Part 4 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 706

Fig. 64 Diagnostic Code 14 (Open In Squib Circuit, Part 5 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 707

Fig. 65 Diagnostic Code 15 (Open In Front Airbag Sensor Circuit, Part 1 Of 5). Corolla, Tercel & Paseo

Fig. 65 Diagnostic Code 15 (Open In Front Airbag Sensor Circuit, Part 2 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 708

Fig. 65 Diagnostic Code 15 (Open In Front Airbag Sensor Circuit, Part 3 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 709

Fig. 65 Diagnostic Code 15 (Open In Front Airbag Sensor Circuit, Part 4 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 710

Fig. 65 Diagnostic Code 15 (Open In Front Airbag Sensor Circuit, Part 5 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 711

Fig 66 Diagnostic Code 22 (Airbag Warning Light System Malfunction, Part 1 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 712

Fig 66 Diagnostic Code 22 (Airbag Warning Light System Malfunction, Part 2 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 713

Fig 66 Diagnostic Code 22 (Airbag Warning Light System Malfunction, Part 3 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 714

Fig 66 Diagnostic Code 22 (Airbag Warning Light System Malfunction, Part 4 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 715

Fig 66 Diagnostic Code 22 (Airbag Warning Light System Malfunction, Part 5 Of 5). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 716

Fig 67 Diagnostic Code 31 (Center Airbag Sensor Assembly Malfunction, Part 1 Of 2). Corolla, Tercel & Paseo

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 717
Fig 67 Diagnostic Code 31 (Center Airbag Sensor Assembly Malfunction, Part 2 Of 2). Corolla, Tercel & Paseo

Transmission Control Systems

Toyota does not utilize diagnostic flowcharts for codes on this vehicle, but rather refers to the Trouble Areas on the Trouble Code Description
Charts. In addition some vehicles also have system and/or component testing which may be found at Non-Trouble Code Procedures and/or
Component Tests.
Basic Inspection
BASIC INSPECTION

When the normal code is displayed in the diagnostic trouble code check, troubleshooting should be performed in the order for all possible
circuits to be considered as the causes of the problems. In many cases, by carrying out the basic engine check shown in the following flow charts,
the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting.

Step 1

Step 2

Step 3

Step 4

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 718

Step 5

Step 6

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 719

Step 7

Step 8

Check For Intermittent Problems

CHECK FOR MOMENTARY INTERRUPTION

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 720

As described in How to Display and Read Diagnostic Trouble Codes, abnormality detection ability in the test mode is increased compared to
that in the normal mode, so that when momentary interruptions or momentary shorts occur in the ECM signal circuits (G, NE, THW, THA, PIM,
VTA) shown in the table, the appropriate diagnostic trouble code is output.

Accordingly, when the diagnostic trouble codes shown in the table (13, 22, 24, 31, 41) are output during the diagnostic trouble code check, and
inspection of the appropriate circuits reveals no abnormality, perform the check for momentary interruption as described below.

By performing the check for momentary interruption, the place where momentary interruptions or momentary shorts are occurring due to poor
contacts can be isolated.

1. CLEAR DIAGNOSTIC TROUBLE CODES (Refer to How to Clear Diagnostic Trouble Codes)

2. SET TEST MODE (Refer to How to Display and Read Diagnostic Trouble Codes)

(a) With the ignition switch off, using SST, connect the terminals TE2 and E1 of the data link connector 1. SST 09843-18020
(b) Start the engine and check to see if the malfunction indicator lamp goes off.

3. PERFORM A SIMULATION TEST

Using the symptom simulation, apply vibration to and pull lightly on the wire harness, connector or terminals in the circuit indicated by the
malfunction code.

In this test, if the malfunction indicator lamp lights up, it indicates that the place where the wire harness, connector or terminals being pulled
or vibrated has faulty contact. Check that point for loose connections, dirt on the terminals, poor fit or other problems and repair as necessary.

NOTE: After cancelling out the diagnostic trouble code in memory and set the test mode, if the malfunction indicator lamp does not go off
after the engine is started, check thoroughly for faulty contact, etc., then try the check again. If the malfunction indicator lamp still
does not go off, check and replace ECM.

Symptom Related Diagnostic Procedures

MATRIX CHART OF PROBLEM SYMPTOMS

When the malfunction code is not confirmed in the diagnostic trouble code check (See: Reading and Clearing Diagnostic Trouble Codes/Reading
Diagnostic Trouble Codes) and the problem still can not be confirmed in the basic inspection (See: Component Tests and General Diagnostics),
then proceed to this step and perform troubleshooting according to the numbered order given in the table below.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 721

The circuits indicated by "X" on the matrix chart can be inspected using the TCCS checker.
Procedure Note
PROCEDURE NOTE

The following troubleshooting procedures are designed for inspection of each separate system, therefore, the procedure may vary somewhat.
However, troubleshooting should be performed while referring to the inspection methods described in this manual.

Before beginning inspection, it is best to first make a simple check of the fuses, fusible links and condition of the connectors.

The following troubleshooting procedures are based on the supposition that the trouble lies in either a short or open circuit in a component
outside the computer or a short circuit within the computer. If engine trouble occurs even though proper operating voltage is detected in the
computer connector, then the computer is faulty and should be replaced.

1. Remove the ECU cover under the center console.

2. Remove the ECU with the harness.
3. Perform all voltage measurements with the connectors connected.
4. Verify that the battery voltage is 11 V or above when the ignition switch is ON.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 722

Voltage Measurement

The EFI circuit can be checked by measuring the voltage at the wiring connectors of the ECU.

Using a voltmeter with high-impedance (10 kohm/volt minimum), measure the voltage at each terminal of the wiring connector.

Connector View

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 723

Standard Values

NOTE: If there is any problem, refer to the test number on the left hand side of the standard values chart.

Resistance Measurement

Check the resistance between each terminal of the wiring connectors.

- Disconnect the connectors from the ECU.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 724

- Measure the resistance at each terminal.

CAUTION:
- Do not touch the ECU terminals.
- The tester probe should be inserted into the wiring connector from the wiring side.

System Check Procedure

EFI SYSTEM CHECK PROCEDURE

1. Remove the ECU cover under the center console.

2. Remove the ECU with the harness.
3. Perform all voltage measurements with the connectors connected.
4. Verify that the battery voltage is 11 V or above when the ignition switch is ON.

Voltage Measurement

The EFI circuit can be checked by measuring the voltage at the wiring connectors of the ECU.

Using a voltmeter with high-impedance (10 kohm/volt minimum), measure the voltage at each terminal of the wiring connector.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 725

Connector View

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 726

Standard Values

NOTE: If there is any problem, refer to the test number on the left hand side of the standard values chart.

Resistance Measurement

Check the resistance between each terminal of the wiring connectors.

- Disconnect the connectors from the ECU.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 727

- Measure the resistance at each terminal.

CAUTION:
- Do not touch the ECU terminals.
- The tester probe should be inserted into the wiring connector from the wiring side.

A/C Cut Control Circuit

AIR CONDITIONING CUT-OFF CONTROL CIRCUIT

Circuit Description

Designed for improved driveability, this circuit cuts off A/C in the presence of one of the following conditions:

- Engine starting
- Immediately following A/C switch engagement
- Take off
- Accelerating from under 40 km/h (25 mph) and under 2,800 rpm

Diagnostic Chart

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 728

Wiring Diagram

Step 1

Step 2

Inspection Procedure

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 729

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 730

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 731

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 732

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 733

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 734

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 735

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 736

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 737

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 738

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 739

Inspection of Feedback Voltage (VF)

INSPECTION OF FEEDBACK VOLTAGE (VF)

1. Warm up the engine.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 740

2. Connect the voltmeter to the check connector terminals VF1 and E1.

PART 1 OF 2

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 741

PART 2 OF 2
Inspection of Oxygen Sensor Feedback Voltage (VF)
INSPECTION OF OXYGEN SENSOR FEEDBACK VOLTAGE

1. WARM UP ENGINE

Allow the engine to warm up to normal operating temperature.

2. INSPECT FEEDBACK VOLTAGE

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 742

Connect the positive (+) probe of a voltmeter to terminal VF1 of the data link connector 1, and negative (-) probe to terminal E1. Perform
the test as follows:

PART 1 OF 3

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 743

PART 2 OF 3

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 744

PART 3 OF 3

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 745

Back Up Power Source Circuit

BACK UP POWER SOURCE CIRCUIT

Circuit Description

Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is off for use by the diagnostic trouble code
memory and air-fuel ratio adaptive control value memory, etc.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 746

Diagnostic Chart

Wiring Diagram

Step 1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 747

Step 2

Step 3

Inspection Procedure
ECM Inspection
ECM INSPECTION

NOTE: The MFI circuit can be checked by measuring the resistance and voltage at the wiring connectors of the ECM.

1. REMOVE FLOOR MAT BRACKET

2. PREPARATION

(a) Disconnect the three connectors from the ECM.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 748

(b) Remove the locks as shown in the illustration so that the tester probe(s) can easily come in.

CAUTION:Pay attention to sections "A" and "B" in the illustration which can easily be broken.

(c) Reconnect the three connectors to the ECM.

3. INSPECT VOLTAGE OF ECM

(a) Turn the ignition switch ON.

(b) Measure the voltage between each terminal of the wiring connectors.

NOTE:
- Perform all voltage measurements with the connectors connected.
- Verify that the battery voltage is 11 V or more when the ignition switch is ON.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 749

Terminal Identification - Except 7A-FE with Automatic

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 750

Terminal Identification - 7A-FE with Automatic

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 751

Standard Values

4. INSPECT RESISTANCE OF ECM

(a) Turn the ignition switch OFF.

(b) Disconnect the three connectors from the ECM.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 752

(c) Measure the resistance between each terminal of the wiring connectors.

Standard Values

CAUTION:
- Do not touch the ECM terminal:.
- The tester probe should be inserted in the wiring connector from the wiring side.

5. INSTALL ECM

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 753

(a) Insert the ECM to the bracket.

(b) Connect the three connectors to the ECM.

6. INSTALL FLOOR MAT BRACKET

ECM Power Source Circuit
ECM POWER SOURCE CIRCUIT

Circuit Description

When the ignition switch is turned on, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay and supplying
power to the terminals + B and + B1 of the ECM.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 754

Diagnostic Chart

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 755

Wiring Diagram

Step 1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 756

Step 2

Step 3

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 757
Step 4

Step 5

Step 6

Step 7

Inspection Procedure
Fuel System Circuit
FUEL SYSTEM CIRCUIT

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 758

Circuit Description-Fuel Pump Control

The fuel pump is switched on (low voltage at terminal FC) when STA is on or while the NE signal is input to the ECM.

In the diagram below, when the engine is cranked, current flows from terminal ST of the ignition switch to the starter relay coil, the starter
relay switches on and current flows to coil L1 of the circuit opening relay. Thus the circuit opening relay switches on, power is supplied to
the fuel pump and the fuel pump operates.

When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil L2 of the circuit opening relay, the relay
switches on and the fuel pump operates.

While the NE signal is generated (engine running), the ECM keeps Tr ON (circuit opening relay ON) and the fuel pump also keeps operating.

Diagnostic Chart

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Wiring Diagram

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Step 1

Step 2

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Step 3

Step 4

Step 5

Inspection Procedure
Idle Air Control (IAC) Valve Circuit
IDLE AIR CONTROL (IAC) VALVE CIRCUIT

Circuit Description

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The rotary solenoid type IAC valve is provided on the intake air chamber and intake air bypassing the throttle valve is directed to the IAC
valve through a passage.

In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed.

The ECM operated only the IAC valve to perform idle-up and provide feedback for the target idling speed, but in the 4A-FE engine of the
Corolla, a VSV for idle-up control is also added (for air conditioning).

Diagnostic Chart

Wiring Diagram

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Step 1

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Step 2

Step 3

Inspection Procedure

Injector Circuit
INJECTOR CIRCUIT

Circuit Description

The injectors are provided to the intake manifold. They inject fuel into the cylinders based on the signals from the engine control module.

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Inspection Using Oscilloscope

- With the engine idling measure between terminals #10, #20 and EO1 of engine control module.

Correct Waveform

Correct Individual Waveform (Magnified)

NOTE: The correct waveform appears as shown in the illustrations above.

Diagnostic Chart

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Wiring Diagram

Step 1

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Step 2

Step 3

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Step 4

Inspection Procedure

Malfunction Indicator Lamp Check

MALFUNCTION INDICATOR LAMP CHECK

1. The malfunction indicator lamp will come on when the ignition switch is turned ON and the engine is not running.

NOTE: If the malfunction indicator lamp does not light up, proceed to troubleshooting of the combination meter (Refer to Instrument
Panel, Gauges and Warning Indicators).

2. When the engine is started, the malfunction indicator lamp should go off.

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If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system.
Park/Neutral Position Switch Circuit
PARK/NEUTRAL POSITION SWITCH CIRCUIT (ONLY VEHICLES WITH A/T)

Circuit Description

The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on the terminal NSW of the ECM is
grounded to body ground via the starter relay thus the terminal NSW voltage becomes OV. When the shift lever is in the D, 2, L or R
position, the park/neutral position switch goes off, so the voltage of ECM terminal NSW becomes battery positive voltage, the voltage of the
ECM internal power source.

If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control
(estimated control), etc.

When the park/neutral position switch is off, code "51" is output in the test mode diagnosis. (This is not abnormal.)

Diagnostic Chart

NOTE: This diagnosis chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the matrix
chart of problem symptoms. See: Symptom Related Diagnostic Procedures

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Wiring Diagram

Step 1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 771

Step 2

Step 3

Inspection Procedure
TE1, TE2 Terminal Circuit
TE1, TE2 TERMINAL CIRCUIT

Circuit Description

Terminals TE1 and TE2 are located in the data link connector 1.

The data link connector 1 located in the engine compartment. When these terminals are connected with the E1 terminal, diagnostic codes in
normal mode or test mode can be read from the malfunction indicator lamp on the combination meter.

Diagnostic Chart

NOTE: If terminals TE1 and TE2 are connected with terminal E1, diagnostic trouble code is not output or test mode is not activated. Even
though terminal TE1 is not connected with terminal E1, the malfunction indicator lamp blinks. For this phenomenon, the likely cause
is an open or short in the wire harness, or malfunction inside the ECM.

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Wiring Diagram

Step 1

Step 2

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 773

Step 3

Inspection Procedure

Pinout Values and Diagnostic Parameters

ECM PINOUT VALUES

When measuring the voltage or resistance of the connector part of the ECM, remove the locks as required in the following procedure and always
insert the test probe into the connector from the wire harness side.

1. PREPARATION

(a) Turn the ignition switch to LOCK position.

(b) Disconnect the connectors from the ECM.
(c) To remove section "A" and "B", carefully pull outward the lock on both sides as shown in the illustration.

CAUTION:Pay attention to section "C" in the illustration which can be easily broken.

(d) Reconnect the connectors to the ECM.

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Part 1

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Part 2

Terminal Identification

NOTE:
*1 Only for Automatic Transaxle vehicles.
*2 Only for California specification vehicles.

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Part 1

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Part 2

Standard Values

NOTE:
* Only for California specification vehicles.

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Technical Service Bulletins

All Technical Service Bulletins:

Number Date Name
CRIB177 Mar 10 Restraints - OCS System Initialization
CRIB176 Dec 09 Body - Approved Collision Repair Methods
CRIB175 Dec 09 Body - HSS/UHSS Cabin Reinforcement Repair/Replacement
CRIB173 Apr 09 Paint - Refinishing Information
CRIB172 Mar 09 Body - Bumper Component Repair
CRIB165 Mar 09 Body - Acid Rain Paint Damage Prevention/Repair
CRIB170 Oct 08 Body - Plastic Bumper Refinishing
SB0258-08 Sep 08 Restraints - Seat Belt Tongue Plate Stopper Replacement
CRIB164 Sep 08 Vehicle - VIN Plate/Certification Label Replacement
SB0144-08 Jul 08 Vehicle - Certification Label Information
SB0138-08 Jul 08 Body/Frame - Protective Wax Coating Information
CRIB167 Jul 08 Body/Interior - Trim Removal & Installation
CRIB163 Feb 08 Body - Sealing Hem-Flanges & Body Seams
CRIB161 Jan 08 Body - Collision Damage Repair Precautions
CRIB159 Dec 07 Body - Corrosion Prevention & Sound Absorption Info.
CRIB160 Dec 07 Restraints - SRS Service Precautions
PG007-07 Nov 07 Vehicle - Replacement VIN Plate Information
EL010R-07 Nov 07 Keyless Entry - Remote Transmitter Programming Guide
CRIB158 Oct 07 Body - Panel Adhesive Information
CRIB156 Aug 07 Electrical - SRS And HV Wiring Repairs
CRIB155 Aug 07 Body/Frame - Sectioning Information
EG034-07 Jun 07 Engine Controls - Bank 1/Bank 2 O2 Sensor identification
TC003-07 Mar 07 Drivetrain - Drive/Axle Shaft Replacement Precautions
PG001R-06 Nov 06 Electrical - Battery Maintenance and Testing
CRIB146 Sep 06 Body - Paintless Dent Repair Information
PG011R-05 Jun 06 Fuel System - Fuel Injector Cleaning Procedure
BO017R-03 Apr 06 Body - Interior Trim Panels/Garnish Loose
EG014-05 Mar 05 Cooling System - Radiator Cap Inspection Procedure
PA003R-02 Feb 05 Paint - Refinishing Bumper Cover
AC009-04 Dec 04 A/C - Sensor Inspection Procedures
EL008R-02 Feb 03 Keyless Entry - Transmitter Programming & Identification
EG003-03 Feb 03 Exhaust System - Sulfur Smell
CRIB122 Feb 03 Body - Body Sectioning
PG027-02 Dec 02 Steering/Suspension - Ball Joint Inspection
BO010-02 May 02 Child Restraint - Seat Top Strap Installation
EG007-02 Mar 02 Valve Cover Oil Baffle - Damage Prevention
BO026-01 Oct 01 Seat Belts - Shoulder Anchor Tape Set
ST001-01 Feb 01 Steering Wheel Nut - Torque Standardization
BR004-00 Oct 00 Brakes - Pad Clicking Noise
AX001-00 Mar 00 Vehicle - Towing Guide.
PG032-99 Dec 99 Year 2000 Readiness Disclosure
TC003-99 May 99 A/T - Fluid Interchangeability
AX006-99 Apr 99 Antitheft - Changes For GBS Glass Breakage System
AX005-99 Apr 99 Antitheft - Programing the Remote Control
TC002-99 Apr 99 Drivetrain - Revised Drive Shaft Grease
AX004-99 Mar 99 Vehicle - Towing Guide
SS003-98 Dec 98 Accessories - Rivet Nut Tool
AC002R-98 Jul 98 A/C - R-12 Air Conditioner System Retrofit.
TC003-98 Jun 98 A/T - Fluid Type T-IV Replaces Type T-II
ST002-98 May 98 Steering - Gearbox Removal Precautions
EL002-98 Apr 98 Interior - Cigarette Lighter Service
AC002-98 Apr 98 A/C - R-12 Air Conditioner System Retrofit
DL001-98 Mar 98 Drive Axles - Front Hub Nut Replacement
SS002-97 Sep 97 Brakes - Booster Push Rod Gauge
PG005-97 Jul 97 Body - Replacement VIN Plates
PG004-97 Jul 97 Body - Replacement Certification Labels
EL005-97 Jul 97 Windows - Power Window Switch Inoperative
AC00297 May 97 A/C - Evaporator Odor
EL00497 Apr 97 Instruments - Turn Signal Operation Improved
CRIB76 Mar 97 Body - Correction of Body Dimensions
TC00496 Dec 96 A/T - Serial Numbers/Identification
BO01196 Dec 96 Interior - Carpet Cleaning Precautions
AC00396 Nov 96 A/C - Alternative Refrigerants and Retrofits
BO00996 Oct 96 Seat Belts - Extender Availability

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Technical Service Bulletins

All Technical Service Bulletins:

Number Date Name

SU00296R Sep 96 Wheels - Balance Adapter Kit Update

NHTSA96V107000 Jun 96 Recall 96V107000: Inadvertent Air Bag Deployment
NHTSA96V107 Jun 96 Recall 96V107: Air Bag Warning Light System Defect
AC00296 May 96 A/C - Compressor Maintenance for Stored Vehicles
ST00196 May 96 Steering - Gear/Wheel Removal With SRS
SU00296 Mar 96 Wheels - Balance Adapter Kit
BO00196 Jan 96 Windows - Wire Type Regulator Assembly Installation
ATRATB345 Jan 96 A/T - Checkball Wear
BO95002R Dec 95 Wipers - Windshield Washer Bottle Modified
B095012 Nov 95 Seat Belts - Front and Rear Extenders
EL95004 Nov 95 Instruments - Wiper Motor Circuit Breaker Inspection
SS95-003 Oct 95 Engine - Tripod Support Bar
PA95001 Sep 95 Paint - Repairs On Polyurethane Bumper
TC95008 Aug 95 M/T - Replacement Parts, Set Required
BR95003 Aug 95 Brakes - Introduction of Shim/Fitting Kits
PG95006 Jul 95 Bolts - Standard Torque Specifications
BO95004 Jul 95 Interior Trim - Instrument Panel Register Sub-Assembly
PG95005 Jun 95 Emissions - Control Label Order Form
EG95002 May 95 Cooling System - Water Pump Seal Improvements
AC95001 Mar 95 A/C - Refrigerant Leak Detection Service Hints
ATRATB294 Jan 95 A/T - Drive Axle and Wheel Lug Nut Torque Specifications
SSCR03 Nov 94 Recall - Unused Wire Harness Connector May Short
NHTSA94V220000 Nov 94 Recall 94V220000: Harness Connector Corrosion
BO94015 Oct 94 Windows - Power Window Regulator Now Available
POL9418 Oct 94 Warranty - Brake Repair
TC94012 Oct 94 Recall - Temporary Spare Tire
SS94003 Aug 94 Tools - Toyota Checker Applications
SS94002 Aug 94 Wiring - New Harness Repair Kit Available
POL9408 Jul 94 Warranty - Replacement Battery Part Numbers
BR94004 Jun 94 Brakes - Pad Kits Now Available Without Hardware
PG94002 Jun 94 Emissions - Control Labels Ordering Form
BO94006 Apr 94 Seat Belts - Extension Availability.
AC94001 Mar 94 A/C - Replacement Refrigerants Damage System
BO94005 Mar 94 Seats - Fabric Loose at Lower Edge of Rear Seat Bolster
SU94002 Mar 94 Suspension - Rear Stabilizer Bar Bushing Squeak/Groan
BR94002 Feb 94 Brakes - Cause and Repair of Vibration and Pulsation
AU94001 Jan 94 Audio - CD Player Won't Play or Skips
AC93005 Oct 93 A/C - Compressor Oil Application & Quantity
ATRATB191 Oct 93 A/T - Failsafe Modes
AU93001 Sep 93 Cellular - Equipment Installation Precautions
PG93005 Aug 93 Repair Manual Corrections - A245E Transaxle
TC93005 Jul 93 A/T - Improved Shift From N to D
TC93002 Jun 93 A/T - 1st and Reverse Brake Parts Standardized
PG93003R Jun 93 A/C - R12 Caution Label Application Instruction Update
AX93002 Jun 93 Antitheft - Glass Breakage Sensor Adjustment
BO93006 Jun 93 Seat Belts - Extenders Availablity
EL93002 Apr 93 Instruments - Clicking or Ticking Noise From Speedometer
BO93003 Apr 93 Paint - Anti-Chip Primer Now Applied
AC93004 Apr 93 A/C - Precautions for Handling Refrigerant Oil
PG93002 Apr 93 ID - Replacement VIN Plates and Certification Labels
BO93002 Mar 93 Body - Front Fender Sub-Assembly Now Available
EL93001 Mar 93 Air Bags - Wait Time After Battery Disconnect to Repair
SS93001 Mar 93 Suspension - Coil Spring Compressor Warnings
SU93001 Feb 93 Repair Manual Corrections - Suspension Arm No. 2
PA92001 Dec 92 Paint - Codes & Cross References
BO92011 Dec 92 Interior Trim - Front Door Arm Rest Cover Retention
AX92005 Dec 92 Body - Mudguard Installation Instructions
AC92005 Nov 92 A/C - Pressure Conversion Reference Chart
AC92004 Oct 92 A/C - R12 and R134A O-Ring Color Identification
SU92002 Oct 92 Suspension - Delco Rear Shock Inspection Procedure
AU92005 Oct 92 Audio - Player Does Not Load or Eject CD
PG92006 Sep 92 Ignition Lock - Key Code & Key Cutter Information
ATRATB132 Sep 92 A/T - Intermittent Electrical Problems

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Technical Service Bulletins

All Technical Service Bulletins:

Number Date Name

EG92003 May 92 Engine - ID Numbers Lengthened For A-Series

ATRATB078 Nov 91 A/T - How To Use A Pressure Gauge
EL91008 Oct 91 Battery - Maintenance For Vehicles In Dealer Inventory
ATRATB028 Oct 90 A/T - Engine Vacuum Testing
ATRATB9002006 Feb 90 A/T - Choosing the Right ATF
ATRATB8930 Oct 89 A/T - Math Part II
ATRATB8927 Sep 89 A/T - Twenty Steps To Successful Repairs
ATRATB8923 Aug 89 A/T - Math Formulas Part I
ATRATB8754 Sep 87 A/T - Front Bushing Wear
ATRATB8748 Aug 87 A/T - Slipping or No-Shift/Metal Sealing Rings

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Vehicle: All Technical Service Bulletins
Technical Service Bulletin # CRIB164 Date: 080901

Vehicle - VIN Plate/Certification Label Replacement

TITLE: REPLACEMENT CERTIFICATION LABELS AND VIN PLATES

SECTION: EXTERIOR

BULLETIN # 164

MODELS: ALL TOYOTA LEXUS and SCION

DATE: SEPTEMBER 2008

Replacement Certification Labels and on a limited basis Vehicle Identification Number (VIN) plates are available by application. If these identifiers
require replacement or transfer to a replacement component, follow instructions outlined in these Technical Service Bulletins:

^ T-SB-0144-08 Replacement Certification Labels - Toyota

^ L-SB-0048-08 Replacement Certification Labels - Lexus

^ S-SB-0039-08 Replacement Certification Labels - Scion

^ PGOO7-07 Replacement VIN Plates - Toyota

^ PGOO7-07 Replacement VIN Plates - Lexus

^ PGOO9-07 Replacement VIN Plates - Scion

Service Bulletins are available from the Technical Information System (TIS) at www.techinfo.toyota.com.Technical Service Bulletin #
SB0144-08 Date: 080731

Vehicle - Certification Label Information

T-SB-0144-08

July 31, 2008

Replacement Certification Labels

Service Category
General

Section
Identification

Market
USA

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Applicability

TSB SUPERSESSION NOTICE

The information contained in this TSB supersedes TSB No. PG008-07.

^ The Notes in the Certification Label Criteria section and in the "Application for Replacement Certification Label" form have been updated.

^ The Note in the Procurement Procedure section has been removed.

TSB No. PG008-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before
proceeding.

Introduction

Replacement Certification Labels (vinyl label installed on driver's door or door post) may be available from Toyota providing the request meets one
of the criteria listed in this TSB.

Warranty Information

Certification Label Criteria (please see important note below)

A replacement certification label may be requested if:

^ The vehicle is in an accident and the label is damaged or is attached to a part that will be replaced during the repair.

^ The label is stolen.

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IMPORTANT NOTE

^ To expedite your request, please provide a clear, legible photograph of the certification regulation label along with the original label. This
will allow TMS Technical Compliance to obtain information from the original label which is not easily available elsewhere. We may be
unable to create a replacement label if this material is NOT submitted.

^ All replacement certification regulation labels for damaged and/or stolen vehicles are subject to approval by TMS Technical Compliance. If
you have specific questions, please.

Procurement Procedure

To request a replacement label complete a copy of the form at the end of this bulletin. Your dealer parts account will be billed for each replacement
of a damaged or stolen label.

Technical Service Bulletin # PG007-07 Date: 071120

Vehicle - Replacement VIN Plate Information

PRODUCT GENERAL INFORMATION
PG007-07

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Title:
REPLACEMENT VIN PLATES

Models:
All Toyota Models

November 20, 2007

TSB UPDATE NOTICE:

The information contained in this TSB supersedes TSB No. PG009-02.
TSB No. PG009-02 is now obsolete and should be discarded. The changes will take place January 1, 2008.

Introduction

Replacement VIN plates (metal plates riveted to dashboard) may be available from Toyota providing the request meets the criteria listed in this
TSB.

Applicable Vehicles

^ All Toyota vehicles.

Warranty Information

Replacement VIN Plate Criteria

A replacement VIN plate may be requested ONLY if:

^ The vehicle is in an accident and the VIN plate is damaged.

^ The vehicle was stolen and the VIN plate is damaged but still available.

NOTE:

^ The original VIN plate being replaced MUST accompany the request.

^ If the VIN plate is stolen, be sure to contact the State Police or your State's Department of Motor Vehicles (DMV). In most cases, the State
DMV will issue a unique number so that the original number can be included on stolen vehicle listings. If this is the case, a replacement
VIN plate is NOT available from Toyota. However, the original VIN, NOT the state issued VIN, must be used on all warranty claims.

Procurement Procedure

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To request a replacement VIN plate, complete a copy of the form at the end of this bulletin. Note that the damaged VIN plate MUST accompany
the request form. Your dealer parts account will be billed $40.00 for each replacement of a damaged VIN plate.

All replacement VIN plates are subject to approval by the Technical Compliance Department. If you have any specific questions, contact them.
Technical Service Bulletin # AX004-99 Date: 990319

Vehicle - Towing Guide

ACCESSORIES
AX004-99

March 19, 1999

Title:

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TOYOTA "DINGHY" TOWING GUIDE

Models:

All Models

Introduction:
The following chart indicates which Toyota vehicles can be Dinghy towed (towed with four wheels on the ground) behind a Motorhome.

CAUTION:
Dinghy towing 6 vehicle behind a Motorhome requires special towing equipment and accessories. Please see your Motorhome Manufacturer /
Service Outlet for recommended towing equipment.

Affected Vehicles

- All Models

Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components. The transmission must be placed in
the "neutral" position when Dinghy towing. Dinghy towing these vehicles does not eliminate the possibility of damage to other vehicle systems
(Body, Chassis, Electrical Systems, etc.).

Warranty Information
Technical Service Bulletin # AX001-00 Date: 000317

Vehicle - Towing Guide.

BULLETIN NUMBER:
AX001-00

DATE:
March 17, 2000

TITLE:
TOYOTA "DINGHY" TOWING GUIDE

MODELS:
All Models

INTRODUCTION
The chart on the next page indicates which Toyota vehicles can be Dinghy towed (towed with four wheels on the ground) behind a Motorhome

CAUTION:

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Dinghy towing a vehicle behind a Motorhome requires special towing equipment and accessories. Please see your Motorhome
Manufacturer/Service Outlet for recommended towing equipment.

Warranty Information

WARRANTY INFORMATION

APPLICABLE VEHICLES

NOTE:
After "Dinghy" Towing, or at the recommended distance limits, let the Engine idle for more than 3 minutes before operating the vehicle or
resuming towing.

NOTE:
Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components, as long as speed/distance limits are
observed. The transmission must be placed in the "neutral" position when Dinghy towing. Dinghy towing these vehicles does not eliminate the
possibility of damage to other vehicle systems (Body, Chassis, Electrical Systems, etc.).
Technical Service Bulletin # PG95006 Date: 950721

Bolts - Standard Torque Specifications

REF.: PRODUCT GENERAL INFORMATION

NO.: PG95-006

DATE: JULY 21, 1995

MODEL: ALL MODELS

STANDARD BOLT TORQUE SPECIFICATIONS

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The bolt mark and class identification information is currently not included in the Standard Bolt Torque Specifications found in the Introduction
section of each Toyota Repair Manual.

SPECIFIED TORQUE FOR STANDARD BOLTS

Technical Service Bulletin # SSCR03 Date: 941121

Recall - Unused Wire Harness Connector May Short

Volume:
III

Number:
TC94-014

Date:
11/21/94

SUBJECT:
SPECIAL SERVICE CAMPAIGN - RO3 (1993 AND 1994 COROLLA WIRE HARNESS CONNECTOR)

Toyota will initiate a Special Service Campaign to modify an unused wire harness connector on certain 1993 and 1994 Toyota Corollas not
equipped with power windows, power door locks and sunroof.

Toyota has determined that an unused wire harness connector on certain subject model sedans operating in cold weather conditions can experience
an electrical short circuit due to salt contamination. When salt water or snow is carried into the vehicle by the driver's shoes it can saturate the
carpet and contaminate a wire harness connector which may be located under the carpet near the driver's left foot. If this occurs, the connector
could heat up and, in the extreme case, result in a fire.

Administrative Information
As required by Federal regulation, dealers must perform the necessary inspection and/or repair on any vehicles acquired in their inventory prior to
sale or lease of the vehicle.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 789

You are requested, using the following information, to modify the unused wire harness connector on the vehicles involved in this campaign.

The following vital information is provided to inform you and your staff of the campaign schedule and your degree of involvement required.

Dealer, Owner Notification

^ Dealer notification package mailing date November, 1994 (copy included)

^ Owner notification letter mailing date: End of November, 1994 (sample included)

Number of Vehicles Involved in Your Region

Only owners of vehicles registered in the States of Connecticut, Illinois, Indiana, Maine, Massachusetts, Michigan1 New Hampshire, New Jersey,
New York, Ohio, Pennsylvania, Rhode Island, Vermont and Wisconsin will be notified (Approximately 16,500 vehicles.) Please refer to the SSC
R03 summary report enclosed in the Regional Service Manager's package. The report indicates the number of vehicles involved in this campaign in
your region.

Vehicles in Dealer Stock

Dealers are required by Federal regulation to perform the campaign procedure for any vehicles in their stock prior to sale or lease of the vehicle.

Parts Ordering Procedure

No parts will be required for this campaign; only standard tools and vinyl electrical tape are needed.

Your cooperation in maximizing the completion rate of the subject vehicles is greatly appreciated.

1. Owner Notification Letter Mailing Date

End of November, 1994

2. Identification of Involved Vehicles

JT2AE04B*R0075233 THRU JT2AE04B*R0090859

JT2AE09E*P0001056 THRU JT2AE09E*P0079375
JT2AE09B*R0001056 THRU JT2AE09B*R0079375
2T1AE09E*PC000030 THRU 2T1AE09E*PC084501
2T1AE09B*RC000030 THRU 2T1AE09B*RC084501

NOTE:
Only owners of Toyota Corolla sedans not equipped with power windows. power door locks and sunroof that are registered in the States of
Connecticut, Illinois, Indiana, Maine, Massachusetts, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island,
Vermont and Wisconsin will be notified.

Do not perform this modification on vehicles within the VIN range that are not operated in any of the above listed fourteen States.

3. Repair Procedures

Refer to the included Technical Instructions.

4. Parts Ordering

No parts will be required for this campaign, only standard tools and electrical vinyl tape are needed. Please refer to the enclosed Primary Marketing
Area(PMA) Dealer/owner list (550 RO3) for your campaign follow-up.

5. Reimbursement Procedures

Submit Special Service Campaign claims following the procedures described in the Toyota Warranty Policy & Procedures Manual.

The operation code to be used for this campaign is as illustrated.

NOTE:
The illustrated operation code includes 0.1 flat rate hour for administrative expenses.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 790

Please review this entire package with your Service and Parts staff to familiarize them with the proper step-by-step procedure and implement this
Special Service Campaign to ensure customer satisfaction.

Wire Harness Connector Modification Procedure

TECHNICAL INSTRUCTIONS FOR 550 RO3

I. OPERATION FLOW CHART

THIS SPECIAL SERVICE CAMPAIGN APPLIES ONLY TO VEHICLES OPERATING IN THE FOLLOWING 14 STATES: CONNECTICUT,
ILLINOIS, INDIANA, MAINE, MASSACHUSETTS, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO,
PENNSYLVANIA, RHODE ISLAND, VERMONT AND WISCONSIN.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 791

II. AREA INVOLVED

III. PARTS AND PREPARATION:

(A) Necessary Parts

^ Vinyl Electrical Tape
(B) Tools
^ Standard Tools

IV. WIRE HARNESS CONNECTOR MODIFICATION PROCEDURE

1. PREPARATION

(a) Install the seat cover and floor cover.

(b) Disconnect the battery negative (-) terminal.

NOTE:
Before disconnecting battery terminal, record the preset radio stations.

2. REMOVE FRONT LH DOOR SCUFF PLATE

(a) Unscrew the resin nut and remove it.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 792

(b) Remove the 4 clips in the order shown in the illustration.

NOTE:
Use a scraper to remove the clips.

3. MODIFY WIRE HARNESS

(a) Remove the vinyl tape used to attach the unused wire harness connector to the ground wire harness.

(b) Cut the wire harness approximately 30 mm (1.18 in) behind the rear edge of the unused connector.

(c) To prevent contact between the cut wires, again cut the 3 wires colored G, R-L and W-R so that all 3 wires are of different lengths from each
other.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 793

(d) Bend the tip of the G, R-L and W-R wires back upon themselves to a distance of about 10 mm(0.39 in), and then tape each wire up with vinyl
tape.

(e) Bind all the wires in the wire harness together with vinyl tape.

(f) Bend the wire harness back on itself one time facing upward, and bind it together with vinyl tape as shown.

(g) Fix the taped-up wire harness onto the ground wire harness using vinyl tape at a location that will prevent the taped up harness from being
under the carpet.

4. REMOVE POWER FUSE

(a) Remove the POWER fuse from the junction block (J/B) No. 1.

NOTE:
The 30A DEFOG fuse is next to it, do not remove it by mistake, the POWER fuse is on the rear side of vehicle.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 794

(b) Pry off the fuse cover using a small (-) screwdriver.

NOTE:
Do not damage the cover by applying too much pressure.

(c) Use snips to cut through the copper wire on both sides and remove the center section as shown.

(d) Reinstall the cover.

5. REINSTALL POWER FUSE

(a) Apply vinyl tape to the upper surface of the fuse cover to indicate that this fuse is not being used.

(b) Reinstall the POWER fuse onto the junction block (J/B) No. 1.

6. REINSTALL FRONT LH SCUFF PLATE

NOTE:
Each clip must be properly inserted in the panel hole to avoid damaging the clip when tapping the clip in. Replace any damaged clips.

7. RECONNECT BATTERY NEGATIVE (-) TERMINAL

8. RESET THE CLOCK AND RADIO STATIONS PRESET BY CUSTOMER

9. REMOVE SEAT COVER AND FLOOR COVER

10. SSC COMPLETION LABEL INSTALLATION

(a) After completing repair and before returning vehicle to the owner, a SSC completion label that is enclosed in the owner's notification must be
affixed to the left front door hinge post near the check strap.

(b) The label is to be filled out as follows:

^ Write in SSC RO3

^ Write in date of repair
^ Write in your Dealer Code

(c) Additional SSC completion labels, in sheets of 50 (P/N 00410-01917), may be ordered through the non-parts system on a 1450 order form or
through the TDN system.

Owner Letter
SSC R03 COROLLA WIRE HARNESS CONNECTOR SAFETY RECALL

Dear Toyota Owner:

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 795

This notice is being sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Certain 1993 and 1994
Toyota Corolla vehicles can experience an electrical short circuit due to salt contamination of a wire harness connector.

WHAT IS THE PROBLEM?

When salt water or snow is carried into the vehicle by the driver's shoes it can penetrate the carpet and repeatedly drip onto the wire harness
connector may be located under the carpet by the drivers left foot. If this occurs, the connector at up and, in the extreme case, result in a fire.

WHAT WILL TOYOTA DO?

Any Toyota dealer will modify the subject wire harness and reposition it to prevent any possibility of short circuits from occurring. These repairs
will be performed at NO COST to you.

WHAT SHOULD YOU DO?

Contact any authorized Toyota dealer and make an appointment to have the wire harness on your vehicle modified as soon as possible.

The labor time for modification of the wire harness is approximately thirty minutes. However, depending upon the dealer's work schedule may be
necessary to make your vehicle available for a longer period of time.

Please present this notice to the dealer when you bring the vehicle in for the repair.

If you no longer own the vehicle, please indicate so on the enclosed postage paid form, providing us with the name and address of the new owner.

WHAT IF YOU HAVE OTHER QUESTIONS?

Please contact any Toyota dealer or call the Toyota Customer Assistance Center at 1-800-331-4331.

If you believe that the dealer or Toyota has failed or is unable to remedy the defect within a reasonable time, you may submit a complaint to the
Administrator, National Highway Traffic Safety Administration, 400 Seventh Street S.W. Washington D.C. 20590, or call the toll free Auto Safety
Hot Line at 800-424-9393 (Washington. D.C. area residents may call 366-0123).

We have sent this notice in the interest of your continued satisfaction with our products and we sincerely regret any inconvenience this condition
may have caused you.

Technical Service Bulletin # SS94002 Date: 940812

Wiring - New Harness Repair Kit Available

REF.: SPECIAL SERVICE TOOLS

NO.: SS94-002

DATE: AUGUST 12, 1994

MODEL: ALL MODELS

WIRE HARNESS REPAIR KIT "B"

The new Wire Harness Repair Kit "B" has been released as an essential Special Service Tool (SST) to supplement the original Wire Harness Repair
Kit. This kit holds an initial supply of 21 new type electrical terminals and connectors as well as the necessary supplies and small tools for most
electrical repairs.

The Wire Harness Repair Kit manual has been updated and now contains an illustrated catalog of all terminals and connectors available for Toyota
vehicles. Connector Replacement Guidelines, a Connector/Terminal Usage Guide, and a Connector Quick Reference Chart have been added as
additional reference. This manual is the only reference available which provides information on properly identifying connectors and terminals.

When components/supplies need to be replaced, refer to page 21 in the manual or the reverse side of this TSB. Note: The manual is no longer
available through the Toyota Non-Parts System. It is available separately under part number 410094 by calling OTC at 1-800-933-8335.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 796

WIRE HARNESS REPAIR KIT "B"

PARTS REPLACEMENT ORDERING INFORMATION:

The parts can be ordered through Toyota Motor Sales on a normal parts order:

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 797

The parts can be ordered from OTC Tool & Equipment Division, SPX Corporation, 655 Eisenhower Drive, Owatonna, Minnesota 55060:

All remaining parts can be purchased from a local supplier.

Technical Service Bulletin # PG93002 Date: 930409

ID - Replacement VIN Plates and Certification Labels

REF.: PRODUCT GENERAL INFORMATION

NO.: PG93-002

DATE: EFFECTIVE APRIL 09, 1993

MODEL: ALL MODELS

VIN PLATES & CERTIFICATION LABELS

Replacement VIN plates (riveted to dashboard) and Certification Labels (affixed to driver's door or door post) are available from Toyota providing
the request meets one of the following criteria:

^ The original label is incorrect (an incorrect Certification Label must accompany the request; an incorrect VIN plate must be returned after
receipt of the new one).

^ The vehicle is in an accident and the plate or label is damaged or is attached to a part that will be replaced during the repair* (the plate or label
to be replaced must accompany the request).

^ The plate or label is stolen*. Be sure to contact State Police or the Department of Motor Vehicles; in many cases they will issue a unique
number so that the original can be included on stolen vehicle listings. When requesting a new plate or label to replace a stolen one, it is
necessary to include a copy of the police or insurance company report.

^ All replacement plates and labels for damaged and/or stolen vehicles are subject to approval by the Technical Compliance Department If you
have any specific questions, contact (310) 781-3390.

Aluminum Certification Plates are no longer available as replacements. If one is requested, a vinyl label containing information from this plate
combined with information from the manufacturer's plate (mounted on the engine compartment side of the cowl panel) will be supplied instead.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 798

To request a replacement plate or label, complete the appropriate portion of the form in this bulletin. Note that damaged VIN plates or labels must
accompany the request form. Your dealer parts account will be billed $10.00 for each replacement of a damaged plate or label. Replacements for
incorrect plates or labels will be provided free of charge.

MAIL THE COMPLETED REQUEST FORM WITH THE REQUIRED ENCLOSURE TO:

TOYOTA MOTOR SALES, U.S.A., INC.

TECHNICAL COMPLIANCE DEPT. S203
19001 S. WESTERN AVENUE
TORRANCE, CA 90509-2991

Technical Service Bulletin # SS002-97 Date: 970926

Brakes - Booster Push Rod Gauge

SPECIAL SERVICE TOOLS
SS002-97

September 26, 1997

Title:
BRAKE BOOSTER PUSH ROD GAUGE (SST)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 799

Models:
ALL MODELS

Introduction When inspecting or making brake booster push rod adjustments with SST 09737-0001 0, it is necessary to assure proper tool
configuration prior to use, The SST has a reversible center plunger that allows it to function on a wide range of Toyota vehicles. Prior to using,
verify that it is configured correctly for the application by checking the master cylinder outer diameter at the point illustrated below. The
dimensions for the SST, Part Number 09737-00010, are also shown in the illustrations.

Parts Information

PART NUMBER PART NAME

09737-00010 Brake Booster Push Rod Gauge (SST)

Warranty Information
Technical Service Bulletin # EL002-98 Date: 980410

Interior - Cigarette Lighter Service

ELECTRICAL
EL002-98

April 10, 1998

Title:
CIGARETTE LIGHTER SERVICE

Models:
All Models

Introduction

When receiving customer complaints to repair the lighter or lighter socket, please carefully investigate the cause of the failure to prevent further
occurrences. If the customer uses the wrong size lighter element or power accessory plug, damage may occur to the lighter socket. When
applicable, instruct the customer to replace the lighter element with original equipment components or to use an appropriate sized accessory plug.
Dimensional information included within this document will instruct you on component specifications.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 800

Service Procedure

1. Determine if the lighter is original equipment by using the specifications shown.

a. If the vehicle has a non-genuine lighter element, it has the possibility to cause a short circuit between the lighter element and the lighter
socket, which can result in an open fuse.

b. A non-genuine lighter element may cause a rattle or bend the socket bimetal contacts.

c. If a non-genuine lighter element is being used, advise the customer to use an original equipment element.

2. If the lighter element is original equipment and the lighter socket is bent or pulled out of the dash, please ask the customer about the
accessory plug being used in the lighter socket.

a. The specifications in the drawing provide the maximum recommended size of accessory plug. If the customer is using an accessory
plug larger than recommended, please advise the customer to use a plug of appropriate size.

b. Using a power plug larger than the given dimensions may damage the lighter socket.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 801

c. If the vehicle has a power point socket, advise the customer to use this socket instead of the lighter socket.

Affected Vehicles

^ All models, all model years

Warranty InformationTechnical Service Bulletin # BO95004 Date: 950714

Interior Trim - Instrument Panel Register Sub-Assembly

REF: BODY

NO.: BO95-004

DATE: JULY 14, 1995

MODEL: AE (TMC)

INSTRUMENT PANEL REGISTER SUB-ASSEMBLY

In order to improve serviceability on '93-'95 TMC built Corollas, the instrument Panel Registers are now available as separate supply parts as
shown below:

REPAIR PROCEDURE:

1. Apply protective tape to the blade of a small flat screwdriver.

2. Remove the Instrument Panel Register by gently prying out near the Hinge Pins on the Register.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 802

INSTRUMENT PANEL REGISTER SUB-ASSEMBLY

NOTE:
As shown in the illustration, the instrument panel Register is held in position by a removable collar on one side. During removal, be careful not
to drop the Collar into the duct.

HINT:
The Collar side for each Register is indicated by arrows as shown in the illustration. The center (A) registers are easily removed by prying first,
with the screwdriver, on the Collar side. The outer (B) Registers should be pried first on the sides without the Collar.

3. Insert the Register as shown in the illustration.

NOTE:
Make sure the Collar is seated correctly in the Register as indicated in the illustration.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 803

Part Number InformationTechnical Service Bulletin # AC92005 Date: 921120

A/C - Pressure Conversion Reference Chart

REF.:
HEATING & AIR CONDITIONING

NO.:
AC92-005

DATE:
NOVEMBER 20, 1992

MODEL:
ALL MODELS

PRESSURE CONVERSION REFERENCE CHART

The 1993 Toyota T-100 repair manual gives air conditioning refrigerant pressure specifications exclusively in the metric units of Pascals and
kg/sq.cm. Since U.S. service equipment is typically marked in the lb/sq.in., refer to the chart in this bulletin for pressure conversion information.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 804

PRESSURE CONVERSION REFERENCE CHART

Technical Service Bulletin # AC95001 Date: 950303

A/C - Refrigerant Leak Detection Service Hints

REF.: HEATING & AIR CONDITIONING

NO.: AC95-001

DATE: MARCH 03, 1995

MODEL: ALL MODELS

SERVICE HINTS FOR REFRIGERANT LEAK DETECTION

Use of electronic leak detectors for checking A/C systems refrigerant leakage is the only method approved by Toyota. This type of leak detector is
sensitive not only to refrigerant, but also sensitive to numerous petrochemical substances (motor oil, gasoline, solvents, etc.) commonly found in a
repair shop environment. Because this sensitivity could diminish the leak detectors capacity for accurate leak detection, some service hints have

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 805
been provided to help increase the accuracy of your diagnosis.

SERVICE HINTS:

1. Visual Inspection: Do a quick visual inspection under the hood for signs of refrigerant leakage. Check for areas of heavy oil leakage at block
and piping joints. Many times these areas have accumulated road dust and dirt.

2. Inspection with leak detector:

NOTE:
Make sure the system is fully charged. Operate the system to increase refrigerant pressure. Shut the system off before inspecting with leak
detector.

A. Checking for leakage at block and piping joints: Wipe the oil/dirt accumulation off the joints with a clean rag. Do not use solvents to clean
the joints. Refrigerant is heavier than air so start checking for leaks with the detector wand about 1/4 inch below the joint. Move the wand
slowly across and around each joint (see illustration below).

B. Checking for leakage at the evaporator: The evaporator drain hose provides an excellent access point to check for refrigerant leakage from
the evaporator. Be sure to raise the Vehicle on a lift so that the evaporator is as far as possible from any petrochemical source that may be on
the shop floor. When leak checking in this area, turn the system off, pinch off the evaporator drain hose, and wait 10 to 15 minutes to allow
the refrigerant to accumulate in the evaporator case. When the system is ready to check, release the drain hose and hold the leak detector
wand about 1/4 inch below the drain opening (see illustration below).

NOTE:
Do not allow the leak detector tip to come in contact with water from the evaporator.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 806

C. Checking for leakage at front compressor seal: Front compressor seal leaks are probably the most difficult leaks to detect accurately. Special
diagnostic procedures must be followed for the best success. Make sure the system is fully charged. Operate the system with a pressure gauge
installed and assure that the system has correct system pressures. Shut off the engine. Begin the leak check by placing the detector probe
along the bottom half of the compressor clutch. Move the wand slowly across the bottom of the compressor clutch. Be careful not to expose
the detector wand tip to any oil residue as this may cause a false leakage reading (see illustration).

D. Checking for leakage at service valves or pressure switches:

Small accumulations of refrigerant gas under the service valve caps or pressure switch connectors is normal. When checking for leaks at these
points, use the following procedures to assure the highest accuracy:

1. Remove the service valve cap or pressure switch connector.

2. Allow the service valve or pressure switch to remain uncapped for approximately 20 minutes. This will allow the air to circulate and carry
away the accumulated refrigerant. (This is a good time to leak check other areas of the system).

3. Do not use compressed air to flush out the service valve or pressure switch cavity. Petroleum residue from in-line oilers or compressor
lubrication may cause false readings,Technical Service Bulletin # PG93003R Date: 930618

A/C - R12 Caution Label Application Instruction Update

REF.: PRODUCT GENERAL INFORMATION

N0.: PG93-003 (REVISED)

DATE: JUNE 18, 1993

MODEL: ALL MODELS - (EXCEPT VD & JA)

APPLYING CAUTION LABEL TO VEHICLES USING R-12 A/C SYSTEMS (REVISED)

Beginning with May 15, 1993 production, the EPA has required two Ozone Depleting Substance (ODS) Caution Labels to be applied on every new
vehicle. The first is required when Methyl Chloroform is used in the vehicle manufacturing process. The second label, a Chlorofluorocarbon
(CFC-12) Caution Label, is required to be installed on new vehicles when the vehicle is equipped with an air conditioning system, manufactured
after May 15, 1993, which utilizes R-12.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 807

All Methyl Chloroform Caution Labels will be applied to vehicles at the manufacturing plant. Vehicles equipped with factory installed R-12 A/C
systems will also have the CFC-12 Caution Label applied at the manufacturing plant.

Vehicles with port or dealer installed A/C will have the CFC-12 Caution Label applied at the, A/C kit installation location. The CFC-12 Caution
Label is ONLY required for A/C kits manufactured after May 15, 1993.

A CFC-12 CAUTION LABEL is supplied with all dealer installed A/C kits, manufactured after May 15, 1993, and must be applied on the inside
upper right (passenger side) of the windshield when any PIO/DIO R-12 kit, manufactured after May 15, 1993, is installed.

NOTE:
Caution labels must be left on vehicle until delivery to a retail customer.

NOTE:
To avoid obstruction of the driver's vision, the label should not extend beyond 90 mm below the upper edge of the windshield.

PART NUMBER INFORMATION:

(Part Number Information, in case label is damaged or missing from kit, manufactured after May 15, 1993).

Part Number Part Name

74541-24010 ODS Caution Label, CFC-12

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 808

The matrix indicates the combination of caution labels (Methyl chloroform and CFC-12) relative to the vehicle or A/C system production date as
shown.

Technical Service Bulletin # AC002-98 Date: 980403

A/C - R-12 Air Conditioner System Retrofit

HEATING & AIR CONDITIONING
AC002-98

April 3, 1998

Introduction

The following information should be used for guidance when retrofitting vehicle air conditioning systems from R-12 to R134a refrigerant.

Affected Vehicles

- 1986-1989 Van, 1986-1992 Cressida & Supra, 1986-1993 Camry, Ceilca, Corolla, MR2, Tercel, 4Runner, Land Cruiser, 1986-1994 Truck,
1991-1993 Prevla, and 1992-1993 Paseo

Parts Information

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 809

- General Parts not included with Set are listed in table.

- Model specific parts are listed in the application table.

Warranty Information

Table of Contents

Affected Vehicles Truck & RV Parts

Service Precautions Required Tools & Materials
Retrofit Kit Parts Retrofitting Overview
Required Parts Repair Procedures
Passenger Vehicle Parts Warranty Information

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 810

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 811

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 812

Required Tools & Materials

A. Required Equipment:
1. R-12 recovery/recycling/recharging equipment
2. R-134a recovery/recycling/recharging equipment
3. Graduated measuring cylinder (for compressor oil)
4. Valve core remover for service valves
5. Air conditioner manifold gauge set
6. Torque Wrench Kit, 00002-50284-01, contains the following:*1

- 14 mm 00002-51410-01
- 17 mm 00002-51710-01
- 22 mm 00002-52216-01
- 27 mm 00002-52724-01

B. Required Parts & Materials:*2

1. R134a Refrigerant
2. Service Fitting Adaptors
3. Caution Labels
4. Compressor oil
5. Receiver/Dryer for R134a
6. 0-Rings for hose connections
7. 0-Rings for Compressor Extension Housing / Service Plate *3
8. Loctite 262 or equivalent

NOTE:

*1 required size(s) dependant upon specific model.

*2 see application information section of this bulletin.

*3 All 10P compressors require installation of compressor 0-rings. It is not necessary to replace compressor 0-rings on vehicles
produced from 1/93 or on DIO/PIO A/C systems with compressor production serial numbers after 1N0001 (10PA type compressors
and TV type compressors).
Retrofitting Overview
A. Refrigerant and Oil Charges
- Oil and refrigerant charge amounts are different after the R-12 system has been retrofitted to R134a. Refrigerant charge amounts are less,
while oil charge amounts are greater, compared to R-12 system requirements.*

B. System Performance
- A slight decrease in system performance may be noticed on some vehicles under certain operating conditions.

C. Refrigerant Pressures
- R134a high side pressures are greater than that of R-12 above ambient temperatures of 68°F

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 813

D. Flushing Requirements
- There is no need to remove or flush R-12 mineral oil from the system. Simply charge the system with the specified type and amount* of
PAG oil to provide proper lubrication.

E. Use of Sight Glass

- Mineral based R-12 oil remains and circulates in the A/C system and does not dissolve in R134a refrigerant.This results in a cloudy
appearance at the sight glass making it impossible to judge the refrigerant charge amount by using the sight glass method. To prevent
misdiagnosis on retrofit vehicles, apply black paint to the sight glass on blockjoint (FF) type receiver/dryers. Union-nut joint (BAG) type
retrofit receiver/dryers are manufactured without a sight glass.

*NOTE:
Refer to the OIL TYPE and CHARGE columns in Application Tables for proper amounts of ND-Oil 8 or ND-Oil 9.
Service Precautions
A. Refrigerant handling
1. Do not handle refrigerant in an enclosed area or near an open flame.
2. Always wear eye protection.
3. Avoid getting liquid refrigerant in your eyes or on your skin.
4. Never heat a container with an open flame.
5. Keep containers below 104°F
6. When heating a refrigerant can with water, keep the valve above water.
7. Never reuse empty service cans.

B. Replacing parts
1. Plug off any open connections to prevent the entry of moisture and dust.
2. Do not remove plugs from receiver/dryer ports until it is ready for installation.

C. Tightening connecting parts

1. Apply a few drops of specified PAG compressor oil to 0-ring fittings before tightening.
2. Avoid twisting refrigerant piping when installing R134a service fitting adapters.
3. Tighten all fittings to specified torque.

NOTE:
Oil removed during R-12 evacuation should not be used with an R134a System.
Repair Procedure
A. Vehicle Inspection:
- Ensure the integrity of the A/C system before proceeding with retrofit.

B. Recover R-12 using R-12 recovery/recycling/recharging equipment:

- Follow Toyota recommended procedure.

C. Install R134a service fitting adapters:

1. Remove valve cores from R-12 service fittings and discard.
2. Clean external threads of the R-12 service fittings.
3. Apply adhesive to threads (Loctite 262 or equivalent), screw on R134a adapter fittings, and tighten to 13 ft.-lb.

NOTE:
Vehicles with more than 2 service fittings will require the installation of additional adaptors. All service fluings must have R134a adaptors
installed.

D. Replace compressor 0-rings (10P only):

1. Remove compressor from vehicle.
2. Install covers on hose connection ports to prevent airborne contamination.
3. Clean compressor body and service valve area using brush and compressed air.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 814
4. Remove service valve plate.
5. Remove 0-rings from service valve plate and discard.
6. Remove extension housing if used, otherwise go to step 7.
a. Separate extension housing from service valve plate.
b. Remove and discard 0-rings.
c. Lubricate and install retrofit 0-rings into extension housing using specified PAG oil (see tables).
d. Reassemble extension housing to service valve plate.

7. Reinstall service valve plate to compressor. Torque bolts to 19 ft.lbs.

8. Reinstall compressor assembly.

E. Replace piping and hose 0-rings:

1. Disconnect suction and discharge hoses from compressor.
2. Remove and discard old 0-rings.
3. Lubricate and install retrofit 0-rings with specified PAG oil (see tables).
4. Disconnect discharge hose from condenser.
5. Remove and discard old 0-rings.
6. Lubricate and install retrofit 0-rings with specified PAG oil (see tables).
7. Reconnect hoses and torque to specification. (Specifications can be found in applicable manuals/guides.)

F. Replace receiver/dryer
1. Remove and discard original R-12 Receiver/Dryer.
2. Using the tables, determine the proper type and amount of PAG oil. Pour 1/2 of the specified oil into the "our" side of the
Receiver/Dryer.

3. Black out the sight glass on block - joint - type receiver/dryer with black paint.

4. Lubricate and install retrofit 0-rings with specified PAG oil (see tables).

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 815

5. Install retrofit Receiver/Dryer.

G. Evacuate, charge, and leak test the system (Use manufacturer's recommended procedure).
1. Evacuate for 45 minutes.
2. Vacuum check.
3. Add compressor oil.
^ Using recovery/recycling/recharging equipment charge the system with the remaining 1/2 of the specified amount of oil from step
F2.
4. Charge system with specified amount of Rl34a. (refer to tables).
5. Perform a gas leak check.

H. Confirm cooling performance of Air Conditioning system.

I. Install retrofit labels:

1. Choose R134a "USE ONLY" label for proper oil type (ND-Oil 8 or ND-Oil 9).
2. Using a ball point pen, enter the proper retrofit refrigerant and oil charges on the caution label.
3. Cross out unused type of compressor oil on caution label.
4. Affix labels in a prominent location such as radiator support, underside of hood, or suspension tower area.
5. Remove any R-12 labels.Technical Service Bulletin # AC002R-98 Date: 980724

A/C - R-12 Air Conditioner System Retrofit.

HEATING & AIR CONDITIONING
AC002-98

July 24, 1998

Title:
R-12 AIR CONDITIONER SYSTEM RETROFIT

Models:
'86-'94 All models with R-12 Systems

Introduction

The following information should be used for guidance when retrofitting vehicle air conditioning systems from R-12 to R134a refrigerant.

Affected Vehicles

^ 1986-1989 Van, 1986-1992 Cressida & Supra, 1986-1993 Camry, Celica, Corolla, MR2, Tercel, 4-Runner, Land Cruiser, 1986-1994 Truck,
1991-1993 Previa, and 1992- 1993 Paseo

Parts Information

^ General Parts not included with Set are listed in table.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 816

^ Model specific parts are listed in the application table.

Warranty Information

Table of Contents

Affected Vehicles Truck & RV Parts

Service Precautions Required Tools & Materials

Retrofit Kit Parts Retrofitting Overview

Required Parts Repair Procedures

Passenger Vehicle Parts Warranty Information

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 817

Passenger Vehicle Application Table

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 818

Truck and Recreational Vehicle Application Table

Required Tools & Materials

A. Required Equipment:

1. R-12 recovery/recycling/recharging equipment

2. R134a recovery/recycling/recharging equipment

3. Graduated measuring cylinder (for compressor oil)

4. Valve core remover for service valves

5. Air conditioner manifold gauge set

6. Torque Wrench Kit, 00002-50284-01, contains the following:*1

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 819

^ 14 mm 00002-51410-01

^ 17 mm 00002-51710-01

^ 22 mm 00002-52216-01

^ 27 mm 00002-52724-01

B. Required Parts & Materials: *2

1. R134a Refrigerant

2. Service Fitting Adaptors

3. Caution Labels

4. Compressor oil

5. Receiver/Dryer for R134a

6. 0-Rings for hose connections

7. 0-Rings for Compressor Extension Housing/Service Plate *3

8. Loctite 262 or equivalent

NOTE:
*1 required size(s) dependant upon specific model.

*2 see application information section of this bulletin.

*3 All 10P compressors require installation of compressor 0-rings. it is not necessary to replace compressor 0-rings on vehicles produced
from 1/93 or on DIO/PIO A/C systems with compressor production serial numbers after 1N0001 10PA type compressors and TV type
compressors).
Retrofitting Overview
A. Refrigerant and Oil Charges

^ Oil and refrigerant charge amounts are different after the R-12 system has been retrofitted to R134a. Refrigerant charge amounts are less,
while oil charge amounts are greater, compared to R-12 system requirements.*

B. System Performance

^ A slight decrease in system performance may be noticed on some vehicles under certain operating conditions.

C. Refrigerant Pressures

^ R134a high side pressures are greater than that of R-12 above ambient temperatures of 68°F

D. Flushing Requirements

^ There is no need to remove or flush R-12 mineral oil from the system. Simply charge the system with the specified type and amount* of
PAG oil to provide proper lubrication.

E. Use of Sight Glass

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 820

^ Mineral based R-12 oil remains and circulates in the A/C system and does not dissolve in R134a refrigerant. This results in a cloudy
appearance at the sight glass making it impossible to judge the refrigerant charge amount by using the sight glass method. To prevent
misdiagnosis on retrofit vehicles, apply black paint to the sight glass on block- joint (FF) type receiver/dryers. Union-nut joint (BAG)
type retrofit receiver/dryers are manufactured without a sight glass.

*NOTE:
Refer to the OIL TYPE and CHARGE columns in Application Tables for proper amounts of ND-Oil 8 or ND-Oil 9.

Service Precautions
A. Refrigerant handling

1. Do not handle refrigerant in an enclosed area or near an open flame.

2. Always wear eye protection.

3. Avoid getting liquid refrigerant in your eyes or on your skin.

4. Never heat a container with an open flame.

5. Keep containers below 104°F

6. When heating a refrigerant can with water, keep the valve above water.

7. Never reuse empty service cans.

B. Replacing Parts

1. Plug off any open connections to prevent the entry of moisture and dust.

2. Do not remove plugs from receiver/dryer ports until it is ready for installation.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 821

C. Tightening connecting parts

1. Apply a few drops of specified PAG compressor oil to 0-ring fittings before tightening.

2. Avoid twisting refrigerant piping when installing R134a service fitting adapters.

3. Tighten all fittings to specified torque.

NOTE:
Oil removed during R-12 evacuation should not be used with an R134a System.

Repair Procedure
A. Vehicle Inspection:

^ Ensure the integrity of the A/C system before proceeding with retrofit.

B. Recover R-12 using R-12 recovery/recycling/recharging equipment:

^ Follow Toyota recommended procedure.

C. Install R134a service fitting adapters:

1. Remove valve cores from R-12 service fittings and discard.

2. Clean external threads of the R-12 service fittings.

3. Apply adhesive to threads (Loctite 262 or equivalent), screw on R134a adapter fittings, and tighten to 13 ft.-lb.

NOTE:
Vehicles with more than 2 service fittings will require the installation of additional adaptors. All service fittings must have R134a
adaptors installed.

D. Replace compressor 0-rings (10P only):

1. Remove compressor from vehicle.

2. Install covers on hose connection ports to prevent airborne contamination.

3. Clean compressor body and service valve area using a brush and compressed air.

4. Remove service valve plate.

5. Remove 0-rings from service valve plate and discard.

6. Remove extension housing if used otherwise go to step 7.

a. Separate extension housing from service valve plate.

b. Remove and discard 0-rings.

c. Lubricate and install retrofit 0-rings into extension housing using specified PAG oil (see tables).

d. Reassemble extension housing to service valve plate.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 822

7. Reinstall service valve plate to compressor. Torque bolts to 19 ft.lbs.

8. Reinstall compressor assembly.

E. Replace piping and hose 0-rings:

1. Disconnect suction and discharge hoses from compressor.

2. Remove and discard old 0-rings.

3. Lubricate and install retrofit 0-rings with specified PAG oil (see tables).

4. Disconnect discharge hose from condenser.

5. Remove and discard old O-rings.

6. Lubricate and install retrofit O-rings with specified PAG oil (see tables).

7. Reconnect hoses and torque to specification. (Specifications can be found in applicable manuals/guides.)

F. Replace receiver/dryer

1. Remove and discard original R-12 Receiver/Dryer

2. Using the tables, determine the proper type and amount of PAG oil. Pour 1/2 of the specified oil into the "OUT" side of the
Receiver/Dryer.

3. Black out the sight glass on block - joint - type receiver/dryer with black paint.

4. Lubricate and install retrofit 0-rings with specified PAG oil (see tables).

5. lnstall retrofit Receiver/Dryer.

G. Evacuate, charge, and leak test the system (Use manufacturer's recommended procedure).

1. Evacuate for 45 minutes.

2. Vacuum check.

3. Add compressor oil.

^ Using recovery/recycling/recharging equipment charge the system with the remaining 1/2 of the specified amount of oil from step
F2.

4. Charge system with specified amount of R134a. (refer to tables).

5. Perform a gas leak check.

H. Confirm cooling performance of Air Conditioning system.

I. Install retrofit labels:

1. Choose R134a "USE ONLY" label for proper oil type (ND-Oil 8 or ND-Oil 9).

2. Using a ball point pen, enter the proper retrofit refrigerant and oil charges on the caution label.

3. Cross out unused type of compressor oil on caution label.

4. Affix labels in a prominent location such as radiator support, underside of hood, or suspension tower area.

5. Remove any R-12 labels.

Technical Service Bulletin # EG92003 Date: 920508

Engine - ID Numbers Lengthened For A-Series

REF.: ENGINE

NO.: EG92-003

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 823

DATE: MAY 8, 1992

MODEL: AT/AE

A-SERIES ENGINE NUMBER

The serial number for A-series engines has been extended to accommodate an increase in engines beyond the number currently allocated.

The extended numbering system places an alphabetical character as the first digit of the engine number.

PRODUCTION EFFECTIVE:

From: April, 1992

Technical Service Bulletin # SS95-003 Date: 951027

Engine - Tripod Support Bar

REF.: SPECIAL SERVICE TOOLS

NO.: SS95-003

DATE: OCTOBER 27, 1995

MODEL: ALL MODELS

ENGINE SUPPORT BAR IMPROVEMENTS

A new engine support bar, P/N 00002-01724, has been released by OTC. This new tripod design engine support bar, which is designed to support
engine weight while transmission service is being performed, supersedes the current bipod engine support bar, P/N 00002-01722.

For dealers who currently own the 00002-01722 engine support bar, OTC has developed an upgrade kit, P/N 00002-01724-U which includes all
necessary components and hardware to convert it to the new tripod design. To avoid the potential for personal injury or property damage, do not
use the existing engine support bar without the new upgrade kit.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 824

DEALER PRICING IS AS FOLLOWS:

For more information and to order these Special Service Tools, please call OTC at 800-933-8335.
Technical Service Bulletin # BR94004 Date: 940624

Brakes - Pad Kits Now Available Without Hardware

REF.: BRAKES

NO.: BR94-004

DATE: JUNE 24, 1994

MODEL: ALL MODELS

INTRODUCTION OF NEW DISC BRAKE PAD KIT

New brake pad kits (minus hardware) and shim grease for the front and rear brakes are now available separately. The current full kit and other
related parts will also continue to be available.

SUPPLY PARTS CHANGE:

PART NUMBER INFORMATION;

For part numbers and availability of these new pad kits, please consult your parts department.

SERVICE INSTRUCTIONS:

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 825

1) All vehicles are to be inspected to insure that the integrity of the complete brake system is maintained. When replacing worn pads, you
should replace the shims, wear indicators, (wear indicators may be riveted onto pads for some models) and shim grease at the same time.
Vehicles found to need extensive hardware replacement, including anti-squeal springs and support plates, should be repaired using the full
pad kit which includes all hardware components.

2) When applying shim grease, apply a thin layer over the shim faces as indicated.

NOTE:
The new shim grease (P/N: 08887-80409) is a dark gray color instead of the current gold color.

3) Anti-squeal springs and support plates may be reused if they are in good condition. When reusing anti-squeal springs and support plates
inspect them for appropriate rebound and no deformation, burrs, cracks, wear, rust, or foreign matedals.

Technical Service Bulletin # BR95003 Date: 950818

Brakes - Introduction of Shim/Fitting Kits

REF.: BRAKES

NO.: BR95-003

DATE: AUGUST 18, 1995

MODEL: ALL MODELS

INTRODUCTION OF BRAKE SHIM KITS & BRAKE FITTING KITS

Full brake kits, with complete hardware, have been discontinued. Shim kits and fitting kits for the front and rear brakes are now available
separately, along with previously released pad kits.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 826

SUPPLY PARTS CHANGES:

PART NUMBER INFORMATION:

For the part numbers of these shim and fitting kits, please consult the most recent Toyota Parts Pricing book.

SERVICE INSTRUCTIONS:

1. All vehicles are to be inspected to insure that the integrity of the complete brake system is maintained. When replacing worn pads, you
should replace the shims, wear indicators, (wear indicators may be riveted onto pads for some models) and shim grease at the same time
using the pad kits and new shim kit. Vehicles found to need extensive hardware replacement, including anti-squeal springs and support
plates, should be repaired using the pad kit, shim kit and fitting kit, which together include all hardware components.

2. When applying shim grease, apply a thin layer over the shim faces as indicated.

3. Anti-squeal springs and support plates my be reused if they are in good condition. When reusing anti-squeal springs and support plates
inspect them for appropriate rebound and no deformation, burrs, cracks, wear, rust, or foreign materials.

Technical Service Bulletin # BR004-00 Date: 001020

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 827
Brakes - Pad Clicking Noise
BRAKES
BR004-00

October 20, 2000

Title:
BRAKE PAD CLICKING NOISE

Models:
'90- '00 All Models

Introduction
A clicking type noise may be noticed when first applying the brakes after changing vehicle travel direction (Drive/Forward to Reverse, Reverse to
Drive/Forward). This is a normal noise caused by the required brake pad-to-caliper clearances. When the direction of travel is changed, the brake
pads may "shift" towards the new direction of travel. When the brake pad contacts the caliper, a clicking noise may be heard.

To minimize this clicking noise, a disc brake caliper grease has been made available for use during brake service/maintenance operations. Under
normal usage conditions this grease should be effective for a period of 6 months to 1 year.

Applicable Vehicles
^ 1990 - 2000 model year Toyota vehicles, all models.

Parts Information

Warranty Information

Application Procedure
There are two types of brake calipers: floating and fixed. Check the type of brake caliper installed on the vehicle by removing the wheel assembly.

1. Floating Type Brake Caliper

A. Lift up or remove the brake caliper and suspend it securely.

HINT:
Do not disconnect the flexible hose from the brake caliper.

B. If equipped with anti-squeal spring: Remove the anti-squeal springs.

C. Remove the brake pads with anti-squeal shims.

D. Remove the pad support plates from the torque plate. Clean any dust from the pad support plates, torque plates and brake pads.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 828

E. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to both sides of the pad support plates.

NOTE:
Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor.

F. If the pad support plate is fixed to the torque plate with adhesive tape, perform the operation according to the flow chart.

G. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the caliper as indicated in the illustration.

H. Install the brake pads with the anti-squeal shims.

I. If equipped with anti-squeal spring: Install the anti-squeal springs.

J. Press the piston in firmly and install the brake caliper.

NOTE:
^ Clean excess grease. from brake pad and caliper.
^ Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor.

K. Install the wheel assembly.

2. Fixed Type Brake Caliper

There are two types of brake pads:

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 829

^ Type "A": Has a projection on the upper and lower side of the brake pad. (See illustration.)

^ Type "B": Has a flat upper and lower edge on the brake pad backing plate.

Type "A" Brake Pad

A. Remove the anti-squeal spring, clip and pad guide pin.

B. Remove the brake pads with the anti-squeal shims.

C. Clean any dust from the brake pads.

D. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the areas indicated in the illustration.

NOTE:
Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor.

E. Install the brake pads with the anti-squeal shims.

NOTE:
Clean excess grease from the brake pads and caliper.

F. Install the pad guide pin, clip and anti-squeal spring.

G. Install the wheel assembly.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 830

Type "B" Brake Pad

A. Remove the clip, pins and anti-rattle spring/pad retainer clip.

B. Remove the brake pads with the anti-squeal shims.

C. Clean any dust from the brake pads.

D. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the areas indicated in the illustration.

NOTE:
Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor.

E. Install the brake pads with the anti-squeal shims.

NOTE:
Clean excess grease from the brake pads and caliper.

F. Install the pad guide pin, clip and anti-squeal spring.

G. Install the wheel assembly.

Technical Service Bulletin # AC00296 Date: 960531

A/C - Compressor Maintenance for Stored Vehicles

REF.: HEATING & AIR CONDITIONING

NO.: AC002-96

DATE: MAY 31, 1996

MODEL: ALL MODELS

A/C COMPRESSOR MAINTENANCE FOR STORED VEHICLES

When a vehicle is stored for a long period, the volume of oil in the A/C compressor may decrease due to oil flow into the condenser, pipes, etc..

If the A/C system is turned on at high engine RPM after a long storage period, A/C compressor damage may result.

To minimize the possibility of damage to the A/C compressor while storing a vehicle, perform the following recommended procedure at least once
a month to lubricate the compressor.

RECOMMENDED PROCEDURE FOR A/C COMPRESSOR LUBRICATION:

1. Turn off A/C and blower switches prior to starting engine.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 831

2. Start and warm-up engine until engine speed drops below 1,000 RPM.

3. Turn on the A/C system using the following settings:

^ A/C switch: On

^ Blower Speed: High

^ Engine speed: Below 1,000 RPM

4. Keep A/C on with engine idling for 30 seconds.

5. Turn off A/C system and stop engine.

Technical Service Bulletin # AC00297 Date: 970509

A/C - Evaporator Odor

HEATING & AIR CONDITIONING
AC002-97

May 9, 1997

Title:
AIR CONDITIONING EVAPORATOR ODOR

Models:
All Models

Introduction
A musty odor may be emitted from the air conditioning system of some vehicles which are usually operated in areas with high temperature and
humidity. It is most noticeable when the air conditioner is first turned "ON" after the vehicle has been parked for several hours. The odor could
result from one or more of the following conditions:

1. Blockage of the evaporator housing drain pipe, resulting in the build up of condensate.

2. Microbial growth in the evaporator, arising from dampness in the evaporator housing where the cooling air flow is dehumidified.

To address excessive air conditioning evaporator odor, check the evaporator housing drain pipe for blockage. If no problems are found, the
evaporator and housing should be cleaned and disinfected using the general procedure, and the model specific procedure on the pages indicated in
the Table of Contents.

Affected Vehicles
^ While this procedure may be used on any Toyota vehicle, this bulletin gives details Vehicles specifically for the AE100 Corolla, SXV/VCV1O
Camry, MCX10 Avalon, MX83 Cressida, AT18O/2O0 Celica, ST184/2O4 Celica, JZA8O Supra, EL42/44/53 Tercel/Paseo, TCR10/20 Previa,
FZJ8O Land Cruiser series as well as recent production Truck, Tacoma, T100, 4Runner and MR2 models.

Tools & Materials

CAUTION:
Wear safety glasses, protective mask, and gloves while working with the freshener.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 832

Table of Contents

General Procedure

1. Preparation of freshener solution:

(a) Invert freshener container and shake vigorously for 30 seconds.

(b) Mix 3.4 fl. oz. of freshener (1 container) with 30 fl. oz. to make 1 qt. of solution.

2. Drying the evaporator:

^ Dry the evaporator for 10 minutes with the following settings:

AC: Off

Air Outlet: Foot

Mode: Recirc.

Blower High

Temp: Max Warm

3. Evaporator Treatment Preparation:

(a) Ensure availability of 3045 psi compressed-air to be used with spray gun for application of freshener.

(b) Place a tray under the evaporator housing drain hose to collect used cleaning solution.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 833

(c) Place shop cloth under the evaporator housing in the vehicle to prevent cleaning solution from dripping onto the floor mat.

4. Vehicle Preparation: See specific model section.

5. Evaporator treatment:

(a) Set HVAC mode as follows:

AC: Off

Air Outlet: Face

Mode: Fresh

Blower: High

Temp: Max Warm

Windows Open

(b) Insert spray nozzle into the filter inlet and spray the entire quantity (1 qt.) of freshener solution into the evaporator while moving the
nozzle around to cover the complete evaporator surface.

(c) Turn the blower OFF.

6. Reinstallation of Parts.

7. Completion of Treatment.

(a) Dry the evaporator for 30 minutes with the following settings:

AC: Off

Air Outlet Foot

Mode: Recirc.

Blower: High

Temp: Max Warm

Windows: Closed

(b) If vehicle still has alcohol smell, open windows for ventilation. Do not turn on the AC switch until the evaporator is completely dry as
this can reduce the effectiveness of the solution.

CAUTION
Do not get Into the vehicle during this drying operation.
Camry ( SXV/VCV10)
1. Removal of parts.

(a) Pull down the carpet from the center console as indicated by the bigger arrow in the illustration.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 834

(b) Remove the plate on the side of the heater unit using steps (1) and (2), indicated with bigger arrows to show direction, in the
illustration.

CAUTION:
1. Do not bend the cable.
2. The plate will be reused.

(c) Remove the blower resistor.

2. Cleaning the Evaporator.

^ Follow the general procedures at the beginning of this bulletin.

3. Reinstallation of parts.

(a) Reinstall the plate on the side of the heater unit using steps (1) and (2), indicated with bigger arrows to show direction, in the
illustration.

CAUTION:
Confirm that the plate is secure.

(b) Restore the carpet to its original position taking care not to bend the cable.
Corolla (AE100)
1. Removal of parts.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 835

(a) Remove the scuff plate from the passenger side door sill.

(b) Open the glove box door and temporarily remove the Air Bag Harness Cover as shown in the illustration.

CAUTION:
Do not disconnect the Air Bag Harness.

(c) Pass the cover up through the hole.

CAUTION:
Take care not to pinch the Air Bag Harness when reinstalling the cover.

(d) Remove the glove box.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 836

(e) Remove the passenger side air duct.

(f) Remove the blower resistor to allow access for the spray nozzle (insert at bigger arrow).

2. Cleaning the Evaporator.

^ Follow the general procedures at the beginning of this bulletin.

3. Reinstallation of parts.

^ Reinstall the parts in the reverse order of removal described in step 1.

CAUTION:
Make sure that the three guides of glove box are Inserted back into the three holes as shown in the Illustration.

CAUTION:
Take care not to pinch the Air Bag Harness when reinstalling the glove box.
Avalon (MCX10)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 837

1. Removal of parts.

(a) Remove lower finish panels.

(b) If manual AC remove blower resistor.
(c) If auto-AC remove power transistor.

2. Cleaning the Evaporator.

^ Follow the general procedures at the beginning of this bulletin.

3. Reinstallation of parts.

^ Reinstall the parts in the reverse order of removal described in step 1.

Cressida (MX83)

1. Removal of parts.

(a) Remove glove box.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 838

(b) Remove power transistor.

2. Cleaning the Evaporator.

^ Follow the general procedures at the beginning of this bulletin.

3. Reinstallation of parts.

^ Reinstall the parts in the reverse order of removal described in step 1.

Celica (AT180/200), (ST184/204)

1. Removal of parts.

(a) Remove glove box.

(b) Remove blower resistor.

2. Cleaning the Evaporator.

^ Follow the general procedures at the beginning of this bulletin.

3. Reinstallation of parts.

^ Reinstall the parts in The reverse order of removal described in step 1.

Supra (JZA80)

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 839

1. Removal of parts.

(a) Remove the glove box, side air duct and the ECM.

(b) Remove evaporator cover.

2. Cleaning the Evaporator.

^ Follow the general procedures at the beginning of this bulletin.

3. Reinstallation of parts.

^ Reinstall the parts in The reverse order of removal described in step 1.

Tercel/Paseo (EL42/44/53)

1. Removal of parts.

(a) Remove glove box.

(b) Remove blower resistor.

2. Cleaning the Evaporation

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 840

^ Follow the general procedures at the beginning of this bulletin.

3. Reinstallation of parts.

^ Reinstall the parts in the reverse order of removal described in step 1.

Previa (TCR10/20)

1. Removal of parts.

(a) Remove air duct and blower motor.

2. Cleaning the Evaporator.

^ Follow the general procedures at the beginning of this bulletin.

3. Reinstallation of parts.

^ Reinstall the parts in the reverse order of removal described in step 1.

Land Cruiser (FZJ80)

1. Removal of parts.

(a) Remove glove compartment door.

(b) Remove blower resistor.

2. Cleaning the Evaporator.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 841

^ Follow the general procedures at the beginning of this bulletin.

3. Reinstallation of parts.

^ Reinstall the parts in the reverse order of removal described in step 1.

MR2, T100, Truck, Tacoma, 4RUNNER, Other

1. Removal of parts.

^ Remove the blower motor.

2. Cleaning the Evaporator.

^ Follow the general procedures at the beginning of this bulletin.

3. Reinstallation of parts.

^ Reinstall the blower motor.Technical Service Bulletin # ST002-98 Date: 980522

Steering - Gearbox Removal Precautions

STEERING

ST002-98

May 22, 1998

Title:
STEERING GEAR REMOVAL/REPLACEMENT

Models:
All Models equipped with SRS Airbag

Introduction
The following information is provided to supplement the Repair Manual procedure for removing/installing the steering gearbox or rack and pinion
on vehicles equipped with a driver's side Supplemental Restraint System (SRS) Airbag.

CAUTION:
When the intermediate shaft is disconnected and the steering wheel is turned freely, the SRS spiral cable may be broken Therefore, as a
precaution, make sure to pass the driver's seat belt through the steering wheel to prevent it from turning freely, as shown below.

After working on SRS/Steering components, always check the operation of the SRS Warning Light. Refer to the appropriate repair manual If any
diagnostic trouble codes are recorded.

Affected Vehicles

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 842
Tercel, Paseo, Corolla, MR2, Celica, Camry, Avalon, Supra, Previa, Sienna, RAV4, 4Runner, Tacoma, T-100 & Land Cruiser equipped with a
driver's side SRS Airbag.

Repair Procedure

1. Position the front wheels facing straight ahead.

Figure # 1

2. Using the driver's seat belt, set the steering wheel so that it does not turn (see Fig. 1).

Figure # 2

3. Paint match marks on the intermediate shaft and control valve shaft (see Fig. 2).

4. Remove the intermediate shaft retaining bolt and disconnect the intermediate shaft (see Fig. 2).

Warranty Information
Technical Service Bulletin # ST00196 Date: 960517

Steering - Gear/Wheel Removal With SRS

REF.: STEERING

NO.: STOO1-96

DATE: MAY 17, 1996

MODELS: ALL MODELS

STEERING GEAR/STEERING WHEEL REMOVAL & INSTALLATION

Any time the steering gear is removed on a vehicle equipped with an SRS airbag, the steering wheel must also be removed. Use of the following
steps for reinstallation and recentering of the steering wheel will prevent possible damage to the spiral cable.

REQUIRED STEPS FOR STEERING GEAR REMOVAL AND INSTALLATION:

Removal:

^ Place front wheels facing straight ahead.

^ Remove the steering wheel pad.

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^ Remove the steering wheel.

Installation:

^ Place front wheels facing straight ahead.

^ Center the spiral cable.

^ Install the steering wheel.

^ Install the steering wheel pad.

STEERING GEAR/STEERING WHEEL REMOVAL PROCEDURES:

Follow the steps below to remove the steering wheel from the vehicle.

1. Place front wheels in the straight ahead position.

2. With ignition switch in lock position, disconnect the negative terminal of the battery.

3. Remove Steering wheel pad.

NOTICE:
If the airbag connector is disconnected with the ignition switch at "ON" or "ACC", a "Diagnostic Trouble Code" will be recorded.

Never use airbag parts from another vehicle. When replacing parts, replace with new parts.

a. Remove the steering wheel lower cover.

b. Using a torx socket wrench, loosen the torx screws until the groove along the screw circumference catches on the screw case. (See Fig.
1)

c. Pull the wheel pad away from the steering wheel and disconnect the airbag connector. (See Fig. 2)

CAUTION:

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 844
When storing the wheel pad, keep the upper surface of the pad facing up.

Never disassemble the wheel pad.

NOTICE:
When removing the wheel pad, take care not to pull the airbag wiring harness.

4. Remove the steering wheel.

a. Disconnect the spiral cable connector.

b. Remove the wheel set nut.

c. Place match marks on the wheel and steering main shaft. (See Fig. 3)

d. Using the appropriate SST, remove the wheel. SST 09950-50010 or 09609-20011 or suitable substitute.

For further disassembly of the steering column, refer to the Steering (SR) section of the Repair Manual.

STEERING GEAR/STEERING WHEEL INSTALLATION PROCEDURES:

Follow the steps below to install the steering wheel.

1. Place front wheels in the straight ahead position.

2. Center spiral cable.

a. Turn the cable counterclockwise by hand until it becomes harder to turn.

b. Then rotate the cable clockwise about 2.5 or 3 turns to align the marks. (See Fig. 4)

3. Install the steering wheel.

a. Align the match marks on the wheel and steering main shaft.

b. Temporarily tighten the wheel set nut.

c. Connect the spiral cable connector.

4. Bleed Power Steering System (when applicable).

5. Check steering wheel center point.

6. Torque steering wheel set nut. See the applicable vehicle's repair manual for the torque specification.

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7. Install and center steering wheel pad.

NOTICE:
Make sure the pad is centered and installed to the specified torque.

If the pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one.

When installing the pad, take care that the wiring does not interfere with other parts and is not pinched between other parts.

a) Connect the airbag wiring connector.

b) Install the pad after confirming that torx screws are in the screw case.

c) Using a torx socket, torque the screws to the specification in the vehicle's Repair Manual. (See Fig. 5)

d) Install the steering wheel lower cover.

SST (SPECIAL SERVICE TOOLS):

OR USE:

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RECOMMENDED TOOLS AND NECESSARY EQUIPMENT:

EQUIPMENT: Torque Wrench

LUBRICANT: ATF DEXRON II or III

Technical Service Bulletin # EG007-02 Date: 020322

Valve Cover Oil Baffle - Damage Prevention

ENGINE
EG007-02

Title:
GENERAL MAINTENANCE TIP

Models:
All '93 - '03 Models

March 22, 2002

Introduction

To help prevent unnecessary complications during the oil fill process, no undue load should be placed on the oil baffle attached to the inside of the
valve cover (see illustration). This baffle is designed to deflect oil and should not be used to support the weight of heavy oil fill devices. These
devices can place stress on the baffle, and bend or break it during the oil fill process.

Applicable Vehicles
^ All 1993 - 2003 model year Toyota vehicles.

Oil Filling Procedure

Please take measures to ensure that the baffle is not damaged during the oil fill process. If it does become damaged, repair it before any collateral
damage occurs.

Warranty Information
Technical Service Bulletin # EG95002 Date: 950526

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Cooling System - Water Pump Seal Improvements
REF.: ENGINE

NO.: EG95-002

DATE: MAY 26, 1995

MODEL: EL, AE, AT, SK, SW, ST, VN, VD, VK, GK, JA

WATER PUMP SEAL IMPROVEMENTS

To improve seal durability and performance for Water Pump Assemblies, production changes were implemented as illustrated.

PARTS INFORMATION:

^ Part numbers remain the same.

^ All service parts are of the new design (after countermeasure).

IMPORTANT NOTICE:
Prior to replacement of a failed Water Pump Assembly, the cooling system must be flushed and refilled using Toyota Genuine Coolant or
similar non-silicate coolant.

WARRANTY INFORMATION:
Technical Service Bulletin # PG027-02 Date: 021204

Steering/Suspension - Ball Joint Inspection

PRODUCT GENERAL INFORMATION
PG027-02

December 4, 2002

Title:
SUSPENSION BALL JOINT INSPECTION

Models:
See Applicable Models

Introduction

This bulletin describes the inspection method and free play specification figures for suspension ball joints. The on-vehicle inspection methods have
been standardized.

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Applicable Vehicles

Warranty Information

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Inspection Information

On-Vehicle Inspection

NOTE:

^ Be sure to check the table for the applicable inspection type based on the vehicle model.

^ Refer to the table for the standard free play values.

1. Inspect Lower Ball Joint Free Play

A. Move the hub up and down by hand (most models with wishbone suspension):

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a. Remove the tire.

b. Install the 2 lug nuts.

c. Inspect the free play while moving the lug nuts up and down at a force of 67 lbf (294 N, 30 kgf).

B. Move the lower arm using a lever (some models with double wishbone type suspension):

a. Lift up the vehicle.

b. Place the tip of the lever to the wheel and inspect the free play while moving the lower arm up and down.

C. Move the lower arm by hand (all models with strut type suspension and some models with wishbone type suspension):

a Lift up the vehicle.

b. Inspect the free play while moving the lower arm up and down at a force of 67 lbf (294 N, 30 kgf).

2. Inspect Upper Ball Joint Free Play

A. Move the upper arm by hand (models with the LOWER control arm linked by a torsion bar, and all models using a coil spring).

a. Remove the front tire.

b. Inspect the free play while moving the upper arm up and down at a force of 67 lbf (294 N, 30 kgf).

B. Move the tire with a lever (models with the UPPER control arm linked by a torsion bar).

a. Lift up the vehicle.

b. Place the lever under the tire, and inspect the tree play while lifting the tire using a wooden stick, etc., as a fulcrum.

3. Inspect the Suspension Arm Ball Joint Free Play

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A. Lift up the vehicle

B. Inspect the free play while moving the control arm by hand.

(Reference)
Free Play Inspection Method (Gauge Installation)

^ Position the dial gauge between the arm (upper or lower) and the knuckle, and measure free play.

(This illustration shows how to measure free play for vehicles with double wishbone type suspension with coil spring.)

4. Inspect Ball Joint Dust Cover

Check for cracks and grease leaks on the dust cover (boots).

Turning Torque Inspection

Inspect Ball Joint Turning Torque

Move the stud back and forth 5 times, and then turn the stud continuously at 3-5 seconds per turn, and measure the turning torque at the 5th turn.

HINT:
Refer to the table for standard values for the turning torque.
Technical Service Bulletin # SS93001 Date: 930305

Suspension - Coil Spring Compressor Warnings

REF.: SPECIAL SERVICE TOOLS

NO.: SS93-001

DATE: MARCH 5, 1993

MODEL: ALL MODELS

USE OF COIL SPRING COMPRESSOR SST # 09727-30020-01

Please observe the following procedure each time this tool is used:

1. Carefully inspect your spring compressor for cracks or other deformation prior to each use.

2. Use only on Toyota vehicles. Use on other application may exceed the tool design limits.

3. Be sure spring is free from its seat (unstuck) prior to compressing.

4. Do not compress the coil spring further than needed to facilitate the repair.

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When using suspension coil spring compressor be sure to follow the instructions outlined in the repair manual as well as the caution label placed on
the tool. (See illustration)

Technical Service Bulletin # SU92002 Date: 921009

Suspension - Delco Rear Shock Inspection Procedure

REF:
SUSPENSION

NO:
SU92-002

DATE:
OCTOBER 9, 1992

MODEL:
AE (N.A.P.)

COROLLA REAR SHOCK INSPECTION OPERATION

Delco rear shock absorbers used on North American built Corollas require a different inspection method than those used on Japan built models
(RM250U page SA-62).

PREVIOUS INSPECTION METHOD:

(a) While pushing the piston rod, check that the pull throughout the stroke is even, and there is no abnormal resistance or noise.

(b) Push the piston rod in fully and release it. Check that it returns at a constant speed throughout.

NEW INSPECTION METHOD:

(a) While pushing the piston rod, check that the pull throughout the stroke is even, and there is no abnormal resistance or noise.

(b) Push the piston rod in so that the base of the notch located on the piston rod aligns with the top of the collar. Release the piston, checking that
it returns at a constant speed throughout.

Caution:

If the shock rod is pushed beyond the notch, oil and gas charge leakage with possible inner seal damage will occur.

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PRODUCTION EFFECTIVE

Technical Service Bulletin # SU00296R Date: 960906

Wheels - Balance Adapter Kit Update

Ref: SUSPENSION

No.: SU002-96 (REVISED)

Date: SEPTEMBER 6, 1996

Model: ALL MODELS

Title: WHEEL BALANCE ADAPTER KIT

To improve the accuracy of Dynamic Off-Car wheel balancing on all OEM Toyota five and six lug wheels, a precision wheel adapter kit must be
used. For the greatest accuracy and repeatability, Toyota recommends using the Haweka adapter kit available through the Toyota Approved Dealer
Equipment catalog. The kit consists of a precision ground centering cone for truck alloy wheels and a flange plate.

PART NUMBER INFORMATION:

NOTE:
Tires that have nylon belts must be warmed-up sufficiently by driving 4 to 5 miles at 45 m.p.h. before balancing. This wilt avoid a cold set flat
spot and restore the tire to its full round condition.

BALANCE PROCEDURE:

The Haweka Flange Plate uses the wheel lug holes and a centering cone to center the wheel on the balancer arbor as the wing nut is tightened, equal
pressure is automatically applied to each stud forcing the wheel to perfectly mount on the balancer (see Figure 1).

1. Use the centering cone and flange plate combination on all five and six lug steel and alloy Toyota wheels. On four lug and other wheels, use
the standard centering cones that come with your balancer.

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2. Verify that the centering cone fits inside the wheel center as well as inside the balance machine hub (see Figure 2). Contact a Dealer
Consultant at Toyota Approved Dealer Equipment or your wheel balance manufacturer for further information.

3. Always install the spring and centering cone toward the back side of the wheel (see Fig. 3).

For additional wheel balancer accessories, refer to the latest Toyota Approved Dealer Equipment catalog (P/N 00451-86023-96T) or contact a
Dealer Consultant at Toyota Approved Dealer Equipment at 1(800) 368-6787.

To place an order, please call Toyota Approved Dealer Equipment at 1 (800) 368-6787.
Technical Service Bulletin # PA95001 Date: 950901

Paint - Repairs On Polyurethane Bumper

REF.: PAINT

NO.: PA95-001

DATE: SEPTEMBER 01, 1995

MODEL: ALL MODELS

PAINT REPAIRS ON POLYURETHANE BUMPER

Polyurethane bumper covers are formed by forcing liquid plastic material into a mold. Lubricant is added to the mold as a release agent to make it
easier to separate the bumper from the mold.

MOLD LUBRICANT CHANGE:

Recently, the mold lubricant (release agent) was changed from a wax type to a soap type on OEM supply parts. The wax lubricant was discontinued
because wax removal from the bumper surface required the use of trichloroethane.

The new mold lubricant (soap type) is easily removed by using a water based cleaner, such as mild soap and water, and a photochemically
non-reactive cleaning agent.

NOTE:
Remove wax from wax type lubricant supply parts according to the paint manufacturer's recommendations.

BUMPER IDENTIFICATION:

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Supply part bumper covers using Soap Type lubricant were introduced in June 1995. An "N" on the part label identifies the new Soap Type
bumpers (see diagram). The "N" identifier on the part number label will be discontinued after July 1996.

For further details on different paint types and application methods, refer to the paint supplier's Technical Manual.

Technical Service Bulletin # PG92006 Date: 920904

Ignition Lock - Key Code & Key Cutter Information

REF.:
PRODUCT GENERAL INFORMATION

NO.:
PG92-006

DATE:
SEPTEMBER 4, 1992

MODEL:
ALL MODELS

1993 KEY CODE AND CUTTER INFORMATION

There will be two new key systems for Corolla for 1993:

^ The Corolla sedan will utilize the same "High Security" lock and key system as the 1992/1993 Camry. The key blanks, codes, and cutting
equipment will also be the same as 1992/1993 Camry.

^ The 1993 Corolla Wagon, however, will feature a totally new key system. This system will require a new cam-set, carriage, codes, and two
new key blanks. Because of this new key and lock design, cutting replacement keys will require an update kit for your Curtis Industries key
cutter. The update kit, No. 20578, contains: (see illustration)

NOTE:
Key blanks for all 1993 Corolla vehicles must be cut on a 47 degree code cutter, equipped with a "brass" colored key clamp. Use of any other
model code cutter, or clamp, can cause keys to stick in the ignition lock, resulting in possible damage to the starting system.

For code and key cutter information on 1993 Corolla and other 1993 model year Toyota vehicles, please refer to the accompanying charts. Contact
your local Curtis representative or call Curtis Industries Customer Service at (216) 951-2400 for further information.

Technical Service Bulletin # BO94015 Date: 941021

Windows - Power Window Regulator Now Available

REF.: BODY

NO.: BO94-015

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DATE: OCTOBER 21, 1994

MODEL: AE, AT ST, SK, VK, GK, JA

WIRE TYPE REGULATOR SUBASSEMBLY, POWER DOOR WINDOW

To improve power door window serviceability on Corolla, Celica, Camry and Supra, a wire regulator subassembly is now available as separate
supply parts. See illustration.

REPAIR PROCEDURES:

^ Verify motor operates properly.

^ If the motor must be replaced, change the complete regulator assembly.
^ If motor operation is correct, replace only the regulator subassembly.

Use the following procedures when replacing the subassembly. Refer to the appropriate section of the repair manual for window regulator removal
procedures.

Window Regulator Disassembly

1. REMOVE COVER PLATE

Screw type cover plate:

^ Remove the two screws and cover plate see Figure 1.

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[Note:]
The screws and cover plate are reusable.

Crimped type cover plate:

^ Pry up the cover plate tab using a small flat-head screwdriver and remove the plate. Do not damage the motor housing see Figure 2.

[Note:]
The cover plate is not reusable.

2. REMOVE WINDOW REGULATOR DRUM AND WIRE GUIDE FROM MOTOR HOUSING USING NEEDLE NOISE PLIERS (SEE
FIGURE 3)

Caution:
Do not use a flat-head screwdriver to remove the window regulator drum and wire guide.
Window Regulator Installation
1. INSERT THE WINDOW REGULATOR DRUM INTO THE MOTOR HOUSING.

[Note:]
^ To prevent the window regulator drum and cable from coming off, do not tilt the drum, subject it to shocks or use force. If the cable
comes off the drum, do not rewind the cable or reuse it. After the window regulator is installed, do not operate it by itself (some window
regulators do not utilize a stopper).

^ Multipurpose grease (P/N 00289-1WG00) should be applied to all moving parts, especially inside the motor housing and sides of drum.

Type "A" holding tool

^ Apply grease inside the motor housing see Figure 4.

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^ Using holding tool type "A", match the holding tool with the motor housing see Figure 5.

^ Push down on the wire guide and window regulator drum while inserting into motor housing.

[Note:]
If you experience difficulty inserting the window regulator drum into the motor housing, slowly slide the window glass carrier bracket
and align the drive shaft of the motor housing with the window regulator drum.

Type "B" holding tool

^ Apply grease inside the motor housing see Figure 4.

^ Using Holding Tool "B", partially insert the window regulator drum into the motor housing see Figure 6.

^ Remove Holding Tool "B" and push the window regulator drum into the motor housing.

[Note:]
If you are experiencing difficulty inserting the window regulator drum into the motor housing, slowly slide the window glass carrier
bracket and align the drive shaft of the motor housing with the window regulator drum.

^ Apply grease to the sides of the window regulator drum.

2. INSTALL COVER PLATE.

Screw Type Cover Plate

^ Install the original cover plate and screws see Figure 7.

Crimped Type Cover Plate

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^ Use adjustable pliers to crimp the tab of the cover plate see Figure 8.

[Note:]
^ Use a new cover plate.

^ Do not hit the cover plate with a hammer, etc.

^ Do not damage the motor housing.

Part Number Information

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 863

[Note:]
^ For the COROLLA, the regulator subassembly includes the cover plate.

^ For the CAMRY, the regulator subassembly includes the cover plate and cushion.

^ First check whether the motor operates normally. If motor operation is normal, replace only the regulator subassembly.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 864

^ If the motor must be replaced, replace the whole regulator assembly.

^ When replacing the subassembly, follow the "Repair Procedures" instructions. Technical Service Bulletin # BO00196 Date:
960126

Windows - Wire Type Regulator Assembly Installation

REF.: BODY

NO.: BO001-96

DATE: JANUARY 26, 1996

MODEL: COR, CEL, CAM, SUP

WIRE TYPE REGULATOR SUBASSEMBLY

The information contained in this TSB updates BO94-015 dated October 21, 1994.

Updates include:

^ The Screw type cover plate is not reusable for Celica and Supra.

^ The regulator sub-assembly Part Number has been added for U.S. production Corolla and Camry

To improve power door window serviceability on Corolla, Celica, Camry and Supra, a wire regulator subassembly is now available as separate
supply parts. See illustration.

REPAIR PROCEDURES:

^ Verify motor operates properly.

^ If the motor must be replaced, change the complete regulator assembly.

^ If motor operates properly, replace only the regulator subassembly.

Use the following procedures when replacing the subassembly. Refer to the appropriate section of the Repair Manual for window regulator removal
procedures.

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WINDOW REGULATOR DISASSEMBLY:

1. Remove cover plate.

^ Screw type cover plate:

Remove the two screws and cover plate. (See Fig. 1)

NOTE:
The screws are reusable.

^ Crimped type cover plate:

Pry up the cover plate tab using a small flat-head screwdriver and remove the plate. Do not damage the motor housing. (See Fig. 2)

NOTE:
The cover plate is not reusable.

2. Remove the window regulator drum and wire guide from the motor housing using needle nose pliers (See Fig. 3)

CAUTION:
Do not use a flat-head screwdriver to remove the window regulator drum and wire guide.

WINDOW REGULATOR INSTALLATION:

1. Insert the window regulator drum into the motor housing.

NOTE:
To prevent the window regulator drum and cable from coming off, do not tilt the drum, subject it to shocks or use force. if the cable comes off
the drum, do not rewind the cable or reuse it. After the window regulator is installed, do not operate it by itself (some window regulators do not
utilize a stopper).

Multipurpose grease (P/N 00289-1WG00) should be applied to all moving parts, especially inside the motor housing and sides of drum.

Type "A" Holding Tool

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^ Apply grease inside the motor housing (See Fig. 4).

^ Using holding tool "A", match the holding tool with the motor housing. (See Fig. 5)

^ Push down on the wire guide and window regulator drum while inserting into motor housing.

NOTE:
If you experience difficulty inserting the window regulator drum into the motor housing, slowly slide the window glass carrier bracket and
align the drive shaft of the motor housing with the window regulator drum.

Type "B" Holding Tool

^ Apply grease inside the motor housing. (See Fig. 4)

^ Using holding tool "B", partially insert the window regulator drum into the motor housing. (See Fig. 6)

^ Remove Holding Tool "B" and push the window regulator drum into the motor housing.

NOTE:
If you are experiencing difficulty inserting the window regulator drum into the motor housing, slowly slide the window glass carrier bracket
and align the drive shaft of the motor housing with the window regulator drum.

^ Apply grease to the sides of the window regulator drum.

2. Install the cover plate.

^ Screw Type Cover Plate

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Install the cover plate and two screws. (See Fig. 7)

NOTE:
^ Use a new cover plate.

^ The two screws can be reused.

^ Crimped Type Cover Plate

Use adjustable pliers to crimp the tab of the cover plate. (See Fig. 8)

NOTE:
^ Use a new cover plate.

^ Do not hit the cover plate with a hammer, etc.

^ Do not damage the motor housing.

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PART NUMBER INFORMATION:

NOTE:
^ For all models, the regulator subassembly includes the cover plate.

^ For the Camry, the regulator subassembly includes the cushion.

^ First check whether the motor operates properly. If motor operates properly, replace only the regulator subassembly.

^ If the motor must be replaced, replace the whole regulator assembly. When replacing the subassembly, follow the "Repair Procedures"
instructions.

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WARRANTY INFORMATION:

Replacement of the front door window regulator under warranty is limited to correction of a problem based upon a customer's complaint. In the
unlikely event that both front window regulators have a problem, "Z" time is to be used for replacement of the opposite side. Please refer to the
Toyota Warranty Policy and Procedures manual, Policy 8.14 for additional details.

For additional information on Camry front door window regulators, refer to TSB BO95-OO9 (dated September 22, 1995) Technical Service
Bulletin # BO94005 Date: 940325

Seats - Fabric Loose at Lower Edge of Rear Seat Bolster

REF: BODY

NO.: B094-005

DATE: MARCH 25, 1994

MODEL: AE

COROLLA REAR SEAT BOLSTER COVER LOOSE

In some Corollas, the rear seat bolster cover fabric may come loose at the lower section of the bolster edges.

The frame retaining channel for the plastic core is spreading outward at the lower section due to excess material tension or insufficient channel
support.

REPAIR PROCEDURE:

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PRODUCTION EFFECTIVE:

PART NUMBER INFORMATION:

Technical Service Bulletin # TC94012 Date: 941003

Recall - Temporary Spare Tire

NO.: TC94-012

DATE: 10/3/94

SUBJECT:
BRIDGESTONE TEMPORARY SPARE TIRE RECALL
(1992-1993 COROLLA AND PASEO TEMPORARY SPARE TIRE)

Bridgestone has determined that certain "T" type temporary use spare tires listed fail to conform to the endurance test of the Federal Motor Vehicle
Safety Standard No. 109 and has initiated a voluntary recall campaign to replace the tires. (The T115/70-D14 TR3 Temporary Spare Tire is used on
the 1992 and 1993 Toyota Corolla and Paseo vehicles.)

Description Tire Size Serial Number

TRACOMPA-3 TR3 T115/70D14 ENTABEE272

" " ENTABEE282

" " ENTABEE292

" " ENTABEE3O2

Take the following step to determine if tire must be replaced:

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Check the description, size, and serial number of the temporary use spare to confirm that it matches one listed above. The serial number is
located on one side of tire in the lower sidewall area directly above the rim flange and is proceeded by the letters "DOT". The 8th and 9th
positions of the serial number, which represents the week the tire was manufactured, will be the only digits that vary. (See example sidewall
drawing).

Owner Letter
Dear Toyota Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Bridgestone has determined that certain "T" type temporary use spare tires listed below fail to conform to the endurance test of the Federal Motor
Vehicle Safety Standard No. 109 and has initiated a voluntary recall campaign to replace the tires. (The T115/70-D14 TR3 Temporary Spare Tire is
used on the 1992 and 1993 Toyota Corolla and Paseo vehicles.)

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Description Tire Size Serial Number

TRACOMPA-3 TR3 T115/70D14 ENTABEE272

" " ENTABEE282

" " ENTABEE292

" " ENTABEE3O2

Vehicle sales registration records show that you may have one of these temporary use spare tires stored in the trunk of your vehicle. Please check
your temporary spare tire to confirm that it is a Bridgestone "Tracompa-3". If is, please take the following steps to determine if your tire must be
replaced:

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1. Immediately check the description, size, and serial number of your temporary use spare to confirm that it matches one listed above. The
serial number is located on one side of your tire in the lower sidewall area directly above the rim flange and is proceeded by the letters
"DOT". The 8th and 9th positions of the serial number, which represents the week the tire was manufactured, will be the only digits that
vary. (See example sidewall drawing).

2. a. If your temporary use spare tire serial number does NOT match one shown above, or if you no longer own the vehicle, simply mark
the appropriate box on the "Tire Recall Notice Reply Card" and drop the card in the mail, postage paid.

b. If your temporary use spare tire has the corresponding designation shown above, the tire will be replaced at no charge to you if it is
returned to a Bridgestone retailer within 60 days of receipt of this letter or receipt of advice that a replacement tire is available,
whichever is longer.

3 In order to avoid any inconvenience, we suggest that upon receipt of this letter you contact a convenient Bridgestone tire retailer by
referring to the Yellow Page section of your phone book under "Tire Dealer".

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4. When contacting the Bridgestone tire retailer, advise that you have received this recall letter. As the "Tracompa-3" temporary use tire is
not a regular retailer stocked tire, the tire will need to be special ordered. Please instruct the retailer to special order the new tire and to
schedule an appointment when the tire arrives. Also, please bring this letter with you when you visit the retailer as it will identify that
your tire needs attention.

5. After the tire has been replaced, please fill in the information requested on the enclosed Tire Recall Notice Reply Card and drop the card
in the mall, postage prepaid.

6. If you have any questions or are unable to make satisfactory contact with a Bridgestone tire retailer, please call the Bridgestone Technical
Service Dept. at 1-800-847-3272.

If you believe we have failed or are unable to effect the remedy without charge as described in this notification, you may submit a complaint to the
Administrator, National Highway Traffic Safety Administration, Washington, DC or call toll-free the Auto Safety Hotline at 1-800-424-9393
(Washington, DC area residents may call 366-0123).

We regret the inconvenience which this recall may cause you, but we are certain you will understand our interest in your satisfaction with
Bridgestone tires and we urge you to act immediately.

Yours very truly,

BRIDGESTONE CORPORATION

Region/Private Distributor General Managers Letter

Volume: III

Number: TC94-O12

Date: 10/3/94

_____ Action

_____ Retain

X Information

TO: ALL REGION/PRIVATE DISTRIBUTOR GENERAL MANAGERS

FROM: W. PORENTO
CORPORATE TECHNICAL SERVICES MANAGER

SUBJECT: BRIDGESTONE TEMPORARY SPARE TIRE RECALL

(1992-1993 COROLLA AND PASEO TEMPORARY SPARE TIRE)

Bridgestone has determined that certain 'T' type temporary use spare tires stored in certain 1993 model year Toyota Corollas and certain 1992 and
1993 model year Toyota Paseos may not meet the endurance test of the Federal Motor Vehicle Safety Standard(FMVSS) 109. Bridgestone will
initiate a voluntary recall campaign to replace the tires.

A letter will be mailed from Bridgestone to the involved owners in early October1 1994. Nationally, there are approximately 4,800 Corollas/Paseos
that may contain the involved spare tire. Enclosed is a letter advising all Toyota dealers about the recall and requesting their assistance to direct
owners to the nearest Bridgestone tire retailer.

In order to motivate vehicle owners to have the involved spare tire replaced as soon as possible, the Bridgestone letter requests that the owner
contact a Bridgestone retailer within 60 days. However, Bridgestone has assured us that owners of the involved tires will not be denied a
replacement tire should they fail to contact a Bridgestone retailer within the indicated 60 day period.

Please review this letter with your staff to familiarize them with the content and to help maximize our combined customer satisfaction efforts.

Thank you for your cooperation.

Toyota Dealer Principals, Service Managers Letter

TO: ALL TOYOTA DEALER PRINCIPALS, SERVICE MANAGERS

SUBJECT: BRIDGESTONE TEMPORARY SPARE TIRE RECALL

(1992-1993 COROLLA & PASEO TEMPORARY SPARE TIRE)

Bridgestone has determined that certain 'T" type temporary use spare tires stored in certain 1993 model year Toyota Corollas and certain 1992 and
1993 model year Toyota Paseos may not meet the endurance test of the Federal Motor Vehicle Safety Standard(FMVSS) 109. Bridgestone will
initiate a voluntary recall campaign to replace the tires.

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A letter will be mailed from Bridgestone(copy attached) to the approximately 4.800 involved owners in early October. 1994. Owners are requested
to check the description, size, and serial number of the temporary use spare tire to confirm the involvement and contact the Bridgestone tire retailer
to special order the replacement tire. If owners contact your dealership for assistance, please refer them to the nearest Bridgestone tire retailer.

In order to motivate vehicle owners to have the involved spare tire replaced as soon as possible. the Bridgestone letter requests that the owner
contact a Bridgestone retailer within 60 days However, Bridgestone has assured us that owners of the involved tires will not be denied a
replacement tire should they fail to contact a Bridgestone retailer within the indicated 60 day period.

Please review this letter with your Service staff to familiarize them with the content and to help maximize our combined customer satisfaction
efforts.

Thank you for your cooperation.

TOYOTA MOTOR SALES, U.S.A, INC.

Technical Service Bulletin # TC002-99 Date: 990409

Drivetrain - Revised Drive Shaft Grease

TRANSMISSION & CLUTCH
TC002-99

April 09, 1999

Title:
REVISED DRIVE SHAFT GREASE

Models:
RAV4, Tercel, Corolla, Celica, Camry, Supra

Introduction:
The greases supplied in replacement Inboard and Outboard Drive Shaft Boot Kits for the following models has been revised.

With this revision, the grease compositions have been changed and are now both the same color. To correctly lubricate each joint, consult the
Service Repair Manual as to which size packet of grease is designated for each Drive Shaft Joint Assembly.

NOTE:
Although inboard and Outboard greases are now the same color, their compositions ere different.

Affected Vehicles:
All RAV4, Tercel1 Corolla, Celica, Camry and Supra Models.

Required Tools and Material:

As outlined in the Service Repair Manual.

Repair Procedure:
Refer to the appropriate Repair Manual for installation and lubrication information for Drive Shaft Joint Assemblies.

Warranty Information:

Technical Service Bulletin # EL91008 Date: 911018

Battery - Maintenance For Vehicles In Dealer Inventory

REF: ELECTRICAL

No.: EL91-008

DATE: OCTOBER 18, 1991

MODEL: ALL MODELS

BATTERY MAINTENANCE FOR VEHICLES IN DEALER INVENTORY

BACKGROUND

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A battery in a stored vehicle is subject to conditions which reduce its' performance and life. These conditions include storage period, temperature,
E.C.U. parasitic drain, and battery load. Because of these factors, battery maintenance is recommended for proper operation and optimal battery
life.

Under Toyota's current battery warranty, there is no coverage for discharged batteries due to lack of maintenance. It is considered the dealers
responsibility to prevent a discharge by keeping the battery fully charged while in stock.

BATTERY MAINTENANCE RECOMMENDATIONS

1. A monthly battery inspection is recommended under normal conditions. If your dealership is located in an area subject to extreme
temperatures (hot or cold), periodic maintenance may need to be performed on a more frequent basis.

2. To reduce battery drain during long storage of in-stock vehicles, the dome light fuse of each vehicle should be removed. It is recommended
that the fuse remain disconnected until time of delivery. This procedure can reduce battery drain 60 - 80 percent.

Note 1:
For your reference, the electrical systems made inoperative by removing the dome light fuse are indicated in the electrical wiring diagram and
current pre-delivery technical service bulletins for each vehicle model.

Note 2:
Additional battery maintenance information is available in the warranty policies and procedures manual.

TEST PROCEDURES

Two test procedures are available for evaluating battery performance. These include:

Open-circuit voltage test procedure Specific gravity test procedure

OPEN-CIRCUIT VOLTAGE TEST PROCEDURE

1. Wait at least 20 minutes after charging or discharging of the battery to allow it to stabilize.

2. With the key out of the ignition, connect the voltmeter across the battery terminals.

3. Read the voltmeter.

TEST RESULTS

1. A fully charged battery will have an open-circuit voltage of at least 12.6 volts.

2. The minimum acceptable voltage is 12.2 volts. If the reading is less than 12.2 volts, a charge is needed.

CHARGING PROCEDURES

1. If test results indicate a charge is necessary, a slow-constant 5 amp charge rate is recommended until the battery reaches a full state of charge.
Be sure to maintain proper electrolyte level.

2. Insure that the charger is turned off before connecting or disconnecting the leads.
Always connect the negative lead last and disconnect it first.

SPECIFIC GRAVITY TEST PROCEDURE

1. Remove vent caps or covers from the battery cells. NOTE: Do not attempt to remove covers from maintenance-free batteries if so equipped.
Instead, utilize the open-circuit voltage test procedure described in this TSB.

2. Take the specific gravity readings with a temperature corrected hydrometer. Follow the procedure described by the manufacturer of your
hydrometer.

3. Record the specific gravity of each cell.

Note:
If a non-temperature corrected hydrometer is being used, the readings need to be adjusted to compensate for electrolyte temperature. For each
10~ F (5.5~ C) above 80~ (26.7~ C), add 0.004 to your readings. For each 10~ F below 80~ F (26.7~ C), subtract 0.0004 from your readings.

TEST RESULTS

1. A fully charged battery will have a specific gravity reading of approximately 1.265.

2. The minimum standard for this test is a reading of 1.200. If the reading is less than 1.200, a charge is needed. Follow the previously noted

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procedures.

3. A difference of 30 points (0.030) or more between highest and lowest cell readings indicates a problem battery. Should you encounter this
situation, attempt one recharge using the slow charge method described in this TSB. Allow the battery to stabilize at least 20 minutes after the
charge cycle is complete. Recheck the specific gravity of each cell. If the deviation in cell readings still exceeds 0.030, the battery must be
replaced.

Technical Service Bulletin # POL9408 Date: 940720

Warranty - Replacement Battery Part Numbers

No: POL94-08
Date: 07/20/94
Ref:

SUBJECT:
REPLACEMENT BATTERY PART NUMBERS FOR OE BATTERIES

This bulletin amends Toyota's policy for replacement of batteries under the new vehicle warranty and the service part warranty.

New Vehicle Battery Warranty

All batteries removed under the guidelines of the new vehicle warranty must be replaced with Toyota 60 month replacement batteries using the
designated part numbers noted on the tables in this bulletin, based on model and model year. Use of a replacement battery other than those
specifically designated will result in the denial of the corresponding warranty claim.

Service Part Battery Warranty

All Toyota failed service part batteries must be replaced with the applicable 60 month Toyota brand battery.

Test Procedures

Please remember that the test procedures outlined in Policy No. 4.11 of the Toyota Warranty Policy and Procedures Manual must be followed
before replacing any battery. Test results (specific gravity, cell readings, and load test) must be accurately recorded on the back of the repair order
hard copy and are required in the Condition/Cause/Remedy text of the warranty claim for the replacement of the battery.

Should you have any questions, contact the Dealer "800" Warranty Assistance Line at 1-800-421-3407.

BATTERY PART NUMBER APPLICABILITY TABLES

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Model Year: 1994

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Model Year: 1993

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Model Year: 1992

Technical Service Bulletin # EL005-97 Date: 970704

Windows - Power Window Switch Inoperative

ELECTRICAL
EL005-97

July 4, 1997

Title:

POWER WINDOW SWITCH INOPERATIVE

Models:

'93 - '97 TMMC Corolla

Introduction The front passenger side power window switch (P/N 84810-12080) may not operate due to lubrication from the wire harness
contaminating the window switch contacts. TMMC changed lubricants from silicone to oil based beginning with the Vehicle Identification
Numbers listed in the table below.

Production Change Information

ENGINE STARTING VIN

4AFE 2T1B*02E*VC182750

7AFE 2T1B*02E*V01 91912

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Repair Procedure

Replace the Power Window Switch, part number 84810-12080.

NOTE:
The lubrication used on the wire harness dries shortly after assembly preventing any further contamination of the window switch. The part
number has not been changed.

Warranty Information

Applicable Warranty:

This repair Is covered under the Toyota Comprehensive Warranty which Is In effect for 36 months or 36,000 miles, whichever comes first, from the
vehicles "In-service" date.
Technical Service Bulletin # AU93001 Date: 930924

Cellular - Equipment Installation Precautions

REF.: AUDIO

NO.: AU93-001

DATE: SEPTEMBER 24, 1993

MODEL: ALL MODELS

PRECAUTIONS FOR MOBILE COMMUNICATION EQUIPMENT INSTALLATION

Two-way communication equipment should work properly in Toyota vehicles when installed correctly and FCC regulations related to power output
and spurious emissions are observed. Two-way radios can be defined as one of the following:

^ Cellular Mobile Telephone

^ Commercial FM Radio (ie, Police, Fire, Business)
^ Citizen Band Radio (CB)
^ Amateur Radio (HAM)

INSTALLATION PRECAUTIONS:

The following precautions should be taken in addition to instructions included in the installation manual of the two-way radio:

1) The antenna should be installed as far away as is reasonably possible from the ECM or other on-board computers/sensors. Refer to the
appropriate sections of the Electrical Wiring Diagram to determine exact locations of these components.

2) The antenna cable must not be routed closer than 20 cm (Approximately 8 inches) to any ECM or other on-board computers/sensors.

3) Antenna and power cables must not be routed alongside or in conjunction with vehicle wire harnesses.

4) Antenna and the power cable should be adjusted to obtain the lowest possible Standing Wave Ratio (SWR).

5) Two-way radio needs to be operated within the legal limits for the applicable class of service.

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Technical Service Bulletin # B095012 Date: 951124

Seat Belts - Front and Rear Extenders

REF.: BODY

NO.: BO95-012

DATE: NOVEMBER 24, 1995

MODEL: ALL MODELS

SEAT BELT EXTENDER (1987 TO 1996 MODEL YEARS)

A special program is available for individuals who require extra length seat belts. Owners of 1987 through 1996 vehicles can now obtain seat belt
extenders at no cost through their local Toyota dealer. (On vehicles from 1982 to 1986 - contact the Toyota Motor Sales (TMS) Customer Relations
Department for availability).

The seat belt extender is available in black only and in lengths of 6", 9", 12", 15" and 18".

Owners are informed of the seat belt extender availability through the Toyota Owner's Manual included in each 1987 or later vehicle (see page 9 for
text of Owner's Manual).

The user must visit a Toyota Dealership to have the required measurements made and complete the seat belt extender worksheet. The worksheet
will allow the proper fitting and selection of a seat belt extender for the customer. The dealer should then determine the part number needed and
place a Critical Order for the item through the TDN Parts Network.

Included are the following 1996 model year updated guides and examples:

Flow Chart
Seat Belt Extender Application/Part Number Chart
Owner Instruction Sheet
Statement included in Owner's Manual
Seat Belt Extender Worksheet

The dealership service department should complete the affixed Seat Belt Extender Label and review the "owner instruction sheet" with the owner.
The dealer should give a copy of the completed worksheet to the owner and keep the original in the customer's file.

To assure utmost owner satisfaction, it is recommended that a dealer designate one person to coordinate all activities related to the seat belt
extender issue.

Due to past sales history, it is recommended that dealers DO NOT stock seat belt extenders due to low demand for the parts and the need for custom
fitting.

SEAT BELT EXTENDER (SBE) FLOW CHART:

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SEAT BELT LABEL SAMPLE

1. Owner requests a seat belt extender from the dealer.

2. Dealer verifies need for a seat belt extender and obtains current copy of TSB and copies the worksheet.

3. Dealer measures the customer and completes the worksheet. Dealer determines the correct part number needed and places a Critical Order for
the part through the TDN Parts Network.

4. Dealer receives the seat belt extender and calls customer in to check fit of the part.

5. If the seat belt extender fit is OK, dealer completes the customer information label on the part, explains usage of the part and gives the
customer a copy of the completed worksheet.

6. Dealer places a copy of the completed worksheet in the customer's records.

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FRONT SEAT EXTENDER APPLICATION TABLE

NOTE:
The front lap belt for all '90 Corolla models and the '90 Tercel is the ALR type. Make sure the ALR is locked when the extender is used. (Do
not use if unlocked)

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REAR SEAT EXTENDER APPLICATION TABLE

Note:
The extender must not be used for the center rear seat belt on any model.

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PART NUMBER INFORMATION:

OWNER INSTRUCTION:

Failure to follow the recommendations indicated below could result in less effectiveness of the seat belt restraint system in case of vehicle collision,
causing personal injury.

1. The seat belt extender must not be used:

(I) By anyone other than for whom it was provided (name recorded on seat belt extender).

(II) In any vehicle and/or seat position other than the one for which it is provided.

2. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the buckle-release buttons of the extender and the seat
belt are located on the same side as shown. You will hear a click when the tab locks into the buckle. Make sure that the connection is secure

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and the seat belt extender is not twisted.

3. When the seat belt extender is provided for rear seat position (with automatic locking retractor), make sure the retractor is locked when in
use.

4. When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle
interior and extender itself.

5. When not in use, remove the extender and store in the vehicle for future use.

OWNER'S MANUAL TEXT:

SEAT BELT EXTENDER

If your seat belt cannot be fastened securely because it is not long enough, a personalized seat belt extender~is available from your Toyota dealer
free of charge.

Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect
to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer.

CAUTION:
When using the seat belt extender, observe the following. Failure to follow these instructions could result in less effectiveness of the seat belt
restraint system in case of vehicle accident, increasing the chance of personal injury.

Never use the seat belt extender if you can fasten the seat belt without it.

Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating
position than the one originally intended for.

To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the "PRESS" signs on the buckle-release buttons of the
extender and the seat belt are both facing outward as shown.

You will hear a click when the tab locks into the buckle.

When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle
interior and extender itself.

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When not in use, remove the extender and store in the vehicle for future use.

SEAT BELT EXTENDER WORKSHEETTechnical Service Bulletin # BO026-01 Date: 011019

Seat Belts - Shoulder Anchor Tape Set

BODY
BO026-01

October 19, 2001

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Title:
SHOULDER BELT ANCHOR TAPE SET

Models:
All Applicable Avalon, Camry, Corolla, Previa, & Sienna

Introduction
To assist customers in preventing particle buildup and preserve the appearance of the shoulder belt anchor, the following procedure has been
developed.

Applicable Vehicles
^ 1996 - 1999 model year Avalon vehicles.
^ 1996 - 2001 model year Camry vehicles.
^ 1993 - 2001 model year Corolla vehicles.
^ 1996 - 1997 model year Previa vehicles.
^ 1998 - 2001 model year Sienna*1 vehicles.

*1 Except rear seat belt.

Parts Information

Warranty Information

Applicable warranty*:

This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first,
from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.

Installation Procedure

1. CLEAN SHOULDER BELT ANCHOR

NOTE:
^ Do not install the tape when the vehicle temperature is below the freezing point.

^ Do not re-use removed fluorocarbon resin tape.

A. Pull out the seat belt about 300 mm and attach a clip as shown in the illustration.

HINT:

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Preventing the seat belt from retraction with a clip will make the following work easier.

B. Put the Velcro tape (in the parts kit) through the hole of the shoulder belt anchor, brush-shaped side to the anchor.

C. Pull both ends of the Velcro tape with your hand and shave off the dirt on the shoulder belt anchor by moving the Velcro tape several
times as shown in the illustration.

NOTE:
Remove the dirt completely. Otherwise, the fluorocarbon resin tape may not adhere properly.

2. INSTALL FLUOROCARBON RESIN TAPE

A. Place the fluorocarbon resin tape onto the seat belt as shown in the illustration.

NOTE:
Before installation of the fluorocarbon resin tape, it is necessary to pre-release the colored film about 5 mm for each side. (Not fully released.)

B. By pulling up the seat belt, put the fluorocarbon resin tape through the hole of the shoulder belt anchor. Match the shoulder belt anchor
to the center of the tape.

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C. Remove the upper side colored film from the fluorocarbon resin tape, and securely affix the tape to the outside of the shoulder belt
anchor.

D. Remove the lower side colored film from the fluorocarbon resin tape, and securely affix the tape to the outside of the shoulder belt
anchor.

NOTE:
^ Be sure to affix the fluorocarbon tape securely along all edges.

^ Pay attention not to make any wrinkles or slack in the fluorocarbon resin tape.

E. Remove the clip.

F. By pulling the seat belt up and down several times, as shown in the illustration, securely affix the fluorocarbon resin tape and confirm
the smoothness of the belt movement.

NOTE:
Affix the fluorocarbon resin tape on the shoulder belt anchor to the other side following the same procedure.

NOTE:
If the seat belt requires cleaning to remove dirt, only use a neutral detergent or lukewarm water to clean. Use the seat belt after it is completely
dried, to confirm proper operation.
Technical Service Bulletin # NHTSA96V107 Date: 960620

Recall 96V107: Air Bag Warning Light System Defect

IF LIQUID IS SPILLED IN THE CONSOLE BOX AREA, THE AIR BAG WARNING LIGHT CAN ILLUMINATE AND STAY "ON"
DURING NORMAL DRIVING CONDITIONS. THIS LEAKAGE CONDITION COULD CAUSE THE AIR BAG TO INADVERTENTLY
DEPLOY. DEALERS WILL INSTALL A PROTECTIVE COVER OVER THE AIR BAG SENSOR TO PREVENT POSSIBLE
MALFUNCTION CAUSED BY THE SPILLING OF LIQUID SUBSTANCES ON THE SENSOR. AIR BAG SENSORS DAMAGED BY
PREVIOUS LIQUID SPILLAGE WILL BE REPLACED.

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SYSTEM: INTERIOR; PASSIVE RESTRAINT; AIR BAG IMPACT SENSOR.

VEHICLE DESCRIPTION: PASSENGER VEHICLES.

OWNER NOTIFICATION: OWNERS HAVE ALREADY BEEN NOTIFIED OF THIS CAMPAIGN.

NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO
NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT TOYOTA AT 1-800-331-4331. ALSO
CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.

1993 GEO PRIZM

1993 TOYOTA COROLLA
1994 GEO PRIZM
1994 TOYOTA COROLLA
1995 GEO PRIZM
1995 TOYOTA COROLLA Technical Service Bulletin # EL00497 Date: 970425

Instruments - Turn Signal Operation Improved

ELECTRICAL
EL004-97

April 25, 1997

Title:
TURN SIGNAL OPERATION: HAZARD SWITCH

Models:
'93-'96 Corolla (NAP)

Introduction:
A production change has been made to the hazard switch to improve the performance of the turn signal in cold ambient temperatures.

Production Change Information

V.I.N. PLANT

INX** ## E # TZ497237 NUMMI

2T1BA02E3VC158201 TMMC

2T1BB02E7VC178500 TMMC

Parts Information

^ Two of the three part numbers for the current supply parts were not changed.

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^ Countermeasure switches can be identified by the production code mark located on the switch housing. Parts production was changed on
October 14, 1996 as indicated in the illustration.

Warranty Information
Technical Service Bulletin # BR94002 Date: 940207

Brakes - Cause and Repair of Vibration and Pulsation

REF: BRAKES
NO.: BR94-002
DATE: FEBRUARY 7, 1994
MODEL: ALL MODELS

BRAKE VIBRATION AND/OR PULSATION

This TSB outlines the causes of brake vibration and pulsation, as well as the best corrective measures to use.

CONTENTS

1) Symptoms of brake vibration and pulsation

2) Cause of vibration/pulsation problems
3) Advantages of using an on-car brake lathe
4) Rotor replacement and off-car brake lathe procedure

1) SYMPTOMS OF BRAKE VIBRATION AND PULSATION

Brake vibration problems generally involve one or both of two phenomena: body vibration and/or pedal pulsation.

A. BRAKE VIBRATION

Applying brakes causes vibration to occur in the instrument panel, steering column, steering wheel, and/or body of the vehicle (see Figure 1).

B. PEDAL PULSATION

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Applying brakes causes the brake pedal to pulsate. This brake pulsation sometimes causes the steering wheel to oscillate when the brakes are
applied (see Figure 2).

2) CAUSE OF VIBRATION/PULSATION PROBLEMS

Brake rotor thickness variation causes brake vibration due to changes in the braking force as thick/thin portions of the rotor pass the pads. Brake
rotor thickness variation can be measured with a micrometer as shown in Figure 3.

There are two factors which cause excessive rotor thickness variation:

A. ROTOR RUN-OUT
- Rotor run-out can be caused by poor mating of flanges between the hub and rotor when assembled as a unit. Manufacturing tolerance
stack-up of the rotor and hub may also cause excessive rotor assembly run-out (see Figure 4).

- If there is rotor run-out, a portion of the rotor comes into contact with the brake pad on each rotor revolution. If left like this, the
portion of the rotor that contacts the brake pad becomes worn, creating thickness variation.

B. EXCESSIVE RUST OR CORROSION ON ROTOR SURFACE

- Driving in areas where salt is applied to road surfaces for winter conditions can cause rust and corrosion when the vehicle is parked for
an extended period of time. This occurs on the area where the brake pads are not in contact with the rotor.

- When a vehicle is driven with rusted rotors, the area with corrosion wears at a different rate than the non-corroded areas, resulting in
excessive thickness variation.

3) Advantages of Using An On-Car Brake Lathe

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Toyota Motor Corporation Engineers strongly recommend that an on-car brake lathe be used for repairing brake vibration and pulsation. This
method improves rotor and hub combined run-out, and is the preferred method when compared to rotor replacement and off-the-car rotor
machining.

A. Technical Advantage of Caliper Mounted Brake Lathe

- Installing the brake lathe in the same position as the caliper results in minimal run-out relative to the caliper.
- Eliminating this run-out minimizes the pad grinding on the rotor and reduces rotor thickness variation.

B. Practical Use Benefits

- Resurfacing rotors on vehicles with rotor/hub assemblies (Land Cruiser, Truck) can be performed easily.
- Vehicles with corrosion between hub and rotor flanges can be machined without removing rotor from hub.

4) Rotor Replacement And Off-Car Brake Lathe Procedures

If an on-car brake lathe is not available at your dealership, it may be necessary to use an off-car lathe or replace rotors. In order to ensure proper
brake vibration and pulsation repairs, pay close attention to the following precautions:

A. Off-Car Brake Lathe Precautions

- Perform routine maintenance of brake lathe components (clearance of arbor shaft to adapters may need to be repaired).
- Clean all adapters and shaft to maintain accuracy of equipment.
- When installing rotor to machine, clean mud, rust, and/or foreign material from the adapters and rotors.
- After installing rotor on machine, check rotor run-out using dial indicator. If run-out is excessive, determine the cause and correct it.
- Follow lathe manufacturer repair procedures. Do not cut excessive amounts off rotor during the first cut to save time.

Note:
Anytime a rotor is machined it must be measured for minimum rotor thickness. The thickness for the rotor is never to be less than minimum
thickness as specified in the appropriate repair manual.

B. Installation of Rotor

- Check wheel bearing pre-load. If excessive movement is found, adjust bearing pre-load.
- Using a dial indicator, measure the rotor 10 mm from the outside edge (see Figure 5).

C. Phase Match Rotor To Hub

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- If rotor run-out is at the maximum value or greater, (refer to appropriate repair manual) index the rotor one lug and measure the run-out
again. Repeat this process, moving the rotor one lug each time, until the position is found where the run-out is at the minimum and
within the maximum value listed in the appropriate repair manual (see Figure 6).

- Tighten lug nuts to the specified torque following a star sequence when installing wheel (see Figure 7).

Note:
00 NOT USE AIR IMPACT WRENCH

Technical Service Bulletin # EL93002 Date: 930430

Instruments - Clicking or Ticking Noise From Speedometer

REF.: ELECTRICAL

NO.: EL93-002

DATE: APRIL 30, 1993

MODEL: SK/VK

CAMRY SPEEDOMETER

To prevent the possibility of clicking or ticking noise from the speedometer, the drive motor circuitry has been modified.

PRODUCTION CHANGE EFFECTIVE:

Build location P/D

Japan August, 1991
TMM October, 1991

PART NUMBER INFORMATION:

The part numbers are affected by this change. Part numbers remained the same.

Part Number Part Name

83110-33010 Speedometer Assy

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83110-33020 Speedometer Assy

MODIFIED IDENTIFICATION PROCEDURE:

Modified parts can be identified by the 4 digit number located on the back of the printed circuit board of the speedometer assembly.

Previous New

0240 0241
0470
0550

Technical Service Bulletin # EL95004 Date: 951110

Instruments - Wiper Motor Circuit Breaker Inspection

REF.: ELECTRICAL

NO.: EL95-004

DATE: NOVEMBER 10, 1995

MODEL: ALL MODELS

WIPER MOTOR CIRCUIT BREAKER INSPECTION PROCEDURE

To eliminate the possibility of Wiper Motor damage, all ND Wiper Motors are equipped with circuit breaker protection.

This circuit breaker is a thermal limiting type and will reset automatically after the Wiper Motor current load returns to normal.

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REPRESENTATIVE LOCATION OF CIRCUIT BREAKER:

INSPECTION PROCEDURE:
^ Inspect the Wiper Fuse.
^ Verify there is power and ground to the Wiper Motor on all speeds (including "Intermittent" or "Mist" if applicable).

After verifying power and ground to the Wiper Motor, follow the procedure below to prevent unnecessary Wiper Motor replacement because of a
temporary open in the Wiper Motor Circuit Breaker.

1) Disconnect the Wiper Motor Harness Connector.

2) Wait (10) minutes before checking continuity.
3) Check the continuity of the motor with an ohmmeter.

If there is no continuity in the Wiper Motor after 10 minutes, replace the Wiper Motor.

REPRESENTATIVE CHECKING PROCEDURE:

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NOTE:
Continuity check can be performed between either the low speed or high speed terminal and the ground terminal of the wiper motor. The
standard resistance of a good wiper motor is approximately 1.5 to 4.5 ohms.

Technical Service Bulletin # SS94003 Date: 940812

Tools - Toyota Checker Applications

REF: SPECIAL SERVICE TOOLS

NO.: SS94-003

DATE: AUGUST 12, 1994

MODEL: ALL MODELS

TOYOTA CHECKER APPLICATIONS (REFERENCE GUIDE)

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ABS CHECKER: '88-'94 MODELS

ABS CHECKER SUB-WIRE HARNESS AND OVERLAY SHEET PART NUMBERS:

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CRUISE CONTROL CHECKER: '87-'93 MODEL

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 904

CRUISE CHECKER: CHECKER SUB-HARNESS PART NUMBERS:

CRUISE CONTROL CHECKER OVERLAY PART NUMBERS:

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ECT CHECKER: '83-'94 MODELS:

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ECT CHECKER SUB-WIRE HARNESS PART NUMBERS:

ECT CHECKER OVERLAY PART NUMBER:

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TCCS:'86-'93 MODEL

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 909

TCCS CHECKER SUB-HARNESS PART NUMBERS:

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 910

THEFT DETERRENT SYSTEM: '85-'93 MODELS

THEFT DETERRENT SYSTEM PART NUMBERS:

Technical Service Bulletin # POL9418 Date: 941010

Warranty - Brake Repair

NO.: POL94-18

DATE: 10/10/94

SUBJECT:
BRAKE REPAIR

In conjunction with the introduction of brake pad-only kits to supplement the full brake pad kits currently available for all Toyota vehicles, TMS
Warranty would like to take this opportunity to clarify warranty policy regarding brake pad replacement and other common brake repairs.

Dealers are reminded that brake pads, as well as brake shoes, are considered wear items and are not warranty eligible for normal use or wear.

When a brake repair is required on a vehicle that is still covered by the applicable warranty, the repair should be performed using proper repair
procedures at minimum cost. Based on this rule, brake repairs shall be performed by replacing or repairing the defective component parts only.
Therefore, when the replacement of any hardware, such as shims, wear indicators, and anti-squeal springs is necessary when replacing brake pad

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kits (only four pads), the cost for such additional replacements may also be included for reimbursement under warranty. If the cost of individual
hardware used plus the pads exceeds the cost of the full kit or the pad kit is not available, then the full kit should be used.

The tables illustrate warrantable conditions, applicable operation and T-codes, and original part numbers to be used in submitting a warranty claim
to TMS.

Please note:
Proper diagnosis and verification of customer complaints is essential to prevent over repair or unnecessary repair. In the unlikely event that
repairs to front and rear brakes are required, they must be submitted on separate claims.

Technical Service Bulletin # SU94002 Date: 940318

Suspension - Rear Stabilizer Bar Bushing Squeak/Groan

REF.: SUSPENSION

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NO.: SU94-002

DATE: MARCH 18, 1994

MODEL: AE

COROLLA REAR STABILIZER BUSHING NOISE

The rear stabilizer bushing rubber has been changed to a self lubricating type to reduce the squeak/groan noises from the rear suspension area on
Corollas.

PART NUMBER INFORMATION:

COROLLA REAR STABILIZER BUSHING NOISE

PRODUCTION EFFECTIVE:

REPAIR PROCEDURE:

For complaint vehicles:

[Step 1:] A) Replace both rear stabilizer bushings with the self lubricating type bushing.

B) Road test the vehicle to confirm the noise has been eliminated. If noise is still present, proceed to Step 2.

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[Step 2:] Remove the rear strut rods and apply silicon or lithium based grease to the locations (see illustration).

Technical Service Bulletin # ST001-01 Date: 010216

Steering Wheel Nut - Torque Standardization

STEERING

ST001-01

February 16, 2001

Title:
STEERING WHEEL NUT SERVICE SPECIFICATION

Models:
All Applicable Models

Introduction

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To make the steering wheel installation procedure similar for all models. the steering wheel nut tightening torque has been standardized.

Warranty Information

Service Information

Technical Service Bulletin # PG004-97 Date: 970718

Body - Replacement Certification Labels

PRODUCT GENERAL INFORMATION

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PG004-97

July 18, 1997

Title:
REPLACEMENT CERTIFICATION LABELS

Models:
All Models

Introduction

Replacement Certification Labels (vinyl label affixed to driver's door or door post) may be available from Toyota providing the request meets one
of the criteria listed.

Affected Vehicles

^ All Toyota vehicles

Certification Label Criteria

1. The vehicle is in an accident and the label is damaged or is attached to a part that Label Criteria will be replaced during the repair.

NOTE:
^ Processing a new label will be delayed if the old certification label is not available.

^ A new label MAY NOT be available if the vehicle is more than five years old and the old label does not accompany this request.

2. The label is stolen.

Procurement Procedure

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To request a replacement label, complete a copy of the form in this bulletin. Your dealer parts account will be billed $10.00 for each replacement of
a damaged or stolen label.

NOTE:
All replacement labels for damaged and/or stolen vehicles are subject to approval by the Technical Compliance Department. If you have any
specific questions, contact (310)781-3390.

Warranty Information

^ No applicable Warranty Information.

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Technical Service Bulletin # PG005-97 Date: 970718

Body - Replacement VIN Plates

PRODUCT GENERAL INFORMATION
PG005-97

July 18, 1997

REPLACEMENT VIN PLATES

Models:
All Models

Introduction

Replacement VIN plates (metal plate riveted to dashboard) may be available from Toyota providing the request meets one of the criteria listed
below.

Affected Vehicles

^ All Toyota vehicles.

Replacement VIN Plate Criteria

^ The vehicle is in an accident and the plate is damaged.

NOTE:
The plate to be replaced MUST accompany the request.

NOTE:
If a plate is stolen, be sure to contact the State Police or the Department of Motor Vehicles. In most cases the state will issue a unique number so
that the original number can be included on stolen vehicle listings. If this is the case, a replacement VIN plate is NOT available from Toyota.
However, the original VIN, NOT the state- issued VIN, must be used on all warranty claims.

Procurement Procedure

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To request a replacement plate, complete a copy of the form in this bulletin. Note that damaged VIN plates must accompany the request form. Your
dealer parts account will be billed $10.00 for each replacement of a damaged plate.

NOTE:
All replacement plates for damaged and/or stolen vehicles are subject to approval by the Technical Compliance Department. If you have any
specific questions, contact (310) 781-3390.

Warranty Information

^ No applicable Warranty Information.

Technical Service Bulletin # SS003-98 Date: 981211

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Accessories - Rivet Nut Tool

SPECIAL SERVICE TOOLS
SS003-9B

December 11, 1998

Title:
RIVET NUT TOOL

Models:
All Models

Introduction
Toyota Motor Sales is making available a tool suitable for installing Rivet Nuts as required by some DIO accessories, such as wind deflectors, roof
Racks, and running boards. The tool is available from Owatonna Tool Company, also known as OTC.

Affected Vehicles
^ All models requiring Rivet Nuts for the installation of an accessory.

Part Number Information

OTC PART NUMBER PART NAME NOTE

00002-95161 Rivet Nut Tool Mandrels for 5, 6 and 8 mm

Rivet Nuts Included*

Ordering Procedure

Rivet Nut Tool may be ordered by calling the OTC Order Desk at 1-800-933-8335. The introductory price for this tool is $460.00.

Warranty Information
Technical Service Bulletin # CRIB76 Date: 970301

Body - Correction of Body Dimensions

COLLISION REPAIR INFORMATION
CRIB76

TITLE: CORRECTION OF BODY DIMENSIONS

SECTION: STRUCTURAL REPAIR BULLETIN #76

MODELS: COROLLA (AEIO#), CAMRY (SXV#, VCVI#)

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DATE: MARCH 1997

Please take time to review the following corrections and then note changes in your Collision Damage Repair manuals.

1. Corrections for 1993-1997 COROLLA (AEIO#) Collision Repair Manual (part # 00400-BR038) page DI-3.

2. Corrections for 1993-1997 COROLLA (AEIO#) Collision Repair Manual (part # 00400-BR038) page DI-10.

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3. Corrections for 1992-1996 Camry Collision Damage Repair Manual (part # 00400-BR032), page DI-7, and corrections for 1992-1996 Camry
Wagon Collision Damage Repair Manual (part # 00400-BR035), page DI-7

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Technical Service Bulletin # CRIB122 Date: 030201

Body - Body Sectioning

COLLISION REPAIR INFORMATION
CRIB122

TITLE: BODY SECTIONING

SECTION: EXTERIOR BULLETIN #122

MODELS: ALL TOYOTA/LEXUS

DATE: FEB2003

Toyota actively promotes quality repairs by providing Collision Repair Centers with updates and changes in collision repair procedures, standards
and technology.

Full body sectioning, also known as "clipping is NOT an approved repair procedure on any Toyota or Lexus vehicle.

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Full body sectioning is generally done on a vehicle that has sustained severe rear end damage, where the front portion of one vehicle is joined to the
rear portion of another vehicle.

Full body sectioning is not approved for the following reasons:

^ Decrease in strength and safety from the original Toyota/Lexus design
^ Poor fit and alignment of the body

^ NVH (squeaks, rattles, etc.)

^ Wind noises and water leaks
^ Diminished protection from rust/corrosion

Always refer to the Toyota/Lexus model-specific repair manual for approved cut/join locations, measurements, welding requirements, and other
important information.
Technical Service Bulletin # EL93001 Date: 930312

Air Bags - Wait Time After Battery Disconnect to Repair

REF.: ELECTRICAL

NO.: EL93-001

DATE: MARCH 12, 1993

MODEL: ALL MODELS

SUPPLEMENTAL RESTRAINT SYSTEM SERVICE INFORMATION

All Toyota SRS systems are equipped with a back up power source so the airbag can still be deployed even if the vehicle battery is damaged in a
collision.

During vehicle service this means that the airbag could be inadvertently deployed if work is started too soon after disconnecting the negative
battery terminal.

Because of slight variations in the Supplemental Restraint System of each model, the period of time specified to wait after removal of the battery
terminal now varies (from 20 - 90 seconds).

New SRS service waiting time specification

To avoid a potential error during servicing of the SRS, the waiting time is being standardized for all models to 90 seconds regardless of what the
specification is in the applicable repair manual. Work should not be started until after 90 seconds has passed from the time the ignition switch is
turned to the lock position and the negative (-) terminal of the battery has been disconnected.

Technical Service Bulletin # NHTSA96V107000 Date: 960620

Recall 96V107000: Inadvertent Air Bag Deployment

If liquid is spilled in the console box area, the air bag warning light can illuminate and stay "on" during normal driving conditions. This leakage
condition could cause the air bag to inadvertently deploy.

Dealers will install a protective cover over the air bag sensor to prevent possible malfunction caused by the spilling of liquid substances on the
sensor. Air bag sensors damaged by previous liquid spillage will be replaced.

System: Interior; Passive restraint; Air bag impact sensor.

Vehicle description: Passenger vehicles.

Owner notification: Owners have already been notified of this campaign.

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Note: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable
time should contact Toyota at 1-800-331-4331. Also contact The National Highway Traffic Safety Administration's auto safety hotline at
1-800-424-9393.

Technical Service Bulletin # AX93002 Date: 930611

Antitheft - Glass Breakage Sensor Adjustment

REF: ACCESSORIES

NO.: AX93-002

DATE: JUNE 11, 1993

MODEL: ALL MODELS '91-'93 MY

ADJUSTING GLASS BREAKAGE SENSOR ON TOYOTA SECURITY SYSTEMS (TVSS & TDSE)

Vehicles equipped with port and dealer installed Toyota security systems may experience an inoperative alarm or "false alarms" due to
misadjustment of the glass breakage sensor.

The sensitivity of the glass breakage sensor may be adjusted lower or higher than recommended, causing the alarm to be inoperative or
over-sensitive.

To correct this condition, readjust the glass breakage sensor to the recommended settings for each Toyota vehicle as indicated in this bulletin.

The sensitivity adjustment screw should be calibrated as follows:

1. Turn the click type adjusting screw counterclockwise until screw stops (do not force screw).

2. Use the sensitivity setting table for model and year that apply.
3. Turn adjustment screw clockwise counting the number of "CLICKS" as indicated in table.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 926

TVSS/TDSE GLASS BREAKAGE SENSOR SENSITIVITY SETTINGS TABLE:

PRODUCTION INFORMATION:

ECM Part Number: 00398-00921 TVSS

00398-00922 TDSE

Technical Service Bulletin # AX006-99 Date: 990423

Antitheft - Changes For GBS Glass Breakage System

ACCESSORIES
AX006-99

Title:
RS3OOO TVIP PROGRAMMING CHANGES
FOR GBS

Models:
All Models

April 23, 1999

Introduction

Starting with 1999 MY, the programming in the RS3000 ECU for the Glass Breakage Sensor (GBS) to trigger the alarm has been changed to
improve the Toyota Vehicle Intrusion Protection (TVIP) system's theft warning feature when glass breakage or impact to the glass is detected.

Previous operation of GBS (for 1998 MY and prior):

^ Upon (first) detection of breakage of the vehicle's glass, the GBS will sound the security system for 5 seconds (3 horn honks).

^ If there is a second detection of glass breakage, within 5 seconds of the first detection, the security system will sound for the full duration of 59
seconds.

Improved operation of GBS (from 1999 MY):

^ Upon (first) detection of breakage of the vehicle's glass, the GBS will sound the security system for 20 seconds.

^ If there is a second detection of glass breakage, the security system will sound for the full duration of 59 seconds, regardless of time between
the first and second detections.

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^ After the first detection, any subsequent detection will trigger the alarm for the full duration of 59 seconds as long as the security system is
armed. The GBS trigger cycle will reset once the security system is disarmed and then rearmed.

This improvement is intended to enhance the previous trigger cycle of the security system and ward off an intruder.

The color of the previous (1998 MY and prior) R53000 ECU was black. The new R53000 ECU color is gray.

Affected Vehicles

^ All Models

Parts Information

PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME

08585-00921 SAME RS3000 Base kit

Warranty Information

Repair Procedure

When performing the RS3OOO System Test, check the Glass Breakage Sensor sensitivity as follows:

1. Press and release the Remote Control's top button to arm the system.

2. Wait two seconds.

3. With the tip of the ignition key (or striker tool), softly tap the center of the driver's door window glass.

^ If the system is triggered (horn sounds for 20 seconds), the sensitivity must be adjusted. Turn the Glass Breakage Sensor ECU's
adjustment screw counterclockwise one notch, and repeat this step again.

4. If the system is not triggered, repeat the glass tapping with moderate force.

^ The system should trigger when the glass is tapped with moderate force. If it is not triggered, turn the Glass Breakage Sensor ECU's
adjustment screw clockwise one notch, and repeat this step again.

CAUTION:
Use caution when performing the step above. Do not tap the window glass with too much force, or the glass may crack or break. Use extra
caution when the temperature is extremely cold.

NOTE:
The Owner's Guide included in the RS3OOO Base Kit is changed to reflect the (GBS logic) improvement. There is no change to the GBS ECU
itself.Technical Service Bulletin # AX005-99 Date: 990409

Antitheft - Programing the Remote Control

ACCESSORIES
AX005-99

April 09, 1999

Title:
TOYOTA VIP RS3000 PROGRAMMING

Models:
All Models

Introduction:
This bulletin describes the procedures that are used to program the two-button remote control for vehicles that are equipped with the dealer or port
installed option (PIO), not the factory security system. For factory security system remote control programming, refer to the appropriate vehicle
repair manual.

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Verification of the dealer or PIO Toyota VIP can easily be performed by identifying the status monitor or remote transmitter.

The remote transmitter has two buttons, Top and Bottom.

The status monitor has a Toyota label, LEO, and microphone.

Starting with 1998 MY, the remote controls for the RS3OOO System were revised with new coding logics. The color of the remote control cases
was changed from Black to Gray to help identify the new remote controls. The new (Gray) remote controls will not work with the R53000 ECU's
produced prior to 1998 MY. The old (Black) remote controls are still available for Service Parts.

NOTE:
The TVIP is programmed to operate with the two remote controls that come with the vehicle. The ECU (computer) can be programmed to
operate with up to four different remote controls. For customer satisfaction, request that any existing remote be furnished when programming a
new or replacement unit.

Affected Vehicles

- All models with dealer or PIO equipped Toyota VIP (RS3OOO)

Warranty Information

Programming Procedure
Programming Procedure: For location of the RS3OOO ECU, refer to ECU Mounting Locations.

I. To program (add) a REMOTE CONTROL to the system:

1. Insert the key into ignition switch, and turn it to ON.

2. Press and hold the ECU's PROGRAMMING SWITCH for 3 seconds.

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The STATUS MONITOR LED turns on for 5 seconds.

NOTE:
YOU MUST PERFORM THE NEXT STEP WITHIN 5 SECONDS.

3. Press and release a REMOTE CONTROL's top or bottom button*.

The STATUS MONITOR LED turns off.
The Piezo chirper chirps once.
The exterior lights flash once.

4. Turn off the ignition. The ECU will now operate with the REMOTE CONTROL just programmed.

Either button on your REMOTE CONTROL can be programmed to operate the system. The bottom button can be programmed to operate a
second vehicle with the Toyota VIP.

II. To erase all REMOTE CONTROL codes from the system:

1. Insert key into the ignition switch, and turn it to ON."

2. Press and hold the ECU's PROGRAMMING SWITCH for 3 seconds.

The STATUS MONITOR LED turns on for 5 seconds.

NOTE:
YOU MUST PERFORM THE NEXT STEP WITHIN 5 SECONDS.

3. Press and hold the ECU's PROGRAMMING SWITCH for over 2 seconds again.

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 930
The STATUS MONITOR LED turns off, then flashes 3 times.
The Piezo chirper" chirps 3 times and the exterior lights flash 3 times

4.Turn off the ignition. The ECU has cleared all REMOTE CONTROL codes; until another REMOTE CONTROL is programmed, the
system will not work with any REMOTE CONTROL.

ECU MOUNTING LOCATIONS

Technical Service Bulletin # PG94002 Date: 940617

Emissions - Control Labels Ordering Form

REF.: PRODUCT GENERAL INFORMATION

NO.: PG94-002

DATE: JUNE 17, 1994

MODEL: ALL MODELS

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EMISSION CONTROL LABEL ORDER FORM CA / U.S.A. (50 STATE CERTIFIED)

Should a California / 50 State Certified Vehicle Emission Control Label be required, please abide by the regulations outlined in this TSB.

Note:
California / 50 State certified Vehicle Emission Control Labels cannot be ordered using normal parts ordering procedures.

To ensure the correct application of these labels, it is necessary to use the following special ordering procedures to obtain a replacement label.

^ Make a copy of the form provided in this bulletin

^ Fill in the required information and mail or fax the form to the address or number indicated.
^ For questions regarding Vehicle Emission Control Information Labels for California / 50 State Certified, call (310) 781-3254.

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Technical Service Bulletin # PG95005 Date: 950630

Emissions - Control Label Order Form

REF: PRODUCT GENERAL INFORMATION

NO.: PG95-005

DATE: JUNE 30, 1995

MODEL: ALL MODELS

EMISSION CONTROL LABEL ORDER FORM CA/5O STATE CERTIFIED

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Should a California/50 State Certified Vehicle Emission Control Label be required, please abide by the regulations outlined in this TSB.

NOTE:
California/50 State certified Vehicle Emission Control Labels cannot be ordered using normal parts ordering procedures.

REGULATIONS

California Revenue and Taxation Code Section 6263 states that only vehicle manufacturers or persons authorized by a manufacturer may affix an
Emission Control Information Label (see sample) to a vehicle. Any person who violates this regulation may be subject to a fine and/or
imprisonment.

Personnel at franchised dealers are authorized to affix such labels to vehicles and are therefore subject to this regulation and the attendant penalties.

1. DO NOT SELL LABELS OVER THE COUNTER, ALWAYS INSTALL THE LABEL ON THE VEHICLE.

2. NEVER INSTALL A LABEL ON A VEHICLE THAT IS NOT A CALIFORNIA/50 STATE EMISSION CERTIFIED VEHICLE.

To ensure the correct application of these labels, it is necessary to use the following special ordering procedures to obtain a replacement label.

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^ Make a copy of the form illustrated.

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^ Fill in the required information and mail or fax the form to the address or number indicated.
^ For questions regarding Vehicle Emission Control Information Labels for California/50 State Certified, call (310) 781-3254.

Technical Service Bulletin # EG003-03 Date: 030224

Exhaust System - Sulfur Smell

ENGINE
EG003-03

February 24, 2003

Title:
SULFUR ODOR FROM EXHAUST

Models:
All Models

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Introduction

Some owners of Toyota vehicles may experience a sulfur-like or "rotten egg" odor from the exhaust system. Sulfur is a natural component of crude
oil from which gasoline is refined and the amount of sulfur can be decreased through the refining process. The amount of sulfur in fuel sold in
California is regulated, however gasoline sold in other states can have substantially higher sulfur content. Sulfur content also varies considerably
between gasoline brands and locations.

Applicable Vehicles
^ All Models.

Repair Procedure

A sulfur odor emitted from the vehicle's tailpipe does not necessarily indicate that there is an issue with the engine's running condition, but is most
likely directly related to the fuel.

^ If the vehicle is exhibiting an excessive sulfur odor, the following checks should be performed:

^ If the MIL light is ON, check for DTCs and repair as necessary.

If no trouble is found after performing the above check, recommend the customer try a different source of fuel.

Replacement of oxygen sensors, air/fuel ratio sensors or catalytic converters will not reduce the odor and will therefore not be considered
warrantable.

Warranty Information
Technical Service Bulletin # PG032-99 Date: 991224

Year 2000 Readiness Disclosure

PRODUCT GENERAL INFORMATION
PG032-99

December 24, 1999

Title:
YEAR 2000 READINESS DISCLOSURE

Models:
All Models

Introduction

Based upon information we have obtained from our suppliers,1 all factory-installed systems in Toyota cars, sports utility vehicles and trucks
distributed and/or sold by Toyota ("Vehicles")2 will not be affected by the change of date from 1999 to the year 2000.

Toyota anticipates no problems with past, current or future Toyota brand vehicles or Genuine Toyota parts and accessories regarding year 2000
readiness. We hope the following information is helpful to you.

Please contact our Customer Service Department at 1-800-331-4331 should you have any other questions.

Applicable Vehicles

All Models

Warranty

WARRANTY STATEMENT WITH RESPECT TO TOYOTA BRAND VEHICLES

Toyota is pleased to confirm that the manufacturer's limited express warranty and Toyota's powertrain warranty warrant that all factory-installed
systems in new Vehicles and Toyota Certified Used Vehicles shall be free of any defect arising solely due to a change in date from the year 1999 to
the year 2000.3

With respect to Vehicles no longer covered under such Toyota limited express warranty. Toyota is not aware of any operational safety or functional
impact the year 2000 date change would have upon any factory-installed system in Toyota Vehicles. Should Toyota become aware of any material
impact to the operational safety or functionality of such systems, Toyota shall publish such information promptly.

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WARRANTY STATEMENT WITH RESPECT TO GENUINE TOYOTA PARTS AND ACCESSORIES

Toyota is pleased to confirm that the manufacturer's limited express warranty warrants that all new Toyota Genuine Parts and Accessories shall be
free of any defect arising solely due to a change in date from the year 1999 to the year 2000. 3

With respect to products no longer covered under a Toyota limited express warranty, Toyota is not aware of any operational safety or functional
impact the year 2000 date change would have upon such products. Should Toyota become aware of any material impact to the operational safety or
functionality of such a product, Toyota shall publish such information promptly.

1 Toyota relies on the statements made by its suppliers and has not independently verified such information.

2 Vehicles includes alternative fuel vehicles.

3 Please refer to terms of limited express warranty for disclaimers, limitations and restrictions.

Parts & Accessories

GENUINE TOYOTA PARTS AND ACCESSORIES

Based upon information we have obtained from our suppliers,1 all new Genuine Toyota Parts and Accessories will not be affected by the change of
date from 1999 to the year 2000.

DEALER-INSTALLED AND OTHER THIRD PARTY-INSTALLED SYSTEMS/PRODUCTS

Our dealers and distributors may sell and/or install products that are not Genuine Toyota Parts and Accessories. Toyota can only determine the Year
2000 readiness status of Genuine Toyota Parts and Accessories. Therefore, the above statements do not apply to products that are not Genuine
Toyota Parts and Accessories or were not installed by the factory. We encourage you to contact your dealer or other relevant third party regarding
products installed on your Toyota vehicle(s) that are not Genuine Toyota Parts and Accessories and/or were not installed by the factory to
determine any Year 2000 issues associated with those products.
Technical Service Bulletin # BO010-02 Date: 020524

Child Restraint - Seat Top Strap Installation

BODY
BO010-02

May 24, 2002

Title:
CHILD RESTRAINT SEAT TOP STRAP BRACKET INSTALLATION

Models:
'83 - '00 All Models

Introduction

Child restraint seat top strap bracket installation procedures are provided to supplement the Owner's Manual. Beginning with 2001 models, the top
strap brackets are factory installed.

NOTE:
^ The child restraint seat top strap assembly is not available as a service part. Contact the child restraint seat manufacturer for recommended

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top strap information, top strap to child restraint seat installation instructions, and top strap retailers.

^ The top strap brackets can only be installed on vehicles that have nuts welded in place by the factory. The locations of these nuts can be
found in the Owner's Manual (for most 1983 and newer models.) Toyota does not recommend modifying vehicles that do not have nuts
welded in place by the factory. Some Land Cruiser and RAV4 vehicles, prior to 2001 model year, may not have these nuts welded in by the
factory.

Applicable Vehicles
^ 1983 - 2000 model year vehicles, all models.

Parts Information

Warranty Information

Installation Procedure/Reference Information

Installation Procedure

Child Restraint Seat Top Strap Bracket Installation

Obtain the exact year and vehicle model Toyota Owner's Manual before beginning installation.

1. Confirm with the customer which seat location(s) they will be installing the child restraint seat. The Owner's Manual seat section provides an
illustration showing available top strap bracket location(s). The illustration page in the Owner's Manual is shown in this bulletin.

NOTE:
Determine which kit parts are needed for each specific child seat location, by referring information in this bulletin.

2. Remove a 20mm diameter area of the carpet or trim material above the bracket mounting location. In some vehicles, a 20mm circle is already
pre-cut into the interior trim material. Once the interior trim material is removed, the nuts welded in by the factory should be visible.

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3. If a 5mm or 15mm spacer is specified, remove the red lock washer from the Bracket Sub-Assembly (P/N 73709-12010) and remove the
10mm spacer. Assure the red lock washer is re-installed onto the bolt. If a 5mm spacer is needed, use the 15mm bolt from the CRS Kit (P/N
04731-22012).

4. Install the bracket assembly, according to the directions in the Owner's Manual. Tighten the bolt to 16.5 - 24.7 N-m, (1.68-2.52 kgf-m, 12.2 -
18.2 ft-lbf).

^ Assure the top strap is attached to the child seat, according to the child seat manufacturer's instructions.

^ Assure the child seat is installed in the vehicle according to the Toyota Owner's Manual (seat section).

Owner's Manual Installation Reference Information

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The illustrations shown contain a reference information chart. This chart contain.

^ Owner's Manual page(s) that provide the illustration showing available top strap bracket location(s). The information goes back to 1983 model
year. 2001 models and newer already had the bracket installed by the factory.

Installation notes, such as bracket spacer sizes for each specific child seat location.

Technical Service Bulletin # BO95002R Date: 951231

Wipers - Windshield Washer Bottle Modified

REF.: BODY

NO.: BO95-002 (REVISED)

DATE: DECEMBER 31, 1995

MODEL: COR (N.A.P.)

COROLLA WINDSHIELD WASHER BOULE

The information contained in this TSB supersedes BO95-002 dated January 20, 1995. The previous TSB should be discarded.

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To improve its strength, the material of the windshield washer bottle (non ABS brake system type) has been changed from High Density
Polyethylene to Polypropylene.

PRODUCTION EFFECTIVE

IDENTIFICATION METHOD

The date stamp is located on the bottle as shown in the previous illustration, and the identification method is as shown.

If the date stamp is 09/05/95 or later, it is a new part.

PRODUCTION PART NUMBER INFORMATION:

WARRANTY INFORMATION:Technical Service Bulletin # PA003R-02 Date: 050214

Paint - Refinishing Bumper Cover

PAINT
PA003-02
REVISED

June 4, 2002

Title
REFINISHING REPLACEMENT BUMPER COVERS

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Models
All '83 - '05 Models

TSB REVISION NOTICE:

^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005 model years. Previous versions of this TSB should be discarded.

Introduction
In cases where a bumper cover is being replaced a special preparation process is necessary to assure the refinish is customer acceptable. This
bulletin provides the recommended refinishing procedure for new bumper covers.

Applicable Vehicles
^ All 1983 - 2005 model year Toyota vehicles.

Required Tools & Material

Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive products.

Warranty Information

Refinishing Procedure

1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water.

Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or
rinsing difficulty.

2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach areas are thoroughly cleaned.

3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach areas are thoroughly rinsed.

4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air from an oil-less compressor may be
substituted for drying with a towel.

5. Degrease the surface with a wax, grease, and silicone remover.

Note: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease, and silicone remover. Carefully follow
application instructions on the container label. Fish eyes or other paint irregularities may result from not following instructions.

6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad should be used during the sanding process. Sand
the entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded.

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7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas are thoroughly cleaned.

8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are thoroughly rinsed.

9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or paper towel.

Note: Never use a red shop towel to wipe the surface (contains silicone).

10. Assure the bumper is firmly held in place to a steady fixture.

11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's recommendations.

12. Apply plastic parts primer to the surface, according to the paint manufacturer's recommendations.

13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish paint system with plasticizer (flex agent) for all
bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint manufacturer's recommendations.

14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80°C (176°F.)

For additional information concerning the refinish process for plastic bumpers/cladding, please contact your respective refinish paint manufacturer's
local representative.

Technical Service Bulletin # BO93002 Date: 930319

Body - Front Fender Sub-Assembly Now Available

REF.: BODY

NO.: BO93-002

DATE: MARCH 19, 1993

MODEL: COROLLA (AE10 #)

IMPROVEMENT OF FRONT FENDER REPLACEMENT SUPPLY PARTS

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In order to improve serviceability on '93 Corolla models, the side panel sub-assy of the front fender, as illustrated, can now be ordered as a separate
supply part.

Note:
Part number for front fender assy does not change.

Technical Service Bulletin # AX92005 Date: 921218

Body - Mudguard Installation Instructions

REF.:
ACCESSORIES

NO.:
AX92-005

DATE:
DECEMBER 18,1992

MODEL:
AE

'93 COROLLA MUDGUARD INSTALLATION INSTRUCTIONS

A mudguard kit is now available for installation on 1993 Corollas (Sedan and Wagon). Be sure to thoroughly clean all attachment areas and
carefully follow the installation procedures.

INSTALLATION PROCEDURE:

Front Mudguard mounting Sedan and Wagon

1. Remove (2) mounting bolts located at points (1) and (2) in front fender protector, behind front tire areas as illustrated. Retain bolts for
reinstallation. (see Figure 1).

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2. Install front mudguard with (1) fitting kit mounting bolt at point A (see Figure 2).

3. Install front mudguard with (2) previously removed mounting bolts (see Figure 3)

Rear Mudguard Mounting Sedan Only

Note:
Before proceeding, make sure you have the Corolla sedan rear Mudguard kit.

1. Remove (1) mounting bolt located at point (5) at bottom of fender well (see Figure 4).

2. Remove (1) mounting bolt located at point 6) behind back tire area as illustrated. Retain bolts for reinstallation. (see Figure 5).

Note:

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Before installing mudguard, verify screw anchor exists at point (6). (See Figure 8 for location of point (6). If none exists, insert square screw
anchor, provided in kit, at point (6).

3. Install rear mudguard at point (c) using (1) previously removed mounting bolt located at bottom of fender well as illustrated (see Figure 6).

4. Align mudguard against body, reinstall (1) previously removed mounting bolt at point "5" as illustrated (see Figure 7)

5. Reinstall (1) fitting kit mounting bolt at point (6) as illustrated (see Figure 8)

Caution:
Be careful not to strip screws.

Rear Mudguard Mounting Wagon Only

Note:
Before proceeding, make sure you have the Corolla Wagon Rear Mudguard Kit.

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1. Remove rubber plug located at point (B) at bottom of fender well as illustrated. Discard rubber plug (see Figure 9).

2. Remove (2) mounting bolts located at points (3) and (4) which secure the rear fender liner as illustrated. Retain bolts for reinstallation (see
Figure 10).

3. Install (1) round fitting kit screw anchor at point (B) as illustrated.

Note:

Before installing mudguard, verify screw anchors exist at points (3) and (4) (see Figure 13). If none exist, insert screw anchor, provided in kit, at
point (3) or (4).

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4. Using (1) fitting kit mounting bolt, install mudguard at point (B) as illustrated (see Figure 12).

5. Align mudguard against body, reinstall (2) previously removed mounting bolts at points (3) and (4) as illustrated (see Figure 13).

Caution:
Be careful not to strip screws.

Note:
Use hardware from kits as needed.

PARTS INFORMATION:

PART NUMBER PART NAME

76621-19215 Front Mudguard, RH Wagon and Sedan

76622-19215 Front Mudguard, LH Wagon and Sedan
76625-19445 Rear Mudguard, RH Sedan only
76626-19445 Rear Mudguard, LH Sedan only
76625-19505 Rear Mudguard, RH Wagon only
76626-19505 Rear Mudguard, LH Wagon only
Technical Service Bulletin # BO92011 Date: 921231

Interior Trim - Front Door Arm Rest Cover Retention

REF.:
BODY

NO.:
B092-011

DATE:
DECEMBER 31, 1992

MODEL:
AE (TMC)

FRONT DOOR ARM REST COVER RETENTION

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Some early 1993 production TMC Corollas (JT2 VIN prefix) may exhibit a loose front door arm rest cover on DX & LE grade vehicles with power
windows. To improve retention characteristics of the cover a production change was made to the lower most clip that attaches the door arm rest
cover to the door trim panel. The revised clip is now available as a replacement part.

PRODUCTION EFFECTIVE:

V.I.N. DATE

JT2AEXXEXP000XXXXSeptember, 1992

Note:
Condition not found on North American Produced Corollas with VIN prefixes of 1NX or 2T1.

PART NUMBER INFORMATION:

Part Name Replacement Part Number Original Part Number

Clip 90468-05096 90080-46069

If described condition is encountered on vehicles prior to production change, clip replacement is recommended.

Technical Service Bulletin # EG014-05 Date: 050328

Cooling System - Radiator Cap Inspection Procedure

ENGINE
EG014-05

Title:
RADIATOR CAP INSPECTION

Models:
All Toyota Models

March 28, 2005

Introduction

The procedure for inspecting the radiator cap has been revised. Please refer to the following procedures when inspecting the radiator cap on all
Toyota models.

Applicable Vehicles

^ All Toyota and Scion models.

Required Equipment

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Warranty Information

Required SSTs

Radiator Cap Identification Procedure

1. Use the illustration below to identify the vehicle's radiator cap type and kPa rating.

2. Proceed to the required inspection procedure for the radiator cap and kPa rating.

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Radiator Cap Inspection Procedure

Type: N-cap, 88 kPa

1. Remove coolant and any foreign material on rubber points "A," "B," and "C."

2. Check that points "A," "B," and "C" are not deformed, cracked, or swollen.

3. Check that points "C" and "D" are not stuck together.

4. Apply engine coolant to points "B" and "C" before using the radiator cap tester.

^ Radiator Cap Tester:

Snap-On/Sun P/N SVTS262A
(or equivalent)

5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the
radiator cap tester:

^ SST P/N 09230-00030-01

(09231-10080-01) or
09230-00020-01 (09231-10060-01) or
09230-00050-01 (09231-10110-01

6. When using the radiator cap tester, tilt it more than 30 degrees.

7. Pump the radiator cap tester several times, and check the maximum pressure.

Pumping speed: 1 pump/second

HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure
valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed
below for one minute.

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Specification:

If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly.

Type: N-cap, 108 kPa

1. Remove coolant and any foreign material on rubber points "A," "B," and "C."

2. Check that points "A," "B " and "C" are not deformed, cracked, or swollen.

3. Check that points "C" and "D" are not stuck together.

4. Apply engine coolant to points "B" and "C" before using the radiator cap tester.

^ Radiator Cap Tester:

Snap-On/Sun P/N SVTS262A
(or equivalent)

5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the
radiator cap tester:

^ SST P/N 09230-00030-01

(09231-10080-01) or
09230-00020-01 (09231-10060-01) or
09230-00050-01(09231-10110-01

6. When using the radiator cap tester, tilt it more than 30 degrees.

7. Pump the radiator cap tester several times, and check the maximum pressure.

Pumping speed: 1 pump/second

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HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure
valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed
below for one minute.

Specification:

If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly.

Type: Compact Cap, 88 kPa

1. Remove coolant and any foreign material on rubber points "A," "B," and "C."

2. Check that points "A" and "B" are not deformed, cracked, or swollen.

3. Check that points "B" and "C" are not stuck together.

4. Apply engine coolant to point "B" before using the radiator cap tester.

^ Radiator Cap Tester:

Snap-On/Sun P/N SVTS262A
(or equivalent)

5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the
radiator cap tester:

^ SST P/N 09230-00030-01

(09231-10080-01) or
09230-00020-01 (09231-10060-01) or
09230-00050-01(09231-10110-01

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6. When using the radiator cap tester, tilt it more than 30 degrees.

7. Pump the radiator cap tester several times, and check the maximum pressure.

Pumping speed: 1 pump/second

HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure
valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed
below for one minute.

Specification:

If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly.

Type: Compact Cap, 108 kPa

1. Remove coolant and any foreign material on rubber points "A," "B," and "C."

2. Check that points "A" and "B" are not deformed, cracked, or swollen.

3. Check that points "B" and "C" are not stuck together.

4. Apply engine coolant to point "B" before using the radiator cap tester.

^ Radiator Cap Tester:

Snap-On/Sun P/N SVTS262A
(or equivalent)

5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the
radiator cap tester:

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^ SST P/N 09230-00030-01

(09231-10080-01) or
09230-00020-01 (09231-10060-01) or
09230-00050-01 (09231-10110-01)

6. When using the radiator cap tester, tilt it more than 30 degrees.

7. Pump the radiator cap tester several times, and check the maximum pressure.

Pumping speed: 1 pump/second

HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure
valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed
below for one minute.

Specification:

If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly.

Type: Plastic Cap, 108 kPa

1. Remove coolant and any foreign material on 0-ring "A."

2. Check that 0-ring "A" is not deformed, cracked, or swollen.

3. Apply engine coolant to 0-ring "A" and rubber point "B" before using the radiator cap tester.

^ Radiator Cap Tester:

Snap-On/Sun P/N SVTS262A

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(or equivalent)

4. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the
radiator cap tester:

^ SST P/N 09230-00030-01

(09231-10080-01) or
09230-00020-01 (09231-10060-01) or
09230-00050-01(09231-10110-01

5. When using the radiator cap tester, tilt it more than 30 degrees.

6. Pump the radiator cap tester several times, and check the maximum pressure.

Pumping speed: 1 pump/second

HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure
valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed
below for one minute.

Specification:

If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly.Technical Service Bulletin #
PG93005 Date: 930820

Repair Manual Corrections - A245E Transaxle

REF.: PRODUCT GENERAL INFORMATION

NO.: PG93-005

DATE: AUGUST 20, 1993

MODEL: MODELS

A245E REPAIR MANUAL CORRECTION

Errors have been found in the following Repair Manual

Pub No. Publication Name

RM311U 1993 A245E Automatic Transaxle Repair Manual

The removal and installation procedure for the counter drive gear bearing outer race and the valve body installation illustration are incorrect for the
following reasons.

^ The counter drive gear bearing outer race and snap ring are supplied with the transaxle case as a set.

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^ The valve body installation illustration does not include the bolt lengths.

Please attach the accompanying revised pages to the applicable pages in your Repair Manual.

Additional repair manual correction pages are available through the Dealer Support Material Network (MDC NPM system) by ordering part
number 00400-RM311-B2024.

Technical Service Bulletin # TC93002 Date: 930625

A/T - 1st and Reverse Brake Parts Standardized

REF.: TRANSMISSION & CLUTCH

NO.: TC93-002

Date: JUNE 25, 1993

MODEL: EL, AE, AT, ST, SW

AUTOMATIC TRANSAXLES 1ST & REVERSE BRAKE (B3)

For parts standardization, the B3 component (1st and reverse brake) has been changed in the A131L, A240/LE, A241E/H, A243L and A244E
automatic transaxles.

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ILLUSTRATION:

AUTOMATIC TRANSAXLES 1ST & REVERSE BRAKE (B3)

Piston, 1st and Reverse Brake

PRODUCTION EFFECTIVE:

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PART NUMBER INFORMATION:

APPLIES TO TRANSMISSION: A244E

Parts are interchangeable as a set only.

APPLIES TO TRANSMISSIONS: A131L, A240L/E, A241E/H, A243L

Parts are interchangeable as a set only.

Technical Service Bulletin # TC00496 Date: 961220

A/T - Serial Numbers/Identification

Ref.: TRANSMISSION & CLUTCH

No.: TC004-96

Date: DECEMBER 20, 1996

Model: ALL MODELS

Title: AUTOMATIC TRANSMISSION SERIAL NUMBERS

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Use the tables to locate and read the original automatic transmission serial number.

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MODEL CODE CHART:

Technical Service Bulletin # ATRATB028 Date: 901001

A/T - Engine Vacuum Testing

BULLETIN: # 028

DATE: October 1990

SUBJECT: Engine Testing With A Vacuum Gauge

TRANSMISSION: All

Engine Testing With A Vacuum Gauge

ENGINE/TRANSMISSION RELATIONS

An important part of transmission diagnosis is to make certain the engine operates properly. If the engine performance is incorrect, the transmission

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will receive the wrong information.

The engine sends signals to the transmission through a vacuum line, throttle cable or both. These signals basically synchronize torque with
transmission line pressure, shift feel and shift timing.

Malfunctions in items like the air filter, spark plugs, EGR valves and other parts of the fuel, electrical and emission systems could result in
improper transmission performance.

VACUUM GAUGE ENGINE PERFORMANCE TESTING

A vacuum gauge shows the difference between outside atmospheric pressure and the amount of vacuum present in the intake manifold.

The pistons in the engine serve as suction pumps and the amount of vacuum they create is affected by the related actions of:

^ Piston rings

^ Valves

^ Ignition system

^ Fuel control system

^ Other parts affecting the combustion process (emission devices, etc.).

Each has a characteristic effect on vacuum and you judge their performance by watching variations from normal.

It is important to judge engine performance by the general location and action of the needle on a vacuum gauge, rather than just by a vacuum
reading. Gauge readings which may be found are as follows:

NORMAL ENGINE OPERATION

At idling speed, an engine at sea level should show a steady vacuum reading between 14" and 22" HG. A quick opening and closing of the throttle
should cause vacuum to drop below 5" then rebound to 23" or more. See figure 1.

GENERAL IGNITION TROUBLES OR STICKING VALVES

With the engine idling, continued fluctuation of 1 to 2 inches may indicate an ignition problem. Check the spark plugs, spark plug gap, primary
ignition circuit, high tension cables, distributor cap or ignition coil. Fluctuations of 3 to 4 inches may be sticking valves. See figure 2.

INTAKE SYSTEM LEAKAGE, VALVE TIMING, OR LOW COMPRESSION

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A vacuum reading at idle much lower than normal can indicate leakage through intake manifold gaskets, manifold-to-carburetor gaskets, vacuum
brakes or the vacuum modulator. Low readings could also be very late valve timing or worn piston rings. See figure 3.

EXHAUST BACK PRESSURE

Starting with the engine at idle, slowly increase engine speed to 3000 RPM, engine vacuum should be equal to or higher than idle vacuum at 3000
RPM.

If vacuum decreases at higher engine RPM's, an excessive exhaust back pressure is probably present.

CYLINDER HEAD GASKET LEAKAGE

With the engine Idling, the vacuum gauge pointer will drop sharply, every time the leak occurs. The drop will be from the steady reading shown by
the pointer to a reading of 10" to 12" Hg or less. If the leak Is between two cylinders, the drop will be much greater. You can determine the location
of the leak by compression tests. See figure 4.

FUEL CONTROL SYSTEM TROUBLES

All other systems in an engine must be functioning properly before you check the fuel control system as a cause for poor engine performance. If the
pointer has a slow floating motion of 4 to 5 inches - you should check the fuel control.

BULLETIN RECAP

^ Engine problems can affect transmission performance.

^ If you suspect an engine problem, connect a vacuum gauge to the intake manifold.

^ Note the location and action of the vacuum gauge needle.

^ Use the information in the bulletin to determine the engine problem.

^ Correct the engine problem before doing extensive calibration work on the transmission.

Technical Service Bulletin # ATRATB078 Date: 911101

A/T - How To Use A Pressure Gauge

BULLETIN : # 078

SUBJECT: Pressure Gauge

APPLICATION: Misc.

DATE: November 1991

HOW TO USE A PRESSURE GAUGE

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A significant number of calls we receive involve improper pressures, so we need to use a pressure gauge when diagnosing problems.

Using a pressure gauge can seem like a formidable task. The reason most people do not use a pressure gauge is because they do not see the value in
using one. Technicians do not see the value because the gauge readings do not tell them how to fix the problem. This article will attempt to show
the technician how to interpret pressure gauge readings so the technician can find the fix to the problem.

It is best to start pressure tests with mainline pressure. Mainline pressure should be checked in each range: P, R, N, D, 3, 2, 1. Each range, except
Park and Neutral, should be checked under three conditions: Slow idle, fast idle, and wide open throttle. A form, as in figure 1 should be made to
record the readings.

If all pressures are within specification at slow idle then the pump and pressure regulator are functioning properly.

If all pressures are low at slow idle, it indicates a potential problem in the pump, pressure regulator, filter, low fluid, or internal leakage. To help
verify where the problem is, check pressures at fast idle. If all the pressures now read normally, it usually indicates a worn pump but the problem
could still be internal leaks.

Internal leaks will usually show up in a particular range. For example a forward clutch leak would have normal pressure in Park, Reverse and
Neutral but have low pressure in all forward ranges. A direct clutch leak will show a pressure drop when the transmission shifts to third and low
pressure in reverse because in most cases, the direct clutch is on in third and reverse.

A restricted filter will usually show up as a gradual pressure drop at higher engine RPM because the filter cannot pass as much fluid as the pump is
trying to draw.

A stuck pressure regulator valve will show up as fixed line pressure which means the same pressure all the time. The pressure may vary with engine
RPM which means low pressure at slow RPM and higher pressure at higher RPM. There will be no boost in pressure from the TV or modulator
system and no reverse boost.

If pressures are high at slow idle it indicates a pressure regulator or throttle pressure problem. On most cars, the modulator controls throttle
pressure. If the transmission has a throttle pressure tap, it will tell you if the throttle pressure circuit is the problem. On GM units without a throttle
pressure tap, remove the TV plunger. If line pressure is now normal then it's a TV problem, if not it's a pressure regulator problem.

Pressures also need to be checked at stall or wide open throttle (WOT). When doing a stall test, always observe safety precautions such as checking
for broken mounts or bad brakes. Testing should always be done under operating conditions. To do a stall test, put the selector in the range to be
tested and with one foot firmly on the brake, press the accelerator to the floor then note your pressure reading. Some technicians will pull the
vacuum line off or pull the TV cable with the engine at fast idle. That is not operating conditions and will not detect a problem of trapped vacuum
or a cable problem.

If all pressure at stall are low, then you should pull the TV cable to maximum or disconnect the vacuum line. If the pressures are now OK, the
problem is in the cable or vacuum system. If the pressures are still low, then the problem is in the pump or control system.

If all pressures at stall are high, then look at the idle pressures. If the idle pressures are also high then this could be a pressure regulator or throttle
system problem. If idle pressures are normal then the problem is in just the throttle system.

The reverse stall test is also a maximum pump output test. If you suspect a weak pump then this test will help find it. Often this will show up as low
pressure at reverse stall but all other pressures including idle will be normal. If a person wanted to become really proficient with a pressure gauge
they should first put a pressure gauge on their own vehicle and leave it there for exactly one week. Every time they drive the car they should watch
the gauge. After one week, they should then put the pressure gauge on every single car in the shop that DOES NOT have a problem. Don't use the
gauge on cars WITH problems yet. After 30 days of using a gauge on units that work properly, they can then start using the gauge on units with
problems. The technician is accustomed to normal readings, abnormal readings will stand out like a sore thumb.

To fix today's transmissions, every professional technician must be proficient in the use of a pressure gauge. The only way to gain this proficiency
is to use the pressure gauge daily. Practice makes perfect.

Technical Service Bulletin # ATRATB132 Date: 920901

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A/T - Intermittent Electrical Problems
TECHNICAL BULLETIN # 132

DATE: Sep. 1992

TRANSMISSIONS: All Electronically Shifted Units

SUBJECT: Intermittent Electrical Problems

APPLICATION: All Electronically Shifted Units

Intermittent Electrical Problems

Wrong gear starts, no upshift, no downshift, falling out of 4th gear, etc may be caused by poor grounds. This applies to any electronically shifted
unit, import or domestic.

To test for a poor ground, connect the black lead of your digital voltmeter directly to the negative battery post and probe the suspect ground wire
with the positive lead. A good ground will read 0.1 volts or less. More than 0.1 volts is a poor ground. Keep in mind the circuit must be operating to
accurately check the ground.

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Using a service manual for the vehicle you are working on, locate the transmission computer ground circuit. In the example shown, B and D are the
grounds. Now with the vehicle running in gear, backprobe B and D with the positive lead. Make sure the negative lead is hooked directly to the
NEGATIVE BATTERY POST. The voltmeter must read 0.1 or less.

Technical Service Bulletin # ATRATB191 Date: 931001

A/T - Failsafe Modes

TECHNICAL BULLETIN # 191

DATE: Oct. 93

TRANSMISSION: None

SUBJECT: Failsafe Modes

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APPLICATION: General

FAILSAFE MODES

Quite often you will find late model vehicles with computer shifted transmissions coming in that start off in "D" in the wrong gear. Instead of 1st,
they take off in 2nd, 3rd or 4th gear.

This can happen for several different reasons, caused by either internal transmission problems, or external control system problems.

Internal transmission causes of this problem can be faulty solenoids or stuck valves.

External control systems can also cause wrong gear starts. Two common external causes are:

^ a complete loss of power or ground to the control system.

^ a failsafe protection strategy initiated by the computer to protect itself or the transmission from an observed problem.

Both the "No Power" problem and the "Fail Safe Strategy" problem result in the same wrong gear start condition. The gears that you get in each
shifter position are the same.

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Use the charts to see if the unit you have with wrong gear starts is in "Fail" or "No Power" mode. If so, you are probably looking for an electrical
problem. If you have gears other than what is shown on this chart, you probably have a valve body or solenoid problem.

Technical Service Bulletin # ATRATB294 Date: 950101

A/T - Drive Axle and Wheel Lug Nut Torque Specifications

TECHNICAL BULLETIN # 294

DATE: 1995

TRANSMISSION: General

SUBJECT: Drive Axle and Wheel Lug Nut Torque

APPLICATION: Service information

AXLE AND LUG NUT SERVICE INFORMATION

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It is critical to tighten the axle and lug nuts to factory specifications.

Important:
The following charts contain both DRIVE AXLE NUT and WHEEL LUG NUT tightening values. Make certain the correct tightening torque is
used by referring to the chart headings.

WARNING
If the factory tightening specifications are not followed, bearing life will be shortened or mechanical loads will not be spread evenly.

^ Install axle(s) and wheel(s).

^ Install nuts and hand tighten.

^ Lower vehicle until wheels begin to touch the ground.

^ Using figures one and two, tighten nuts to specifications illustrated in the following tables.

Note
Some vehicles use torque-to-yield bolts. These bolts should be tightened an additional amount beyond the listed torque specification. The extra
amount is listed in degrees.

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Acura/ AMC/ Audi/ Buick/ Cadillac

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Cadillac/ Chevrolet/ Chrysler/ Daihatsu/ Dodge/ Eagle/ Ford/ Geo

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Honda/ Hyundai/ Infiniti/ Isuzu/ Lexus/ Lincoln/ Mazda/ Mercury/ Mitsubishi/ Nissan/ Oldsmobile

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Oldsmobile/ Peugeot/ Plymouth/ Pontiac/ Renault/ Saab/ Saturn/ Sterling/ Subaru

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Suzuki/ Toyota/ VW/ Volvo/ Yugo

Technical Service Bulletin # ATRATB345 Date: 960101

A/T - Checkball Wear

DATE: 1996

TECHNICAL BULLETIN # 345

TRANSMISSION: All, with rubber checkballs

SUBJECT: Checkball wear

APPLICATION: Toyota

Toyota Checkball Wear

Harsh Shifts Due to Checkball Failure

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Toyota Corolla L4 1587cc 1.6L DOHC (4A-FE) 992

Harsh Shift complaints are often caused by checkballs that have worn-out and blown through the separator plate. A more durable checkball is
available from Toyota. the original design checkballs were black in color. The new design, which are much more durable, are blue. Technical
Service Bulletin # ATRATB8748 Date: 870801

A/T - Slipping or No-Shift/Metal Sealing Rings

TSB 87-48 (Aug)

SUBJECT: Metal sealing rings

Various Units

PROBLEM: Slipping, or sometimes no-shift

POSSIBLE SOLUTION: Sealing rings could be under-size.

1. Always inspect rings as outlined in SIL 84-29

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2. Place ring in bore of drum where they will be running. (See Figures 1 & 2)

3. Sealing rings should be snug in bore; rings should fit all around the drum. (drum could be out-of-round)

4. Air check all drums. (Use 30 PSI air pressure only.) If air escapes you have leaks -- better find now, than later. This represents lost clutch
pressure, and could result in soft application and burned friction material.

5. Following these steps will help you save money, plus help you build better units.

Technical Service Bulletin # ATRATB8754 Date: 870901

A/T - Front Bushing Wear

TSB 87-54 (Sept)

SUBJECT: ALL AUTOMATICS

PROBLEM: Front Bushing Wear

CAUSE:
When diagnosing front pump bushing wear, the cause may be:

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1. Excessive CONVERTER HUB RUN-OUT. This may, or may not be due to a faulty torque converter.

The torque converter can be checked visually, and with a dial indicator. (See Figure 1) Hub run-out should not exceed .010".

2. BROKEN, BENT OR CRACKED FLYWHEELS can also cause run-out. If the torque-converter-to-flywheel bolts have been loose, the
flywheel holes can become egg-shaped, or the torque converter pads may wear into the flywheel, causing run-out.

3. Another possibility is WEAR IN THE CRANKSHAFT, where it supports the torque converter pilot.(See Figure 2)

Often the crankshaft is only worn in a small area where the torque converter pilot has been against it.

If only a portion of the crankshaft is worn, rotate the crankshaft until the worn area is at 12:00 o'clock.

When the torque converter is pushed forward into the crankshaft, the torque converter pilot will bottom on a good portion, and should center
properly.

Technical Service Bulletin # ATRATB8923 Date: 890801

A/T - Math Formulas Part I

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TSB: 89-23 (Aug)

SUBJECT:
TRANSMISSION MATH FORMULAS (Your most valuable tool)

Transmission math formulas are not reserved exclusively for engineers. Understanding some basic mathematical formulas can be one of your most
valuable tools.

The following information contained in this bulletin will discuss various basic formulas dealing with:

1. Shift Speed
2. Pressure
3. Speedometer ratios

Take the time, now, to understand these relatively simple concepts.

You will be saving yourself many problems, and considerable frustration, and also dollars, in the future.

Shift Speed and Pressure

SHIFT SPEED AND PRESSURE

To figure the area of a circle (valve or servo):

Radius (which is 1/2 the diameter) x Radius x 3.14159 = Area

EXAMPLE: A 1" diameter circle has a radius of 0.5"

0.5 x 0.5 x 3.14159 = 0.785

Therefore a 1" diameter circle has an Area of 0.785 sq. inches

Pressure x Area = Force

EXAMPLE: 100 psi line pressure, on a servo with an area of 2 square inches = force

So, 100 psi line pressure x 2 sq in = 200 pounds of force.

Force divided by Area = Pressure

EXAMPLE: 200 lbs divided by 2" = 100 psi

Force divided by Pressure = Area

EXAMPLE: 200 lbs divided by 100 psi = 2 inches

THINGS WE CAN DO WITH THESE FORMULAS:

EXAMPLE: A 700 R4 has 62 psi of line pressure at Idle.

The PR spring weighs 6.5 lbs

The tip (reaction end) of the PR valve has a diameter of 0.365" (0.365 divided by 2 = 0.1825 radius) 0.1825 x 0.1825 x 3.14159 = 0.1046" area

We want 75 psi of line pressure at Idle

First, let's see if those numbers add up, using: Pressure x Area = Force

62 psi x 0.1046 = 6.48, or 6 1/2 lb PR Spring

We want 75 psi:
Pressure x Area = Force (Spring) 75 psi x 0.1046 = 7.85 lb spring

What if we put in an 8 lb Spring? Force divided by Area = Pressure

8 lbs divided by 0.1046 = 76.48 or 76 1/2 line pressure

Now, let's look at RATIO.

Ratio is the relationship in quantity, amount or size, between two or more things.

In our example ratio is: How many psi each pound of spring will add.

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Pressure divided by Force = Ratio

EXAMPLE: 62 psi divided by 6.5 lbs = 9.5 ratio Each pound of spring will increase pressure 9.5 psi

Force x Ratio = Pressure

EXAMPLE: 6.5 lbs x 9.5 = 61.75 or 62 psi

(Let's add 1 lb of spring, and see if we get 9.5 more psi.)

Force x Ratio = Pressure

EXAMPLE: 7.5 lbs x 9.5 = 71.25

New pressure Old pressure = Pressure difference

71.25 minus 61.75 = 9.5 psi change (by adding 1 lb of spring)

Once you know the ratio, a lot can be determined. Pressure divided by Ratio = Force

62 psi (actually 61.75) divided by 9.5 = 6.5 lb spring

The ratio never changes. This means that if I know that line pressure is 55 psi at idle, in a 700 R4, the the PR spring must be 5.78 lbs.

Pressure divided by Ratio = Force

So, 55 psi divided by 9.5 = 5.78 lbs.

Now, let's look at a math formula for shift speeds.

Suppose we had shift speeds of 15 mph and 20 mph, for the 1-2 & 2-3 shifts on a transmission. 20 mph may be too early for the 2-3 shift. If we
adjust TV modulator, we will move both shifts. We don't want to do that because the 1-2 shift is fine, so let's work with just the 2-3 shift spring.

EXAMPLE: Original spring divided by Original MPH = Ratio

As, 4 lbs divided by 25mph = 0.2

Ratio x Desired MPH = New Spring

0.2 x 25 mph = 5 lb spring

A 5 lb spring will raise the shift on this transmission to 25 mph.

All you need to know is -- Where is it shifting now (at MINIMUM throttle) and what does the spring weigh.

This formula will get you very close, but may be a "tad" off, because we are not accounting for TV pressure helping the spring. This is why you
want to check it at minimum throttle, so TV has the least effect.

Speedometer Ratios
Finally, let's look at speedometer ratios.

Suppose we put an exchange transmission in a car, and now the speedometer is off, because the speedometer drive gear has a different tooth count.
What do we have to do to the driven gear to correct it?

Let's say the old drive gear had 7 teeth and the old driven gear had 21 teeth. The exchange unit had 8 teeth on the drive gear.

Old Drive Gear divided by the New Drive Gear = Ratio

7 teeth divided by 8 teeth = 0.875

Old Driven Gear divided by Ratio = New Driven Gear

21 teeth divided by 0.875 = 24 teeth

A 24 tooth driven gear will correct the speedometer error.

Let's do one more speedometer change. This time the old drive is 9, and the new drive is 10. The old driven gear is still 21.

Old Drive Gear divided by New Drive Gear = Ratio

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9 tooth divided by 10 tooth = 0.9

Old Driven Gear divided by Ratio = New Driven Gear

21 tooth divided by 0.9 = 23.33 teeth

We can't get a 23.3 tooth count so we round it off to 23 teeth. Now the speedometer will be close, but not exact, because we had to round off the
number.

Technical Service Bulletin # ATRATB8927 Date: 890901

A/T - Twenty Steps To Successful Repairs

TSB 89-27 (Sept)

SUBJECT: TWENTY STEPS TO SUCCESSFUL TRANSMISSION REPAIR

1. As you start work on a transmission, read your ATRA bulletins pertaining to that transmission. (If you do this every time, before you know it
you'll have the bulletins memorized.)

2. Clean the entire transmission, including the valve body.

3. Check pumps, valve bodies, and cases for warpage.

4. Flat file pumps, valve bodies, and cases. (Just a few strokes with the file to knock off high spots and handle burrs.)

5. Check all pump gear clearances.

6. Check planet pinion endplay and side to side motion.

7. Soak all planet assemblies.

8. Soak all friction material for 15-30 minutes.

9. Sand, tumble, or replace all steel plates.

10. Re-surface all drums on which a band rides.

11. Replace all rotating oi1 control rings.

12. Check all oil control rings, and rubber products in their bores for proper fit.

13. Replace all major support bushings and bushings that control lube oil.

14. Pre-lubricate all bushings and thrust washers.

15. Pre-lube pumps.

16. Pre-fill torque converters.

17. Use available manuals to find specifications.

18. Set correct clutch and band clearances

19. Take the time to set total unit endplay

20. Use a torque wrench on all pumps and valve bodies.

Technical Service Bulletin # ATRATB8930 Date: 891001

A/T - Math Part II

TSB: 89-30 (Oct)

SUBJECT: TRANSMISSION MATH - Part II

Planetary Gear Sets:

Knowing the gear ratios of an automatic transmission can come in handy at times -- especially when you're swapping transmission types or
differentials. The problem is in trying to find a manual with the ratios listed. What do you do?

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BREAK OUT THE CALCULATOR, AND FIGURE IT OUT.

When you figure the gear ratios for planetary gear sets, it is just like any other gear set. You divide the output gear by the input. Also, don't count
the idler gear; planetaries are considered idler gears. Set them aside, their tooth count doesn't matter.

Now for the tricky part -- which gear do you consider the input, and which one the output? Figure 1 shows a planetary gear set with 34 teeth on the
ring gear and 20 teeth on the Sun gear.

FOR GEAR REDUCTION, one of the gears is held stationary, and the other is used for the INPUT. THE TOOTH COUNT FOR THE OUTPUT
GEAR IS THE SUM OF THE SUN GEAR AND THE RING GEAR, so if you are using the Sun gear for the input, then the ring gear + the Sun
gear divided by the Sun gear = Ratio.

EXAMPLE: 34 + 20 divided by 20 = 2.7:1 This is how 1st gear on a THM 700 R4 is calculated. (See figure)

When the ring gear is used as the input, then the ring gear + the Sun gear divided by the ring gear = Ratio.

EXAMPLE: 34 + 20 divided by 34 = 1.58 This is now 2nd gear on a THM 350 is calculated. (See figure)

FOR OVERDRIVE, the sum of the ring gear + Sun gear is used for the input tooth count.

So, IF THE SUN GEAR IS HELD, then the ring gear divided by (ring gear + Sun gear) = Ratio

EXAMPLE: 34 divided by (34 + 20) = .63:1 Look familiar?

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The A4LD, the THM 200-4R, the A-140E, the A-40D, the THM 325-4L are some of the units that use this method of getting overdrive. (See
figure)

If the ring gear is held, then the Sun gear divided by (ring gear = Sun gear) = Ratio

EXAMPLE: 20 divided by (34 + 20) = .37:1 (See figure)

REVERSE IS THE EASIEST - THE PLANET IS HELD.

The Sun gear is the input, and the ring gear is the output. The formula for this is: The ring gear divided by the Sun gear = Ratio.

EXAMPLE: 34 divided by 20 = 1.7 (See figure)

Occasionally, the ring gear is used as the input, and the Sun gear as the output.

The formula for this is: The Sun gear divided by the ring gear = Ratio.

EXAMPLE: 20 divided by 34 = .59

(See figure)

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Notice that the output is overdriven.

A transmission using this method must use another planetary gear set to reduce the output. The Mercedes W3A-040 is a good example of this

To get more than one gear forward and a reverse, requires multiple, or compound planetary gear sets.

Two of the most common of these are the SIMPSON GEAR SET, used in transmissions like the THM 350, the Ford C-4, and the TF 6 & 8, and the
RAVIGNEAUX GEAR SET, found in transmissions such as the FMX, the AOD, and the T-35.

Figuring out all the ratios for these transmissions is a little tricky, so I'll give you the formulas, and let you figure out how these formulas were
derived.

THE SIMPSON GEAR SET:

For this example I'll use a THM 200, which has 74 TEETH ON THE FRONT RING GEAR, 42 TEETH ON THE FRONT SUN GEAR, 30
TEETH ON THE REAR SUN GEAR, AND 62 TEETH ON THE REAR RING GEAR.

The formula for 1ST GEAR is: rear ring divided by rear Sun x front Sun plus front Sun + front ring divided by front ring.

EXAMPLE: On the THM 200, it would be:

62 divided by 30 x 42 + 42 + 74 divided by 74 = 2.74:1

SECOND GEAR is easy: Front Sun + front ring divided by front ring.

EXAMPLE: 42 + 74 divided by 74 = 1.57:1

THIRD GEAR is Direct Drive, or 1:1

REVERSE is rear ring divided by rear Sun

EXAMPLE: 62 divided by 30 = 2.06

THM 440-T4 (BACKWARDS SIMPSON):

The THM 440 T4 is sort of a backwards version of a Simpson gear set, and although it looks complicated, it really is very simple.

The front Sun gear has 26 teeth, while the rear Sun gear has 42. The front ring gear has 62 teeth, but keep in mind that it is part of the rear carrier,
just as the rear ring gear is part of the front carrier, with a tooth count of 74.

As I said earlier, the THM 440 T4 is sort of a backwards version of a Simpson gear set, so in figuring the ratio for 1ST GEAR -- it is identical,
except you substitute the words "front" and "rear" in the appropriate places. Front ring divided by front sun x rear Sun + rear Sun + rear ring
divided by rear ring = Ratio

EXAMPLE: 62 divided by 26 x 42 + 42 + 74 divided by 74 = 2.92:1

2ND GEAR: Rear Sun + rear ring divided by rear ring

Example: 42 + 74 divided by 74 = 1.57:1

3RD GEAR: Direct Drive, or 1:1

4TH GEAR: Front ring divided by (front Sun + front ring = Ratio

EXAMPLE: 62 divided by (26 + 62) = .74:1

RAVIGNEAUX GEAR SET:

This is considered a compound gear set, and for this example I'll use an AOD, which has:

36 teeth on the front Sun gear

30 teeth on the rear Sun gear, and

72 teeth on the ring gear

The formula for first gear is: Ring gear divided by rear Sun gear = Ratio

EXAMPLE: 72 divided by 30 = 2.4:1

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SECOND GEAR formula is: Rear Sun + front Sun divided by rear Sun x Ring divided by (Ring + front Sun)

EXAMPLE: (30 + 36) divided by 30 x 72 divided by (72 + 36) = Ratio 66 divided by 30 x 72 divided by 108 = 1.47

THIRD GEAR is Direct, or 1:1

FOURTH GEAR is: Ring gear divided by (ring gear + front Sun gear) = Ratio

EXAMPLE: 72 divided by (72 + 36) = .67:1

REVERSE on a Ford AOD is: Ring gear divided by front Sun gear.

EXAMPLE: 72 divided by 36 = 2:1

Technical Service Bulletin # ATRATB9002006 Date: 900201

A/T - Choosing the Right ATF

TRANSMISSION: ALL

BULLETIN: # 9002006

SUBJECT: Automatic Transmission Fluid

DATE: Feb 1990

AUTOMATIC TRANSMISSION FLUID

CHOOSING YOUR ATF

Different ATF's (Automatic Transmission Fluid) can have different frictional properties which can produce different shift characteristics. You may
have already experienced problems like lock-up shudder, or squawks on shifts and have corrected them by changing the fluid. This alone tells, you
that friction material and fluids are critical in today's cars.

MEETING THE O.E.M. SPECIFICATIONS

The first thing to consider when choosing an ATF is "Does it meet the O.E.M. specification?" ATF's wishing to be labeled as DEXRON II and/or
MERCON must first meet the respective minimum requirements. It's important to note that even though the specification for DEXRON II and
MERCON are currently very similar, THEY ARE NOT IDENTICAL. Also note, even fluids which meet the same specification may not be
identical. One fluid may just meet a specification and, another may far surpass it. You should know what your fluids properties are! You can get
that information from your fluid supplier.

EVALUATING YOUR FLUID

Ask your supplier to prove (certify) that the fluid meets O.E.M. specifications (MERCON OR DEXRON II). He will do that by supplying you with
the license (certification) number issued to him by the O.E.M.

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A DEXRON-II license number (sometimes referred to as a "D" number) will always start D-2. A typical DEXRON license number can be seen in
Figure 2.

MERCON license numbers will be six digits starting with M as shown in Figure 3..

TRY TO MEET SEVERAL SPECIFICATIONS!

DEXRON II and MERCON have different minimum specifications, so a product that meets BOTH specifications may be better then those meeting
only one spec. Meeting other specs, in addition to the first two can be an added benefit. If a fluid is licensed as DEXRON II AND MERCON as
well as others like Allison C-4, or Caterpillar TO-2/TO-4, it means the fluid had to pass more tests and may be a better fluid.

Lastly, demand that the license numbers be placed on all your invoices especially if you buy in bulk. If your supplier is unwilling, it is very likely
that they are supplying you an unlicensed fluid. Licensed suppliers are required to supply the license numbers to their customers as part of their
agreement with the O.E.M.

OTHER THINGS TO CHECK

So now you've narrowed your choices down to a few suppliers that have O.E.M. license numbers. How do you compare two fluids that meet the
same O.E.M. Spec.? Ask your supplier to give you the viscometrics on the fluid you buy.

An excellent "bench mark of the overall quality of a fluid is its viscosity at -40 degrees. This is measured in "centipoise" or "cPs". DEXRON II
specification says viscosity will be no more then 50,000 cPs @ - 40 degrees. (Some poor fluids have tested at over 1,000,000 cPs) In general, the
lower the number, the better the fluid.

Keep in mind that as the number goes down the price of the fluid usually goes up. (You get what you pay for) Most good fluids will average around

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35,000 cPs. Hydrotreated (or Hydrocracked) fluids average around 20,000 cPs or less. (Hydrotreating is a refining process done to the base oil to
clean out contaminants or impurities) Synthetic ATF's average 10,000 cPs or less, and some are as low as 5000 cPs. Viscosity at -40 degrees is a
function of the base stock from which the ATF is made. A low number indicates a premium base oil OR an expensive refining process.
(Hydrotreating)

FOR ADDITIONAL INFORMATION:

Transmission Digest August '89

Page 91 December '89 Page 51

BULLETIN RECAP

^ Only use fluids with O.E.M. approvals.

^ Try to get a fluid that meets more than one spec (e.g DEXRON II AND MERCON)

^ Check the viscosity at -40 degrees. The lower the number the better.

^ Avoid bargain basement fluids with no license numbers.

Technical Service Bulletin # AU92005 Date: 921001

Audio - Player Does Not Load or Eject CD

REF:
AUDIO

NO:
AU92-005

DATE:
OCTOBER 30, 1992

MODEL:
ALL MODELS

'92 FUJITSU TEN 34210/34212 PIO/DIO CD PLAYER

The CD mechanism has been changed to improve loading/eject operations on the 34210/ 34212 CD player.

'92 Fujitsu Ten 34210/34212 PIO/DIO CD Player

CONDITION

CD player will not accept or does not eject CD.

CAUSE

Levers in the CD mechanism become misaligned causing the mechanism to jam during loading/eject operations.

CORRECTION:

Exchange the CD player.

Production change was made effective 2/92.

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Exchange CD players which have been countermeasured can be identified by a RED MARK next to the Serial Number on the bottom of the CD
player. Fujitsu Ten started shipping countermeasured exchange CD players starting 6/92.

Technical Service Bulletin # TC003-98 Date: 980619

A/T - Fluid Type T-IV Replaces Type T-II

TRANSMISSION & CLUTCH
TC003-98

June 19, 1998

Title:
AUTOMATIC TRANSMISSION FLUID TYPE T-IV

Models:
ALL MODELS

Introduction

The introduction of Automatic Transmission Fluid type T-IV makes type T-II obsolete. Use type T-IV for all applications that specify ATF type
T-II.

Affected Vehicles

^ All vehicles with Automatic Transmissions specified to use ATF Types T-II or T-IV.

Parts Information

Warranty Information
Technical Service Bulletin # TC003-99 Date: 990521

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A/T - Fluid Interchangeability

TRANSMISSION & CLUTCH
TC003-99

Title:
AUTOMATIC TRANSMISSION FLUIDS

Models:
All Models

May 21, 1999

REVISION NOTICE:

The information contained in this TSB updates TC003-98 dated June 19, 1998.

Introduction

Automatic Transmission Fluid Type T-IV now replaces Type T-II fluid. Use Type T-IV for all applications that specify ATF Type T-II.

Please refer to the following table for the interchangeability between each ATF.

Affected Vehicles

^ All vehicles produced after 1993 with Automatic Transmissions specified to use ATF Type T, T-II and T-IV.

NOTICE:
With the exception of mixing ATF Type T with Type T-IV fluids, different types of fluids must not be mixed.

Parts Information

SIZE NEW PART NUMBER PART NAME

4 Liter 08886-01705 ATF Type T-IV

Warranty InformationTechnical Service Bulletin # SU93001 Date: 930205

Repair Manual Corrections - Suspension Arm No. 2

REF: SUSPENSION

NO.: SU93-001

DATE: FEFRUARY 5, 1993

MODEL: COROLLA (AE)

LOWER SUSPENSION ARM NO. 2 INSTALLATION

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The '93 Corolla Repair Manual procedure contains the following instructions for installing the Rear Suspension No. 2 Lower Arm (reference page
SA-82):

Because several suppliers are used for the No. 2 Lower Suspension Arm, the inside direction may be identified by any of the following marks
shown below:

1. Non-functional threads.
2. Relief cut on rod adjustment tube.
3. Gold colored nut.
4. Letter "R" stamped on rod adjustment tube.
5. Paint mark (as listed in Repair Manual).

Technical Service Bulletin # NHTSA94V220000 Date: 941104

Recall 94V220000: Harness Connector Corrosion

An unused harness connector for power windows, power door locks and sunroof was improperly routed under the floor carpet in the left kick panel.
If the vehicle is operated in cold weather conditions where large amounts of road salts are used, the salt water or snow carried into the vehicle by
the driver's shoes can penetrate the carpet and drip onto the connector resulting in the formation of a salt bridge between the terminals. This causes
an electrical short inside the harness, and can result in a vehicle fire.

Dealers will remove the unused harness connector.

System: Electrical system: Wiring.

Vehicle description: Corolla passenger vehicles built in Japan or Canada not equipped with power windows, power door locks and sunroof,
registered in the following states: CT, IL, IN, ME, MA, MI, NH, NJ, NY, OH, PA, RI,VT, AND WI.

Note: If your vehicle is presented to an authorized dealer on an agreed upon service date and the remedy is not provided free of charge within a
reasonable time, please contact Toyota at 1-800-331-4331. Also contact The National highway Traffic Safety Administration's auto safety hotline at
1-800-424-9393. Technical Service Bulletin # SU00296 Date: 960322

Wheels - Balance Adapter Kit

REF.: SUSPENSION

NO.: SUOO2-96

DATE: MARCH 22, 1996

MODEL: ALL MODELS

WHEEL BALANCE ADAPTER KIT

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To improve the accuracy of Dynamic Off-Car wheel balancing on all OEM Toyota five and six lug wheels, a precision wheel adapter kit must be
used. For the greatest accuracy and repeatability, Toyota recommends using the Haweka adapter kit available through the Toyota Approved Dealer
Equipment catalog. The kit consists of a precision ground centering cone for truck alloy wheels and a flange plate.

PART NUMBER INFORMATION:

NOTE:
Tires that have nylon belts must be warmed-up sufficiently by driving 4 to 5 miles at 45 m.p.h. before balancing. This will avoid a cold set flat
spot and restore the tire to its full round condition.

BALANCE PROCEDURE:

The Haweka Flange Plate uses the wheel lug holes and a centering cone to center the wheel on the balancer arbor. As the wing nut is tightened,
equal pressure is automatically applied to each stud forcing the wheel to perfectly mount on the balancer (see Figure 1).

1. Use the centering cone and flange plate combination on all five and six lug steel and alloy Toyota wheels. On four lug and other wheels, use
the standard centering cones that come with your balancer.

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2. Verify that the centering cone fits inside the wheel center as well as inside the balance machine hub (see Figure 2). Contact a Dealer
Consultant at Toyota Approved Dealer Equipment or your wheel balance manufacturer for further information.

3. Always install the spring and centering cone toward the back side of the wheel (see Figure 3).

For additional wheel balancer accessories, refer to the latest Toyota Approved Dealer Equipment catalog (P/N 00451-86023-96T) or contact a
Dealer Consultant at Toyota Approved Dealer Equipment at 1(800) 368-6787.

To place an order, please call Toyota Approved Dealer Equipment at 1 (800) 368-6787.
Technical Service Bulletin # BO017R-03 Date: 060424

Body - Interior Trim Panels/Garnish Loose

BODY

BO017-03
REVISED

Title:
TRIM GARNISH LOOSE

Models:
'91 - '07 All Models

September 9, 2003

TSB REVISION NOTICE:

^ April 24, 2006: Model year applicability has been defined to 1991 - 2007.
The Inspection/Replacement Procedure has been updated with parts information for applicable model year Avalon, Camry, and Solara
vehicles.

^ March 3, 2004: The TSB has been changed to include new inspection and replacement instructions.

Previous versions of this TSB should be discarded.

Introduction

Customers may experience an interior trim panel either loose or fitting poorly due to a deformed or missing panel attachment clips. When a trim

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garnish (A, B, C, or D pillar garnish, door trim panel, etc.) is removed and reinstalled using the old clips, there is a possibility that the garnish may
exhibit a loose condition. To prevent this condition from occurring, please use the following procedures.

Applicable Vehicles

1991 - 2007 model year Toyota vehicles.

Warranty Information

Inspection/Replacement Procedure

All Models:

All trim panel attachment clips must be inspected prior to reassembly and replaced if any damage or wear is detected. If NO damage is visible, the
clip may be reused. Always check to make sure that the garnish is properly attached after reinstallation of all interior trim panels.

2005 - 2006 model year Avalon, 2002 - 2007 model year Camry, and 2004 - 2006 model year Solara:

When removing the A-pillar garnish panels, replace the plastic attachment clips. Refer to the table below for appropriate part numbers. Technical
Service Bulletin # AU94001 Date: 940121

Audio - CD Player Won't Play or Skips

REF: AUDIO
NO.: AU94-001
DATE: JANUARY 21, 1994

MODEL:
ALL MODELS (EXCEPT SUPRA)

CD SKIPS OR WON'T PLAY ON '92-193 PANASONIC RADIO / CD PLAYER

'92-'93 56804 / 56805 Panasonic 3-in-1 radio's and 74805 / 74806 PIO / DIO CD changer's optical mechanism has been modified to improve the
following conditions:

1) CD skips
2) CD won't play and displays "Err"

DIAGNOSTIC PROCEDURE:

Use a known good CD, disk for diagnosis.

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1 CD skips / won't play are frequently caused by the condition of the CD disks, or other external factors. Verify that CD skips / won't play are
not caused by any of the following:

^ CD is inserted with the wrong side up.

^ Damaged or dirty CD's (scratches, debris, oil, fingerprints on CD's).
^ Rough road surfaces causing the CD to skip.
^ Objects bumping the CD changer.

2) After verifying that the CD disk is in good condition, exchange the radio or CD changer. Countermeasured units will have an orange mark
next to the serial number on the ID label.

Exchange units have been countermeasured starting 6/93.

CD CLEANING PROCEDURE:

1) Clean the CD playing surface (shiny side) by wiping the CD radially (from the center to the outer edge) with a soft clean cloth. Do not wipe
in a circular motion. Make sure that all contaminates have been removed from the playing surface.

2) If there are shavings on the edge of the CD, rub the edge of the CD with the side of a pencil until the shavings are removed.

Please return exchanged unit immediately to Panasonic.

PRODUCTION EFFECTIVE: (See Illustration)

Technical Service Bulletin # BO93003 Date: 930423

Paint - Anti-Chip Primer Now Applied

REL: BODY

NO.: B093-003

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DATE: APRIL 23, 1993

MODEL: SW, AE, AC

STONE CHIPPING

To improve stone chip resistance, anti-chip primer has been applied to the areas shown.

Technical Service Bulletin # PA92001 Date: 921231

Paint - Codes & Cross References

REF:
PAINT

NO.:
PA92-001

DATE:
DECEMBER 31, 1992

MODEL:
ALL MODELS

1993 PAINT & REFINISH FORMULA CODES

The following is a listing of 1993 Toyota paint codes and corresponding refinish formula codes from refinish paint companies -- Sherwin Williams,
BASF, Du Pont, PPG, SpiesHecker, Sikkens and Herberts Standox.

NOTE:

^ The paint color code is found on the driver's-side door or door jam on the Certification/Regulation label (white vinyl label).

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^ Colors listed as Pearl (P) or Metallic (M) have a clearcoat top coat finish.

^ Where two (2) formula numbers are listed for the same color, the first number is the base coat and the second number is the pearl (mica) coat.

^ The paint manufacturer's reference codes are identical to Toyota color codes, however a "TOY" prefix is used. Example: Toyota's 045 White
= "TOY045".

- Sikkens

- Herberts Standox

Please contact your local warehouse jobber or paint manufacturers representative for the actual paint mixing formulas or for additional assistance.

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1993 PAINT & REFINISH FORMULA CODES

Technical Service Bulletin # BO01196 Date: 961213

Interior - Carpet Cleaning Precautions

Ref.: BODY

No.: BO011-96

Date: DECEMBER 13, 1996

Model: ALL MODELS

Title: CARPET CLEANING PROCEDURES

Electrical components, wire harnesses1 and connectors in the cabin and trunk areas are not waterproof and therefore, are not protected against
excessive moisture that may occur during carpet cleaning. Additionally, some vehicles may have audio amplifiers, vehicle security system
computers and CD changers under the front seat area which may be damaged by excess moisture. The illustration is an example of the typical
component locations.

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When cleaning the carpet in the vehicle, use dedicated carpet cleaning equipment such as the carpet and upholstery cleaners found in the Toyota
Approved Dealer Equipment publication.

NOTE:
Even with dedicated carpet cleaning equipment, you must be careful not to soak electrical components located under the seat.
Technical Service Bulletin # DL001-98 Date: 980306

Drive Axles - Front Hub Nut Replacement

DRIVELINE/DIFFERENTIAL
DL001-98

MARCH 6, 1998

TITLE:
FRONT AXLE HUB NUT REPLACEMENT

MODELS:
'92 - '98 TERCEL, PASEO, COROLLA, CELICA, CAMRY
'96 - '98 RAV4

Introduction

Due to a change of the friction control treatment on the nut thread, both types of Front Axle Hub Nuts (silver and black) for 1992-1998 Tercel,
Paseo, Corolla, Celica, Camry and 1996-1998 RAV4s are NOT reusable.

NOTE: When replacing the Front Axle Hub Nut the new part must be the same color as the old part. When replacing a Silver nut -- use a NEW
Silver nut and when replacing a Black nut -- use a NEW Black nut.

Affected Vehicles

- 1992-1998 Tercel, Paseo, Corolla, Celica, Camry and 1996-1998 RAV4s.

Parts Information

PART NUMBER PART NAME COLOR

90179-22020 Nut, Axle Hub Silver

90178-22001 Nut, Axle Hub Black

Warranty Information
Technical Service Bulletin # TC93005 Date: 930730

A/T - Improved Shift From N to D

REF: TRANSMISSION & CLUTCH

NO.: TC93-005

DATE: JULY 30, 1993

MODEL: AE92

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FORWARD CLUTCH (C1) ACCUMULATOR A131L A/TM

To improve shift feel from "N" to "D", the following modifications have been made:

1. Modified transaxle case with the addition of C1 accumulator control pressure hole.

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2. Modified C1 accumulator piston.

3. Modified B2 accumulator piston.

4. Additional O-ring for upper C1 accumulator piston.

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5. Modified compression spring for C1 accumulator.

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6. Modified compression spring for B2 accumulator.

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7. Modified compression spring for C2 accumulator.

8. Throttle Valve Cam identification number change.

9. Valve body plate identification/number change.

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10. Modified accumulator control valve and downshift spring.

PRODUCTION EFFECTIVE:

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PART NUMBER INFORMATION:

Technical Service Bulletin # EL008R-02 Date: 030228

Keyless Entry - Transmitter Programming & Identification

ELECTRICAL
EL008-02
REVISED

December 20, 2002

Title:
WIRELESS TRANSMITTER & PROGRAMMING GUIDE

Models:
All Applicable

TSB REVISION NOTICE:

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^ February 28, 2003: In Wireless Transmitter Identification section Figures 5, 9, 10,1 2, and 13 as shown are updated to include 2003 model
year; Figure 11 updated to include 1999 and 2003 model year.

^ January 17, 2003: 2003 model year added to Solara in the Application Chart.

^ The information contained in this TSB supercedes TSB EL010-01, dated October 26, 2001. The previous TSB, EL010-01, should be
discarded.

Introduction

Difficulties during Remote Keyless Entry Transmitter Programming can arise due to confusion between Toyota Factory Wireless systems and
Toyota Port/Dealer installed systems. This bulletin will assist in identifying the system/correct remote transmitters for each vehicle, and provide the
location of the most accurate programming procedure for each system.

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Applicable Vehicles
^ All applicable Toyota vehicles.

Warranty Information

System Identification

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The table contains all of the necessary information to correctly identify the type of system installed, and where to go to get programming
procedures for each vehicle.

NOTE:
Should a vehicle having both VIP and Factory systems available (as identified in the following table) be brought in without any remotes (or one
non-working remote), use the following tips to help determine which type of wireless system (O.E. or PIO/PIO) the vehicle has.

^ Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while entry-grade vehicles will tend to have
VIP For example, the 2001 Camry XLE has Factory RKE, but the LE and CE grades have VIP.

^ Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the dashboard or on the center console. Most
VIP systems will have this.

^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located, refer to the part label.

^ Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the "confirmation mode" and see
if any "Lock/Unlock" response is received, if so, the vehicle has a factory system.

Technical Service Bulletin # AC00396 Date: 961129

A/C - Alternative Refrigerants and Retrofits

Ref.: HEATING & AIR CONDITIONING

Date: NOVEMBER 29, 1996

No.: AC003-96

Model: ALL MODELS

Title: ALTERNATE REFRIGERANTS AND A/C RETROFIT

The E.P.A. has officially banned the manufacture of Refrigerant 12 (Freon) after January 1, 1996. As a result, surplus supplies of R-12 will begin to
dwindle over the next several years until, eventually, R-12 will no longer be available.

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This uncertainty about the availability of R-12 has caused significant concerns for Toyota dealers when servicing HVAC systems not using R-134a
refrigerant. Similarly, the reduced availability of R-12 has prompted demands for R-134a retrofit kits and/or alternate refrigerants. This TSB will
clarify Toyota's current recommendations for servicing and retrofitting HVAC systems on Toyota vehicles using R-12 refrigerant.

ALTERNATE REFRIGERANTS:

Previously, the E.P.A. has endorsed other alternative refrigerants. These endorsements, combined with the uncertain future availability of R-12,
have lead to a limited acceptance of using alternative refrigerants when servicing or retrofitting R-12 HVAC systems. Use of these refrigerants can
lead to several service related problems, including:

^ Poor system performance and leak detection capabilities.

^ Contamination of R-12 and R-134a during refrigerant recovery and recycling.

Recently the E.P.A. released a statement clarifying that approval of alternative refrigerants relates only to the toxicology, flammability, ozone
depletion and global warming characteristics. The approval does not imply acceptability of alternative refrigerants use with respect to serviceability
or performance.

TOYOTA MOTOR SALES, U.S.A. ENDORSES THE USE OF R-134A AS THE ONLY ACCEPTABLE ALTERNATIVE REFRIGERANT FOR
VEHICLES USING R-12.

R-12 AVAILABILITY:

It is estimated that existing R-12 supplies will meet market demand in 1996. Beyond that, Toyota will supply R-12 to it's dealers from a strategic
reserve. These strategic reserves are allocated specifically for distribution to Toyota dealers for repair of their customers' R-12 HVAC systems.
TMS projects these reserves may meet dealer demand through early 1998. After that, we believe R-12 will no longer be readily available and
dealers will begin to retrofit customer vehicles with R-134a.

RETROFIT ISSUES:

Toyota has completed development of retrofit parts for all later model Toyota vehicles - using R-12 refrigerant. These parts will be produced in
harmony with market demand, based on R-12 availability.

The parts necessary for a typical retrofit will generally include:

^ Receiver Dryer

^ 0-Rings

^ Fittings

^ Labels

^ Oil

A TSB outlining retrofit procedures will be released when the retrofit kits become available.

For additional information, contact the Toyota Environmental Assistance Network Hotline at 1-800-542-3914.
Technical Service Bulletin # AC94001 Date: 940325

A/C - Replacement Refrigerants Damage System

REF.: HEATING & AIR CONDITIONING

NO.: AC94-001

DATE: MARCH 25, 1994

MODEL: ALL MODELS

ALTERNATIVE REFRIGERANTS

Beginning with the Montreal Protocol signed in April 1988, auto manufacturers world-wide committed to phase-out the use of ozone damaging
Refrigerant R-12, also known as Freon. All automobile manufacturers are re-designing new production vehicles to use non ozone depleting R-134a
which is the only universally approved replacement refrigerant for R-12. Toyota has completely converted to R-134a on all new vehicles built after
February 1994.

Several independent companies have begun marketing alternative refrigerants which they claim can replace R-12 when servicing vehicles in the
dealership. These R-12 replacements, commonly referred to as blends or hydrocarbon based refrigerants, have the potential to cause damage to

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Toyota AC systems and in some cases can cause personal injury to the service technician or the end-user. Toyota strongly discourages the use of
these refrigerants in any Toyota vehicle.

Furthermore, dealer technicians should be cautious of vehicles that may be labeled or otherwise identified to contain such refrigerants. Servicing
these vehicles can contaminate your AC refrigerant recovery equipment causing refrigerant stored in the recovery machine to be rendered unusable.
Also, if the contaminated refrigerant equipment is then used on subsequent repairs, the dealership may unknowingly contaminate other owner's
vehicles.

For all Toyota models and years that are designed to operate on R-12, continue to service with R-12 as long as it is available which is expected to
be two or more years. When research is complete and R-12 becomes difficult to acquire, Toyota will provide parts and procedures to properly
retrofit an R-12 vehicle to non-ozone depleting R-134a.

Technical Service Bulletin # TC95008 Date: 950818

M/T - Replacement Parts, Set Required

REF.: TRANSMISSION & CLUTCH

NO.: TC95-008

DATE: AUGUST 18, 1995

MODEL: EL, AE, ST & SW

PARTS F9R C5 #, C14 #, & C15 # MANUAL TRANSAXLES

For replacement of manual transaxle parts on the Tercel, Paseo, Corolla, Celica and MR2, refer to the following information:

When replacing the Hub Sleeve No. 2 or Reverse Gear on C5 #, C14 #, and C15 # manual transaxles, use the applicable parts replacement sets
listed below along with applicable 2nd or 3rd gear (when listed). The parts listed must be replaced as a set due to the adoption of an uneven pitch
chamfer for 2nd and 3rd gears.

PART NUMBER INFORMATION:

Hub Sleeve No. 2 (Before June 1990 Production Vehicles): When replacing Hub Sleeve No. 2 on vehicles Produced before June 1990 (all transaxle
serial numbers), refer to the table.

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Hub Sleeve No. 2 (June 1990 to April 1991 Production Vehicles): When replacing Hub Sleeve No. 2 on vehicles produced June 1990 to April 1991
(all transaxle serial numbers), refer to the table.

Hub Sleeve No. 2 (April 1991 to June 1994 Production Vehicles): When replacing Hub Sleeve No. 2 on vehicles produced April 1991 to June
1994, refer to the table.

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Reverse Gear (Before June 1990 Vehicle Production): When replacing Reverse Gear on Vehicles produced before June 1990 (all transaxle serial
numbers), refer to table.

Reverse Gear (June 1990 To April 1991 Vehicle Production): When replacing Reverse Gear on vehicles produced June 190 to April 1991 (all
transaxle serial numbers), refer to table.

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Reverse Gear (April 1991 to June 1994 Vehicle Production): When replacing Reverse Gear on vehicles produced April 1991 to June 1994, refer to
tables.

Transaxle number starts with "Z" or has no front letter (Z000-00000)

Technical Service Bulletin # AC92004 Date: 921009

A/C - R12 and R134A O-Ring Color Identification

REF:
HEATING & AIR CONDITIONING

NO:
AC92-004

DATE:
OCTOBER 9, 1992

MODEL:
ALL MODELS

AIR CONDITIONER SYSTEM O-RING COLOR CHANGE

With the change-over to new air conditioning refrigerant R134a (HFC134a), there is a need to distinguish between R12 and R134a O-rings.

Beginning with May, 1992 production, the color of R12 O-rings has been changed from black to brown. The following charts describe O-ring color
and material application for both R12 and R134a systems.

NBR: Nitrile Butadiene Rubber

H-NBR: Hydrated Nitrile Butadiene Rubber

NOTE:
Part Numbers remain unchanged.

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RBR: Rubber used in HFC134a systems

SERVICE HINT:

There will be a transition period where both black and brown R-12 O-Rings are in distribution. You are advised to use up your current stock as well
as additional stock of Black R-12 O-Rings first. This will help prevent confusion when R134a systems are introduced.

Technical Service Bulletin # BO00996 Date: 961025

Seat Belts - Extender Availability

Ref.: BODY

No.: B0009-96

Date: OCTOBER 25, 1996

Model: ALL MODELS

Title:
SEATBELT EXTENDER FOR 1993 THROUGH 1997 MODELS

Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local
Toyota dealer.

^ The extender is available in black only, in 6, 9, 12, 15 and 18 inch lengths.

^ Owner's are informed of the seat belt extender availability through the Toyota Owner's Manual included in each vehicle.

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The customer (individual requiring the extender) must visit a Toyota Dealership to have the required measurements made and to complete the seat
belt extender worksheet. The worksheet will allow the proper fitting and selection of a seat belt extender for the customer. The dealership personnel
should then determine the applicable part number and place a Critical Order through the TDN Parts Network.

Included in this bulletin is the information covering the 1993 through 1997 model years:

Contents

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Procedure & Flow Chart

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Application Charts & Notes

Part Number Information

Owner Instruction Sheet

Statement from Owners Manual

Seat Belt Extender Worksheet

The dealership service department should complete the affixed Seat Belt Extender Label and review the "owner instruction sheet" with the
customer. The dealership should give a copy of the completed worksheet to the customer and keep the original in the customer's file.

To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the seat belt
extender issue.

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From past sales history, it is recommended that dealerships do not stock seat belt extenders due to low demand and the need for customer fitting.

SAMPLE SEAT BELT LABEL:

PART NUMBER INFORMATION:

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Procedure
1. Owner requests a seat belt extender from the dealer.

2. Dealer verifies the need for a seat belt extender and obtains a current copy of TSB and copies the worksheet.

3. Dealer measures the customer and completes the worksheet. Dealer determines the correct part number and places a Critical Order for the
part through the TDN Parts Network.

4. Dealer receives the seat belt extender and calls the customer in to check fit of the part.

5. If the seat belt extender fit is OK, dealership personnel completes the customer information label on the part, explains usage of the part and
gives the customer a copy of the completed worksheet.

6. Dealer places a copy of the completed worksheet in the customer's records.

NOTES:

*1. If dimension "L" is under 24 inches the extender must not be used due to its design and construction. This applies to front lap seat belts
for the following models:

^ '93 & '94 Tercel

^ '93, '94, '95 Paseo

^ '93 Corolla 4WD Wagon

*2. This seat belt was supplied by TOKAI RIKA. Make sure that the identification mark on the back side if the seat belt buckle is the same as
shown.

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*3. This seat belt was supplied by QSS. Make sure that the identification mark on the back side if the seat belt buckle is the same as shown.

*4 Extenders must not be used for center front seat belt positions for Avalon, Tacoma, Compact Pickup and T1OO with bench seats or for
the center rear seat belt positions except for 1997 Camry.
Owner Instruction
Failure to follow the recommendations indicated below could result in less effectiveness of the seat belt restraint system in case of vehicle collision,
causing personal injury.

1. The seat belt extender must not be used:

(a) By anyone other than for whom it was provided (name recorded on seat belt extender).

(b) In any vehicle and/or seat position other than the one for which it is provided.

2. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the buckle-release buttons of the extender and the seat
belt are located on the same side as shown. You will hear a click when the tab locks into the buckle. Make sure that the connection is secure
and the seat belt extender is not twisted.

3. When the seat belt extender is provided for rear seat position (with automatic locking retractor), make sure the retractor is locked when in
use.

4. When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle
interior and extender itself.

5. When not in use, remove the extender and store in the vehicle for future use.

Owner's Manual Text

Seat belt extender

If your seat belt cannot be fastened securely because it is not long enough, a personalized seat belt extender is available from your Toyota dealer
free of charge.

Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect

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to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer.

CAUTION:
When using the seat belt extender, observe the following. Failure to follow these instructions could result in less effectiveness of the seat belt
restraint system in case of vehicle accident, increasing the chance of personal injury.

^ Never use the seat belt extender if you can fasten the seat belt without it.

^ Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating
position than the one originally intended for.

To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the "PRESS" signs on the buckle-release buttons of the
extender and the seat belt are both facing outward as shown.

You will hear a click when the tab locks into the buckle.

When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle
interior and extender itself.

When not in use, remove the extender and store in the vehicle for future use. Technical Service Bulletin # BO93006 Date: 930604

Seat Belts - Extenders Availablity

REF.: BODY

NO.: B093-006

DATE: JUNE 04, 1993

MODEL: ALL MODELS

SEAT BELT EXTENDER (1983 TO 1993 MODEL YEARS)

A special program is available for individuals who require extra length seat belts. Owners of 1983 through 1993 vehicles can now obtain seat belt
extenders at no cost through their local Toyota dealer. (On vehicles prior to 1983-contact TMS-CR for availability)

The extender is available in one color only and in lengths of 6", 9", 12", 15" and 18".

Owners are informed of the seat belt extender availability through the Toyota Owner's Manual included in each 1987 or later vehicle.

The owner must visit a Toyota Dealership to have the required measurements made and complete the application form. The completed application
form will be forwarded to the TMS Customer Relations Department for processing (additional application forms are available at no cost by
ordering the following part number through the TDN-Non Parts system, (P/N 00403-00001-3M) QTY 1 = 5 forms.

To ensure timely delivery of the extender to the owner, the application must be filled out completely and signed by the applicant.

Included are the following 1993 model year updated guides and examples:

Flow Chart

^ Seat Belt Extender Application/Part Number Chart

^ Owner Instruction Sheet
^ Statement included in Owner's Manual
^ Sample of completed form

The appropriate seat belt extender will be forwarded to the dealership parts department at no charge in about two weeks from receipt of the form.
The dealership service department should complete the affixed Seat Belt Extender Label and review the "owner" instruction sheet with the owner.

To assure utmost owner satisfaction, it is recommended that a dealer designate one person to coordinate all activities related to the seat belt

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extender issue.

Flowchart - Procedure

FLOW CHART

Seat Belt Label

1. Owner request to dealer.

2. Dealer verifies need for extender and provides "application for seat belt extender" to owner. Dealer processes application form and sends it to
TMS Customer Relations Department.

^ Dealer retains copies 3 & 4 to process delivery to customer.

3. TMS Customer Relations Department records application form, copies 1 & 2.

^ Retain files in computer and microfilm.

^ Determines appropriate extender length for customer

^ Informs TMS Parts Department to ship parts to dealer.

4. Dealer records appropriate information on the label attached to the belt extender and contacts owner.

5. Dealer gives extender to owner. To determine the proper part number, locate the "series" on the following charts then refer to the part number
chart to find the appropriate part number for the "series" and length.
Front Seat

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Front Seat - Extender Application Table

Note:
The front lap belt for all '90 Corolla models and the '90 Tercel is the ALR type. Make sure the ALR is locked when the extender is used.
Rear Seat

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Rear Seat - Extender Application Table

*3 For TMC production Corolla Sedan (on and after April, 1990 production, '91, & '92 models), if dimension "L2" & "L1" is under 13 inches (see
figure 3), the extender must not be used.

Note:
The extender must not be used for the center rear seat belt on any model.
Seat Belt Extender Part Number Chart

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PART NUMBER INFORMATION:

Owner Instruction
Failure to follow the recommendation indicated below could result in less effectiveness of the seat belt restraint system in case of vehicle collision,
causing personal injury.

1. The seat belt extender must not be used:

(I) By anyone other than for whom it was provided (name recorded on seatbelt extender).
(II) In any vehicle or seat position other than the one for which it is provided.

2. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the buckle-release buttons of the extender and the seat
belt are located on the same side as shown. You will hear a click when the tab locks into the buckle. Make sure that the connection is secure
and the seat belt extender is not twisted.

3. When the seat belt extender is provided for rear seat position (with automatic locking retractor), make sure the retractor is locked when in
use.

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4. When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle
interior and extender itself.

5. When not in use, remove the extender and store in the vehicle for future use.
Owner's Manual Text
Seat belt extender

If your seat belt cannot be fastened securely because it is not long enough, a personalized seat belt extender is available from your Toyota dealer
free of charge.

Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect
to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer.

CAUTION:
When using the seat belt extender, observe the following. Failure to follow these instructions could result in less effectiveness of the seat belt
restraint system in case of vehicle accident, increasing the chance of personal injury.

Never use the seat belt extender if you can fasten the seat belt without it. Remember that the extender provided for you may not be safe when used
on a different vehicle, or for another person and at different seating positions than specified.

To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the buckle-release buttons of the extender and the seat belt are
located on the same side as shown.

You will hear a click when the tab locks into the buckle.

When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle
interior and extender itself.

When not in use, remove the extender and store in the vehicle for future use.

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Technical Service Bulletin # BO94006 Date: 940422

Seat Belts - Extension Availability.

REF.: BODY

NO.: B094-006

DATE: APRIL 22, 1994

MODEL: ALL MODELS

SEAT BELT EXTENDER (1985 TO 1994 MODEL YEARS)

A special program is available for individuals who require extra length seat belts. Owners of 1985 through 1994 vehicles can now obtain seat belt
extenders at no cost through their local Toyota dealer. (On vehicles prior to 1985 - contact TMS-CR for availability)

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The extender is available in black only and in lengths of 6", 9", 12", 15" and 18".

Owners are informed of the seat belt extender availability through the Toyota Owner's Manual included in each 1987 or later vehicle.

The owner must visit a Toyota Dealership to have the required measurements made and complete the application form. The completed application
form will be forwarded to the TMS Customer Relations Department for processing (additional application forms are available at no cost by
ordering the following part number through the Dealer Support Material Network MDC NPM system, P/N 00403-00001-3M QTY 1 = 5 forms).

To ensure timely delivery of the extender to the owner, the application must be filled out completely and signed by the applicant.

Included are the following 1994 model year updated guides and examples:

Flow Chart Seat Belt Extender Application/Part Number Chart Owner Instruction Sheet Statement included in Owner's Manual Sample of
completed form

The appropriate seat belt extender will be forwarded to the dealership parts department at no charge in about two weeks from receipt of the form.
The dealership service department should complete the affixed Seat Belt Extender Label and review the "owner instruction sheet" with the owner.

To assure utmost owner satisfaction, it is recommended that a dealer designate one person to coordinate all activities related to the seat belt
extender issue.

Flow Chart

Flow Chart and Seat Belt Label

1. Owner request to dealer.

2. Dealer verifies need for extender and provides "application for seat belt extender" to owner. Dealer processes application form and sends it to
TMS Customer Relations Department - A102.

^ Dealer retains copies 3 & 4 to process delivery to customer.

3. TMS Customer Relations Department records application form, copies 1 & 2.

^ Retain files in computer and microfilm.

^ Determines appropriate extender length for customer

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^ Informs TMS Parts Department to ship parts to dealer.

4. Dealer records appropriate information on the label attached to the belt extender and contacts owner.

5. Dealer gives extender to owner. To determine the proper part number, locate the model, type and "series" on the charts then refer to the part
number chart to find the appropriate part number for the "series" and length.

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Owner Instruction
Failure to follow the recommendation indicated below could result in less effectiveness of the seat belt restraint system in case of vehicle collision,
causing personal injury.

1. The seat belt extender must not be used:

(I) By anyone other than for whom it was provided (name recorded on seat belt extender).

(II) In any vehicle or seat position other than the one for which it is provided.

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2. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the buckle-release buttons of the extender and the seat
belt are located on the same side as shown. You will hear a click when the tab locks into the buckle. Make sure that the connection is secure
and the seat belt extender is not twisted.

3. When the seat belt extender is provided for rear seat position (with automatic locking retractor), make sure the retractor is locked when in
use.

4. When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle
interior and extender itself.

5. When not in use, remove the extender and store in the vehicle for future use.
Owner's Manual Text
Seat belt extender

If your seat belt cannot be fastened securely because it is not long enough, a personalized seat belt extender is available from your Toyota dealer
free of charge.

Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect
to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer.

CAUTION:
When using the seat belt extender, observe the following. Failure to follow these instructions could result in less effectiveness of the seat belt
restraint system in case of vehicle accident, increasing the chance of personal injury.

^ Never use the seat belt extender if you can fasten the seat belt without it.

^ Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person and at different seating
positions than specified.

To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the buckle-release buttons of the extender and the seat belt are
located on the same side as shown.

You will hear a click when the tab locks into the buckle.

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When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle
interior and extender itself.

When not in use, remove the extender and store in the vehicle for future use.

Technical Service Bulletin # AC93004 Date: 930409

A/C - Precautions for Handling Refrigerant Oil

REF.: HEATING & AIR CONDITIONING

NO.: AC93-004

DATE: APRIL 09, 1993

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MODEL: ALL MODELS

HFC-134A REFRIGERANT OIL HANDLING PRECAUTIONS

Special precautions need to be exercised when handling the new refrigerant oils for HFC-134a systems.

^ ND-OIL8 is used in systems utilizing swash plate type compressors (10P/10PA).

^ ND-OIL9 is used in systems utilizing through-vane (TV) type compressors.

Do not allow either of these oils (ND-OIL8 or ND-OIL9) to come into contact with any of the vehicles surfaces. It will cause discoloration of
painted surfaces and deteriorate components made from acrylic or ABS (Acrylonitrile Butadiene Styrene).

PRECAUTION:

When servicing a HFC-134a system, use only approved Toyota Special

Service Tools to perform refrigerant recovery. Use of unapproved tools may cause unnecessary release of refrigerant into the atmosphere, oil

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contamination of vehicle surfaces or damage system components.

SPECIAL CARE SHOULD ALSO BE TAKEN TO INSURE THAT THE HIGH AND LOW SIDE SERVICE VALVE CAPS ARE INSTALLED
AFTER ANY WORK IS COMPLETED ON A SYSTEM.

Technical Service Bulletin # AC93005 Date: 931022

A/C - Compressor Oil Application & Quantity

REF.: HEATING & AIR CONDITIONING

NO.: AC93-005

DATE: OCTOBER 22, 1993

MODEL: ALL MODELS

A/C COMPRESSOR OIL APPLICATIONS

Care must be taken to use only refrigerant oil which is compatible to the vehicle's system. Following are A/C oil application charts for both R-12
and HFC-134a systems:

R-12 SYSTEMS

NOTE:

Use only the recommended oil for Tercel/Paseo thru-vane type compressors in order to prevent the possibility of compressor failure.

HFC-134A SYSTEMS

Technical Service Bulletin # AC009-04 Date: 041216

A/C - Sensor Inspection Procedures

HEATING & AIR CONDITIONING
AC009-04

Title:
SENSOR INSPECTION FOR AIR
CONDITIONING SYSTEM

Models
'89 - Current All Models

December 16, 2004

Introduction

This service bulletin contains inspection procedures to more precisely confirm proper operation of the following temperature sensors of the air
conditioning system. Follow the procedures in this service bulletin when inspecting these sensors. These contents will be reflected in future repair
manuals.

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^ Room Temperature Sensor

^ Ambient Temperature Sensor

^ Air Duct Sensor

^ Evaporator Temperature Sensor

^ Solar Sensor Room Humidity Sensor

Applicable Vehicles

All 1989 - Current model year Toyota vehicles.

Warranty Information

Inspection Procedure

1. Inspect Room Temperature Sensor.

A. Measure the sensor resistance.

NOTE:

^ Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.

^ When measuring, the sensor temperature must be the same as the ambient temperature.

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HINT:
As the temperature increases, the resistance decreases.

2. Inspect Ambient Temperature Sensor.

A. Measure the sensor resistance according to the selected graph (specification).

NOTE:

^ Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.

^ When measuring, the sensor temperature must be the same as the ambient temperature.

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HINT:
As the temperature increases, the resistance decreases.

3. Inspect Air Duct Sensor.

A. Measure the sensor resistance according to the table and graph (specification).

NOTE:

^ Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.

^ When measuring, the sensor temperature must be the same as the ambient temperature.

HINT:
As the temperature increases, the resistance decreases.

4. Inspect Evaporator Temperature Sensor.

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Select the appropriate graph (specification) using the table.

NOTE:
Please inspect the sensors for model years not indicated by this bulletin, according to the instructions in the applicable repair manual.

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A. Measure the sensor resistance according to the selected graph (specification).

NOTE:

^ Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.

^ When measuring, the sensor temperature must be the same as the ambient temperature.

HINT:
As the temperature increases, the resistance decreases.

5. Inspect Solar Sensor.

Four types of solar sensors are used on Toyota vehicles depending on the vehicle specifications. The inspection procedure for each type of
sensor differs from the others. Select the appropriate inspection procedure from the table according to vehicle specifications and perform the
inspection.

Procedure A:

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a. Disconnect the solar sensor connector.

b. Measure the resistance between terminals 1 and 2 of the solar sensor under the following conditions:

^ Cover the sensor with a cloth to avoid direct light.

^ Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light.

NOTE:

^ Terminal 1 of the sensor is always on the right, when the lock is facing up. When using an analog tester, connect the positive (+) lead
to terminal 2 and negative (-) lead to terminal 1 of the solar sensor.

HINT:
If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.

Standard:

Procedure B:

a. Disconnect the solar sensor connector.

b. Measure the resistance between terminals 2 and 3 of the solar sensor under the following conditions:

^ Cover the sensor with a cloth to avoid direct light.

^ Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light.

NOTE:
When using an analog tester, connect the positive (+) lead to terminal 3 and negative (-) lead to terminal 2 of the solar sensor.

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HINT:
If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.

Standard:

Procedure C:

a. Turn the ignition switch ON.

b. Measure the voltage between terminals TSR (+) and CLTE (-) of the connector under the following conditions:

^ Cover the sensor with a cloth to avoid direct light.

^ Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light.

HINT:

^ If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.

^ Do not disconnect the solar sensor connector.

Standard:

c. Measure the voltage between terminals TSL (+) and CLTE (-) of the connector under the following conditions:

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^ Cover the sensor with a cloth to avoid direct light.

^ Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light.

HINT:

^ If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.

^ Do not disconnect the solar sensor connector.

Standard:

Procedure D:

a. Turn the ignition switch ON.

b. Using the tester, measure the voltage between terminals TSD (+) and CLTE (-) of the connector under the following conditions:

^ Cover the sensor with a cloth to avoid direct light.

^ Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light.

HINT:

^ If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.

^ Do not disconnect the solar sensor connector.

Standard:

6. Inspect Room Humidity Sensor.

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Measure the humidity and output voltage of the humidity sensor when the sensor is installed on the vehicle and the temperature at the
humidity sensor position (room temperature sensor position) is 77°F (25°C). If the output voltage is within the specifications according to the
graph and table, the sensor is normal.

HINT:
For the inspection procedure of the room temperature sensor, refer to "Room Temperature Sensor Inspection Procedure" in this bulletin.

A. Turn the ignition switch to the ON position.

B. Measure the voltage between terminal VO (3) and GND (2) of the room humidity sensor.

C. Measure the humidity and voltage when the room temperature (humidity sensor position) is 77°F (25°C). According to the result,
determine whether the sensor is normal or not.Technical Service Bulletin # PG011R-05 Date: 060609

Fuel System - Fuel Injector Cleaning Procedure

PRODUCT GENERAL INFORMATION
PG011-05
REVISED

October 13, 2005

Title:
FUEL INJECTOR CLEANING

Models:
'90 - '06 Toyota & Scion Models With Port Electronic Fuel Injection

TSB REVISION NOTICE:

^ June 9, 2006: In the Required Tools & Material section, part numbers have been updated (TYG S-Line Device and Toyota Adaptor Pak),
and the note with ordering information has been updated. Previous versions of this TSB should be discarded.

Introduction

Due to fuel quality concerns, some Toyota and Scion vehicles with Port Electronic Fuel Injection may experience clogged or blocked fuel injectors.
The following procedure has been developed to clean the fuel injectors.

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Applicable Vehicles:
^ All 1990 - 2006 Toyota and Scion models equipped with Port Electronic Fuel Vehicles Injection (EFI).

Required Tools & Material

Warranty Information

Repair Procedure

1. If the fuel injector nozzles are visibly blocked or if the injectors do NOT pass the fuel injector volume test, complete the fuel injector power
flush using the following instructions:

A. Before an injector cleaning is performed, it is recommended that the following items be cleaned with Toyota Throttle Plate Cleaner
(P/N 00289-1TP00):

^ Idle air control device

^ Throttle plate (both sides if possible)

^ Throttle body

B. Bring the engine to operating temperature.

C. Disconnect the fuel pump electrical connector.

D. Start the engine. After the engine has stalled, turn the ignition switch OFF.

E. Disable the fuel return line by blocking the line or installing the appropriate plug in the return outlet, if applicable.

NOTE:
Do NOT clamp plastic lines.

F. Install the device adapter to the fuel line and then secure the swivel fitting on the end of the hose.

G. Make sure the ball valve on the device is turned OFF (valve handle is crosswise to device). Screw the can of EFI cleaner (P/N
00289-1PF14) onto the device can adapter.

H. Open the valve on the device, start the vehicle, and allow it to run until the engine stalls.

I. Turn the ball valve OFF and remove the empty can.

J. Place a shop towel over the can adapter and slowly open the ball valve to depressurize the system.

K. Remove supply and return line adapters, reconnect vehicle fuel supply and return lines (replacing any fuel line gaskets and seals), and
connect the fuel pump electrical connector.

L. Before starting the vehicle, pressurize the fuel system and check for leaks.

Run the engine for 4 - 5 minutes, and then snap the throttle several times to dislodge any carbon that may remain in the system.

2. Add 1 can of Toyota Non-Pressurized Fuel Injector Cleaner Fuel Tank Additive (P/N 08813-0080DS) to the fuel tank.

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3. Road test the vehicle to verify normal operation.

Technical Service Bulletin # PG001R-06 Date: 061128

Electrical - Battery Maintenance and Testing

PRODUCT GENERAL INFORMATION
PG001-06

Title:
BATTERY MAINTENANCE FOR
IN-STOCK VEHICLES & PRE-DELIVERY

Models:
All Models & Model Years

January 26, 2006

TSB REVISION NOTICE:

^ November 28, 2006: "Required SSTs" have been updated (SST P/N 00002-MCGR8 has been added). "Recommended Equipment" has been
removed (superseded by SST P/N 00002-MCGR8). Screen prints and text have been updated in the "Battery Inspection Procedure".
"Battery Service Procedure" has been renamed "Battery Inspection Results". Two sections have been added for SST P/N 00002-MCGR8:
"Battery Charging Procedure" and "Battery Charging Results". PLEASE READ ENTIRE TSB.

Previous versions of this TSB should be discarded.

TSB UPDATE NOTICE:

The information contained in this TSB supersedes TSB No. PG017-02.
TSB No. PGO17-02 is now obsolete and should be discarded.

Introduction

A battery in a stored vehicle is subject to conditions that can reduce its performance and life. These conditions include storage period, temperature,
parasitic drain, and battery load. Because of these factors, battery inspection and maintenance are required in order to ensure proper operation and
optimal battery life.

As a matter of policy, Toyota does not provide battery warranty coverage for discharged and/or failed batteries due to lack of maintenance. It is the
dealer's responsibility to maintain the specified State of Charge (SOC) of the vehicle's battery while in stock and assure proper State of Charge
(SOC) at delivery.

To eliminate customer service concerns due to an undercharged battery during the first few weeks of ownership, all dealers should check battery
State of Charge (SOC) and recharge, if necessary, within 48 hours of delivery to customers.

Applicable Vehicles

^ All models and model years.

Warranty Information

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Required SSTs

Battery Inspection Procedure

All vehicles are to be inspected according to the procedures listed below using the Digital Battery System Analyzer (P/N 00002-V8150-KIT) no
more than 48 hours prior to customer vehicle delivery.

In hybrid vehicles, the Digital Battery System Analyzer (SST P/N 00002-V81 50-KIT) is to be used ONLY on the AUXILIARY (12 volt) battery.

1. Connect test clamps to the battery. (If the analyzer does NOT power up automatically, press the POWER button.)

2. Select the correct USER ID (if applicable) and press the NEXT soft key.

3. Enter USER PIN (if applicable) and press the NEXT soft key.

NOTE:
For details on defining USER ID or PIN, refer to the NVS-8150 Instruction Manual.

4. Press the NEXT soft key (if applicable) when the HELLO screen appears to proceed to the Main Menu.

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5. Choose BATTERY TEST and press the SELECT soft key.

6. Select IN VEHICLE and press the NEXT soft key.

7. Select MODEL and press the NEXT soft key.

NOTE:

^ "MODEL" or "STOCK # " MUST be used to receive a warranty code if the tester determines that the battery is bad.

^ "MODEL" and "STOCK#" are linked to custom algorithms and are the most accurate testing procedures.

8. Select the appropriate model and press the NEXT soft key.

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9. Select OEM battery type and press the NEXT soft key.

10. Choose the correct battery (model number and CCA) and press the NEXT soft key.

11. Aim the infrared (IR) temperature measurement sensor at the negative (-) battery post and press the NEXT soft key.

The battery is now being tested. The progress bar fills in across the screen while testing.

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12. Read or print the battery test results (press the PRINT soft key to print).

Battery Inspection Results

Once the test completes, proceed with one of the 5 procedures below according to the BATTERY CONDITION results.

1. Battery Condition: "GOOD BATTERY"

Return the battery to service.

2. Battery Condition: "GOOD-RECHARGE"

Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8) and return it to service.

3. Battery Condition: "CHARGE & RETEST"

Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8) and retest.

NOTE:
Failure to fully charge the battery before retesting may cause false readings.

4. Battery Condition: "REPLACE BATTERY"

Replace the battery.

NOTE:
A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery. Retest the battery using the
out-of-vehicle test before replacing it.

5. Battery Condition: "BAD CELL-REPLACE"

Replace the battery. The decision indicates a bad cell within the battery.

CAUTION:

^ If "FROZEN BATTERY" is displayed as the test result, allow the battery to reach a temperature of 40°F (4°C) before retesting.

^ NEVER CHARGE A FROZEN BATTERY GASES MAY FORM, CRACKING THE CASE AND CAUSING BATTERY ACID TO
LEAK.

Battery Charging Procedure

If the battery requires charging, follow the procedures below using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8).

1. Connect the charger cables to the positive (+) and negative (-) battery terminals.

2. Plug the charger into the 110V outlet and turn the switch to the ON position.

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3. Select appropriate USER ID (if applicable) and press the NEXT soft key.

4. Enter USER PIN (if applicable) and press the NEXT soft key.

NOTE:
For details on defining USER ID or PIN, refer to the GR8 Instruction Manual.

5. Press the NEXT soft key when the HELLO screen appears to proceed to the Main Menu.

6. Select CHARGING from the Main Menu screen and press the SELECT soft key.

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7. Select DIAGNOSTIC from the Charge Menu screen and press the SELECT soft key.

8. Select IN VEHICLE and press the NEXT soft key.

9. Select MODEL and press the NEXT soft key.

NOTE:

^ "MODEL" or "STOCK # " MUST be used to receive a warranty code if the tester determines that the battery is bad.

^ "MODEL" and "STOCK # " are linked to custom algorithms and are the most accurate testing procedures.

10. Select the appropriate model and press the NEXT soft key.

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11. Select OEM battery type and press the NEXT soft key.

12. Choose the correct battery (model number and CCA) and press the NEXT soft key.

The battery will be tested before charging will occur. The progress bar fills in across the screen while testing.

The charger starts charging upon completion of testing. The screen displays the status of charge.

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13. Read or print the battery test results.

P 1/4: BATTERY RESULTS

P 2/4: STATE OF CHARGE (SOC)

P 3/4: STATE OF HEALTH (SOH)

P 4/4: WARRANTY CODE

To print:
Align the Midtronics IR Printer
(P/N 00002-A0870, component of
P/N 00002-V8150-KIT) in front of the
IR port on the charger and select the
PRINT soft key.

Battery Charging Results

Once the test completes, proceed with 1 of the 3 procedures below according to the BATTERY CONDITION results.

1. Battery Condition: "GOOD BATTERY"

Return the battery to service.

2. Battery Condition: "REPLACE BATTERY"

Replace the battery. Print the RESULTS screen for WARRANTY CODE by pressing the PRINT soft key.

NOTE:
A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery. Retest the battery using the
out-of-vehicle test before replacing it.

3. Battery Condition: "BAD CELL-REPLACE"

Replace the battery. The decision indicates a bad cell within the battery. Print the RESULTS screen for WARRANTY CODE by pressing the
PRINT soft key.

Battery Replacement

If a vehicle battery needs to be replaced for a warrantable condition, complete a Warranty Battery Label and affix it to the failed battery for proper

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warranty parts and claim processing. Include the Vehicle Identification Number ("IN) and warranty code on the Warranty Battery Label.

Battery Maintenance

Recommended Battery Maintenance:

In addition to this new pre-delivery battery test, a monthly battery inspection is still required for stored vehicles. If your dealership is located in an
area subject to extreme temperatures (hot or cold), periodic maintenance may need to be performed more frequently.

To reduce parasitic battery drain on vehicles in storage for one week or more, the negative (-) battery cable should always be disconnected to
reduce battery discharge. When the negative (-) battery cable is reconnected, please check and reset electrical components, such as the clock, radio,
etc., and re-initialize all applicable systems/functions.

Refer to the appropriate model and year service bulletins for specific details. For example:

^ TSB No. PD008-05, "Power System Initialization During PDS" (2005 model year)

^ TSB No. PDO14-06, "Power System Initialization During PDS" (2006 model year) Technical Service Bulletin # TC003-07 Date:
070306

Drivetrain - Drive/Axle Shaft Replacement Precautions

TRANSMISSION & CLUTCH
TC003-07

Title:
DRIVESHAFT ASSEMBLY
REPLACEMENT

Models:
'90 - '07 Toyota

Introduction
The purpose of this bulletin is to provide information regarding anti-corrosion grease that is present on replacement driveshaft assemblies. It is
important to remove this grease prior to installing the hub nut to prevent overtightening. This also applies when reusing an old driveshaft that may
have come into contact with oil or foreign matter.

Applicable Vehicles

^ 1990 - 2007 model year Toyota vehicles.

Required Tools & Material

Repair Procedure

Clean the threaded area of the driveshaft with Toyota Brake Cleaner (or equivalent) to remove the anti-corrosion grease, oil, or foreign matter
before installing the driveshaft into the vehicle.

NOTE:

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A new axle hub nut may be required when installing the driveshaft. Check the Repair Manual procedure for more information.

Warranty InformationTechnical Service Bulletin # EG034-07 Date: 070628

Engine Controls - Bank 1/Bank 2 O2 Sensor identification

ENGINE
EG034-07

Title:
ENGINE BANK 1 AND BANK 2 A/F AND
O2 IDENTIFICATION

Models:
'93 - '08 Applicable Models

June 28, 2007

The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded.

Introduction

This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor
replacement.

This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV),
1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE.

^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.

^ Bank 2 (B2) refers to the bank opposite bank 1.

^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.

^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.

Warranty Information

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Applicable Vehicles

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Engine Bank Identification

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A/F and 02 Sensor Identification

Technical Service Bulletin # CRIB146 Date: 060901

Body - Paintless Dent Repair Information

TITLE: PAINTLESS DENT REPAIR

SECTION: EXTERIOR BULLETIN # 146

MODELS: TOYOTA, SCION AND LEXUS

DATE: SEPTEMBER 2006

Toyota has developed the following guidelines for the use of "Paintless Dent Repair (PDR) procedures on all Toyota, Scion and Lexus vehicles.

PDR is used to reduce the cost of repairing minor dents and to avoid color match and refinish issues that may arise. Be sure to choose your PDR
service provider carefully and always review their professional qualifications to ensure they are up to date on the latest PDR techniques and
procedures.

Repair Precautions

^ Always refer to the specific vehicle schematic (available from your PDR provider) for locations where PDR is possible.

^ Pay close attention to the locations of accessories and subassemblies that may utilize wire harnesses or drain hoses, etc.

^ PDR is often complicated by panel contour, placement of reinforcements, and location of electrical and mechanical components.

^ PDR Technicians should be aware of and take the necessary precautions to prevent damage to electrical and mechanical components while
performing PDR repairs.

General Repair Guidelines

^ The PDR process should only be considered when the exterior paint surface is not broken or cracked. A 30X power hand held microscope

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(available from most body shop jobbers) should be used to determine if the paint surface shows evidence of cracking.

^ Pushing and prying on the back side of body panels can disrupt the factory rust and corrosion protective coatings. PDR technicians must take
steps to prevent corrosion coating damage or restore it with approved equivalent materials. PDR service companies performing PDR repairs
should be knowledgeable and capable of restoring corrosion protective coatings damaged during PDR repairs.

PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER MANAGER AND COLLISION REPAIR TECHNICIANS

^ Prying, pushing, or pulling on body panels may cause stretching beyond the flexible limits of the paint coatings causing delamination (paint
coating separation) or micro-cracking. These conditions may not be immediately detectable (use a 30X magnifying hand-held microscope to
inspect for cracks).

Important:
The PDR process uses special tools to access otherwise inaccessible areas. Drilling of holes, prying away or cutting reinforcements or
welded structural components to gain access to perform a PDR is strictly prohibited and, if done, may void the manufacturer's corrosion
protection warranty.

^ Using blocks or wedges between window moldings and door glass (for tool access) is also prohibited. This process can damage window
moldings and reduce the factory designed-in pressure of the inner belt molding on the base of the door glass.

^ Window guard protectors must be used to protect window glass during PDR operations.

Specific Repair Guidelines

^ Panels with multiple dents, including hail damage, may be considered for PDR as long as the original panel integrity (strength) is maintained. If
a panel exhibits any evidence of loss of strength due to the number of dents, the panel should not be considered for PDR. If after performing a
PDR repair the panel exhibits evidence of loss of strength, the panel must be repaired using conventional body shop processes.

^ Round/oval dents may be removed if they are 2 inches or more away from panel edges or body lines and are no larger than the diameter of a
soft ball.

^ Creases that are up to 4 long may be considered for removal.

Note:
Sharp creases cannot be removed using PDR.

^ Dents or protrusions, of up to 6mm, from the reverse side, on hoods, trunks, fenders, and quarter panels may be considered, but extreme caution
must be used during this type of repair due to the higher potential of damaging the paint surface. Remember no broken paint.Technical
Service Bulletin # EL010R-07 Date: 071110

Keyless Entry - Remote Transmitter Programming Guide

ELECTRICAL
EL010-07
REVISED

Title:
WIRELESS TRANSMITTER &
PROGRAMMING GUIDE

Models:
'90 - '08 Applicable Toyota

November 9, 2007

TSB REVISION NOTICE:

^ November 10, 2007: A TSB reference has been updated in the Programming column of the Application Chart.

Previous versions of this TSB should be discarded.

TSB UPDATE NOTICE:

The information contained in this TSB supersedes TSB No. EL008-02. TSB No. EL008-02 is now obsolete and should be discarded.

Introduction

Difficulties during Remote Keyless Entry (RKE) Transmitter Programming can arise due to confusion between Toyota Factory Wireless systems
and Toyota Port/Dealer installed systems. This bulletin will assist in identifying the system/correct remote transmitters for each vehicle, and provide
the location of the most accurate programming procedure for each system.

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Applicable Vehicles

^ 1990 - 2008 model year applicable Toyota vehicles.

Warranty Information

System Identification

The Application Chart contains all of the necessary information to correctly identify the type of system installed, and where to go to get
programming procedures for each vehicle.

Should a vehicle having both VIP and Factory systems available (as identified in the Application Chart) be brought in without any remotes (or one
non-working remote), use the following tips to help determine which type of wireless system (O.E. or PIO/DIO) the vehicle has.

^ Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while entry-grade vehicles will tend to have VIR
For example, the 2001 Camry XLE has Factory WRKE, but the LE and CE grades have VIR

^ Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the dashboard or on the center console. Most VIP
systems will have this.

^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located, refer to the part label.

^ Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the "confirmation mode" and see if
any "Lock/Unlock" response is received, if so, the vehicle has a factory system.

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Application Chart

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Wireless Transmitter Identification

Technical Service Bulletin # SB0258-08 Date: 080902

Restraints - Seat Belt Tongue Plate Stopper Replacement

T-SB-0258-08

September 2, 2008

Seat Belt Tongue Plate Stopper Replacement

Service Category
Vehicle Interior

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Section
Seat Belt

Market
USA

Applicability

TSB SUPERSESSION NOTICE

The information contained in this TSB supersedes TSB No. BO017-07.

^ Applicability has been updated to include 2008 model year vehicles.

TSB No. BO017-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before
proceeding.

Introduction

For situations where only the seat belt stopper is broken a new service part has been developed to eliminate the need to replace the entire seat belt
assembly. Follow the installation procedure below to utilize this new part.

Warranty Information

APPLICABLE WARRANTY

^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs
first, from the vehicle's in-service date.

^ Warranty application is limited to correction of a problem based upon a customer's specific complaint.

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Parts Information

Repair Procedure

1. Shift the tongue plate to the upper portion of the tongue plate stopper and temporarily hold it with a clip or tape.

2. Remove any pieces of the original tongue plate stopper in the webbing with a pair of diagonal pliers.

NOTE

Be careful not to damage the webbing, since this may compromise the safety of this seatbelt.

CAUTION

Damaged or weakened seat belts may break in an accident and injure the occupant. The seat belt assembly MUST be replaced if:

^ The webbing is cut, frayed, worn, or damaged.

^ It has been used during a severe impact (inspect the label to ensure no impact damage has occurred)

Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful NOT to damage the webbing during
repair.

3. Install the NEW tongue plate stopper

A. Install a NEW tongue plate stopper in the hole of the webbing.

NOTE

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Be sure to install the stopper in the correct direction as shown in the illustration.

B. Pinch the tongue plate stopper into the webbing using the tool shown in Figure 3 or use a small "C" clamp.

NOTE

To prevent damage to the plastic tongue plate stopper when using a "C" clamp device, use light to moderate clamping force when
crimping the two halves of the tongue plate stopper together.

HINT

Press the adjustment screw locating the male and female parts of the tongue plate stopper parallel to each other.

CAUTION

For this procedure, do not use pliers. They may damage the webbing.

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C. Tighten the c-clamp until the space between its jaws are 4.5 - 5.0 mm (0.18 in. -0.20 in.) Figures 5 & 6

D. Verify the male pin of the tongue plate stopper has deformed evenly in the hole of the female part and is firmly held to the belt
webbing.

Technical Service Bulletin # SB0138-08 Date: 080721

Body/Frame - Protective Wax Coating Information

T-SB-0138-08

July 21, 2008

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Permanent-Type Protective Wax Coatings

Service Category
Vehicle Exterior

Section
Paint/Coatings

Market
USA

Applicability

Introduction

Toyota uses two types of permanent protective wax coatings; one is yellow-brown and the other is black. The yellow-brown (cavity wax) is used
for interior body panels (i.e. hoods trunk lids doors engine compartment components etc.). The black (underbody wax) is used on the underside of
the body floor separate frame (if equipped) as well as inside the fenderwell areas. Both types of waxes provide substantial corrosion protection to
the aforementioned areas and components.

These permanent-type protective wax coatings should not be removed from the vehicle unless body work is to be done in an area coated with the
protective wax. It is essential that these wax coatings be restored to areas where the wax was removed during body repairs. Replacement wax
coatings are available from local automotive chemical suppliers.

NOTE:
^ Any underbody wax that has been inadvertently sprayed on the exhaust system by the factory will normally dissipate in a few miles.

Warranty Information

Parts Information

Cleaning Procedure

If necessary removal of any wax coating overspray on the exterior paint finish may be removed easily with Toyota bug and Tar Remover. Be sure
to wash the paint surface with Toyota Liquid Car Wash before using the Bug and Tar Remover (this will prevent scratching of the paint surface
from dirt trapped in the wax coating.)

Technical Service Bulletin # CRIB155 Date: 070801

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Body/Frame - Sectioning Information
TITLE: BODY & FRAME SECTIONING

SECTION: EXTERIOR

BULLETIN # 155

MODELS: ALL TOYOTA, LEXUS, and SCION MODELS

DATE: AUGUST 2007

Approved panel replacement procedures, including non-structural and structural sectioning specifications for unibody vehicles are model-, and
component-specific. Frame component sectioning is not an approved procedure. Cut and join locations, welding specifications, illustrations, and
instructions can be found in model-specific Repair Manuals for Collision Damage. Specifications provided are for new undamaged original
equipment service parts. Visit www.techinfo.toyota.com to access repair manuals and technical information.

Body Sectioning with salvage parts is not an approved repair method. This position is stated clearly in CRIB # 122 Full Body Sectioning, released
February 2003.

Frame Sectioning is considered partial replacement of a frame rail or component, and is not an approved repair procedure on full frame Toyota and
Lexus vehicles. This position is stated clearly in CRIB # 136 Full Frame Components, released September 2003. CRIB # 136 provides information
to enhance a collision repair professional's ability to make better decisions about frame repairs, and should not be interpreted to include every frame
component replacement scenario. For more detailed information on this topic plan to attend Toyota/Lexus Collision Repair & Refinish,
Non-Structural and Structural Body Repair Training. Visit www.crrtraining.com for training registration information.

Technical Service Bulletin # CRIB158 Date: 071001

Body - Panel Adhesive Information

TITLE: PANEL ADHESIVE

SECTION: EXTERIOR

BULLETIN # 158

MODELS: ALL TOYOTA, LEXUS, and SCION

DATE: OCTOBER 2007

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The application or use of panel adhesive is limited to the approved procedures published in Toyota, Lexus, and Scion model-specific Collision
Damage Repair Manuals. The following illustration is an example of specifications that include the use of adhesive. Please review collision repair
manuals (mwww.techinfo.toyota.com) for complete instructions and symbol translations.

INSTALLATION POINT

^ Apply adhesive (3M(TM) Automix(TM) Panel Bonding adhesive # 8115) to the area indicated by *1.

^ Perform spot-welding on the flange indicated by *2.

Note:
Panel-bonding and weld-bonding are not approved procedures.

Definitions:

^ Panel-bonding is a substitution of any specified welds with adhesive material.

^ Weld-bonding is squeeze-type resistant spot-welding through adhesive. Technical Service Bulletin # CRIB161 Date: 080101

Body - Collision Damage Repair Precautions

TITLE: COLLISION DAMAGE REPAIR PRECAUTIONS

SECTION: STRUCTURAL

BULLETIN # 161

MODELS: ALL TOYOTA, LEXUS, and SCION

DATE: JANUARY 2008

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The following collection of precautions is intended to reinforce Toyota's position on some key collision repair topics, and should not be considered
all inclusive or a substitute for training. For more information on these and other important collision repair and refinish topics plan to attend
Collision Repair & Refinish Training. Visit the CR&R website (www.crrtraining.com) for schedule and registration information. Technical
Service Bulletin # CRIB163 Date: 080201

Body - Sealing Hem-Flanges & Body Seams

TITLE: SEALING HEM-FLANGES & BODY SEAMS

SECTION: EXTERIOR

BULLETIN # 163

MODELS: ALL TOYOTA LEXUS and SCION

DATE: FEBRUARY 2008

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To assure factory corrosion prevention measures are replicated during body repairs always use a like-kind and quality automotive grade sealer on
hem-flanges and body seams. During manufacturing specialized materials are used however aftermarket materials are readily available to match
factory quality application and purpose. OE replacement body components are not supplied with seam sealer.

If replacement body components are not seam sealed or if poor quality materials are used; the Toyota new car corrosion warranty may be voided on
the affected components and adjoining parts and systems which are caused to fail or rust by those components. Refer to CPS-Toyota/Scion Policy
4.17 and CPS Lexus Policy 4.15 for details on what is not covered by the new vehicle limited warranty.

Refer to model-specific Collision Damage Repair Manuals for Body Panel Sealing Area specifications available from the Technical Information
System (TIS) at (www.techinfo.toyota.com). The following door sealing illustration is supplied as an example. Technical Service Bulletin #
CRIB165 Date: 090301

Body - Acid Rain Paint Damage Prevention/Repair

TITLE: ACID RAIN PAINT FINISH DAMAGE - PREVENTION & REPAIR

SECTION: EXTERIOR

BULLETIN # 165

MODELS: ALL TOYOTA LEXUS and SCION

DATE: MARCH 2008

Condition & Cause

'Acid Rain' is the result of rainwater and other forms of airborne moisture mixing with atmospheric impurities, often referred to as industrial fallout.
The mixing forms varying degrees of corrosive acidic compounds that can settle on exposed surfaces. Depending on geographic location,
concentration level, and length of exposure; vehicle paint finish damage can occur. Horizontal surfaces such as roof, hood, and trunk panels are
most vulnerable.

Prevention of Finish Damage

While Toyota, Lexus, and Scion paint finishes are engineered to look great and provide long-term durability, if not cared for properly they can
sustain damage as a result of acid rain exposure. Exposure can occur at any time in the life-cycle of a vehicle, be it transport, storage, or consumer
use.

Dealers should refer to the Toyota Warranty Policy and Procedures Manual,

Policy No.2.3 for information on Storage and Protection of New Vehicles.

Detailed information is also provided on proper finish care in the Owner's Manual of all models.

In brief, following washing and wax application recommendations should keep paint looking good.

Inspection & Repair

Acid rain damage can usually be identified visually and by touch. Stains look similar to hard-water spotting however, advanced stages of damage

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result in etching and depressions from the corrosive effect. Lightly rubbing a finger across a suspected acid rain stain may help to confirm etching.

University of Toyota e-learning course E257- Vehicle Delivery Quality- Paint Finish Repair, provides detailed information on paint finish types,
damage assessment methods, and repair techniques. And, Collision Repair & Refinish T101 and L101 'Paint Finish Repair' provide hands-on
training. There is no substitute for a good training experience. Visit (www.crrtraining.com) for more information about hands-on training.
Technical Service Bulletin # CRIB167 Date: 080701

Body/Interior - Trim Removal & Installation

TITLE: TRIM REMOVAL & INSTALLATION

SECTION: GENERAL BULLETIN #167

MODELS: ALL TOYOTA LEXUS and SCION

DATE: JULY 2OO8

During collision repair and refinish operations it is often necessary to remove interior and exterior trim. Instructions and illustrations for removal
and installation of trim can be found in the Interior and Exterior Panels/Trim section of model-specific Repair Manuals at
www.techinfo.toyota.com. Collision repair professionals can view illustrations, step by step instructions, and helpful tips. Illustrations identify the
type, quantity, and location of fasteners, as well as non-reusable items.

This information can enhance productivity and reduce damage to reusable trim and fasteners. It is important to remove and install trim properly, as
improper installation may result in poor fit and unwanted noises that may negatively impact quality and customer satisfaction. Most important,
improperly installed interior trim may become projectiles during airbag deployment.

The illustration is provided as an example of available information shown.Technical Service Bulletin # CRIB160 Date: 071201

Restraints - SRS Service Precautions

TITLE: SRS PRECAUTIONS

SECTION: ELECTRICAL

BULLETIN # 160

MODELS: ALL TOYOTA LEXUS and SCION

DATE: DECEMBER 2007

For vehicles equipped with Supplemental Restraint System (SRS) Airbags and Seat Belt Pretensioners failure to follow diagnostics and servicing
procedures in the correct sequence could cause the SRS to deploy unexpectedly and lead to serious injury. Furthermore if a mistake is made while
servicing the SRS it is possible the SRS may fail to operate properly. Be sure to read and follow all applicable precautions and service information
closely. SRS service information can be found in model-specific Repair Manuals (www.techinfo.toyota.com).

Important SRS Precautions include. but are not limited to:

^ When troubleshooting the SRS, always check for Diagnostic Trouble Codes (DTC's) before disconnecting the battery.

^ If one or more DTC's are displayed, note each DTC, then disconnect; the negative (-) battery terminal, the malfunctioning circuit, and the SRS

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computer connector.

^ Work must be started no less than 90 seconds after the SRS power source has been disconnected to allow for back-up power discharge.

^ In minor collisions where the SRS does not deploy, all SRS components and wiring should be inspected before further use of the vehicle.

^ Never use SRS components or wiring from another vehicle, use only new Genuine OE parts.

^ Before body repairs, remove airbag sensor assemblies if shocks are likely to be applied near the sensors.

^ Never attempt to disassemble or repair airbags, pretensioners, or sensor assemblies.

^ Do not attempt to refinish any SRS components, covers, or trim. Refinish materials may alter deployment characteristics.

^ Do not expose any SRS components or wiring to excessive heat or open flame.

^ Do not probe SRS wiring with a test light. Use a voltmeter/ohm meter with high impedance (minimum 10 kC)) for troubleshooting.

^ When using electric welding anywhere on the vehicle, disconnect the 12 volt battery and the center airbag sensor assembly connectors. These
connectors contain shorting pins. This feature reduces the possibility of airbag deployment due to current entering the squib wiring.

^ Never connect or disconnect the center airbag connectors without the sensor being secured in its factory installed location.

^ Never reuse a center airbag sensor that has been involved in a collision where the SRS has deployed.

^ Never repair SRS wiring or connectors. Replace damaged wiring. Technical Service Bulletin # CRIB170 Date: 081001

Body - Plastic Bumper Refinishing

TITLE: PLASTIC BUMPER REFINISHING

SECTION: REFINISH

BULLETIN # 170

MODELS: ALL TOYOTA LEXUS and SCION

DATE: OCTOBER 2008

When it is necessary to replace a damaged plastic bumper, proper consideration should be given to preparation and refinishing to ensure high
quality, long-term durability, and customer satisfaction. While it is important to follow paint manufacturer recommendations for application of
refinish materials, this bulletin provides Toyota recommended procedures for cleaning and preparation of original equipment (OE) raw plastic
bumpers.

Background:

Toyota bumper covers are manufactured using several types of plastic however, cleaning and preparation procedures outlined here are applicable to
all Toyota, Lexus, and Scion raw plastic OE bumpers.

Soap-base mold release agent replaced the wax-base type beginning in 1995 to reduce volatile organic compound (VOC) emissions produced by
the use of cleaning solvents. This topic is covered in Collision Repair Information Bulletin (CRIB) #69. Thorough cleaning with recommended
soap and water removes soap-base mold release agent.

Cleaning and Preparation:

^ Wash new part thoroughly inside and out with a hot water and ph neutral wax-free carwash soap solution. Rinse well and dry with clean towels.

Cleaning and Preparation, Continued-

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^ Clean exterior surface and all edges thoroughly with paint manufacturer recommended plastic parts cleaner or water-base wax and grease
remover, or a 1-1 mixture of isopropyl alcohol and deionized water.

^ Scuff exterior surface and all edges with a medium to fine scuff pad (as recommended by paint manufacturer), with sanding paste and clean
water. Repeat wash sequence, rinse well and dry with clean towels.

^ Examine the bumper closely, especially hard to reach areas. Re-scuff any areas that do not appear to have been scuffed sufficiently. Repeat
wash- rinse-dry sequence.

^ Make final surface inspection and clean with paint manufacturer recommended cleaner or a 1-1 mixture of isopropyl alcohol and deionized
water.

^ Apply anti-static measures.

^ Apply adhesion promoter per paint manufacturer7s recommendations.

^ Apply primer and topcoats per paint manufacturer7s recommendations.

Note:
Toyota recommends the use of adhesion promoter and elastifier for all OE raw plastic bumpers to ensure adhesion, flexibility, and long-term
durability of topcoats; and the use of refinish materials that meet or exceed the Toyota new vehicle limited paint finish warranty.

Toyota, Lexus and Scion bumpers are primarily made from TSOP (Toyota Super Olefin Polymer). This type of plastic requires the use of adhesion
promoters. However, the application of adhesion promoters on earlier model bumpers made from PP/TPU (Polypropylene/Thermoplastic Urethane)
and PUR (Polyurethane) is also recommended.Technical Service Bulletin # CRIB172 Date: 090301

Body - Bumper Component Repair

COLLISION REPAIR INFORMATION
FOR THE COLLISION REPAIR PROFESSIONAL

TITLE: BUMPER COMPONENT REPAIR

SECTION: EXTERIOR BULLETIN # 172

MODELS: ALL TOYOTA LEXUS and SCION

DATE: MARCH 2009

While it may seem cost effective to repair damaged bumper components specifically impact energy absorbers and reinforcements there is no way to
certify that a repaired part will function as originally intended under all future operating conditions and subsequent collisions. Original Equipment
bumper components comply with Federal Motor Vehicle Safety Standards established under the National Highway Traffic Safety Administration
Title 49 Part 581. Therefore it is recommended to replace damaged bumper impact energy absorbers and reinforcements with genuine new original
equipment replacement parts only.

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For more information on collision damage repair topics please refer to Collision Repair Information Bulletin # 161 Collision Damage Repair
Precautions and plan to attend Toyota Collision Repair & Refinish Training. Visit www.crrtraining.com for training information. Technical
Service Bulletin # CRIB173 Date: 090401

Paint - Refinishing Information

COLLISION REPAIR INFORMATION
FOR THE COLLISION REPAIR PROFESSIONAL

TITLE: TOPCOAT SAND & POLISH

SECTION: REFINISH BULLETIN # 173

MODELS: ALL TOYOTA LEXUS AND SCION

DATE: APRIL 2009

Customers have high expectations for automotive paint finish appearance and expect repairs to match factory color gloss and texture. Flawed
refinish appearance is a cause of concern and will likely have a negative affect on customer satisfaction and retention.

Toyota recognizes the reality of paint finish application in the shop environment. In addition to color matching and blending countermeasures to
remove paint process intrusion (dirt nibs) are necessary to achieve an undetectable finish match. This is also common in manufacturing plants when
process intrusion is encountered. Countermeasures are defined as; ultra-fine sanding to level nibs followed by polishing to a level of gloss and
texture consistent with the original finish. Technicians undertaking these tasks should review applicable technical data sheets for product process
and handling instructions as well as applicable safety information.

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Topcoat sand and polish is one of many paint finish repair techniques covered in Toyota T101 and Lexus L101 Paint Finish Repair training. Please
visit for scheduling and registration information.Technical Service Bulletin # CRIB156 Date: 070801

Electrical - SRS And HV Wiring Repairs

TITLE: SRS & HV WIRING REPAIRS

SECTION: ELECTRICAL

BULLETIN # 156

MODELS: ALL TOYOTA LEXUS and SCION MODELS

DATE: AUGUST 2007

There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and
connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in
these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com.

If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require
replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or
components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components.Technical Service
Bulletin # CRIB159 Date: 071201

Body - Corrosion Prevention & Sound Absorption Info.

COLLISION REPAIR INFORMATION
FOR THE COLLISION REPAIR PROFESSIONAL

TITLE: CORROSION PREVENTION & SOUND ABSORBING MEASURES

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SECTION: EXTERIOR BULLETIN #159

MODELS: ALL TOYOTA LEXUS and SCION

DATE: DECEMBER 2007

To assure repairs and replacement components meet strict factory standards, all corrosion preventive coatings and sound absorbing materials must
be replicated to match OE application and purpose. In addition, the use of weld thru primer is strongly recommended during welding operations.

If the following materials are not restored to OE like-kind and quality road noise may be amplified and the Toyota new car corrosion warranty may
be voided on the affected components and adjoining parts and systems which are caused to fail or rust by those components. Refer to
CPS-Toyota/Scion Policy 4.17 and CPS Lexus Policy 4.15 for details on what is not covered by the new vehicle limited warranty.

^ Seam Sealer ^ Cavity Wax ^ ED Primer

^ Undercoating ^ Frame Finish Coatings ^ Chip Resistant Coatings

^ Sound Absorbing Materials

Please refer to model-specific Collision Damage Repair Manuals (www.techinfo.toyota.com) for specifications illustrations instructions and
locations of these coatings.Technical Service Bulletin # CRIB175 Date: 091201

Body - HSS/UHSS Cabin Reinforcement Repair/Replacement

COLLISION REPAIR INFORMATION
FOR THE COLLISION REPAIR PROFESSIONAL

TITLE: HSS & UHSS CABIN REINFORCEMENT REPAIR & REPLACEMENT

SECTION: STRUCTURAL BULLETIN # 175 (revised)

MODELS: ALL TOYOTA LEXUS and SCION

DATE: DECEMBER 2009

Model-specific Collision Damage Repair Manuals' contain Structural Outline' illustrations that identify locations and strength ratings for High
Strength Steel (HSS) and Ultra High Strength Steel (UHSS) components throughout body and frame structures. This information is provided so that
collision repair professionals can make informed decisions on repair and replacement of components that provide high margins of crash safety to
vehicle occupants.

Because occupant safety is such a high priority, HSS and UHSS occupant cabin reinforcement repair is not recommended.

Do not use the following occupant cabin reinforcement repair procedures:

^ Hot and cold straightening methods

^ Sectioning of 980 MPa and 590 MPa strength-rated pillar reinforcements

^ Sectioning of 440 MPa rated components at locations other than those specified

This recommendation is based on a reduction in reinforcement strength and crash energy management revealed during research and testing

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conducted by Toyota Motor Corporation. Repaired and/or improperly sectioned reinforcements failed to exhibit the strength and performance
ratings of genuine new original equipment service parts installed to specification. Therefore damaged occupant cabin reinforcements must be
replaced.

When reinforcements must be replaced always follow welding specifications and adhere to documented model-specific cut and join locations and
procedures.Technical Service Bulletin # CRIB176 Date: 091201

Body - Approved Collision Repair Methods

COLLISION REPAIR INFORMATION
FOR THE COLLISION REPAIR PROFESSIONAL

TITLE: APPROVED COLLISION REPAIR METHODS

SECTION: STRUCTURAL BULLETIN # 176 (revised)

MODELS: ALL TOYOTA LEXUS and SCION

DATE: DECEMBER 2009

During collision repair straightening operations it is often necessary to stress-relieve metal components to return them or attached components to
original shape alignment and strength. It is also often necessary to replace or section damaged weld-on components. The following information is
intended to provide an overview of approved repair methods and repair methods that are not recommended for these operations. This information
also reinforces specific precautions currently published in Collision Repair Information Bulletins (CRIBs) and those covered in
instructor-facilitated hands-on training.

Instructor facilitated hands-on training information is available at www.crrtraining.com. All pertinent collision repair specifications and precautions
are covered in-depth during the following training courses:

^ Course # 301 Non-Structural Body Repair Training

^ Course # 460 Structural Body Repair Training

Collision Repair Information Bulletins can be accessed at www.techinfo.toyota.com. Refer to the following bulletins for more detailed information
on applicable collision repair topics and precautions:

^ CRIB # 122 Full Body Sectioning

^ CRIB # 155 Body & Frame Sectioning

^ CRIB # 157 Collision Parts Position Statement

^ CRIB # 158 Panel Adhesive

^ CRIB # 161 Collision Damage Repair Precautions

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^ CRIB # 172 Bumper Component Repair

^ CRIB # 174 Welding Prius UHSS

^ CRIB # 175 HSS & UHSS Occupant Cabin Reinforcement Repair & Replacement
Technical Service Bulletin # CRIB177 Date: 100301

Restraints - OCS System Initialization

COLLISION REPAIR INFORMATION
FOR THE COLLISION REPAIR PROFESSIONAL

TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION

SECTION: ELECTRICAL BULLETIN # 177

MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS

DATE: MARCH 2010

Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front
and side airbags based on seat occupancy passenger weight and seat belt latch engagement.

If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction
Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC).

NOTE:
It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not
cleared the system may not operate properly.

Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or
capable diagnostic tester.

Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly
regardless of occupancy:

^ The OCS Electronic Control Unit (ECU) is replaced

^ Accessories such as a seatback tray are installed on the passenger seat

^ The passenger seat is removed and replaced or reinstalled

^ The vehicle is involved in an accident or collision

Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com

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