Toyota2004–2007

Corolla 1.6: Common faults & known problems

Common faults & known problems

6 known faults documented in workshop bulletins. Of these, one concerns the engine and fuel system and one the electrical and ignition. Symptoms, causes, repair steps and part numbers are shown where supplied.

Engine & fuel system

1 documented fault — symptoms, causes and workshop fixes.

Ticking noise from top half of engine

Overview

Affects
All models with 3ZZ-FE/4ZZ-FE engine codes, →06/07.
Parts
3 parts

Cause

Unsatisfactory design of hydraulic tappets.

Repair

  1. Remove all hydraulic tappets and check for damage.
  2. Replace damaged hydraulic tappets and associated valves.
Parts3 parts
Parts listed in the bulletin
PartPart numberQty
Hydraulic tappetRefer to manufacturerAs required
Inlet valve13711-22040As required
Exhaust valve13715-22040As required

Data: Motorwise Workshop. Bulletin 5.

Electrical & ignition

1 documented fault — symptoms, causes and workshop fixes.

One or both headlamps do not operate when switched on

Affects All models.

Cause

Internal failure of combination switch.

Repair

  1. Replace combination switch.

Data: Motorwise Workshop. Bulletin 6.

Steering

1 documented fault — symptoms, causes and workshop fixes.

ESP warning lamp illuminated

Incorrect calibration of steering angle sensor.

Overview

Affects
All models with electronic stability program (ESP).
Fault codes
C1288

Symptoms

Trouble code stored: C1288. Unable to program steering angle sensor.

Repair steps

  1. Ensure steering in straight-ahead position.
  2. Ensure steering angle sensor aligned with steering column.
  3. Carry out steering angle sensor calibration.

Data: Motorwise Workshop. Bulletin 4.

Clutch & gearbox

1 documented fault — symptoms, causes and workshop fixes.

Squeaking noise when clutch pedal depressed or released

Affects rightHandAll models with manual transmission, →02/05. leftHandAll models with manual transmission, →03/05.Fit modified part

Symptoms

Erratic clutch pedal action. Gears difficult to engage.

Cause

Faulty clutch master cylinder.

Repair

  1. Fit modified clutch master cylinder.

Data: Motorwise Workshop. Bulletin 2.

Air conditioning & heating

1 documented fault — symptoms, causes and workshop fixes.

Musty odour from air conditioning (AC) when operating

Overview

Affects
All models with air conditioning (AC).
Remedy
Fit modified part
Parts
3 parts

Cause

Faulty AC evaporator temperature sensor.

Faulty AC amplifier.

Repair

  1. Models with ATC: Fit modified AC evaporator temperature sensor. Fit modified AC amplifier.
  2. Models with MTC: Fit modified AC evaporator temperature sensor. Fit auxiliary wiring harness between AC evaporator temperature sensor and AC wiring harness.
Parts3 parts
Parts listed in the bulletin
PartPart numberQty
AC evaporator temperature sensor88620-120801
AC amplifier88650-12A111
Auxiliary wiring harness22648-127501

Data: Motorwise Workshop. Bulletin 3.

Other

1 documented fault — symptoms, causes and workshop fixes.

Excessive noise from auxiliary drive belt

Affects Corolla, engine code: 3ZZ-FE (VIN →SB1KM20E20F022720). Corolla, engine code: 4ZZ-FE (VIN →SB1KZ20E60F027498).

Cause

Auxiliary drive belt tensioner pulley damaged.

Repair

  1. Renew auxiliary drive belt tensioner pulley.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Tensioner pulley13570-220101

Data: Motorwise Workshop. Bulletin 1.

Glossary

Technical terms used in this guide.

VIN
Vehicle identification number — 17 characters, found at the base of the windscreen and on the V5C logbook
AC
Air conditioning — the system that cools the cabin
ATC
Automatic temperature control — climate control that holds the temperature you set
ESP
Electronic stability programme — brakes individual wheels to stop a skid
Steering Angle Sensor
Tells the stability-control system which way the steering wheel is pointing
Trouble Code
A standardised fault code stored by a control module, read with a diagnostic tool
Wiring Harness
The bundled cables that carry power and signals around the vehicle
Auxiliary Drive Belt
The belt that drives the alternator, water pump, steering pump or air-conditioning compressor
Calibration
Setting a sensor or module so its readings match the real world
Evaporator
The air-conditioning heat exchanger in the dashboard that cools the cabin air

Frequently asked questions

What are the common faults with the Toyota Corolla 1.6?

This guide contains six workshop bulletins for the Toyota Corolla 1.6. Of these, one concerns the engine and fuel system and one the electrical and ignition. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Toyota Corolla 1.6 have these faults?

No. These are patterns documented across the model by workshops, not predictions for an individual vehicle. Where a fault applies only to certain vehicles or VIN ranges, that is listed with the fault.

Can I check for Toyota Corolla 1.6 faults myself?

Many of them. The documented symptoms can be seen, heard or felt during a test drive.

Related guides

Glossary term

See in the glossary →