air TOYOTA COROLLA 2003 E120 / 9.G Repair Manual

’03 Corolla U (L/O 0201)
1882003 MY COROLLA_U (OM12744U)
Toyota, through its diligent research, de-
sign and use of the most advanced
technology available, has done its part to
help prevent corrosion and has provided
you with the finest quality vehicle
construction. Now, it is up to you. Proper
care of your Toyota can help ensure long
term corrosion prevention.
The most common causes of corrosion
to your vehicle are:
The accumulation of road salt, dirt and
moisture in hardtoreach areas under
the vehicle.
Chipping of paint, or undercoating
caused by minor accidents or by
stones and gravel.
Care is especially important if you live
in particular areas or operate your ve-
hicle under certain environmental condi-
tions:
Road salt or dust control chemicals will
accelerate corrosion, as will the pres-
ence of salt in the air near the sea
coast or in areas of industrial pollution.
High humidity accelerates corrosion es-
pecially when temperatures range just
above the freezing point.
Wetness or dampness to certain parts
of your vehicle for an extended period
of time, may cause corrosion even
though other parts of the vehicle may
be dry.
High ambient temperatures can cause
corrosion to those components of the
vehicle which are prevented from
quickdrying due to lack of proper ven-
tilation.
The above signifies the necessity to keep
your vehicle, particularly the underside, as
clean as possible and to repair any dam-
age to paint or protective coatings as
soon as possible.
To help prevent corrosion on your
Toyota, follow these guidelines:
Wash your vehicle frequently. It is, of
course, necessary to keep your vehicle
clean by regular washing, but to prevent
corrosion, the following points should be
observed:
If you drive on salted roads in the
winter or if you live near the ocean,
you should hose off the undercarriage
at least once a month to minimize cor-
rosion.
High pressure water or steam is effec-
tive for cleaning the vehicle’s underside
and wheel housings. Pay particular
attention to these areas as it is difficult
to see all the mud and dirt. It will do
more harm than good to simply wet the
mud and debris without removing them.
The lower edge of doors, rocker panels
and frame members have drain holes
which should not be allowed to clog
with dirt as trapped water in these
areas can cause corrosion.
Wash the underside of the vehicle thor-
oughly when winter is over.
See “Washing and waxing your Toyota” on
page 189 for more tips.
Check the condition of your vehicle’s
paint and trim. If you find any chips or
scratches in the paint, touch them up im-
mediately to prevent corrosion from start-
ing. If the chips or scratches have gone
through the bare metal, have a qualified
body shop make the repair.
Protecting your Toyota from
corrosion

’03 Corolla U (L/O 0201)
1912003 MY COROLLA_U (OM12744U)
CAUTION
Vehicles with side airbags:
Be careful not to splash water or
spill liquid on the floor. This may
prevent the side airbags from acti-
vating correctly, resulting in serious
injury.
Do not wash the vehicle floor with
water, or allow water to get onto
the floor when cleaning the vehicle
interior or exterior. Water may get
into audio components or other
electrical components above or un-
der the floor carpet (or mat) and
cause a malfunction; and it may
cause body corrosion.
Vinyl interior
The vinyl upholstery may be easily
cleaned with a mild soap or detergent
and water.
First vacuum over the upholstery to re-
move loose dirt. Then, using a sponge or
soft cloth, apply the soap solution to the
vinyl. After allowing it to soak in for a few
minutes to loosen the dirt, remove the dirt
and wipe off the soap with a clean damp
cloth. If all the dirt do not come off, re-
peat the procedure. Commercial foaming
type vinyl cleaners are also available
which work well. Follow the manufacturer ’s
instructions.
NOTICE
Do not use solvent, thinner, gasoline
or window cleaner on the interior.
Carpets
Use a good foamtype shampoo to
clean the carpets.
Begin by vacuuming thoroughly to remove
as much dirt as possible. Several types of
foam cleaners are available; some are in
aerosol cans and others are powders or
liquids which you mix with water to pro-
duce a foam. To shampoo the carpets,
use a sponge or brush to apply the foam.
Rub in overlapping circles.
Do not apply water—the best results are
obtained by keeping the carpet as dry as
possible. Read the shampoo instructions
and follow them closely.
Seat belts
The seat belts may be cleaned with
mild soap and water or with
l ukewarm
water.
Use a cloth or sponge. As you are clean-
ing, check the belts for excessive wear,
fraying, or cuts.
NOTICE
 Do not use dye or bleach on the
belts—it may weaken them.
 Do not use the belts until they be-
come dry.
Cleaning the interior

’03 Corolla U (L/O 0201)
1922003 MY COROLLA_U (OM12744U)
Windows
The windows may be cleaned with any
household window cleaner.
NOTICE
When cleaning the inside of the rear
window, be careful not to scratch or
damage the heater wires or connec-
tors.
Air conditioning control panel, car au-
dio, instrument panel,
c onsole panel,
and switches
Use a soft damp cloth for cleaning.
Soak a clean soft cloth in water or luke-
warm water then lightly
w ipe off dirt.
NOTICE
 Do not use organic substances (sol-
vents, kerosene, alcohol,
g asoline,
etc.) or alkaline or acidic solutions.
These chemicals can cause discol-
oring, staining or peeling of the
surface.
 If you use cleaners or polishing
agents, make sure their ingredients
do not include the substances men-
tioned above.
If you use a liquid car freshener, do
not spill the liquid onto the ve-
hicle’s interior surfaces. It may con-
tain the ingredients mentioned
a-
bove. Immediately clean any spill
using the method mentioned above.
Leather Interior
The leather upholstery may be cleaned
with neutral detergent for wool.
Remove dirt using a soft cloth dampened
with 5% solution of neutral detergent for
wool. Then thoroughly wipe off all traces
of detergent with a clean damp cloth.
After cleaning or whenever any part of the
leather gets wet, dry with a soft clean
cloth. Allow the leather to dry in a venti-
lated shaded area.
NOTICE
 If a stain should fail to come out
with a neutral detergent, apply a
cleaner that does not contain an
organic solvent.
 Never use organic substances such
as benzine, alcohol or gasoline, or
alkaline or acid solutions for clean-
ing the leather as these could
cause discoloring.
 Use of a nylon brush or synthetic
fiber cloth, etc. may scratch the
fine grained surface of the leather.
 Mildew may develop on soiled leath-
er upholstery. Be especially careful
to avoid oil spots. Try to keep your
upholstery always clean.
 Long exposure to direct sunlight
may cause the leather surface to
harden and shrink. Keep your ve-
hicle in a shaded area, especially in
the summer.

’03 Corolla U (L/O 0201)
1952003 MY COROLLA_U (OM12744U)
VEHICLE MAINTENANCE AND CARE
Maintenance requirements196
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General maintenance 197
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . Does your vehicle need repairing?...
.
. . . . . . . . . . . . . . . . . . . . . . . . . 199
Emissions Inspection and Maintenance (I/M) programs200
. . . . . . . . .
For scheduled maintenance information, please refer to the
“Scheduled Maintenance Guide” or “Owner’s Manual Supplement”.
SECTION 6

’03 Corolla U (L/O 0201)
1962003 MY COROLLA_U (OM12744U)
Your Toyota vehicle has been designed for
fewer maintenance requirements with long-
er service intervals to save both your time
and money. However, each regular mainte-
nance, as well as daytoday care, is
more important than ever before to ensure
smooth, troublefree, safe, and economical
drivings.
It is the owner ’s responsibility to make
sure the specified maintenance, including
general maintenance service, is performed.
Note that both the new vehicle and emis-
sion control system warranties specify that
proper maintenance and care must be per-
formed. See “Owner ’s Warranty Informa-
tion Booklet” or “Owner ’s Manual Supple-
ment” for complete warranty information.
General maintenance
General maintenance items are those day
today care practices that are important to
your vehicle for proper operation. It is the
owner ’s responsibility to insure that the
general maintenance items are performed
regularly.
These checks or inspections can be done
either by yourself or a qualified technician,
or if you prefer, your Toyota dealer will be
pleased to do them at a nominal cost.Scheduled maintenance
The scheduled maintenance items listed in
the “Scheduled Maintenance Guide” or
“Owner ’s Manual Supplement” are those
required to be serviced at regular inter-
vals.
For details of your maintenance schedule,
read the “Scheduled Maintenance Guide”
or “Owner ’s Manual Supplement”.
It is recommended that any replacement
parts used for maintenance or for the
repair of the emission control system
be Toyota supplied.
The owner may elect to use nonToyota
supplied parts for replacement pur-
poses without invalidating the emission
control system warranty. However, use
of replacement parts which are not of
equivalent quality may impair the effec-
tiveness of the emission control sys-
tems.
You may also elect to have mainte-
nance, replacement, or repair of the
emission control devices and system
performed by any automotive repair es-
tablishment or individual without invali-
dating this warranty. See “Owner’s War-
ranty Information Booklet” or “Owner’s
Manual Supplement” for complete war-
ranty information.Where to go for service?
Toyota technicians are welltrained spe-
cialists and are kept up to date with the
latest service information through technical
bulletins, service tips, and indealership
training programs. They learn to work on
Toyotas before they work on your vehicle,
rather than while they are working on it.
You can be confident that your Toyota
dealer ’s service department performs the
best job to meet the maintenance require-
ments on your vehicle—reliably and eco-
nomically.
Your copy of the repair order is proof that
all required maintenance has been per-
formed for warranty coverage. And if any
problems should arise with your vehicle
while under warranty, your Toyota dealer
will promptly take care of it. Again, be
sure to keep a copy of the repair order
for any service performed on your Toyota.
What about doityourself maintenance?
Many of the maintenance items are easy
to do yourself if you have a little mechani-
cal ability and a few basic automotive
tools. Simple instructions for how to per-
form them are presented on page 201 in
Section 7.
Maintenance requirements

’03 Corolla U (L/O 0201)
1992003 MY COROLLA_U (OM12744U)
Battery condition
Check the battery condition by the indica-
tor color. See page 222 in Section 73 for
additional information.
Brake fluid level
Make sure the brake fluid level is correct.
See page 213 in Section 72 for addition-
al information.
Engine oil level
Check the level on the dipstick with the
engine turned off and the vehicle parked
on a level spot. See page 210 in Section
72 for additional information.
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 page 213 in Section 72 for addition-
al 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” on
page 147 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?

’03 Corolla U (L/O 0201)
2002003 MY COROLLA_U (OM12744U)
Some states have vehicle emission in-
spection programs which include OBD
(OnBoard Diagnostics) checks.
The OBD system monitors the operation
of the emission control system. When the
OBD system determines that a problem
exists somewhere in the emission control
system, the malfunction indicator lamp
comes on. In this case, your vehicle may
not pass the I/M test and need to be
repaired. Contact your Toyota dealer to
service the vehicle.
Even if the malfunction indicator lamp
does not come on, your vehicle may not
pass the I/M test as readiness codes
have not been set in the OBD system.
Readiness codes are automatically set
during ordinary driving. However, when the
battery is disconnected or run down, the
codes are erased. Also, depending on
your driving habits, the codes may not be
completely set. Also, if the malfunction indicator lamp had
come on recently due to temporary mal-
function such as a loose fuel tank cap,
your vehicle may not pass the I/M test.
The malfunction indicator lamp will go off
after taking several driving trips, but the
error code in the OBD system will not be
cleared unless about 40 trips or more are
taken.
If your vehicle does not pass the I/M test
even the malfunction indicator lamp does
not come on, contact your Toyota dealer
to prepare the vehicle for retesting.
Emissions Inspection and
Maintenance (I/M) programs

’03 Corolla U (L/O 0201)
2042003 MY COROLLA_U (OM12744U)
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.
Be extremely cautious when work-
ing on the battery. It contains poi-
sonous and corrosive sulfuric acid.
Warning: Battery posts, terminals
and related accessories contain lead
and lead compounds, chemicals
known to the State of California to
cause cancer and reproductive
harm. Wash hands after handling.
NOTICE
Remember that battery and ignition
cables carry high currents or volt-
ages. Be careful of accidentally
causing a short circuit.
 Add only demineralized or distilled
water to fill the radiator. And if you
spill some of the coolant, be sure
to wash off with water to prevent it
from damaging the parts or paint.
 Do not allow dirt or anything else
to fall through the spark plugholes.
 Use only spark plugs of the speci-
fied type. Using other types will
cause engine damage, loss of per-
formance or radio noise.

’03 Corolla U (L/O 0201)
2052003 MY COROLLA_U (OM12744U)
Do not reuse iridiumtipped spark
plugs by cleaning or regapping.
 Do not overfill automatic transmis-
sion fluid, or the transmission
could be damaged.
 Do not drive with the air cleaner
filter removed, or excessive engine
wear could result. Also backfiring
could cause a fire in the engine
compartment.
 Be careful not to scratch the glass
surface with the wiper frame.
 When closing the engine hood,
check to see that you have not for-
gotten any tools, rags, etc.
Front
Rear
When jacking up your vehicle with the
jack, position the jack correctly as
shown in the illustrations.
CAUTION
When jacking, be sure to observe the
following to reduce the possibility of
personal injury:
Follow jacking instructions.
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 wheels on the opposite
side of the jack up point 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.
Positioning the jack

’03 Corolla U (L/O 0201)
2132003 MY COROLLA_U (OM12744U)
To check the fluid level, simply look at
the seethrough reservoir. The level
should be between the “MAX” and
“MIN” lines on the reservoir.
It is normal for the brake fluid level to go
down slightly as the brake pads wear. So
be sure to keep the reservoir filled.
If the reservoir needs frequent refilling, it
may indicate a serious mechanical prob-
lem. If the level is low, add SAE J1703 or
FMVSS No.116 DOT 3 brake fluid to the
brake reservoir.
Remove and replace the reservoir cap by
hand. Fill the brake fluid to the dotted
line. This brings the fluid to the correct
level when you put the cap back on.
Use only newly opened brake fluid. Once
opened, brake fluid absorbs moisture from
the air, and excess moisture can cause a
dangerous loss of braking.
CAUTION
Take care when filling the r
eservoir
because brake fluid can harm your
eyes and damage painted surfaces. If
fluid gets in your eyes, flush your
eyes with clean water immediately. If
you still feel uncomfortable with your
eyes, go to the doctor.
NOTICE
If you spill some of the fluid, be sure
to wash it off with water to prevent
it from damaging the parts or paint.
If cold O.K.
If cold add If hot O.K.
If hot add
Close
Open
Check the fluid level through the reser-
voir. If necessary, add automatic trans-
mission fluid DEXRON
 II or III.
If the vehicle has been driven around 80
km/h (50 mph) for 20 minutes (a little
more in frigid temperatures), the fluid is
hot (60 C—80 C or 140 F—175 F). You
may also check the level when the fluid
is cold (about room temperature,
10 C—30 C or 50 F—85 F) if the engine
has not been run for about five hours.
Checking brake fluid Checking power steering fluid