2008 TOYOTA COROLLA Service Repair Manual

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This is the Highly Detailed factory service repair manual for the2008 TOYOTA COROLLA, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.2008 TOYOTA COROLLA Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: Introduction Preparation Service Specifications Diagnostics Engine Control System Fuel Emission Control Intake Engine Mechanical Exhaust Cooling Lubrication Ignition Starting and Charging Front Suspension Rear Suspension Tire Wheel Drive Shaft Propeller Shaft Brake Parking Brake Automatic Transmission Manual Transmission Clutch Steering Column Power Steering Heater and Air Conditioner Supplemental Restraint System Seat Belt Lighting Wiper and Washer Audio and Visual System Wiring Communication System Windshield Window Glass Instrument Panel Meter Seat Theft Defferent Door Lock Sliding Roof Convertible Engine Hood Door Exterior Interior Trim Vehicle Control System Cruise Control Maintenance Alphabetical Index File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have2008 TOYOTA COROLLA Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: https://www.aservicemanualpdf.com/ Thanks for visiting!
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  • 1. INTRODUCTION PREPARATION SERVICE SPECIFICATIONS DIAGNOSTICS ENGINE CONTROL SYSTEM FUEL EMISSION CONTROL INTAKE ENGINE MECHANICAL EXHAUST COOLING LUBRICATION IGNITION STARTING & CHARGING FRONT SUSPENTION REAR SUSPENTION TIRE & WHEEL DRIVE SHAFT / PROPELLER SHAFT BRAKE PARKING BRAKE AUTOMATIC TRANSMISSION / TRANS MANUAL TRANSMISSION/TRANSAXLE CLUTCH STEERING COLUMN POWER STEERING HEATER & AIR CONDITIONER SUPPLEMENTAL RESTRAINT SYSTEM 1 2 3 5 10 11 12 13 14 15 16 17 18 19 26 27 28 30 32 33 40 41 42 50 51 55 60
  • 2. SEAT BELT LIGHTING WIPER & WASHER AUDIO & VISUAL SYSTEM WIRING COMMUNICATION SYSTEM WINDSHIELD/WINDOWGLASS/MIRROR INSTRUMENT PANEL/METER SEAT THEFT DETTERENT & DOOR LOCK SLIDING ROOF/CONVERTIBLE ENGINE HOOD/DOOR EXTERIOR/INTERIOR TRIM VEHICLE CONTROL SYSTEM CRUISE CONTROL MAINTENANCE ALPHABETICAL INDEX 61 65 66 67 68 69 70 71 72 73 74 75 76 80 82 99
  • 3. 0103I–08 N17080 Filler Cap Float Reservoir Tank z Grommet Clip Slotted Spring Pin : Specified torque z Non–reusable part Cylinder Piston Push Rod Washer Snap Ring Boot z Gasket Lock Nut Clevis Pin Clevis N·m (kgf·cm, ft·lbf) 12 (120, 9) 15 (155, 11) –INTRODUCTION HOW TO USE THIS MANUAL 01–1 4AuthorĂ: DateĂ: 2004 COROLLA (RM1037U) HOW TO USE THIS MANUAL GENERAL INFORMATION 1. GENERAL DESCRIPTION (a) This manual is made in accordance with SAE J2008. (b) Generally, repair operations can be separated in the following 3 main processes: 1. Diagnosis 2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting 3. Final Inspection (c) This manual explains the 1st process of ”Diagnosis” (found in the ”Diagnostics” section), the 2nd pro- cess of ”Removing and Installing, Replacing, Disassembling, Installing and Checking, and Adjusting”, but the 3rd process of ”Final Inspection” is omitted. (d) The following essential operations are not written in this manual. However, these operations must be performed in actual situations. (1) Operations with a jack or lift (2) Cleaning of a removed part when necessary (3) Visual check 2. INDEX (a) An alphabetical INDEX section is provided at the end of the book as a reference to help you find the item to be repaired. 3. PREPARATION (a) Use of special service tools (SST) and special service materials (SSM) may be required, depending on the repair situation. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the Preparation section of this manual. 4. REPAIR PROCEDURES (a) Component drawing is placed under the title where necessary. (b) Non–reusable parts, grease application area, precoated parts and tightening torque are specified in the component drawings. Example:
  • 4. Illustration: what to do and where Component part No. Detailed text: how to perform task Task heading: what you will be doing Set part No. D31132 SST 01–2 –INTRODUCTION HOW TO USE THIS MANUAL 5AuthorĂ: DateĂ: 2004 COROLLA (RM1037U) (c) Tightening torque, grease application area, and non–reusable parts are described as important points in the procedures. NOTICE: There are cases where such information can only be explained by using an illustration. In these cases, all the information such as torque, oil, etc. are described in the illustration. (d) Installing procedures are performed in the reverse order of the removal and only the important points are described. (e) Only items with points are described in the procedure, and the operational portion and content are placed using an illustration. In the explanations, details of the operational method, standard value and notices are placed. (f) There may be a case where the illustrations of similar models are used. In that case, specific details may be different from the actual vehicle. (g) The procedures are presented in a step–by–step format: (1) The illustration shows what to do and where to do it. (2) The task heading tells what to do. (3) The explanation text tells how to perform the task and gives other information such as specifica- tions and warnings. Example: HINT: This format provides an experienced technician with a FAST TRACK to the necessary information. The task heading can be read at a glance when necessary and the text below provides detailed information. Important specifications and warnings always are written in bold type to stand out from the rest of the text. 5. SERVICE SPECIFICATIONS (a) Specifications are presented in bold type throughout the manual. You never have to leave the proce- dure to look up your specifications. The specifications are also found in the Service Specifications sec- tion for quick reference. 6. TERMS DEFINITION CAUTION Indicates the possibility of injury to you or other people. NOTICE Indicates the possibility of damage to the components being repaired. HINT Provides additional information to help you to perform the repair efficiently.
  • 5. –INTRODUCTION HOW TO USE THIS MANUAL 01–3 6AuthorĂ: DateĂ: 2004 COROLLA (RM1037U) 7. SI UNIT (a) The units given in this manual are primarily expressed according to the SI UNIT (International System of Units), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf)
  • 6. 01031–06 D27356 A B D27359 A B C 01–4 –INTRODUCTION IDENTIFICATION INFORMATION 7AuthorĂ: DateĂ: 2004 COROLLA (RM1037U) IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION AND SERIAL NUMBERS 1. VEHICLE IDENTIFICATION NUMBER (a) The vehicle identification number is stamped on the ve- hicle identification number plate and certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label 2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER (a) The engine serial number is stamped on the cylinder block of the engine, and the transaxle serial number is stamped on the housing, as shown in the illustration. A: 1ZZ–FE B: C59 C: A245E
  • 7. 010D8–02 1 2 3 46 5 D25016 –INTRODUCTION REPAIR INSTRUCTION 01–5 8AuthorĂ: DateĂ: 2004 COROLLA (RM1037U) REPAIR INSTRUCTION PRECAUTION 1. BASIC REPAIR HINT (a) HINTS ON OPERATIONS 1 Looks S Always wear a clean uniform. S Hat and safety shoes must be worn. 2 Vehicle protection S Set a grill cover, fender cover, seat cover and floor mat before starting the operation. 3 Safe operation S In case of working with 2 or more persons, be sure to check safety of one another. S When working with the engine running, pay attention to the ventilation of the workshop. S In case of operating on high–temperature parts, rotating, moving and vibrating parts, pay attention not to burn or injure yourself. S When jacking up the vehicle, be sure to support the specified location with a safety stand. S When lifting up the vehicle, apply a safety equipment. 4 Preparation of tools and measuring gauge S Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement. 5 Removal and installation, disassembly and assem- bly operations S Diagnose with a thorough understanding of the trouble phenomenon and perform effective operations. S Before removing the parts, check the assembly for general condition, deformation and damage. S When the structure is complicated, take a note or put match marks so as not to make mistakes that affect the function of the parts. S Clean and wash the removed parts if necessary, and assemble them after a thorough check. 6 Removed parts S Place the removed parts in the correct order to avoid mixing up or making them dirty. S As for non–reusable parts such as gasket, O–ring, and self lock nut, change them to new ones following the instruction of this manual. S Sort out the parts for replacement in a box and show them to the customer. (b) JACKING UP AND SUPPORTING VEHICLE (1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page 01–17).
  • 8. Z11554 Seal Lock Adhesive BE1367 Medium Current Fuse and High Current Fuse Equal Amperage Rating D27353 V35001 Illustration Symbol Part Name Abbreviation FUSE MEDIUM CURRENT FUSE HIGH CURRENT FUSE FUSE M–FUSE H–FUSE 01–6 –INTRODUCTION REPAIR INSTRUCTION 9AuthorĂ: DateĂ: 2004 COROLLA (RM1037U) (c) PRECOATED PARTS (1) Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. (2) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (3) When reusing precoated parts, clean off the old adhesive and dry the part with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. NOTICE: Perform the torque checking with the lower limit value of the torque tolerance. (4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave it for a specified time until it hardens. (d) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks. (e) BOLTS, NUTS AND SCREWS (1) Carefully observe all the specifications for tightening torques. Always use a torque wrench. (f) Fuses. (1) When replacing fuses, be sure that a new fuse has the correct amperage rating. DO NOT exceed the rating, or use one with a lower rating.
  • 9. D25786 Shape (Example) Removal/Installation Clip Remover Pliers Screwdriver Scraper Protective Tape Clip Protective Tape –INTRODUCTION REPAIR INSTRUCTION 01–7 10AuthorĂ: DateĂ: 2004 COROLLA (RM1037U) (g) CLIPS (1) The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If the clip is damaged during the a procedure, always replace it with a new clip.
  • 10. V35004 Shape (Example) Removal/Installation Removal Installation Removal Installation Removal Installation 01–8 –INTRODUCTION REPAIR INSTRUCTION 11AuthorĂ: DateĂ: 2004 COROLLA (RM1037U)
  • 11. D25063 CORRECTWRONG D25064 L1 L2 D02612 L2L1 D01201 –INTRODUCTION REPAIR INSTRUCTION 01–9 12AuthorĂ: DateĂ: 2004 COROLLA (RM1037U) (h) REMOVAL AND INSTALLATION OF VACUUM HOSES (1) To disconnect vacuum hoses, pull them by holding the end, not the middle of the hose. (2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected. (3) After completing the job, make a double check whether the vacuum hoses are properly connected. A label under the hood shows the proper layout. (4) When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step–down adapter for adjustment. Once the hose has been stretched, it may leak air. (i) TORQUE WHEN USING TORQUE WRENCH WITH EX- TENSION TOOL (1) In case of tightening with a torque wrench which has an extended length by combining the torque wrench with SST or extension tool, if you tighten un- til the reading of the torque wrench reaches the specified torque value, the actual torque becomes excessive. (2) In this manual, only the specified torque is de- scribed. In case of using SST or an extension tool, calculate the reading of the torque wrench by the following formula. (3) Formula T’=T x L2/(L1 + L2) T’ Reading of torque wrench {N⋅m (kgf⋅cm, ft⋅lbf)} T Torque {N⋅m (kgf⋅cm, ft⋅lbf)} L1 Length of SST or extension tool (cm) L2 Length of torque wrench (cm)
  • 12. 01–10 –INTRODUCTION REPAIR INSTRUCTION 13AuthorĂ: DateĂ: 2004 COROLLA (RM1037U) 2. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER HINT: The vehicle is equipped with an SRS (Supplemental Restraint System), such as the horn button assembly, the instrument panel passenger airbag assembly, the front seat airbag assembly, the center airbag sensor assembly, the front airbag sensor, the side airbag sensor and the seat belt pretensioner. Failure to carry out the service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing. It may lead to a serious accident. Furthermore, if a mistake is made in servicing the supplemental restraint system, it is possible that the SRS will fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully. Then follow the correct procedure described in this manual. (a) GENERAL NOTICE (1) Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diag- nostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the supplemental restraint system, always check the diagnostic trouble codes before disconnecting the battery (See page 05–424). (2) Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. (The supplemental restraint system is equipped with a back–up power source, so, if work is started within 90 seconds after disconnecting the negative (–) terminal cable from the battery, the SRS may deploy.) When the negative (–) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So, before starting work, make a record of the memorized con- tents in each memory system. Then, when work is finished, reset the clock and audio systems as before. To avoid erasing the memory in each memory system, never use a back–up power supply from another battery. (3) Even in case of a minor collision where the SRS does not deploy, the horn button assembly, the instrument panel passenger airbag assembly, the front seat airbag assembly and the seat belt pretensioner should be inspected (See pages 60–14, 60–26, 60–32 and 61–9). (4) Never use SRS related parts from another vehicle. When replacing parts, replace them with new parts. (5) Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. (6) Never disassemble and repair the airbag sensor assembly, the horn button assembly, the instru- ment panel passenger airbag assembly, the front seat airbag assembly or the seat belt preten- sioner. (7) If the airbag sensor assembly, the side airbag sensor assembly, the horn button assembly, the instrument panel passenger airbag assembly, the front seat airbag assembly or the seat belt pre- tensioner have been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. (8) Do not directly expose the airbag sensor assembly, the horn button assembly, the instrument panel passenger airbag assembly, the front seat airbag assembly or the seat belt pretensioner to hot air or flames. (9) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of an electrical circuit. (10) Information labels are attached to the SRS components. Follow the instructions on the notices. (11) After work on the supplemental restraint system is completed, check the SRS warning light (See page 05–424).
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  • 14. D25079 Mark D27357 Example: CORRECT WRONG Z13950 Example: –INTRODUCTION REPAIR INSTRUCTION 01–11 14AuthorĂ: DateĂ: 2004 COROLLA (RM1037U) (b) SPIRAL CABLE (in Combination Switch) (1) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may occur. Refer to page 60–22 on this manual concerning the correct installation of the steering wheel. (c) HORN BUTTON ASSEMBLY (with Airbag) (1) When removing the horn button assembly or handling a new horn button, it should be placed with the pad top surface facing upward. Placing it with the pad surface facing downward may lead to a serious accident if the airbag accidentally inflates. Also, do not place the horn button on top of one another. (2) Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous). (3) Grease should not be applied to the horn button assembly, and the pad should not be cleaned with detergents of any kinds. (4) Store the horn button assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (4 yellow pins) under the steer- ing column near the combination switch connector before starting work. (6) When disposing of the vehicle or the horn button assembly alone, the airbag should be deployed using an SST before disposal (See page 60–14). Perform the operation in a safe place away from electrical noise.
  • 15. D27358 Example: CORRECT WRONG Z13951 Example: 01–12 –INTRODUCTION REPAIR INSTRUCTION 15AuthorĂ: DateĂ: 2004 COROLLA (RM1037U) (d) INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (1) Always store a removed or new instrument panel passenger airbag assembly with the airbag inflation direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous). (3) Grease should not be applied to the instrument panel passenger airbag assembly, and the airbag door should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (4 yellow pins) installed on the assembly before starting work. (6) When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST before disposal (See page 60–26). Perform the operation in a safe place away from electrical noise. (e) FRONT SEAT AIRBAG ASSEMBLY (1) Always store a removed or new front seat airbag assembly with the airbag inflation direction fac- ing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous). (3) Grease should not be applied to the front seat airbag assembly, and the airbag door should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (2 yellow pins) installed on the assembly before starting work.
  • 16. D27360 Example: D26613 Example: –INTRODUCTION REPAIR INSTRUCTION 01–13 16AuthorĂ: DateĂ: 2004 COROLLA (RM1037U) (6) When disposing of a vehicle or the side airbag assembly alone, the airbag should be deployed using an SST before disposal (See page 60–32). Perform the operation in a safe place away from electrical noise. (f) SEAT BELT PRETENSIONER (1) Never measure the resistance of the seat belt pretensioner (This may cause the seat belt preten- sioner to activate, which is very dangerous). (2) Never disassemble the seat belt pretensioner. (3) Never install the seat belt pretensioner to another vehicle. (4) Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F) without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the connector (2 yellow pins) before starting work. (6) When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensioner should be activated before disposal (See page 61–9). Perform the operation in a safe place away from electrical noise. (7) The seat belt pretensioner is hot after activation, so let it cool down sufficiently before disposal. Never appl
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