I TOYOTA COROLLA FR REPAIR MANUAL | FOR CHASSIS & BODY | INTRODUCTION [J CLUTCH MANUAL TRANSMISSION [J AUTOMATIC TRANSMISSION KA PROPELLER SHAFT [J FRONT AXLE AND SUSPENSION REAR AXLE AND SUSPENSION [Gf BRAKE SYSTEM [EJ STEERING Ky BODY ELECTRICAL SYSTEM [E BoDY & AIR CONDITIONING SYSTEM EX SERVICE SPECIFICATIONS [i STANDARD BOLT TIGHTENING TORQUE [i SI METRIC CONVERSION TABLE sst ED ELECTRICAL WIRING DIAGRAMS [iING INTRODUCTION — Vehicle Lift and Support Locations VEHICLE LIFT AND SUPPORT LOCATIONS ‘Seam Notehes > Seam Notches JACK POSITION —— Front .......... Center of front suspension erossmember Rear s....cs... Centar of rear axle housing PANTOGRAPH JACK POSITION —-——(_) SUPPORT POSITION Safety standcL CLUTCH Page TROUBLESHOOTING . cL 2 CHECK AND ADJUSTMENT OF CLUTCH PEDAL ... + CL3 BLEEDING OF CLUTCH SYSTEM .. + Ld CLUTCH MASTER CYLINDER .. cL4 CLUTCH RELEASE CYLINDER . - CL 6 CLUTCH UNIT ...... . CL7CLUTCH roubleshooting TROUBLESHOOTING Preblem Posible cause Remedy Page Hird to shifter wit | Clutch pedal teeray excesive ‘Adust pod treepay cus ane ah Clutch release cylinder faulty. Repair release cylinder cLé Gun mostreyindr folly Repair maser eyindet cus Catch die out of true. ining aresy or | Inspect cuteh dis as broken Spine on input shat or clutch ese crty | Repl as necessary cu? or butred Cuten pressure pat faulty Aeolace euch cover ous Trarwmision jumps | Clutch pilot bearing worn Replace pit bering cus out of ger i | t + Chute sos | Gluten pedal restayinsutfcent ‘Aust pedal resiay cus | Clutch disc tining oly or worn out Inspect elutch dis | cts | ressute pat fauty Replace clutch cover me) | Release fork binds Inspect release fork | cua Clutch grabecnatters | Clutch die ining oily or wer out Irapeteuteh die cs Pressure plate futty Replace cutch cover cus Chutch diaphragm spring bending Align clutch diaphragm cunt | Engine mounts tose Repeiro necessary Clutch petal spongy Airin clutch nes Bled clutch system 3 Clutch release cylinder fouty Repair wlese cylinder cs luc most eying fouty Repsir maser evinder cus Clute nosy Loose part inside nowsing Repair as necessary | Release bearing worn or dirty Replace release bearing cut0 Pilot bearing worn Replace pilot beeing cue Release fork or linkage sticks Repair as necessaryCLUTCH — Check and Adjustment of Clutch Pedal, Bleeding of Clutch System cL3 Push Rod Play and Freeplay Adjust Point Pedal Height Adjust Point Pedal Height CHECK AND ADJUSTMENT OF CLUTCH PEDAL 1, CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from asphalt shoot: LHD 161 — 171 mm (6.34 — 6.73 in) RHD 162 — 172 mm (6.38 ~ 6.77 in.) 2. IF NECESSARY, ADJUST PEDAL HEIGHT (a) Remove the instrument tower finish panel and air duct. (b) Loosen the lock nut and turn the stopper bolt until ‘the height Is correct. Tighten the lock nut. 3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD PLAY ARE CORRECT (Pedal Freeplay) Push in on the pedal until the beginning of clutch resis tance is felt Pedal freeplay: 13 — 23 mm (0.51 - 0.91 in.) Push rod play at pedal top: 1.0 ~ 5.0 mm (0.039 ~ 0.197 in.) 4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND PUSH ROD PLAY {a) Loosen the lock nut and turn the push rod until the freeplay and push rod play are correct, (b) Tighten the lock nut, {c) After adjusting the peda! freeplay, check the pedal height (d) Install the air duct and instrument lower finish pane! BLEEDING OF CLUTCH SYSTEM NOTE: If any work is done on the clutch system or if air is suspected in the clutch lines, bleed the system of air, CAUTION: DO NOT let brake fluid remain on a painted ‘surface, Wash it off immediately. 1, FILL CLUTCH RESERVOIR WITH BRAKE FLUID Check the reservoir frequently. Add fluid if necessary. 2. CONNECT VINYL TUBE TO BLEEDER PLUG Insert the other end of the tube in a half-full container of brake fluid. 3. BLEED CLUTCH LINE (a) Slowly pump the clutch pedal several times, {b) While depressing the pedal, loosen the bleeder plug until the fluid starts to run out, Then close the bleeder plug (c) Repeat this procedure until there are no more air bubbies in the fluid.cL4 CLUTCH lutch Master Cylinder CLUTCH MASTER CYLINDER COMPONENTS ) Push the yoke into the transmission. SST 09325-12010 (M/T) 09325-20010 (A/T) 2. CONNECT PROPELLER SHAFT FLANGE TO Marks COMPANION FLANGE ON DIFFERENTIAL (a) Align the marks on the flanges and connect the flanges with four bolts and nuts. (o) Torque the bolts and nuts. Torque: 350 kg-om (25 ft-lb) 3. CONNECT CENTER SUPPORT BEARING TO BODY {3Joint Type) (a) Place a height spacer between the body and center support bearing, and install the two mounting bolts, finger tight NOTE: Some vehicles do not have a spacer. In this case, it is not necessary to insert one. (b) Check that the bearing bracket is at right angles to the propeller shaft, Adjust the bracket if necessary. fc) Cheek that the center line of the center bearing is set to the center line of the bracket when the vehicle is in @ no-load condition. Adjust the bracket if necessary. Center Line [d) Torque the mounting bolts. 375 kg-cm (27 ft-lb) Torqut the inter ke of peiller : the ater bolts $10 ary. set sin ary. FRONT AXLE AND SUSPENSION TROUBLESHOOTING FRONT WHEEL ALIGNMENT FRONT AXLE HUB. FRONT AXLE SHOCK ABSORBER FRONT SUSPENSION .......... Ball Joint Lower Arm . Strut Bar... Stabilizer Bar» FA2 FRONT AXLE AND SUSPENSION — Troubleshooting : TROUBLESHOOTING ~ 2 — ' [Problem Possible cause Remedy Poe Wanders/pulls Tires worn or improperly inflated Replace tire o inflate tres to FA3 ' proper pressure Alignment incortect Cheek front end alignment FAs | Wheel bearing sdjusted t0 tight ‘Adjust whee! bearing FAS t Front or rear suspansion parts loose or Tighten or replace suspension part broken | Steering linkage loosen or worn Tighten or replace steering linkage | SR-3 Stecting gar out of adjustment or broken | Adjust oF repair steering gear SR, 33 Bottoming Vehicle overlosced Reduce load Springs weak Replace spring FAN Swoysipitcres | Tiesimproperly inflated T” tntate tives to proper premuie | PAS " srabilizer bar bent or broken Inepaet stabilizer bar Frais | | Front wheel shimmy | Tires worn or impreperty inflated Replace tire or inflate tres to Fad i proper pressure | Wheels out of balance Balance wheets ! Alignment incorrect ‘Check frontend alignment FAS Wheel bearings worn or improperly adjusted | Replace or adjust wheel bearings | FAS, 8 Ball joints oF bushings woen Inspect ball joints and bushings | Faa | | steering linkage tooxe or worn Tighten or replace steering liekage | SR-3 i ' Stwering gear out of adjustment or broken | Adjust or repair steering gear || SR-11,33] | ‘Abnormal tive wear | Tires improper'y inflates Inflate tres to proper pressure FAR | Alignment incerreet Check torn FAS ' Suspension parts wotn Replace suspension parts \