engine TOYOTA COROLLA 2004 E120 / 9.G Manual PDF

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2004 COROLLA from Oct. ’03 Prod. (OM12859U)
SPECIFICATIONS
Specifications
Dimensions and weights252
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Engine 252
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Fuel 252
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Service specifications 253
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Tires 255
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Fuses 255
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SECTION 8

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mm (in.)
Overall length
4530 (178.3)
Overall width1700 (66.9)
Overall height∗1480 (58.3)
Wheelbase2600 (102.4)
Front tread1480 (58.3)
Rear tread1460 (57.5)
∗: Unladen vehicle
Vehicle capacity weight (occupants + lug-
gage), kg (lb.): 385 (850)
Towing capacity (trailer weight + cargo weight), kg (lb.):
680 (1500) Model:
1ZZ −FE
Type: 4 cylinder in line, 4 cycle, gasoline
Bore and stroke, mm (in.): 79.0 91.5 (3.11 3.60)
Displacement, cm
3 (cu. in.):
1794 (109.5) Fuel type:
Unleaded gasoline, Octane Rating 87
(Research Octane Number 91) or higher
Fuel tank capacity, L (gal., Imp. gal.): 50 (13.2, 11.0)
Dimensions and weights EngineFuel

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ENGINE
Valve clearance (engine cold), mm (in.):Intake 0.15—0.25 (0.006—0.010)
Exhaust 0.25—0.35 (0.010—0.014)
Spark plug type: DENSO SK16R11
NGK IFR5A11
Spark plug gap, mm(in.): 1.1 (0.043)
ENGINE LUBRICATION
Oil capacity (drain and ref ill),
L (qt., Imp. qt.):
With filter 3.7 (3.9, 3.3)
Without filter 3.5 (3.7, 3.1)
“Toyota Genuine Motor Oil” is filled in
your Toyota vehicle. Use Toyota approved
“Toyota Genuine Motor Oil” or equivalent
to satisfy the following grade and
viscosity.
Oil grade: API grade SL “Energy −Conserving” or
ILSAC multigrade engine oil is recom-
mended. Recommended oil viscosity:
SAE 5W −30
Outside temperature
Please contact your Toyota dealer for fur-
ther details. COOLING SYSTEM
Total capacity, L (qt., Imp. qt.):
6.5 (6.9, 5.7)
Coolant type: “Toyota Genuine Long Life Coolant” is
filled in your Toyota vehicle. In order to
avoid technical problems, we strongly
recommend using “Toyota Genuine Long
Life Coolant” or equivalent.
With ethylene− glycol type coolant for a
proper corrosion protection of aluminum
components
Do not use alcohol type antifreeze or
plain water alone.
Please contact your Toyota dealer for
further details.
Service specifications

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BATTERY
Open voltage
∗ at 20C (68 F):
12.6—12.8 V Fully charged
12.2—12.4 V Half charged
11.8—12.0 V Discharged
∗: Voltage that is checked 20 minutes af- ter the key is removed with all the
lights turned off.
Charging rates: 5 A max.
CLUTCH
Pedal free play, mm (in.): 5—15 (0.2—0.6)
Fluid type: SAE J1703 or FMVSS No.116 DOT 3
MANUAL TRANSAXLE
Oil capacity, L (qt., Imp. qt.): 1.9 (2.0, 1.7)
Oil type: Gear oil API GL −4 or GL −5
Recommended oil viscosity: SAE 75W −90 AUTOMATIC TRANSAXLE
Fluid capacity (drain and refill),
L (qt., Imp. qt.):
Up to 3.0 (3.2, 2.6)
Fluid type: Toyota Genuine ATF Type T −IV
Change automatic transmission fluid only
as necessary.
Generally, it is necessary to change
automatic transmission fluid only if your
vehicle is driven under one of the Special
Operating Conditions listed in your
“Scheduled Maintenance Guide” or
“Owner ’s Manual Supplement”. When
changing the automatic transmission fluid,
use only “Toyota Genuine ATF Type T −IV”
(ATF JWS3309 or NWS6500) to aid in
assuring optimum transaxle performance.
Notice: Using automatic transmission
fluid other than “Toyota Genuine ATF
Type TIV” may cause deterioration in
shift quality, locking up of your trans-
mission accompanied by vibration, and
ultimately damage the automatic trans-
mission of your vehicle.
Please contact your Toyota dealer for fur-
ther details. BRAKES
Minimum pedal clearance when depressed
with the force of 490 N (50 kgf, 110 lbf)
with the engine running, mm (in.):
70 (2.8)
Pedal free play, mm (in.): 1—6 (0.04—0.24)
Pad wear limit, mm (in.): 1.0 (0.04)
Lining wear limit, mm (in.): 1.0 (0.04)
Parking brake adjustment when pulled with
the force of 196 N (20 kgf, 44 lbf): 6—9 clicks
Fluid type: SAE J1703 or FMVSS No.116 DOT 3
STEERING
Wheel free play: Less than 30 mm (1.2 in.)
Power steering fluid type: Automatic transmission fluid DEXRON II
or III

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Engine compartment
Tires
Ti r e siz e
P185/65R15 86S Front
P195/65R15 89S210 (2.1, 30)
210 (2.1, 30) Rear
210 (2.1, 30)
210 (2.1, 30) Wheel size
15 6 JJ
15 6 JJ
Compact spare tire kPa (kgf/cm
2 or bar, psi) Wheel size
T125/70R16 96M 420 (4.2, 60) 16  4T
W h eel nu t to rq u e, N·m (kg f· m, ft· l b f ) : 103 (10.5, 76)
NOTE: For a complete information on tires (e.g. replacing tires or replacing wheels), see “Checking tire inflation pressure” through “Aluminum
wheel precautions”, pages 229 through 237, in Section 7 −2.
Tire size and cold tire inflation pressure:
kPa (kgf/cm
2 or bar, psi)
Fuses

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2004 COROLLA from Oct. ’03 Prod. (OM12859U)
Instrument panel
Fuses (type A)1. FOG 15 A: Front fog lights
2. HEAD LH UPR 10 A: Left−hand head-
light (high beam)
3. HEAD RH UPR 10 A: Right−hand
headlight (high beam), high beam indi-
cator light
4. SPARE 30 A: Spare fuse
5. SPARE 15 A: Spare fuse
6. SPARE 10 A: Spare fuse
7. MAIN 30 A: Starting system, “AM2”
fuse 8. DOME 15 A:
Car audio system, clock,
personal lights, interior light, trunk light,
open door warning light, wireless re-
mote control system
9. HORN 10 A: Horn
10. HAZARD 10 A: Emergency flashers ,
turn signal lights
11. EFI 15 A: Multiport fuel injection sys-
tem/sequential multiport fuel injection
system, emission control system
12. ALTS 5 A: Charging system
13. HEAD LH LWR 10 A: Left−hand head-
light (low beam)
14. HEAD RH LWR 10 A: Right−hand
headlight (low beam)
15. TAIL 15 A: Tail lights, license plate
lights, instrument panel lights , instru-
ment cluster lights
16. OBD 7.5 A: On−board diagnosis sys-
tem
17. WIPER 25 A: Windshield wipers
18. AM2 15 A: Charging system, multiport
fuel injection system/sequential multi-
port fuel injection system, starting sys-
tem, SRS airbag system 19. STOP 15 A:
Stop lights, high mounted
stoplight, anti −lock brake system, shift
lock control system, engine control sys-
tem, cruise control system
20. DOOR 25 A: Power door lock system
21. AM1 25 A: “CIG” fuse
22. ECUIG 10 A: Electric cooling fan,
anti −lock brake system, shift lock con-
trol system, cruise control system
23. RR WIPER 15 A: No circuit
24. A/C 10 A: Air conditioning system
25. INV 15 A: No circuit
26. P/POINT 15 A: Power outlet (in the
rear console box)
27. ECUB 10 A: Daytime running light
system
28. CIG 15 A: Power outlet (on the instru-
ment panel) or cigarette lighter, car au-
di

o system, clock, power rear view mir-
ror control, shift lock control system
29. GAUGE 10 A: Gauges and meters, air
conditioning system, daytime running
light system, charging system, auto
anti −glare inside rear view mirror, pow-
er windows, cruise control system, rear
window defogger, back −up lights, front
passenger ’s seat belt reminder light

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30. WASHER 15 A: Windshield washer
31. MHTR/DEF IUP 10 A: Engine control
system
Fuses (type B)
32. ABS NO.1 30 A: Anti−lock brake sys-
tem
33. RDI FAN 30 A: Electric cooling fan
34. ABS NO.2 40 A: Anti−lock brake sys-
tem
35. HEAD MAIN 40 A: “HEAD LH UPR”,
“HEAD RH UPR”, “HEAD LH LWR” and
“HEAD RH LWR” fuses
36. HTR 40 A: Air conditioning system
37. DEF 40 A: Rear window defogger,
“M −HTR/DEF I −UP” fuse
38. POWER 30 A: Power windows, electric
moon roof
Fuse (type C)
39. ALT 100 A: Charging system, “ABS
NO.1”, “ABS NO.2”, “RDI FAN”, “FOG”,
“HTR”, “AM1”, “POWER”, “DOOR”,
“ECU −B”, “TAIL”, “STOP”, “P/POINT”,
“INV” and “OBD” fuses

’04 Corolla_U (L/O 0306)
2004 COROLLA from Oct. ’03 Prod. (OM12859U)
Publication No. OM12859U
Part No. 01999-12859
Printed in Japan 01−0310 −00
Quick index
 If a service reminder indicator or warning buzzer comes on 88 . . . . . . . . .
 If your vehicle will not start 182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. .
 If your engine stalls while driving 185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 If your vehicle overheats 185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . .
 If you have a flat tire 186 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . .
 If your vehicle needs to be towed 196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 Tips for driving during break −in period 146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 How to start the engine 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . .
 General maintenance 211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
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Gas station information
Fuel type:
UNLEADED gasoline, Octane Rating 87 (Research Octane Number 91)
or higher
See page 146 for detailed information.
Fuel tank capacity:
50 L (13.2 gal., 11.0 lmp. gal.)
Engine oil:
API grade SL “Energy −Conserving” or ILSAC multigrade engine oil is
recommended.
See page 224 for detailed information.
Automatic transaxle fluid: Toyota Genuine ATF Type T −IV
See page 254 for detailed information.
Tire information: See pages 229 through 237.
Tire inflation pressure: See page 255.
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’04 Corolla_U (L/O 0306)
2004 COROLLA from Oct. ’03 Prod. (OM12859U)
Where to obtain the Repair Manual
The repair manual for COROLLA, written in
English, may be purchased as applicable from
a ny Toy ota dea l er.
Pub. Name: 2004 COROLLA Repair Manual
Pub. No.: RM1037U1 RM1037U2
Maintenance procedures for the engine,
chassis, body, electric al system, and more,
are clearly explained and illustrated.
Periodic maintenance and tuneup
Periodic maintenance and tuneup helps to pre-
vent small problems from growing into larger ones lat-
er on. The repair manual outlines exactly what main-
tenance is required and clearly explains how to do the
work yourself stepbystep.
Areas covered include such things as spark plug re-
placement, valve clearance adjustment and engine oil
and filter replacement.