engine TOYOTA COROLLA 2002 E120 / 9.G Workshop Manual

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3. Look for obvious coolant leaks from theradiator, hoses,and under the vehicle.
However, note that water draining from
the air conditioning is normal if it has
been used.
CAUTION
When the engine is running, keep
hands and clothing away from the
moving fan and engine drive belts.
4. If the coolant is leaking, stop the en-gine immediately. Call a Toyota dealer
for assistance.
5. If there are no obvious leaks, check the coolant reservoir. If it is dry, add
coolant to the reservoir while the en-
gine is running. Fill it about half full.
CAUTION
Do not attempt to remove the radiator
cap when the engine and radiator are
hot. Serious injury could result from
scalding hot fluid and steam blown
out under pressure.
6. After the engine coolant temperaturehas cooled to normal, again check the
coolant level in the reservoir. If neces-
sary, bring it up to half full again. Seri-
ous coolant loss indicates a leak in the
system. You s hould have it checked as
soon as possible at your Toyota dealer. 1. Reduce your speed gradually, keeping
a straight line. Move cautiously off the
road to a safe place well away from
the traffic. Avoid stopping on the center
divider of a highway. Park on a level
spot with firm ground.
2. Stop the engine and turn on your emergency flashers.
3. Firmly set the parking brake and put the transmission in “P” (automatic) or
reverse (manual).
4. Have everyone get out of the vehicle on the side away from traffic.
5. Read the following instructions thor- oughly.
CAUTION
When jacking, be sure to observe the
following to reduce the possibility of
personal injury:
Follow jacking instructions.
If you have a flat tire—

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Do not put any part of your body
under the vehicle supported by the
jack. Personal injury may occur.
Do not start or run the engine while
your vehicle is supported by the
jack.
Stop the vehicle on a level firm
ground, firmly set the parking brake
and put the transmission in “P”
(automatic) or reverse (manual).
Block the wheel diagonally opposite
to the one being changed if neces-
sary.
Make sure to set the jack properly
in the jack point. Raising the ve-
hicle with jack improperly posi-
tioned will damage the vehicle or
may allow the vehicle to fall off the
jack and cause personal injury.
Never get under the vehicle when
the vehicle is supported by the jack
alone.
Use the jack only for lifting your
vehicle during wheel changing.
Do not raise the vehicle with some-
one in the vehicle.
When raising the vehicle, do not
put an object on or under the jack.
Raise the vehicle only high enough
to remove and change the tire.
NOTICE
Do not continue driving with a de-
flated tire. Driving even a short dis-
tance can damage a tire and wheel
beyond repair.Compact spare tire
The compact spare tire is designed for
temporary emergency use only.
The compact spare tire is identified by the
distinctive wording “TEMPORARY USE
ONLY” molded into the side wall of the
tire.
The standard tire should be repaired and
replaced as soon as possible.
The compact spare tire saves space in
your luggage compartment, and its lighter
weight helps to improve fuel economy and
permits easier installation in case of a flat
tire.

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NOTICE
Only use specified towing eyelet;
otherwise your vehicle may be dam-
aged.
A driver must be in the vehicle to steer
it and operate the brakes.
Towing in this manner may be done only
on hardsurfaced roads for a short dis-
tance and at low speeds. Also, the
wheels, axles, drive train, steering and
brakes must all be in good condition.
CAUTION
Use extreme caution when towing ve-
hicles. Avoid sudden starts or erratic
driving maneuvers which would place
excessive stress on the emergency
towing eyelets and towing cable or
chain. The eyelets and towing cable
or chain may break and cause serious
injury or damage.
NOTICE
Use only a cable or chain specifically
intended for use in towing vehicles.
Securely fasten the cable or chain to
the towing eyelets provided.
Before towing, release the parking brake
and put the transmission in neutral (manu-
al) or “N” (automatic). The key must be
in “ACC” (engine off) or “ON” (engine run-
ning).
CAUTION
If the engine is not running, the pow-
er assist for the brakes and steering
will not work so steering and braking
will be much harder than usual.
If you cannot shift the selector lever
out of “P” position to other positions
even though the brake pedal is de-
pressed, use the shift lock override but-
ton as follows:1. Turn the ignition key to “LOCK” position. Make sure the parking
brake is applied.
2. Pry up the cover with a flatbladed screwdriver or equivalent.
If you cannot shift automatic
transmission selector lever

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3. Insert your finger into the hole topush down the shift lock override
button. You can shift out of “P”
position only while pushing the but-
ton.
4. Shift into “N” position.
5. Insert the cover.
6. Start the engine. For your safety, keep the brake pedal depressed.
Be sure to have the system checked by
your Toyota dealer as soon as possible. You can purchase a new key at your
Toyota dealer if you can give them the
key number.
See the suggestion given in “Keys” in
Section 12.
If your keys are locked in the vehicle and
you cannot get a duplicate, many Toyota
dealers can still open the door for you,
using their special tools. If you must
break a window to get in, we suggest
breaking the smallest side window be-
cause it is the least expensive to replace.
Be extremely cautious to avoid cuts from
the glass.
If you lose your keys

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If you are a skilled doityourself mechan-
ic, the Toyota service manuals are recom-
mended. Please be aware that doityour-
self maintenance can affect your warranty
coverage. See “Owner ’s Warranty Informa-
tion Booklet” or “Owner ’s Manual Supple-
ment” for the details.Listed below are the general maintenance
items that should be performed as fre-
quently as specified. In addition to check-
ing the items listed, if you notice any
unusual noise, smell or vibration, you
should investigate the cause or take your
vehicle to your Toyota dealer or a quali-
fied service shop immediately. It is recom-
mended that any problem you notice be
brought to the attention of your dealer or
the qualified service shop for their advice.
CAUTION
Make these checks only where ade-
quate ventilation can be obtained if
you run the engine.
OUTSIDE THE VEHICLE
Items listed below should be performed
from time to time, unless otherwise
specified.
Tire pressure
Check the pressure with a gauge every
two weeks, or at least once a month. See
Section 72 for additional information.Tire surface and wheel nuts
Check the tires carefully for cuts, damage
or excessive wear. See Section 72 for
additional information. When checking the
tires, make sure no nuts are missing, and
check the nuts for looseness. Tighten
them if necessary.
Tire rotation
Rotate the tires according to the mainte-
nance schedule. (For scheduled mainte-
nance information, please refer to the
“Scheduled Maintenance Guide” or “Own-
er ’s Manual Supplement”.) See Section
72 for additional information.
Fluid leaks
Check underneath for leaking fuel, oil, wa-
ter or other fluid after the vehicle has
been parked for a while. If you smell fuel
fumes or notice any leak, have the cause
found and corrected immediately.
Doors and engine hood
Check that all doors including trunk lid
operate smoothly and all latches lock se-
curely. Make sure the engine hood sec-
ondary latch secures the hood from open-
ing when the primary latch is released.
INSIDE THE VEHICLE
Items listed below should be checked
regularly, e.g. while performing periodic
services, cleaning the vehicle, etc.
General maintenance

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Lights
Make sure the headlights, stop lights, tail
lights, turn signal lights, and other lights
are all working. Check headlight aim.
Service reminder indicators and warning
buzzers
Check that all service reminder indicators
and warning buzzers function properly.
Steering wheel
Be alert for changes in steering condition,
such as hard steering or strange noise.
Seats
Check that all front seat controls such as
seat adjusters, seatback recliner, etc. op-
erate smoothly and that all latches lock
securely in any position. Check that the
head restraints move up and down
smoothly and that the locks hold securely
in any latched position. For foldingdown
rear seatbacks, check that the latches
lock securely.
Seat belts
Check that the seat belt system such as
buckles, retractors and anchors operate
properly and smoothly. Make sure that the
belt webbings are not cut, frayed, worn or
damaged.Accelerator pedal
Check the pedal for smooth operation and
uneven pedal effort or catching.
Clutch pedal
Check the pedal for smooth operation.
Brake pedal
Check the pedal for smooth operation and
that the pedal has the proper clearance.
Check the brake booster function.
Brakes
At a safe place, check that the brakes do
not pull to one side when applied.
Parking brake
Check that the lever has the proper travel
and that, on a safe incline, your vehicle
is held securely with only the parking
brake applied.
Automatic transmission “Park” mecha-
nism
Check the lock release button of the se-
lector lever for proper and smooth opera-
tion. On a safe incline, check that your
vehicle is held securely with the selector
lever in “P” position and all brakes re-
leased.
IN THE ENGINE COMPARTMENT
Items listed below should be checked
from time to time, e.g. each time when
refueling.
Washer fluid
Make sure there is sufficient fluid in the
tank. See Section 73 for additional in-
formation.
Engine coolant level
Make sure the coolant level is between
the “FULL” and “LOW” lines on the see
through reservoir when the engine is cold.
See Section 72 for additional information.
Battery electrolyte level
Make sure the electrolyte level of all bat-
tery cells is between upper and lower lev-
el lines on the case. Add only distilled
water when replenishing. See Section 73
for additional information.
Brake fluid level
Make sure the brake fluid level is correct.
See Section 72 for additional information.
Engine oil level
Check the level on the dipstick with the
engine turned off and the vehicle parked
on a level spot. See Section 72 for addi-
tional information.

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Power steering fluid level
Check the level through the reservoir. The
level should be in the “HOT” or “COLD”
range depending on the fluid temperature.
See Section 72 for additional information.
Exhaust system
If you notice any change in the sound of
the exhaust or smell exhaust fumes, have
the cause located and corrected immedi-
ately. (See “Engine exhaust cautions” in
Section 2.)Be on the alert for changes in perfor-
mance, sounds, and visual tipoffs that
indicate service is needed. Some impor-
tant clues are as follows:
Engine missing, stumbling, or pinging
Appreciable loss of power
Strange engine noises
A leak under the vehicle (however, wa-
ter dripping from the air conditioning
after use is normal.)
Change in exhaust sound (This may
indicate a dangerous carbon monoxide
leak. Drive with the windows open and
have the exhaust system checked im-
mediately.)
Flatlooking tire; excessive tire squeal
when cornering; uneven tire wear
Vehicle pulls to one side when driving
straight on a level road
Strange noises related to suspension
movement
Loss of brake effectiveness; spongy
feeling brake or clutch pedal;pedal al-
most touches floor; vehicle pulls to one
side when braking
Engine coolant temperature continually
higher than normalIf you notice any of these clues, take your
vehicle to your Toyota dealer as soon as
possible. It probably needs adjustment or
repair.
CAUTION
Do not continue driving with the ve-
hicle unchecked. It could result in se-
rious vehicle damage and possibly
personal injury.
Does your vehicle need
repairing?

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DOITYOURSELF MAINTENANCE
Introduction
Engine compartment overview206
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Fuse locations 207
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Doityourself service precautions ns 208. . . . . . . . . . . . . . . . . . . . . . . . .
Positioning the jack 209
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. . . . .
Parts and tools 210
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. . . . . . . . .
SECTION 7 1

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1. Power steering fluid reservoir
2. Engine oil level dipstick
3. Engine oil filler cap
4. Brake fluid reservoir
5. Fuse blocks
6. Battery
7. Engine coolant reservoir
8. Electric cooling fans
9. Windshield washer fluid tank
Engine compartment overview

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If you perform maintenance by yourself,
be sure to follow the correct procedure
given in this section.
You should be aware that improper or in-
complete servicing may result in operating
problems.
Performing doityourself maintenance
during the warranty period may affect your
warranty coverage. Read the separate
Toyota Warranty statement for details and
suggestions.
This section gives instructions only for
those items that are relatively easy for an
owner to perform. As explained in Section
6, there are still a number of items that
must be done by a qualified technician
with special tools.
For information on tools and parts for do
ityourself maintenance, see “Parts and
tools”.
Utmost care should be taken when work-
ing on your vehicle to prevent accidental
injury. Here are a few precautions that
you should be especially careful to ob-
serve:CAUTION
When the engine is running, keep
hands, clothing, and tools away
from the moving fan and engine
drive belts. (Removing rings,
watches, and ties is advisable.)
Right after driving, the engine
compartment—the engine, radiator,
exhaust manifold and spark plug
boots, etc.—will be hot. So be care-
ful not to touch them. Oil, fluids
and spark plugs may also be hot.
If the engine is hot, do not remove
the radiator cap or loosen the drain
plugs to prevent burning yourself.
Do not smoke, cause sparks or al-
low open flames around fuel or the
battery. Their fumes are flammable.
Do not get under your vehicle with
just the body jack supporting it. Al-
ways use automotive jack stands or
other solid supports.
Be sure that the ignition is off if
you work near the electric cooling
fans or radiator grille. With the
ignition on, the electric cooling fans
will automatically start to run if the
engine coolant temperature is high
and/or the air conditioning is on.
Use eye protection whenever you
work on or under your vehicle
where you may be exposed to flying
or falling material, fluid spray, etc.
Used engine oil contains potentially
harmful contaminants which may
cause skin disorders such as in-
flammation or skin cancer, so care
should be taken to avoid prolonged
and repeated contact with it. To re-
move used engine oil from your
skin, wash thoroughly with soap
and water.
Do not leave used oil within the
reach of children.
Dispose of used oil and filter only
in a safe and acceptable manner.
Do not dispose of used oil and fil-
ter in household trash, in sewers or
onto the ground. Call your dealer or
a service station for information
concerning recycling or disposal.
Doityourself service
precautions