14–82

ENGINE MECHANICAL – CHAIN SUB–ASSY

140OH–01

REPLACEMENT
1. REMOVE ENGINE UNDER COVER RH
2. DRAIN COOLANT (See page 16–7)
3. REMOVE FRONT WHEEL RH

4. REMOVE CYLINDER HEAD COVER NO.2

(a) Remove the 2 nuts, 2 clips and cylinder head cover.

A65077

5. REMOVE FAN AND GENERATOR V BELT

(a) Turn the V–ribbed belt tensioner slowly clockwise and
loosen it. Then, remove the fan and generator V belt and
put back the V–ribbed belt tensioner little by little and fix
it quietly.

A60622

6. SEPARATE VANE PUMP ASSY (See page 51–8)

NOTICE:
Do not disconnect the hose.
7. REMOVE GENERATOR ASSY (See page 19–16)

8. REMOVE ENGINE MOUNTING INSULATOR

SUB–ASSY RH
(a) Remove the PS oil pump reservoir and put it aside.
(b) Place a wooden block between the jack and engine, and
set the jack, then remove the 4 bolts, the 2 nuts and en-
gine mounting insulator RH.

A01045

A64005

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ENGINE MECHANICAL – CHAIN SUB–ASSY

9. DISCONNECT ENGINE WIRE

(a) Remove the 5 clamps from the 5 clamp brackets.
(b) Disconnect the 4 ignition coil connectors.

A64021

(c) Remove the bolt and nut installing the engine wire.

A64022

10. REMOVE IGNITION COIL ASSY

(a) Remove the 4 bolts and 4 ignition coils.

A64023

11. DISCONNECT VENTILATION HOSE

(a) Disconnect the ventilation hose from the cylinder head
cover.

A65078

12. DISCONNECT VENTILATION HOSE NO.2

(a) Disconnect the ventilation hose from the cylinder head
cover.

A64058

2004 COROLLA (RM1037U)

Author: Date: 1093

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ENGINE MECHANICAL – CHAIN SUB–ASSY

13. REMOVE CYLINDER HEAD COVER SUB–ASSY

(a) Remove the 9 bolts, 2 seal washers, 2 nuts, 3 clamp
brackets and cylinder head cover.

A64856

14. SET NO. 1 CYLINDER TO TDC/COMPRESSION

Mark Mark (a) Turn the crankshaft pulley, and align its groove with timing
mark ”0” of the timing chain cover.
(b) Check that the point marks of the camshaft timing sprock-
et and VVT timing sprocket are in straight line on the tim-
ing chain cover surface as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360) and align the
Mark
marks as above.
Timing Chain
Cover Surface

Groove
A62185

15. REMOVE CRANKSHAFT PULLEY

(a) Using SST, remove the pulley bolt.
SST 09960–10010 (09962–01000, 09963–01000)
(b) Remove the crankshaft pulley from the crankshaft.

SST
A62837

16. REMOVE V–RIBBED BELT TENSIONER ASSY

(a) Remove the bolt, nut and V–ribbed belt tensioner.
HINT:
Handle a jack up and down to remove the bolt.

A11858

2004 COROLLA (RM1037U)

Author: Date: 1094

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ENGINE MECHANICAL – CHAIN SUB–ASSY

17. REMOVE WATER PUMP ASSY (See page 16–8)

18. REMOVE TRANSVERSE ENGINE ENGINE

MOUNTING BRACKET
(a) Remove the 3 bolts and transverse engine engine mount-
ing bracket.

A12816

19. REMOVE CRANK POSITION SENSOR

(a) Remove the 2 bolts installing the crank position sensor.

B00086

20. REMOVE CHAIN TENSIONER ASSY NO.1

(a) Remove the 2 nuts and chain tensioner.
NOTICE:
Be sure not to revolve the crankshaft without the chain ten-
sioner.
Push

A62178

21. REMOVE TIMING CHAIN OR BELT COVER

SUB–ASSY
(a) Remove the 11 bolts and nuts.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover by prying the portions be-
tween the cylinder head and cylinder block with a screw-
driver.
NOTICE:
A10076 Be careful no tot damage the contact surfaces of the timing
chain cover, cylinder head and cylinder block.

2004 COROLLA (RM1037U)

Author: Date: 1095

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ENGINE MECHANICAL – CHAIN SUB–ASSY

22. REMOVE TIMING GEAR COVER OIL SEAL

(a) Using a screwdriver, remove the oil seal.

A30848

23. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1

24. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and chain tensioner slipper.

25. REMOVE CHAIN SUB–ASSY

(a) Remove the timing chain with the crankshaft timing gear
plying screwdrivers as shown in the illustration.
NOTICE:

Put shop rag to protect the engine.

In case of revolving the camshafts with the chain off
the sprockets, turn the crankshaft 1/4 revolution for
valves not to touch the pistons.
A30857

26. INSTALL CHAIN SUB–ASSY

(a) Set No. 1 cylinder to TDC/compression.
(1) Turn the hexagonal wrench head portion of the
camshafts, and align the point marks of the cam-
shaft timing sprockets.

A10079

(2) Using a crankshaft pulley bolt, turn the crankshaft

Upward Set Key and set the set key on the crankshaft upward.

A62170

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Author: Date: 1096

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ENGINE MECHANICAL – CHAIN SUB–ASSY

(b) Install the timing chain on the crankshaft timing sprocket

Yellow
with the yellow color link aligned with the timing mark on
Color Line
the crankshaft timing sprocket.
HINT:
Three yellow color links are on the chain.

Timing Mark
A62171

(c) Using SST, install the crankshaft timing sprocket.

SST 09223–22010

SST
A62172

Yellow Color Mark (d) Install the timing chain on the camshaft timing sprockets
with the yellow color links aligned with the timing marks on
the camshaft timing sprockets.

Timing Mark A62173

27. INSTALL CHAIN TENSIONER SLIPPER

(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf)

28. INSTALL CRANKSHAFT POSITION SENSOR PLATE

NO.1
(a) Install the plate with the ”F” mark facing forward.

A30867

2004 COROLLA (RM1037U)

Author: Date: 1097

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ENGINE MECHANICAL – CHAIN SUB–ASSY

29. INSTALL TIMING GEAR COVER OIL SEAL

(a) Apply MP grease to a new oil seal lip.
SST
(b) Using SST, tap in the oil seal until its surface is flush with
the timing chain cover edge.
SST 09223–22010
NOTICE:
Keep the lip off foreign materials.

A62174

Seal Width 30. INSTALL TIMING CHAIN OR BELT COVER SUB–ASSY

4 – 5 mm (a) Remove any old packing material from the contact sur-
face.
(b) Apply seal packing in the shape of bead (Diameter 3.5
mm – 4.5 mm (0.1379 – 0.177 in.)) consequently as
shown in the illustration.
Seal packing:
Water pump part part No. 08826–00100 or equivalent
Seal Packing
A62175 Other part part No. 08826–00080 or equivalent.
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not put into engine oil within 2 hours after instal-
ling.
Timing Chain Cover side:

3 (0.118)
3 (0.118)

B B
A 4.5 (0.177)
A 7 (0.276) 12 (0.472) 6 (0.236)
3 (0.118)
Width 4 (0.157)

A–A B–B
C
08826–00100 or equivalent C–C
08826–00080 or equivalent
(mm (in.)) C
A65676

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ENGINE MECHANICAL – CHAIN SUB–ASSY

(c) Install the timing chain cover with the 11 bolts and nut.
Torque:
A A A: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf)
A B: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf)
A
(d) Using a torx wrench socket (E8), install the stud bolt.
A Torque: 9.5 N⋅m (97 kgf⋅cm, 84 in.⋅lbf)

B
A

A A A A65677

31. INSTALL CHAIN TENSIONER ASSY NO.1

(a) Check the O–ring is clean, and set the hook as shown in
Raise the illustration.
Push

Hook
Pin
A62177

(b) Apply engine oil to the chain tensioner and install it withe
2 nuts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
NOTICE:
When installing the tensioner, set the hook again if the
Push hook release the plunger.

A62178

32. INSTALL CRANK POSITION SENSOR

(a) Install the crank position sensor with the 2 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)

B00086

2004 COROLLA (RM1037U)

Author: Date: 1099

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ENGINE MECHANICAL – CHAIN SUB–ASSY

33. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING

BRACKET
(a) Install the transverse engine engine mounting bracket
with the 3 bolts.
Torque: 47 N⋅m (479 kgf⋅cm, 35 ft⋅lbf)

A12816

34. INSTALL WATER PUMP ASSY (See page 16–8)

35. INSTALL V–RIBBED BELT TENSIONER ASSY

(a) Install the V–ribbed belt tensioner with the nut and bolt.
Torque:
Nut 29 N⋅m (296 kgf⋅cm, 21 ft⋅lbf)
Bolt 69 N⋅m (704 kgf⋅cm, 51 ft⋅lbf)

A11858

36. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Using SST, install the crankshaft pulley bolt.
SST 09960–10010 (09962–01000, 09963–01000)
Torque: 138 N⋅m (1,407 kgf⋅cm, 102 ft⋅lbf)

SST
A62837

(c) Turn the crankshaft counter clockwise, and disconnect

the plunger knock pin form the hook.

Disconnect

Hook

Pin Turn
A62180

2004 COROLLA (RM1037U)

Author: Date: 1100

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ENGINE MECHANICAL – CHAIN SUB–ASSY

(d) Turn the crankshaft clockwise, and check that the slipper
is pushed by the plunger.
HINT:
If the plunger does not spring out, press the slipper into the
chain tensioner with a screwdriver so that the hook is released
Plunger from the knock pin and the plunger springs out.

Push Turn
A62181

37. INSTALL CYLINDER HEAD COVER SUB–ASSY

Seal Packing (a) Remove any old pacing (FIPG) material.
(b) Apply seal packing to 2 locations as shown in the illustra-
tion.
Seal packing: Part No. 08826–00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after
A62182 applying seal packing.

Do not put into engine oil 2 hours after installing.
(c) Install the cylinder head cover and 3 cable brackets with
A A A the 9 bolts, 2 seal washers and 2 nuts. Uniformly tighten
the bolts and nuts, in the several passes.
A
Torque:
B B A 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf)
B 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
A

A A
A A

A65687

38. INSTALL IGNITION COIL ASSY

(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)

A64023

2004 COROLLA (RM1037U)

Author: Date: 1101

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ENGINE MECHANICAL – CHAIN SUB–ASSY

39. INSTALL ENGINE WIRE

(a) Install the engine wire with the bolt and nut.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)

A64022

40. INSTALL ENGINE MOUNTING INSULATOR

SUB–ASSY RH
(a) Install the engine mounting insulator with the 4 bolts and
2 nuts.
Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf)

A64005

41. INSTALL GENERATOR ASSY (See page 51–8)

42. INSTALL VANE PUMP ASSY (See page 51–8)

43. INSTALL CYLINDER HEAD COVER NO.2

(a) Install the cylinder head cover with the 2 nuts and 2 clips.
Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf)

A65077

44. INSTALL FRONT WHEEL RH

Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)
45. ADD COOLANT (See page 16–7)
46. CHECK ENGINE COOLANT LEAK (See page 16–7)
47. CHECK ENGINE OIL LEAK

2004 COROLLA (RM1037U)

Author: Date: 1102