The 9th Generation COROLLA
Start from scratch in the creation of new value.
"Break the link with the past and target a global standard for the 21st century."
Takeshi Yoshida,
Development Leader of the 9th Generation COROLLA
Production Period (2000 – 2006)
*Production period in Japan. The period of introduction for this generation model may vary by region.
In 2000, new car sales in Japan were continuing to fall due to the continued sluggish economy, and each automotive manufacturer faced concerns about the inability to sell their cars. In the midst of these conditions, the 9th generation COROLLA was born and marketed with the catchphrase "New Century Value". Development leader, Takeshi Yoshida challenged the development team with a theme of "start from scratch". With this theme, developments proceeded by daringly breaking away from the "can't fail" image of the COROLLA, which had been fostered to become a worldwide brand, as the team accepted the challenge to create new value for the upcoming 21st century.
The major characteristics of the 9th generation COROLLA included interior comfort and high level quality and finish that rivaled that of higher grade vehicles, as well as ease of use and reliability. To begin developments, the team first wiped away the basic concept of the existing "COROLLA", and completely redesigned all areas beginning with the platform. Innovative approaches were adopted in all aspects including incorporating a European exterior design plan for the first time. The result was a COROLLA that transcended all other COROLLAs with high comprehensive performance and superior total balance. With this, the COROLLA brand was reborn as worldwide strategic vehicle suited for the 21st century standards with sufficient family car features. Competition in Japan intensified due to the impact of the economic climate in Japan and the emergence of tough competitors, but the COROLLA's world market share including market share in Europe, the US, and Asia, continued to increase, and in 2005, 1.39 million COROLLAs were sold worldwide, further reaffirming the brilliance of the COROLLA as a global car.
In 1997, the year that Takeshi Yoshida embarked on the development of the 9th generation COROLLA, the popularity of the sedan began to diminish in the domestic market with the emergence of the minivan, and it also became apparent that the class of consumers purchasing COROLLAs was getting older. To Yoshida, this reflected a loss in brand brilliance that had been enjoyed in the past.
During the development of the 9th generation, the drop in brand strength had reached such a serious state in the domestic market that the team even examined the possibility of changing the name "COROLLA". However, Yoshida did not approve of this proposal. His reason for not approving the change was that when he was involved in the development of the SOLUNA, a local production model developed as a strategic vehicle for Asia, he learned firsthand that the COROLLA was a historical brand fostered to the point that it had gained a favorable reputation worldwide. Thus, based on personal experience, Yoshida insisted that the name remain the same, and as a result, the vehicle name "COROLLA" continues to be used even today.
Although Yoshida elected not to change the name, he recognized that the car itself needed a huge change. Yoshida expounded on the mindset of that time. "I constantly heard about how the COROLLA was a 'can't fail' vehicle for Toyota. However, I believed that if a manufacturer is overly concerned about failure and ultimately places priority on cost and production ease, that manufacturer will end up making a product that is convenient for themselves. I pondered a great deal about how I could change this mindset." With this, Yoshida emphasized the need to "start from scratch" ― breaking away from the ordinary concept of the class, targeting high standards in a wide range of arrays including design, performance, and quality, and even forgetting about the name "COROLLA".
From the initial stages of development, a technique referred to as "Large Room Developments" was introduced to encourage cooperation between each department. With this technique, the development staff, representatives from the production plants, members of the Design department, and cooperative manufacturers gathered together in one room and proceeded with the tasks at hand. As a result, the intentions of each department were smoothly communicated, and each department and group assumed responsibility as the team pursued the same goal ― "creation of a global standard for the 21st century."
Three major items were targeted in the development of the 9th generation. First, "packaging, style, and quality that broke away from the conventional concept for this class." Yoshida believed that convenience was an obvious necessity for the 21st century, and that performance and quality that responded to the senses, such as comfort and beauty, would be highly regarded. The second area of priority was "an authentic ride that can be enjoyed by all". To enable everyone to enjoy a high quality drive that responds to the senses, the newest technology was generously introduced and no compromises were made in the area of fundamental vehicle performance. Finally, the third priority area was "safety and environmental performance demanded by the new century". For this area, the team aggressively tackled the necessities for safety and the environment that would be expected in future cars.
The COROLLA was the constant pushing force for motorization in Japan. And in overseas markets, the COROLLA had become a hallmark for quality, customer satisfaction, and value for money provided by Japan-made products. With this history, in addition to complying with the needs of the ripened market in Japan, satisfying needs in overseas markets had become a theme that could not be set aside. As developments progressed and as the team searched for a "21st century global standard", Yoshida became aware of the COROLLA's origin. Each successive COROLLA had always been a product that did not betray the needs of the era. This included quality, ease of use, and high versatility that allowed the car to be driven anywhere. Providing the customer with this type of "reassurance" was an incredibly important role of the COROLLA as a global family car. Another element that could not be set aside with the COROLLA was enabling even more people to experience the COROLLA quality, and gain a high degree of satisfaction.
At the end of June 2006, the total number of COROLLAs produced exceeded 31.6 million units, giving the COROLLA the record for the greatest number of vehicles produced and sold worldwide. And thus, the DNA of the COROLLA will continue to be inherited in the future as new history is engraved.
The release of the 9th generation COROLLA began with two body variations including the sedan and wagon (Fielder), and with the release, the coupe model (Levin) was discontinued. Later, a 5-door hatchback (RunX) was added to the lineup, and a 3-door hatchback model was also made available for the overseas market. Also, continuing from the previous generation, the minivan type Multi Purpose Vehicle (Spacio, COROLLA Verso in Europe) with 3-row seats was added to the 9th generation lineup. In Japan and in the US, a light cross country model (Voltz / Matrix) was released as a derivative model, bringing the total number of body type variations to six.
Engine variations were renovated, and all gasoline engines were a part of the "New Generation BEAMS (Breakthrough Engine with Advanced Mechanism System) Engine-series" and adopted the VVT-i (Variable Valve Timing-intelligent) system. Four types of gasoline engines were available including the 1.3-liter 2NZ-FE, the 1.5-liter 1NZ-FE, the 1.8-liter 1ZZ-FE, and the new 2ZZ-GE sports engine. For the diesel engine, the 2.2-liter 3C-E engine was continued from the 8th generation, bringing the total number of engine types to five. In addition, the 1.4-liter 4ZZ-FE and 1.6-liter 3ZZ-FE gasoline engines, and the 1.4-liter 1ND-TV and 2.0-liter 1CD-FTV diesel engines were made available for the overseas markets.
The exterior design of the 9th generation COROLLA was based on flowing, perpetual styling that utilized advanced packaging with characteristic features that included a long wheelbase, wide treads, and big cabin. The front and rear overhangs were shortened and the sense of vehicle status was increased, skillfully balancing youthfulness and a refined image. Even with its increased overall height, the new model portrayed a carefree image.
The interior design adopted a simple, lasting design with an emotional, youthful image. A sense of massiveness and elegance were skillfully balanced with a form that expanded freely and created gradual curves in the crosswise direction from the center of the instrument panel, and the stately form that expanded widely in the vertical direction of the center cluster. A bright, top and bottom 2-tone color scheme was adopted to complete an interior trim that was comprehensively coordinated in color and form. As a result, a high quality space comparable to that of a class above was achieved within a compact body size.
All gasoline engines for the 9th generation COROLLA were newly designed with the generous use of advanced technology, such as VVT-i (Variable Valve Timing-intelligent system)*, and both higher output and better fuel economy were achieved.
* The 2ZZ-GE engine adopted the VVTL-i (Variable Valve Timing and Lift-intelligent) system.
VVT-i is a valve timing mechanism that incorporates electronic control in the VVT (Variable Valve Timing) system adopted by the 4A-GE engine of the 7th generation. The conventional VVT system altered the opening and closing timing of the intake valves during low speeds and high speeds and used a condition based switching method. In contrast, the VVT-i system targeted higher output, better fuel efficiency, and lower emissions, and used a method that constantly controlled the intake valve timing. With the adoption to this model, the VVT-i system evolved from a mechanism that focused on a sporty drive to one that focused on overall performance and efficiency, and is now widely used in many engines.
For the NZ series and ZZ series engines, various new technologies were adopted, such as a slanted squish combustion chamber for stabilized combustion, and an offset crankshaft to reduce engine friction loss.
All engines were developed and tuned with emphasis on performance in the practical range. The 1.3-liter 2NZ-FE was designed for a maximum output of 65kW / 6000rpm and a maximum torque of 123Nm / 4400rpm, while the 1.5-liter 1NZ-FE reached a maximum output of 81kW / 6000rpm and a maximum torque of 143Nm / 4200rpm. The 1.8-liter 1ZZ-FE engine generated a maximum output of 100kW / 6000rpm and a maximum torque of 171Nm / 4200rpm and provided a high quality drive and excellent fuel economy.
The Sports twin cam 4A-GE engine, which for 17 long years had supported the COROLLA Sports models, finally reached the end of its important role, and the 1.8-liter 2ZZ-GE engine was newly adopted beginning with the 9th generation COROLLA. This engine shared the basic concept of the 1ZZ-FE but was developed to display sportier characteristics. In addition to the continuously variable intake valve timing offered by the VVT-i, a VVTL-i mechanism was also adopted to control the amount of valve lift on both the intake and exhaust sides. Furthermore, high rotation and higher output were pursued by adopting a short stroke design, a higher compression ratio, and larger diameter valves, and a maximum output of 140kW / 7600rpm and a maximum torque of 180Nm / 6800rpm were achieved.
On the other hand, the 2.2-liter 3C-E diesel engine was inherited and adopted from the 8th generation COROLLA. Minute modifications were made, such as adopting a cross flow intake and exhaust method and an electronically controlled fuel injection pump to generate a maximum output of 58kW / 4400rpm and a maximum torque of 147Nm / 2400rpm.
For the transmission, a newly developed, electronically controlled 4-speed automatic transmission called the Super ECT (Electronically Controlled Transmission) was adopted. This transmission incorporated high precision hydraulic control for smooth shift quality and good response. Other highly advanced control technologies included an ascending and descending control and a flex lockup control. The flex lockup control, together with the reduced operating friction of the transmission itself, contributed to fuel economy, and equipping the 9th generation COROLLA with this Super ECT resulted in good fuel efficiency with excellent response suited for the next-generation global standard.
With the adoption of a new platform, a MacPherson strut suspension was adopted for the front, and an ETA-beam or a double wishbone suspension was adopted for the rear. A MacPherson strut suspension with an L-shaped lower arm similar to that of the past was adopted for the front suspension but was entirely redesigned, and the suspension geometry was optimized. Also, stabilizers were adopted in all vehicles to ensure roll rigidity and superior riding comfort. The ETA-beam suspension adopted on the rear of FF models was a type of torsion beam suspension. This suspension uses the changes in the camber angle and toe angle that occur due to the toe-correct bushing and torsion of the axle beam to achieve riding comfort and stability both when turning and when driving in a straight line. The rear suspension used in the 4WD models was a compact double wishbone suspension with optimally positioned arms and a sub frame. This suspension was also equipped with a stabilizer, an ideal suspension configuration for 4WD properties.
The steering mechanism was also completely redesigned, and a power steering system was adopted in all vehicles. In some models, the newly developed column-type electric power steering system was adopted. This power steering system calculated the amount of assistance necessary based on vehicle speed and engine speed, used a motor and speed reduction device to generate the assist torque when steering, and provided a natural steering feeling. Also, because assist force was only generated when steering, better fuel efficiency performance was achieved and the structure was simplified with fewer component parts.
In addition to the attractive appearance, aerodynamic characteristics were also pursued for the 9th generation COROLLA, and smooth air flow was ensured along the underbody. Also, wind noise was reduced and aerodynamic performance was improved with a flush surface design for the merging points of the glass, pillars, and roof, and by adopting a fender liner spats.
In the development of the 9th generation COROLLA, excellent quality that responds to the senses and can be felt by all was pursued, and comfort and features that exceeded its class were provided. Optitron meters with excellent visibility were adopted in the combination meters, and silhouette meters that are gentle on the eyes with a luxurious image were made available. The navigation system and audio unit were positioned in the center of the instrument panel in an easy to see location to ensure visibility and operability while driving. The heater control panel was available with either digital push buttons or dial type switches, and consideration was given to the color and size of the lettering to achieve easy to use, easy to see, highly functional switches. The operability of each of the switches was also improved and a good operation feeling was achieved. Storage spaces were designed for ease of use, practicality, and functionality. The glove box in particular was equipped with an air damper so that it opened slowly in the same manner as luxury vehicles.
Also, a high level of quietness comparable to that of a class above was achieved by expanding the use of sound insulation material and adopting structures to suppress wind noise around the outer mirrors and doors.
Safety performance and environmental performance demanded by the new century were targeted, class top level safety performance was pursued, and multiple aspects were considered for the environment.
First, in the area of active safety, a good range of vision was ensured by adopting multi reflector lamps with excellent light distribution performance and mirrors with good visibility. In addition, fundamental safety performance was pursued by enhancing the hardware, including a newly designed suspension, a high rigidity body structure, and a brake mechanism that exhibited superior braking force. Efforts were also made to enhance safety on a software aspect by introducing numerous safety devices including VSC (Vehicle Stability Control system), TRC (Traction Control system), ABS (Anti-lock Brake System), and Brake assist function.
On the other hand, for passive safety, a collision safety body structure was achieved by adopting an impact absorption body structure and a high strength cabin. In addition, various types of safety equipment were introduced to contribute to the maintenance of top level collision safety performance. Examples included SRS (Supplemental Restraint System) airbags, head impact alleviation structures for the interior garnish, and WIL (Whiplash Injury Lessening) concept seat structures that alleviated impact on the neck area in a rear end collision.
For environmental performance, CO2 emissions, which cause global warming, were considered, and efforts were made to improve fuel efficiency. Drastic improvements were made to fuel efficiency by adopting VVT-i for the gasoline engine and the Super ECT automatic transmission, and by implementing thorough weight reduction measures. In addition, efforts were made to improve the warming properties of the catalyst and to achieve cleaner emissions. Furthermore, considerations were made to increasing overall recyclability and reducing environmentally burdensome materials. Highly recyclable TSOP (Toyota Super Olefin Polymer) material was aggressively adopted and materials that do not contain lead were used.
Other Technologies and Equipment
● Grip type outside door handles
● Multi reflector rear combination lamps
● Gated AT shift lever
● 6-speed manual transmission
● V flex full time 4WD
● EBD (Electronic Brake force Distribution)
● ISOFIX compliant child seat anchor
● Package tray trim using kenaf materials
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Major Specifications
*The specifications listed here are for the displayed vehicle (shown in the photo on the left) at the Corolla 40 year anniversary event held in August 2006 in Tokyo, Japan.
Specifications of displayed vehicle : 9th generation
Model code : DBA-NZE121-AEPEK
Grade : 1.5G sedan
Model year : 2006
Vehicle price (JPY) : 1,617,000
Vehicle weight (kg) : 1060
Minimum turning radius (m) : 4.9
Overall length (mm) : 4410
Overall width (mm) : 1695
Overall height (mm) : 1470
Wheelbase (mm) : 2600
Min. ground clearance (mm) : 160
Interior dimensions:
length (mm) : 1925
width (mm) : 1430
height (mm) : 1230
Passengers : 5
Engine type : 1NZ-FE
No. of cyls & arrangement : Inline 4-cylinder DOHC 16-valves
Fuel : Gasoline
Engine displacement (cc) : 1496
Fuel consumption (km/L) : -
60 km/h constant speed driving : -
10 mode fuel efficiency : -
10.15 mode driving : 17.2
Transmission type : 4-speed automatic Super ECT
Drive train : FF
Max. output : 110PS / 6000rpm (NET)
Vehicle Diagram and Dimensions
Secret of COROLLA
Redesigning the COROLLA in half the time
In the development of the 9th generation COROLLA, the design team listened to ideas from overseas, and design studies were done at overseas offices as well. In the end, determining the design was quite an event. Initially, developments advanced based on the ideas given from design bases in Japan. However, when the in-house screening stage was reached, a certain executive indicated that "the design was no different from the COROLLAs of the past." The design was thrown out, and the team was instructed to redesign the COROLLA within what was now a very strict deadline with almost half of the development period already exhausted. So once again, designers went back to the drawing boards, and new designs were examined by both domestic and overseas offices. The team targeted a universal body design for all markets, and to do so, corrected the design direction to gain support on a worldwide scale. As it turned out, ideas from the European design offices were chosen, and the COROLLA took on an overseas design for the first time.
World famous Hollywood star in a world famous car
The 9th generation COROLLA sedan developed for North America included the sports grade "XRS" equipped with the new sporty 2ZZ-GE engine, a 6-speed manual transmission, and flashy aerodynamic parts for greater spice. The person appointed to promote the appeal of the vehicle's driving excitement in advertisements was the famous Hollywood star, Brad Pitt.
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Rabu, 05 Maret 2008
Corolla Generasi Ke-8
The 8th Generation COROLLA
Pursuing the intrinsic economic efficiency of family cars.
"Concern for environmental problems and safety. One answer to the radically changing era."
Takayasu Honda,
Development Leader of the 8th Generation COROLLA
Production Period
1995 - 2000
*Production period in Japan. The period of introduction for this generation model may vary by region.
The 8th generation COROLLA appeared on the market in May 1995 during a time when Japan was facing a sluggish economy, and strong considerations were being sought for the environment and economic efficiency. The COROLLA, which with every generation had been developed as the best compact car for harmony between the society and its members, was developed this time as well with just the right size and a high level of quality. First, the team targeted harmonization with society and pursued economic efficiency (resource conservation), environmental performance, and safety. As a result, a high rigidity body and top level fuel efficiency were achieved through significant weight reductions. Safety performance was also firmly maintained by enhancing safety equipment, and careful consideration was given to environmental aspects including improving recyclability and achieving even cleaner emissions from the diesel engine.
This 8th generation COROLLA, which maintained high level quality while achieving harmonization between society and its members, held firmly to COROLLA's number one position in domestic sales, which had continued since 1969, in part because of the enthusiasm of the sales staff and the popularity of the wagon.
The era of Japan's booming economy, which had continued for many years, came to an end, and with this, rapid changes began to occur in the social environment, and preferences for luxury items shifted to an era that sought simple yet sturdy goods. A greater awareness of environmental issues was developed, and consumers demanded that goods be manufactured with consideration of the global environment and in harmony with the society. In the midst of these changes, developments of the 8th generation COROLLA began.
Development leader Takayasu Honda stated the following concerning developments of the 8th generation COROLLA. "Wanting to maintain the status of 'the best' compact car, I believed that in addition to polishing its appearance and driving performance, our first thoughts should be of harmonization with society, because the COROLLA is the most sold car globally. I believed that we could answer the needs for a socially responsible car by focusing on safety and environmental measures." The development theme pursued based on this idea was "a slim, healthy car." In other words, Honda's challenge was to lose the fat, develop the muscles, and create a well toned, healthy car.
The team's first focus, from the viewpoint of resource conservation and energy savings, was on making significant weight reductions and improvements in fuel efficiency. However, a critical development point was also to maintain collision safety performance, which could easily lead to an increase in weight. To solve these contradicting issues, the team began conversing with the Manufacturing departments from the initial development stage and obtained opinions on an ideal body structure. Then the team used computer analysis to optimize the structure and widely adopted high tensile steel sheet metal. As a result, a high rigidity body was realized with up to 50kg weight reduction for the sedan, and 70kg for the coupe, and good fuel efficiency was realized.
Another major focus in the development of the 8th generation COROLLA, reflecting the times, was the concern for "the total cost of ownership." This concept was established in an effort to reduce the total cost that pertained to vehicle ownership, including the initial vehicle price and maintenance costs. After ensuring safety and environmental performance, the team thoroughly pursued total cost reductions by improving the engine's fuel economy and reducing the weight of the body. In addition, the team considered ways to curb repair costs should the vehicle become damaged, and adopted a horizontally partitioning structure for the front bumper.
The COROLLA was created in 1966 as a vehicle to clear the way for motorization in Japan and has become well loved throughout the world. As stated by Development leader, Takayasu Honda, the 8th generation COROLLA was released to the world in May 1995 as a car that transcended generations and nationalities.
At the time of its initial release, the 8th generation COROLLA was available in five different body types including a 4-door sedan, a 2-door coupe, and the van from the previous model, as well as a wagon and a hardtop (COROLLA Celles), which had both undergone a minor model change. Later in January 1997, the MPV (known as the COROLLA Spacio in Japan and New Zealand, and as the COROLLA Verso in Europe) was added to the lineup as a new body type. The MPV in particular gained a favorable reputation for its diverse seat arrangements made possible with three (or two, depending on the country) rows of seats.
A total of five engine variations were available including four gasoline engines and the 2.0-liter OHC 2C-III diesel engine. The gasoline engines included the 1.3-liter 4E-FE, the 1.5-liter High-mecha twin cam 5A-FE, and the 1.6-liter 4A-FE and 4A-GE engines. In August 1998, in the latter half of the model period, the 2C-III diesel engine was replaced by the 2.2-liter 3C-E engine.
The 8th generation COROLLA was newly designed with a clean-cut taste, with a roomy cabin that was easy to get in and out of, and with body panels utilizing simple, solid surfaces. With this model, the team pursued a well-balanced sedan design that would stay fresh for many years, and while exploring new design tastes, the designers also pursued a design that contributed to excellent visibility and operability. Specifically, considerations were made for easy recognition of the front end and corner areas from the driver seat by providing an energetic hood relief that extended from the hood area to the headlamps. Likewise in the rear, superior functional beauty and a sense of high quality was also achieved with the rear combination lamps that emphasized a clean image, the lowered rear glass frame for better visibility in the rear direction, the ducktail shaped trunk lid, and the lowered trunk opening height for ease of loading and unloading cargo.
The theme of the interior design was "clean & comfortable", and with this theme, the design team pursued clear, refreshing taste with a high level of quality. Ample seating space was ensured while maintaining just the right size for a compact car, and a compact design with good visibility was realized without any sense of being cramped. The new model also featured superior usability including controls that were easily within reach from a natural seating posture. Specifically, the overall interior width and height were expanded, and the front head clearance was enlarged in the upward, forward, and sideways directions to further increase the sense of liberation. The instrument panel took on a generous, simple, horizontal design, and its height was lowered to reduce any sense of constriction on the passengers. Also, the center cluster, which in the past had been divided into three sections, was integrated for a more refreshed impression. Moreover, a luxurious image was expressed by adopting three-dimensionally designed door trim with integrated armrests and pockets.
All 5 types of engines available at the time of the new model's initial release were carried over from the 7th generation. These engines included the High-mecha twin cam 1.3-liter 4E-FE, the 1.5-liter 5A-FE, the 1.6-liter 4A-FE, and the Sports twin cam 1.6-liter 4A-GE gasoline engines, and the 2.0-liter 2C-III diesel engine. However, the high efficiency oriented High-mecha twin cam engine, the Sports twin cam engine for sporty driving, and the High-torque diesel engine designed for good fuel economy were all significantly tweaked for better performance while perfecting the unique qualities of each engine.
For the 5A-FE and 4E-FE, the prime engines of the COROLLA, the team strived to achieve noticeable improvements in performance, while keeping in mind economic efficiency and operational ease. Targeted refinements included the increase of torque in the practical application range, and achieving an even better fuel efficiency. To realize this, a broad array of changes were made, such as adopting an Idle Speed Control (ISC) device, expanding the fuel cut off range when decelerating, reducing friction, and making changes in the intake and exhaust systems. As a result, the 5A-FE engine generated a maximum output of 100ps / 5600rpm and a maximum torque of 14.0kg-m / 4400rpm, and the 4E-FE engine achieved a maximum output of 88ps / 5600rpm and a maximum torque of 11.8kg-m / 4600rpm. The lowered maximum output of these two engines compared to the 7th generation model became a major topic of conversation at that time. This was the result of preference for stress-free operational ease in daily use rather than peak power in the high speed range. However, other than when emissions regulations were tightened, or when engine output measurement methods were changed, a lowering of output figures had generally not been done before then.
On the other hand, for the Sports twin cam 4A-GE engine, the team targeted a higher output in the high speed range, suited for sporty driving, and smooth power delivery through the entire speed range. Advanced technology from the former model was inherited including the 5-valve mechanism, the VVT (Variable Valve Timing) mechanism, and independent throttle valves for each cylinder, and changes were made to the valve operating system, intake and exhaust systems, and combustion chamber to achieve a high revving, high output engine with a maximum output of 165ps / 7800rpm and a maximum torque of 16.5kg-m / 5600rpm. Also, a single muffler with a built-in variable valve was adopted in place of the conventional dual muffler. With this muffler, appearance from the rear of the vehicle was enhanced, and higher performance was achieved together with a lower noise level.
The injection pump characteristics were changed for the 2C-III diesel engine to comply with stricter domestic emissions regulations, and the emissions volume of black smoke and NOx was reduced to achieve an even cleaner engine. However, no changes were made to the maximum output and maximum torque, which remained at 73ps / 4700rpm and 13.2kg-m / 2800rpm respectively. The 1.6-liter 4A-FE underwent further reductions in weight, but the output figures remained unchanged at a maximum output of 115ps / 6000rpm and a maximum torque of 15.0kg-m / 4800rpm.
Transmissions were also carried over from the 7th generation model. Manual transmission was available in either a 4-speed or 5-speed version, while the automatic transmission was available in a 3-speed, 4-speed, or a 4-speed with ECT-S. Resin parts were also adopted for a more lightweight design, and the shift stroke of the manual transmission was shortened for an improved shift feeling. The component parts of the automatic transmission were reviewed for a better match with the engine characteristics, and changes were made to the hydraulic characteristics to achieve smooth departure acceleration and response.
As in the past, a MacPherson strut suspension with an L-type lower arm was adopted for the front, and a dual-link type MacPherson strut suspension was adopted for the rear. Stress analysis using advanced technology was done on each component part to achieve optimized characteristics and significant weight reductions. As a result, high level handling performance and driving stability were achieved and unpleasant vibration (harshness) and noise were reduced. In addition, the gear ratio and hydraulic properties of the power steering system were changed to achieve a smoother steering feel.
In 4A-GE engine models equipped with a Super-strut suspension, a torque sensitive helical LSD, suited for sporty driving, was adopted for the first time in Japan on an front wheel drive vehicle. With this setup, if the inside wheels starts spinning while cornering, optimum driving force is immediately delivered to the outside wheels to achieve stable cornering and excellent controllability.
Developments of the 8th generation COROLLA progressed with priority on improving seating comfort while maintaining just the right size for a compact car. The front seats were developed with the idea of achieving comfortable seats that do not cause fatigue even on long drives. The support and fit of the seats were improved and secure seating comfort was achieved by optimizing the shape of the seatbacks and seat cushions. The seatbacks were designed with a contour close to the shape of the human body for maximum support and even pressure distribution. The cushions provided a mild seating comfort and improved vibration absorption with high elasticity, high density urethane foam. On the function aspect, the reclining adjustment allowance of the driver's seat was expanded, and the level of freedom in driving posture was widened. For the rear seat, the volume at the top of the seatback and the thickness of the seat cushion pads were increased to improve support and fit, and a stable seating posture was achieved. In the sporty grade models, high-support sports seats manufactured by Recaro were made available as an option.
In the equipment area, the team also meticulously pursued comfort and convenience. Features included a tilt & slide power moonroof that provided interior ventilation and a liberating feeling, a wireless door lock remote control system, a 6-speaker COROLLA live sound system, and map lamps with a room lamp function. A wide array of storage spaces were also provided including a large capacity glove box, a gadget case in the lower panel of the driver's seat, and pull-out type cup holders. The height of the luggage opening was also lowered to make loading and unloading of cargo easier. A superior level of quietness, which greatly impacts interior comfort, was also achieved by analyzing vibration and noise properties through computer simulation and through repeated evaluations in an actual vehicle. In addition to reducing vibration transmission to the body, sound insulating and sound absorbing materials were optimally positioned to reduce vibration and noise, and differences in surface levels of exterior body parts were reduced to achieve a flush surface design, reducing wind noise as well.
In the area of safety, the design team thoroughly pursued measures for preventive safety to prevent an accident before it occurs, and measures for collision safety to minimize damage should an accident occur.
For preventive safety, an exterior design with easily recognizable front and rear overhangs, easy to operate meters and switches with excellent visibility, and seats that do not cause fatigue even on long drives, and such were adopted. These features maintained a comfortable environment for the driver to implement optimum driving maneuvers at all times. In addition, ABS to suppress tire lockup during sudden braking, high mount stop lamps to increase visibility for trailing vehicles, and a rear spoiler with a built-in LED stop lamp were available.
In the area of collision safety performance, a body structure that efficiently absorbs impact energy during a front or rear end collision, side door beams that suppress deformation when a side collision occurs, and energy absorption materials were adopted to help minimize damage to the cabin. Other safety features included a new impact absorption steering column, SRS (Supplemental Restraint System) airbags, and 3-point ELR (Emergency Locking Retractor) seatbelts. As a result of thoroughly pursuing safety performance in this way, passenger protection performance was achieved that cleared both the safety standards in Japan and the side impact standards of the US, the strictest standards in the world.
On the other hand, the team also dealt aggressively with energy conservation, resource conservation, and nature protection. The 8th generation COROLLA contributed to suppressing global warming by adopting a lightweight body structure and optimizing engine control, which enhanced fuel efficiency and reduced CO2 emissions. From the viewpoint of efficiently utilizing resources, TSOP (Toyota Super Olefin Polymer), a material that excels in recyclability, was adopted in the bumper, cowl louver, and such, and recyclable material was used in the luggage trim and floor carpet. In addition, numerous environmental protection measures were implemented such as adopting a horizontally partitioning front bumper structure designed for easier repair, reducing the amount of resin and rubber used, stamping material symbol designations on the primary components, and adopting a new refrigerant for the air conditioning unit.
Other Technologies and Equipment
● Semi concealed wipers to improve visual quality and reduce wind noise
● Ignition key illumination for improved nighttime use
● Wood grained center cluster with a sense of luxury
● One-push power window and power door lock switches centralized in the armrest of the driver's seat
● Luggage mat integrated with the spare tire board to prevent mat slippage
● AT shift position indicator integrated in the meters
● Radio antenna embedded in the rear window glass
● Rear seat center armrest
● Buzzer to prevent driver from forgetting the keys
----000----
Major Specifications
*The specifications listed here are for the displayed vehicle (shown in the photos on the left) at the Corolla 40 year anniversary event held in August 2006 in Tokyo, Japan.
Specifications of displayed vehicle : 8th generation
Model code : E-AE110-AEPEK
Grade : 1500SE-Saloon sedan
Model year : 1995
Vehicle price (JPY) : 1,457,000
Vehicle weight (kg) : 1020
Minimum turning radius (m) : 4.8
Overall length (mm) : 4285
Overall width (mm) : 1690
Overall height (mm) : 1385
Wheelbase (mm) : 2465
Min. ground clearance (mm) : 150
Interior dimensions:
length (mm) : 1875
width (mm) : 1435
height (mm) : 1165
Passengers : 5
Engine type : 5A-FE
No. of cyls & arrangement : Inline 4-cylinder DOHC 16-valves
Fuel : Gasoline
Engine displacement (cc) : 1498
Fuel consumption (km/L) : -
60 km/h constant speed driving : 23.8
10 mode fuel efficiency : -
10.15 mode driving : 14.6
Transmission type : 4-speed automatic with 2WAY OD
Drive train : FF
Max. output : 100PS / 5600rpm (NET)
Vehicle Diagram and Dimensions
Secret of COROLLA
Overseas production surpassing domestic production
The COROLLA has become a car that is cherished by every nation throughout the world. To increase the export volume and allow even more customers to enjoy the splendor of the COROLLA, overseas production was started in Malaysia in 1968. Then in 1999, the production volume in Japan was surpassed by the overseas production volume as the COROLLA transformed into a vehicle cherished worldwide, living up to its name in form and content. Today, the COROLLA is produced in 16 nations and regions throughout the world.
Space efficiency ― a topic of conversation
In the past, the COROLLA Wagon had a strong image as a trusty work-use model. However, around 1987, its popularity amongst younger consumers began to increase. The 8th generation COROLLA Wagon, which became a topic of conversation for its unique TV commercial, was nicknamed "Coro-gon." With its excellent space efficiency, the model was a good match for the lifestyle of that period, and in Japan, a sales volume was recorded that gained on that of the sedan.
The newly developed engine that had already existed in the past generation
The domestic COROLLA, which was reborn as a 9th generation model in 2000, proudly adopted the "new" 1ZZ-FE engine with VVT-i. However, the predecessor to this engine, the 1ZZ-FE engine without VVT-i, had already been adopted by the 8th generation COROLLA produced in North America. This reversal of new technology being first adopted in an overseas model ahead of a domestic model occurred because the COROLLA is sold and produced worldwide. The 9th generation COROLLA sold in North America also adopted this engine with VVT-i as was done in Japan.
Pursuing the intrinsic economic efficiency of family cars.
"Concern for environmental problems and safety. One answer to the radically changing era."
Takayasu Honda,
Development Leader of the 8th Generation COROLLA
Production Period
1995 - 2000
*Production period in Japan. The period of introduction for this generation model may vary by region.
The 8th generation COROLLA appeared on the market in May 1995 during a time when Japan was facing a sluggish economy, and strong considerations were being sought for the environment and economic efficiency. The COROLLA, which with every generation had been developed as the best compact car for harmony between the society and its members, was developed this time as well with just the right size and a high level of quality. First, the team targeted harmonization with society and pursued economic efficiency (resource conservation), environmental performance, and safety. As a result, a high rigidity body and top level fuel efficiency were achieved through significant weight reductions. Safety performance was also firmly maintained by enhancing safety equipment, and careful consideration was given to environmental aspects including improving recyclability and achieving even cleaner emissions from the diesel engine.
This 8th generation COROLLA, which maintained high level quality while achieving harmonization between society and its members, held firmly to COROLLA's number one position in domestic sales, which had continued since 1969, in part because of the enthusiasm of the sales staff and the popularity of the wagon.
The era of Japan's booming economy, which had continued for many years, came to an end, and with this, rapid changes began to occur in the social environment, and preferences for luxury items shifted to an era that sought simple yet sturdy goods. A greater awareness of environmental issues was developed, and consumers demanded that goods be manufactured with consideration of the global environment and in harmony with the society. In the midst of these changes, developments of the 8th generation COROLLA began.
Development leader Takayasu Honda stated the following concerning developments of the 8th generation COROLLA. "Wanting to maintain the status of 'the best' compact car, I believed that in addition to polishing its appearance and driving performance, our first thoughts should be of harmonization with society, because the COROLLA is the most sold car globally. I believed that we could answer the needs for a socially responsible car by focusing on safety and environmental measures." The development theme pursued based on this idea was "a slim, healthy car." In other words, Honda's challenge was to lose the fat, develop the muscles, and create a well toned, healthy car.
The team's first focus, from the viewpoint of resource conservation and energy savings, was on making significant weight reductions and improvements in fuel efficiency. However, a critical development point was also to maintain collision safety performance, which could easily lead to an increase in weight. To solve these contradicting issues, the team began conversing with the Manufacturing departments from the initial development stage and obtained opinions on an ideal body structure. Then the team used computer analysis to optimize the structure and widely adopted high tensile steel sheet metal. As a result, a high rigidity body was realized with up to 50kg weight reduction for the sedan, and 70kg for the coupe, and good fuel efficiency was realized.
Another major focus in the development of the 8th generation COROLLA, reflecting the times, was the concern for "the total cost of ownership." This concept was established in an effort to reduce the total cost that pertained to vehicle ownership, including the initial vehicle price and maintenance costs. After ensuring safety and environmental performance, the team thoroughly pursued total cost reductions by improving the engine's fuel economy and reducing the weight of the body. In addition, the team considered ways to curb repair costs should the vehicle become damaged, and adopted a horizontally partitioning structure for the front bumper.
The COROLLA was created in 1966 as a vehicle to clear the way for motorization in Japan and has become well loved throughout the world. As stated by Development leader, Takayasu Honda, the 8th generation COROLLA was released to the world in May 1995 as a car that transcended generations and nationalities.
At the time of its initial release, the 8th generation COROLLA was available in five different body types including a 4-door sedan, a 2-door coupe, and the van from the previous model, as well as a wagon and a hardtop (COROLLA Celles), which had both undergone a minor model change. Later in January 1997, the MPV (known as the COROLLA Spacio in Japan and New Zealand, and as the COROLLA Verso in Europe) was added to the lineup as a new body type. The MPV in particular gained a favorable reputation for its diverse seat arrangements made possible with three (or two, depending on the country) rows of seats.
A total of five engine variations were available including four gasoline engines and the 2.0-liter OHC 2C-III diesel engine. The gasoline engines included the 1.3-liter 4E-FE, the 1.5-liter High-mecha twin cam 5A-FE, and the 1.6-liter 4A-FE and 4A-GE engines. In August 1998, in the latter half of the model period, the 2C-III diesel engine was replaced by the 2.2-liter 3C-E engine.
The 8th generation COROLLA was newly designed with a clean-cut taste, with a roomy cabin that was easy to get in and out of, and with body panels utilizing simple, solid surfaces. With this model, the team pursued a well-balanced sedan design that would stay fresh for many years, and while exploring new design tastes, the designers also pursued a design that contributed to excellent visibility and operability. Specifically, considerations were made for easy recognition of the front end and corner areas from the driver seat by providing an energetic hood relief that extended from the hood area to the headlamps. Likewise in the rear, superior functional beauty and a sense of high quality was also achieved with the rear combination lamps that emphasized a clean image, the lowered rear glass frame for better visibility in the rear direction, the ducktail shaped trunk lid, and the lowered trunk opening height for ease of loading and unloading cargo.
The theme of the interior design was "clean & comfortable", and with this theme, the design team pursued clear, refreshing taste with a high level of quality. Ample seating space was ensured while maintaining just the right size for a compact car, and a compact design with good visibility was realized without any sense of being cramped. The new model also featured superior usability including controls that were easily within reach from a natural seating posture. Specifically, the overall interior width and height were expanded, and the front head clearance was enlarged in the upward, forward, and sideways directions to further increase the sense of liberation. The instrument panel took on a generous, simple, horizontal design, and its height was lowered to reduce any sense of constriction on the passengers. Also, the center cluster, which in the past had been divided into three sections, was integrated for a more refreshed impression. Moreover, a luxurious image was expressed by adopting three-dimensionally designed door trim with integrated armrests and pockets.
All 5 types of engines available at the time of the new model's initial release were carried over from the 7th generation. These engines included the High-mecha twin cam 1.3-liter 4E-FE, the 1.5-liter 5A-FE, the 1.6-liter 4A-FE, and the Sports twin cam 1.6-liter 4A-GE gasoline engines, and the 2.0-liter 2C-III diesel engine. However, the high efficiency oriented High-mecha twin cam engine, the Sports twin cam engine for sporty driving, and the High-torque diesel engine designed for good fuel economy were all significantly tweaked for better performance while perfecting the unique qualities of each engine.
For the 5A-FE and 4E-FE, the prime engines of the COROLLA, the team strived to achieve noticeable improvements in performance, while keeping in mind economic efficiency and operational ease. Targeted refinements included the increase of torque in the practical application range, and achieving an even better fuel efficiency. To realize this, a broad array of changes were made, such as adopting an Idle Speed Control (ISC) device, expanding the fuel cut off range when decelerating, reducing friction, and making changes in the intake and exhaust systems. As a result, the 5A-FE engine generated a maximum output of 100ps / 5600rpm and a maximum torque of 14.0kg-m / 4400rpm, and the 4E-FE engine achieved a maximum output of 88ps / 5600rpm and a maximum torque of 11.8kg-m / 4600rpm. The lowered maximum output of these two engines compared to the 7th generation model became a major topic of conversation at that time. This was the result of preference for stress-free operational ease in daily use rather than peak power in the high speed range. However, other than when emissions regulations were tightened, or when engine output measurement methods were changed, a lowering of output figures had generally not been done before then.
On the other hand, for the Sports twin cam 4A-GE engine, the team targeted a higher output in the high speed range, suited for sporty driving, and smooth power delivery through the entire speed range. Advanced technology from the former model was inherited including the 5-valve mechanism, the VVT (Variable Valve Timing) mechanism, and independent throttle valves for each cylinder, and changes were made to the valve operating system, intake and exhaust systems, and combustion chamber to achieve a high revving, high output engine with a maximum output of 165ps / 7800rpm and a maximum torque of 16.5kg-m / 5600rpm. Also, a single muffler with a built-in variable valve was adopted in place of the conventional dual muffler. With this muffler, appearance from the rear of the vehicle was enhanced, and higher performance was achieved together with a lower noise level.
The injection pump characteristics were changed for the 2C-III diesel engine to comply with stricter domestic emissions regulations, and the emissions volume of black smoke and NOx was reduced to achieve an even cleaner engine. However, no changes were made to the maximum output and maximum torque, which remained at 73ps / 4700rpm and 13.2kg-m / 2800rpm respectively. The 1.6-liter 4A-FE underwent further reductions in weight, but the output figures remained unchanged at a maximum output of 115ps / 6000rpm and a maximum torque of 15.0kg-m / 4800rpm.
Transmissions were also carried over from the 7th generation model. Manual transmission was available in either a 4-speed or 5-speed version, while the automatic transmission was available in a 3-speed, 4-speed, or a 4-speed with ECT-S. Resin parts were also adopted for a more lightweight design, and the shift stroke of the manual transmission was shortened for an improved shift feeling. The component parts of the automatic transmission were reviewed for a better match with the engine characteristics, and changes were made to the hydraulic characteristics to achieve smooth departure acceleration and response.
As in the past, a MacPherson strut suspension with an L-type lower arm was adopted for the front, and a dual-link type MacPherson strut suspension was adopted for the rear. Stress analysis using advanced technology was done on each component part to achieve optimized characteristics and significant weight reductions. As a result, high level handling performance and driving stability were achieved and unpleasant vibration (harshness) and noise were reduced. In addition, the gear ratio and hydraulic properties of the power steering system were changed to achieve a smoother steering feel.
In 4A-GE engine models equipped with a Super-strut suspension, a torque sensitive helical LSD, suited for sporty driving, was adopted for the first time in Japan on an front wheel drive vehicle. With this setup, if the inside wheels starts spinning while cornering, optimum driving force is immediately delivered to the outside wheels to achieve stable cornering and excellent controllability.
Developments of the 8th generation COROLLA progressed with priority on improving seating comfort while maintaining just the right size for a compact car. The front seats were developed with the idea of achieving comfortable seats that do not cause fatigue even on long drives. The support and fit of the seats were improved and secure seating comfort was achieved by optimizing the shape of the seatbacks and seat cushions. The seatbacks were designed with a contour close to the shape of the human body for maximum support and even pressure distribution. The cushions provided a mild seating comfort and improved vibration absorption with high elasticity, high density urethane foam. On the function aspect, the reclining adjustment allowance of the driver's seat was expanded, and the level of freedom in driving posture was widened. For the rear seat, the volume at the top of the seatback and the thickness of the seat cushion pads were increased to improve support and fit, and a stable seating posture was achieved. In the sporty grade models, high-support sports seats manufactured by Recaro were made available as an option.
In the equipment area, the team also meticulously pursued comfort and convenience. Features included a tilt & slide power moonroof that provided interior ventilation and a liberating feeling, a wireless door lock remote control system, a 6-speaker COROLLA live sound system, and map lamps with a room lamp function. A wide array of storage spaces were also provided including a large capacity glove box, a gadget case in the lower panel of the driver's seat, and pull-out type cup holders. The height of the luggage opening was also lowered to make loading and unloading of cargo easier. A superior level of quietness, which greatly impacts interior comfort, was also achieved by analyzing vibration and noise properties through computer simulation and through repeated evaluations in an actual vehicle. In addition to reducing vibration transmission to the body, sound insulating and sound absorbing materials were optimally positioned to reduce vibration and noise, and differences in surface levels of exterior body parts were reduced to achieve a flush surface design, reducing wind noise as well.
In the area of safety, the design team thoroughly pursued measures for preventive safety to prevent an accident before it occurs, and measures for collision safety to minimize damage should an accident occur.
For preventive safety, an exterior design with easily recognizable front and rear overhangs, easy to operate meters and switches with excellent visibility, and seats that do not cause fatigue even on long drives, and such were adopted. These features maintained a comfortable environment for the driver to implement optimum driving maneuvers at all times. In addition, ABS to suppress tire lockup during sudden braking, high mount stop lamps to increase visibility for trailing vehicles, and a rear spoiler with a built-in LED stop lamp were available.
In the area of collision safety performance, a body structure that efficiently absorbs impact energy during a front or rear end collision, side door beams that suppress deformation when a side collision occurs, and energy absorption materials were adopted to help minimize damage to the cabin. Other safety features included a new impact absorption steering column, SRS (Supplemental Restraint System) airbags, and 3-point ELR (Emergency Locking Retractor) seatbelts. As a result of thoroughly pursuing safety performance in this way, passenger protection performance was achieved that cleared both the safety standards in Japan and the side impact standards of the US, the strictest standards in the world.
On the other hand, the team also dealt aggressively with energy conservation, resource conservation, and nature protection. The 8th generation COROLLA contributed to suppressing global warming by adopting a lightweight body structure and optimizing engine control, which enhanced fuel efficiency and reduced CO2 emissions. From the viewpoint of efficiently utilizing resources, TSOP (Toyota Super Olefin Polymer), a material that excels in recyclability, was adopted in the bumper, cowl louver, and such, and recyclable material was used in the luggage trim and floor carpet. In addition, numerous environmental protection measures were implemented such as adopting a horizontally partitioning front bumper structure designed for easier repair, reducing the amount of resin and rubber used, stamping material symbol designations on the primary components, and adopting a new refrigerant for the air conditioning unit.
Other Technologies and Equipment
● Semi concealed wipers to improve visual quality and reduce wind noise
● Ignition key illumination for improved nighttime use
● Wood grained center cluster with a sense of luxury
● One-push power window and power door lock switches centralized in the armrest of the driver's seat
● Luggage mat integrated with the spare tire board to prevent mat slippage
● AT shift position indicator integrated in the meters
● Radio antenna embedded in the rear window glass
● Rear seat center armrest
● Buzzer to prevent driver from forgetting the keys
----000----
Major Specifications
*The specifications listed here are for the displayed vehicle (shown in the photos on the left) at the Corolla 40 year anniversary event held in August 2006 in Tokyo, Japan.
Specifications of displayed vehicle : 8th generation
Model code : E-AE110-AEPEK
Grade : 1500SE-Saloon sedan
Model year : 1995
Vehicle price (JPY) : 1,457,000
Vehicle weight (kg) : 1020
Minimum turning radius (m) : 4.8
Overall length (mm) : 4285
Overall width (mm) : 1690
Overall height (mm) : 1385
Wheelbase (mm) : 2465
Min. ground clearance (mm) : 150
Interior dimensions:
length (mm) : 1875
width (mm) : 1435
height (mm) : 1165
Passengers : 5
Engine type : 5A-FE
No. of cyls & arrangement : Inline 4-cylinder DOHC 16-valves
Fuel : Gasoline
Engine displacement (cc) : 1498
Fuel consumption (km/L) : -
60 km/h constant speed driving : 23.8
10 mode fuel efficiency : -
10.15 mode driving : 14.6
Transmission type : 4-speed automatic with 2WAY OD
Drive train : FF
Max. output : 100PS / 5600rpm (NET)
Vehicle Diagram and Dimensions
Secret of COROLLA
Overseas production surpassing domestic production
The COROLLA has become a car that is cherished by every nation throughout the world. To increase the export volume and allow even more customers to enjoy the splendor of the COROLLA, overseas production was started in Malaysia in 1968. Then in 1999, the production volume in Japan was surpassed by the overseas production volume as the COROLLA transformed into a vehicle cherished worldwide, living up to its name in form and content. Today, the COROLLA is produced in 16 nations and regions throughout the world.
Space efficiency ― a topic of conversation
In the past, the COROLLA Wagon had a strong image as a trusty work-use model. However, around 1987, its popularity amongst younger consumers began to increase. The 8th generation COROLLA Wagon, which became a topic of conversation for its unique TV commercial, was nicknamed "Coro-gon." With its excellent space efficiency, the model was a good match for the lifestyle of that period, and in Japan, a sales volume was recorded that gained on that of the sedan.
The newly developed engine that had already existed in the past generation
The domestic COROLLA, which was reborn as a 9th generation model in 2000, proudly adopted the "new" 1ZZ-FE engine with VVT-i. However, the predecessor to this engine, the 1ZZ-FE engine without VVT-i, had already been adopted by the 8th generation COROLLA produced in North America. This reversal of new technology being first adopted in an overseas model ahead of a domestic model occurred because the COROLLA is sold and produced worldwide. The 9th generation COROLLA sold in North America also adopted this engine with VVT-i as was done in Japan.
Corolla Generasi Ke-7
The 7th Generation COROLLA
High-end, impressive COROLLA.
"Shifting COROLLA value to the range of emotions and sensitivity."
Akihiko Saito,
Development Leader of the 7th Generation COROLLA
Production Period (1991-1995)
*Production period in Japan. The period of introduction for this generation model may vary by region.
The 7th generation COROLLA was developed by carefully pursuing the fundamental performances of driving, turning, and stopping, and dramatic improvements were made to every aspect. This 7th generation COROLLA debuted in June 1991 with the catchphrase "Big and Safety". However, in 1991, the booming economy of Japan began to take a downward turn, and this impacted new car sales throughout the country. The 7th generation, which had been developed as a masterpiece, was no exception in being impacted by this sluggish economy, and unfortunately, the sales volume in Japan did not grow as had been expected. Needs of the public also began to change as focus shifted to quality as well as price. The 7th generation COROLLA boasted of a high level of completeness and was replete with abundant equipment that appealed to the consumer. However, the design team became keenly aware of the importance of having a correct understanding of the times and customer needs. Despite these backgrounds, a production volume of 2.4 million units was recorded, and the top market share in its class was steadily maintained. In fact, many 7th generation COROLLAs can still be seen on the road as it has maintained its image as a good car, and still treasured by many even today.
The economy of Japan at that time had enjoyed continued abundance, and the value sought in vehicles had diversified. This in turn led to a further increase in customers with preferences for higher grade vehicles. With these conditions, the 6th generation COROLLA was a big hit with its higher level quality that surpassed the boundaries of family cars, so planning and development of the 7th generation COROLLA was started based on a concept of keeping with the previous model and "not being caught in the boundaries of family cars".
Generations of COROLLAs had accomplished a significant role as a family car that had led Japan's motorization, and by this time, The COROLLA series had become the worldwide leader of family cars. With this in mind, the design team targeted the creation of a 7th generation COROLLA that was, once again, ahead of the upcoming generation. The basic concept was to "create the next generation standard". Under this concept, Development leader Akihiko Saito analyzed the needs of the new generation. With the values of the public changing from pursuing "material abundance" to fulfilling "the heart and mind," Saito realized that the upcoming generation would value a product that "deeply inspired the soul" of the customers. Saito came up with the keyword "deep impression" and emphasized that, "The impression that a car makes is first developed when the essential functions and performance significantly exceed expectations." With this basic idea in mind, the team carefully pursued fundamental vehicle performances including driving, turning, and stopping.
Development of the 7th generation COROLLA proceeded around three specific themes. First, create style that overflows with beauty and amenity space that is gentle on the passengers. Second, further evolve the fundamental driving performance of "driving", "turning", and "stopping." And third, pursue thorough safety and reliability for a sense of security that satisfies the soul. Saito did not focus on merely increasing the levels of these areas, but rather believed that dramatic improvements in a new dimension would lead to the creation of a "next generation standard".
In order to enhance all aspects of "driving", "turning", and "stopping", all development departments such as the engine and suspension departments were integrated, and this team stayed at a test course in Shibetsu City in Hokkaido for a total of six months where they faced the challenge of evolving the vehicle's fundamental performance to a new dimension. The test course in Shibetsu was selected because it had winding curves like that of everyday European roads, and the team could emulate the authentic ride of European-manufactured vehicles. Exhaustive testing and discussions were held to the point that, later, the team referred to this period of development as the "Shibetsu Training Camp." There, the defensive barriers between each department were cleared away, opinions were contributed even by those without direct responsibility, and the team worked diligently to create a new level of quality.
Development leader Saito expressed his aspirations when developments first began as he stressed to the team, "Create a vehicle that customers can select with confidence, rather than a vehicle that customers can tolerate with." The 7th generation COROLLA, which expressed a high level of completeness and quality suited for the "next-generation standard," achieved maturation that deeply impressed the customers. In addition to the high quality finish of the interior that surpassed that of higher grade vehicles, the elaborately finished exterior was accepted by all age groups and exhibited the height of Toyota's technical strength.
Two types of body variations were available when the 7th generation model was initially released including the sedan and 2-door coupe (COROLLA Levin), and later, the wagon and van were added to the lineup. The following year, the 3-door hatchback (COROLLA FX) and the 4-door hard top (COROLLA Celles) were added simultaneously for a final total of six body variations.
Gasoline engines were available in five types including the 1.3-liter 4E-FE, the 1.5-liter 5A-FE, the 1.6-liter 4A-FE, the Sports twin cam 4A-GE, and the supercharged 4A-GZE. For the diesel engine, the 2.0-liter 2C was adopted, for a total of six engine types.
The design of the 7th generation focused on an image with an abundance of "curves." Body panels were deeply drawn toward the body ends, giving this model a rich body design that expressed a "high class family sedan" style with the image of luxury and driving performance. While emphasizing high quality, many characteristic traits of the COROLLA were retained as well. Notable features included large irregularly shaped headlamps, horizontal radiator grille, and integrated front bumper designed for maximum cooling performance and aerodynamics. The interior as well took on a "curved" theme and achieved a dramatic increase in the level of design and material quality. The instrument panel was configured from smoothly curved lines, and four round meters with good visibility were adopted. The safety pad in particular was designed with a large, integrated form with minimal gaps and parting lines, further enhancing the high quality image.
All gasoline engines of the 7th generation COROLLA were designed as EFI (Electric Fuel Injection) equipped double overhead cam engines. These EFI & twin cam engines were called 2nd generation High-mecha twin cam engines, and notable characteristics included the designed head cover, surge tank, and hydraulic engine mounts adopted on all vehicles to contribute to superior NV performance.
The 1.3-liter 4E-FE engine was developed based on the conventional 2E engine, converted to EFI and High-mecha twin cam configuration with increased displacement. This engine generated a maximum output of 100ps / 6600rpm and a maximum torque of 11.8kg-m / 5200rpm.
The 1.5-liter 5A-FE engine, inherited from the 6th generation, incorporated new designs in various areas around the cylinder head, and a maximum output of 105ps / 6000rpm and a maximum torque of 13.8kg-m / 4800rpm were generated. By optimizing the intake port shape in particular, an air swirl was generated inside the combustion chamber for efficient combustion, and high output was achieved. In addition, a knock control was incorporated in the engine control system to suppress knocking and to achieve optimal ignition timing and combustion at all times. Furthermore, torque control was adopted in automatic transmission models to reduce the shift shock that occurs when changing gears, and an engine profile with mild, easy to handle output and torque was achieved.
The 1.6-liter 4A-FE engine adopted a dual exhaust manifold to improve performance and generated a maximum output of 115ps / 6000rpm and a maximum torque of 15.0kg-m / 4800rpm. The Sports twin cam 4A-GE with the same 1.6-liter displacement underwent modifications to the extent that it could be called a newly designed engine. Output improvements were targeted, and the intake volume was increased by adopting a 5-valve design with three intake valves and two exhaust valves per cylinder. In addition, agile response like that of a sports engine was achieved using four independent throttle valves ― one for each cylinder. Also, a Variable Valve Timing (VVT) system was adopted for the intake side camshaft to supplement low and medium speed torque, and a maximum output of 160ps / 7400rpm and a maximum torque of 16.5kg-m / 5200rpm were generated, realizing a sporty engine beyond that of the past. No major changes in particular were made to the supercharged 4A-GZE engine that was continued from the 6th generation COROLLA, but minor changes were made to the exhaust system, and a maximum output of 170ps / 6400rpm and a maximum torque of 21.0kg-m / 4400rpm were achieved.
For the diesel engine, the 2.0-liter 2C-III diesel engine was adopted. This was the engine available on the 4WD models of the 6th generation. For the 7th generation COROLLA, this diesel engine was optimized for use in FF vehicles by altering the valve timing and the shape of the exhaust manifold, and a maximum output of 73ps / 4700rpm and a maximum torque of 13.5kg-m / 2800rpm were achieved.
The transmission basically followed that of the 6th generation COROLLA. Priority was focused on the shift feeling for manual transmissions, and subtle changes were made to the unit and its operating system. These changes included adopting a triple-cone synchromesh, adding a shift wire moderation adjustment mechanism, and making changes to the shift knob. The daring adoption of a heavier shift lever with mass damper, a first for Toyota, led to minimal vibration and a good shift feeling. In automatic transmissions, the newly developed Super flow torque converter was adopted to achieve powerful departure and acceleration performance and to significantly improve fuel efficiency.
Similar to the 6th generation COROLLA, a 4-wheel strut suspension was adopted with L-type lower arms in the front and dual-link arms for the rear. The component parts and characteristics were reviewed, and superior handling stability was ensured. In addition, the TEMS (Toyota Electronic Modulated Suspension) was adopted in higher grade models. For enhanced comfort, the former 2-step setting of "SOFT" and "HARD" was upgraded with the addition of a third step, "MEDIUM", making possible a finer adjustment of damping characteristics.
Separate from these suspensions, a newly developed Super-strut suspension was made available for the Coupe (Levin) and 3-door hatchback (FX). This suspension, which provided high cornering performance comparable to a double wishbone configuration, supplemented the weaknesses of the conventional MacPherson strut suspension, and minimized extreme wheel alignment changes by suppressing the tilt of the tires when cornering. Also, unstable vibration and torque steer, which had been the weak point of front wheel drive vehicles with high output engines, were reduced. This contributed to allowing the tires to exhibit their full potential, and as a result, overall cornering performance was significantly enhanced.
For the steering mechanism, rack & pinion steering similar to that of the 6th generation COROLLA was adopted. Two types of steering mechanisms were available in the 7th generation COROLLA including the proven "engine speed sensitive power steering," and the newly adopted "New Progressive Power Steering.” The newly adopted steering system controlled the firmness of the steering wheel according to vehicle speed and road surface reaction force. This enabled easy operation at low speeds, which was light enough to be turned with one finger, and a firm and stable steering feel at high speeds.
In the development of the 7th generation COROLLA, the team pressed onward with efforts to increase quality beyond the boundaries of family cars, a task set forth by the 6th generation, and paid close attention to every detail. For the interior space, comfortable seating space was achieved by primarily expanding the head clearance, rear legroom, and interior width. To improve comfort in the rear seat in particular, the arrangement of the seat rails of the front seat was reviewed, and the rear seat leg space was expanded. The switches were completely redesigned and converted to switches that are easy to operate with an improved operation feeling. In higher grade models, automatic air conditioning was adopted as standard equipment. Other deluxe equipment was also prepared including vehicle speed sensitive door locks, automatic headlamps, a clearance sonar that detected obstacles and urged caution to the driver, and a wireless key-less entry system. As a result, an increase in quality was achieved that went beyond expectations and significantly exceeded the boundaries of family cars.
Various safety devices were made available in the 7th generation COROLLA to accommodate the customers' increased consciousness toward safety, and equipment was enhanced in line with that of present day vehicles. The 4-wheel Anti-lock Brake System (ABS) used to suppress tires from locking during sudden braking, and the high mount stop lamp, which increased visibility for trailing vehicles, were made available as options on all models. In addition, a computer analyzed collision safety body structure, driver's seat SRS (Supplemental Restraint System) airbags, and side door beams were adopted. Furthermore, safety performance was also considered from a hardware aspect and efforts were made to ensure braking force. This included adopting ventilated front disc brakes in all vehicles, and in some models, adopting large diameter disc rotors and opposed piston brake calipers.
Other Technologies and Equipment
● Viscous LSD (Limited Slip Differential)
● Electric combination meters
● Seats made by Recaro
● 3-point seatbelts for the rear seat
● Projector fog lamps
● Flame retardant treatment of interior parts
---000---
Major Specifications
*The specifications listed here are for the displayed vehicle (shown in the photo on the left) at the Corolla 40 year anniversary event held in August 2006 in Tokyo, Japan.
Specifications of displayed vehicle : 7th generation
Model code : E-AE100-AEMEK
Grade : 1500SE-L sedan
Model year : 1991
Vehicle price (JPY) : 1,398,000
Vehicle weight (kg) : 1010
Minimum turning radius (m) : 4.8
Overall length (mm) : 4270
Overall width (mm) : 1685
Overall height (mm) : 1380
Wheelbase (mm) : 2465
Min. ground clearance (mm) : 150
Interior dimensions:
length (mm) : 1820
width (mm) : 1420
height (mm) : 1155
Passengers : 5
Engine type : 5A-FE
No. of cyls & arrangement : 4270
Fuel : Gasoline
Engine displacement (cc) : 1498
Fuel consumption (km/L) : -
60 km/h constant speed driving : 27.5
10 mode fuel efficiency : 16.4
10.15 mode driving : -
Transmission type : 5-speed manual
Drive train : FF
Max. output : 105PS / 6000rpm (NET)
Vehicle Diagram and Dimensions
Secret of COROLLA
COROLLA and the world's most famous super car
The Sports twin cam 4A-GE engine was modified for the 7th generation COROLLA to the point that it could be called a newly designed engine. The major characteristic of this engine was its valve mechanism of 5 valves per cylinder. This 5-valve configuration is rare even in present day performance cars, and certainly not found in family cars. For instance, Ferrari has adopted 5-valve engines in some of their super sports cars.
High-end, impressive COROLLA.
"Shifting COROLLA value to the range of emotions and sensitivity."
Akihiko Saito,
Development Leader of the 7th Generation COROLLA
Production Period (1991-1995)
*Production period in Japan. The period of introduction for this generation model may vary by region.
The 7th generation COROLLA was developed by carefully pursuing the fundamental performances of driving, turning, and stopping, and dramatic improvements were made to every aspect. This 7th generation COROLLA debuted in June 1991 with the catchphrase "Big and Safety". However, in 1991, the booming economy of Japan began to take a downward turn, and this impacted new car sales throughout the country. The 7th generation, which had been developed as a masterpiece, was no exception in being impacted by this sluggish economy, and unfortunately, the sales volume in Japan did not grow as had been expected. Needs of the public also began to change as focus shifted to quality as well as price. The 7th generation COROLLA boasted of a high level of completeness and was replete with abundant equipment that appealed to the consumer. However, the design team became keenly aware of the importance of having a correct understanding of the times and customer needs. Despite these backgrounds, a production volume of 2.4 million units was recorded, and the top market share in its class was steadily maintained. In fact, many 7th generation COROLLAs can still be seen on the road as it has maintained its image as a good car, and still treasured by many even today.
The economy of Japan at that time had enjoyed continued abundance, and the value sought in vehicles had diversified. This in turn led to a further increase in customers with preferences for higher grade vehicles. With these conditions, the 6th generation COROLLA was a big hit with its higher level quality that surpassed the boundaries of family cars, so planning and development of the 7th generation COROLLA was started based on a concept of keeping with the previous model and "not being caught in the boundaries of family cars".
Generations of COROLLAs had accomplished a significant role as a family car that had led Japan's motorization, and by this time, The COROLLA series had become the worldwide leader of family cars. With this in mind, the design team targeted the creation of a 7th generation COROLLA that was, once again, ahead of the upcoming generation. The basic concept was to "create the next generation standard". Under this concept, Development leader Akihiko Saito analyzed the needs of the new generation. With the values of the public changing from pursuing "material abundance" to fulfilling "the heart and mind," Saito realized that the upcoming generation would value a product that "deeply inspired the soul" of the customers. Saito came up with the keyword "deep impression" and emphasized that, "The impression that a car makes is first developed when the essential functions and performance significantly exceed expectations." With this basic idea in mind, the team carefully pursued fundamental vehicle performances including driving, turning, and stopping.
Development of the 7th generation COROLLA proceeded around three specific themes. First, create style that overflows with beauty and amenity space that is gentle on the passengers. Second, further evolve the fundamental driving performance of "driving", "turning", and "stopping." And third, pursue thorough safety and reliability for a sense of security that satisfies the soul. Saito did not focus on merely increasing the levels of these areas, but rather believed that dramatic improvements in a new dimension would lead to the creation of a "next generation standard".
In order to enhance all aspects of "driving", "turning", and "stopping", all development departments such as the engine and suspension departments were integrated, and this team stayed at a test course in Shibetsu City in Hokkaido for a total of six months where they faced the challenge of evolving the vehicle's fundamental performance to a new dimension. The test course in Shibetsu was selected because it had winding curves like that of everyday European roads, and the team could emulate the authentic ride of European-manufactured vehicles. Exhaustive testing and discussions were held to the point that, later, the team referred to this period of development as the "Shibetsu Training Camp." There, the defensive barriers between each department were cleared away, opinions were contributed even by those without direct responsibility, and the team worked diligently to create a new level of quality.
Development leader Saito expressed his aspirations when developments first began as he stressed to the team, "Create a vehicle that customers can select with confidence, rather than a vehicle that customers can tolerate with." The 7th generation COROLLA, which expressed a high level of completeness and quality suited for the "next-generation standard," achieved maturation that deeply impressed the customers. In addition to the high quality finish of the interior that surpassed that of higher grade vehicles, the elaborately finished exterior was accepted by all age groups and exhibited the height of Toyota's technical strength.
Two types of body variations were available when the 7th generation model was initially released including the sedan and 2-door coupe (COROLLA Levin), and later, the wagon and van were added to the lineup. The following year, the 3-door hatchback (COROLLA FX) and the 4-door hard top (COROLLA Celles) were added simultaneously for a final total of six body variations.
Gasoline engines were available in five types including the 1.3-liter 4E-FE, the 1.5-liter 5A-FE, the 1.6-liter 4A-FE, the Sports twin cam 4A-GE, and the supercharged 4A-GZE. For the diesel engine, the 2.0-liter 2C was adopted, for a total of six engine types.
The design of the 7th generation focused on an image with an abundance of "curves." Body panels were deeply drawn toward the body ends, giving this model a rich body design that expressed a "high class family sedan" style with the image of luxury and driving performance. While emphasizing high quality, many characteristic traits of the COROLLA were retained as well. Notable features included large irregularly shaped headlamps, horizontal radiator grille, and integrated front bumper designed for maximum cooling performance and aerodynamics. The interior as well took on a "curved" theme and achieved a dramatic increase in the level of design and material quality. The instrument panel was configured from smoothly curved lines, and four round meters with good visibility were adopted. The safety pad in particular was designed with a large, integrated form with minimal gaps and parting lines, further enhancing the high quality image.
All gasoline engines of the 7th generation COROLLA were designed as EFI (Electric Fuel Injection) equipped double overhead cam engines. These EFI & twin cam engines were called 2nd generation High-mecha twin cam engines, and notable characteristics included the designed head cover, surge tank, and hydraulic engine mounts adopted on all vehicles to contribute to superior NV performance.
The 1.3-liter 4E-FE engine was developed based on the conventional 2E engine, converted to EFI and High-mecha twin cam configuration with increased displacement. This engine generated a maximum output of 100ps / 6600rpm and a maximum torque of 11.8kg-m / 5200rpm.
The 1.5-liter 5A-FE engine, inherited from the 6th generation, incorporated new designs in various areas around the cylinder head, and a maximum output of 105ps / 6000rpm and a maximum torque of 13.8kg-m / 4800rpm were generated. By optimizing the intake port shape in particular, an air swirl was generated inside the combustion chamber for efficient combustion, and high output was achieved. In addition, a knock control was incorporated in the engine control system to suppress knocking and to achieve optimal ignition timing and combustion at all times. Furthermore, torque control was adopted in automatic transmission models to reduce the shift shock that occurs when changing gears, and an engine profile with mild, easy to handle output and torque was achieved.
The 1.6-liter 4A-FE engine adopted a dual exhaust manifold to improve performance and generated a maximum output of 115ps / 6000rpm and a maximum torque of 15.0kg-m / 4800rpm. The Sports twin cam 4A-GE with the same 1.6-liter displacement underwent modifications to the extent that it could be called a newly designed engine. Output improvements were targeted, and the intake volume was increased by adopting a 5-valve design with three intake valves and two exhaust valves per cylinder. In addition, agile response like that of a sports engine was achieved using four independent throttle valves ― one for each cylinder. Also, a Variable Valve Timing (VVT) system was adopted for the intake side camshaft to supplement low and medium speed torque, and a maximum output of 160ps / 7400rpm and a maximum torque of 16.5kg-m / 5200rpm were generated, realizing a sporty engine beyond that of the past. No major changes in particular were made to the supercharged 4A-GZE engine that was continued from the 6th generation COROLLA, but minor changes were made to the exhaust system, and a maximum output of 170ps / 6400rpm and a maximum torque of 21.0kg-m / 4400rpm were achieved.
For the diesel engine, the 2.0-liter 2C-III diesel engine was adopted. This was the engine available on the 4WD models of the 6th generation. For the 7th generation COROLLA, this diesel engine was optimized for use in FF vehicles by altering the valve timing and the shape of the exhaust manifold, and a maximum output of 73ps / 4700rpm and a maximum torque of 13.5kg-m / 2800rpm were achieved.
The transmission basically followed that of the 6th generation COROLLA. Priority was focused on the shift feeling for manual transmissions, and subtle changes were made to the unit and its operating system. These changes included adopting a triple-cone synchromesh, adding a shift wire moderation adjustment mechanism, and making changes to the shift knob. The daring adoption of a heavier shift lever with mass damper, a first for Toyota, led to minimal vibration and a good shift feeling. In automatic transmissions, the newly developed Super flow torque converter was adopted to achieve powerful departure and acceleration performance and to significantly improve fuel efficiency.
Similar to the 6th generation COROLLA, a 4-wheel strut suspension was adopted with L-type lower arms in the front and dual-link arms for the rear. The component parts and characteristics were reviewed, and superior handling stability was ensured. In addition, the TEMS (Toyota Electronic Modulated Suspension) was adopted in higher grade models. For enhanced comfort, the former 2-step setting of "SOFT" and "HARD" was upgraded with the addition of a third step, "MEDIUM", making possible a finer adjustment of damping characteristics.
Separate from these suspensions, a newly developed Super-strut suspension was made available for the Coupe (Levin) and 3-door hatchback (FX). This suspension, which provided high cornering performance comparable to a double wishbone configuration, supplemented the weaknesses of the conventional MacPherson strut suspension, and minimized extreme wheel alignment changes by suppressing the tilt of the tires when cornering. Also, unstable vibration and torque steer, which had been the weak point of front wheel drive vehicles with high output engines, were reduced. This contributed to allowing the tires to exhibit their full potential, and as a result, overall cornering performance was significantly enhanced.
For the steering mechanism, rack & pinion steering similar to that of the 6th generation COROLLA was adopted. Two types of steering mechanisms were available in the 7th generation COROLLA including the proven "engine speed sensitive power steering," and the newly adopted "New Progressive Power Steering.” The newly adopted steering system controlled the firmness of the steering wheel according to vehicle speed and road surface reaction force. This enabled easy operation at low speeds, which was light enough to be turned with one finger, and a firm and stable steering feel at high speeds.
In the development of the 7th generation COROLLA, the team pressed onward with efforts to increase quality beyond the boundaries of family cars, a task set forth by the 6th generation, and paid close attention to every detail. For the interior space, comfortable seating space was achieved by primarily expanding the head clearance, rear legroom, and interior width. To improve comfort in the rear seat in particular, the arrangement of the seat rails of the front seat was reviewed, and the rear seat leg space was expanded. The switches were completely redesigned and converted to switches that are easy to operate with an improved operation feeling. In higher grade models, automatic air conditioning was adopted as standard equipment. Other deluxe equipment was also prepared including vehicle speed sensitive door locks, automatic headlamps, a clearance sonar that detected obstacles and urged caution to the driver, and a wireless key-less entry system. As a result, an increase in quality was achieved that went beyond expectations and significantly exceeded the boundaries of family cars.
Various safety devices were made available in the 7th generation COROLLA to accommodate the customers' increased consciousness toward safety, and equipment was enhanced in line with that of present day vehicles. The 4-wheel Anti-lock Brake System (ABS) used to suppress tires from locking during sudden braking, and the high mount stop lamp, which increased visibility for trailing vehicles, were made available as options on all models. In addition, a computer analyzed collision safety body structure, driver's seat SRS (Supplemental Restraint System) airbags, and side door beams were adopted. Furthermore, safety performance was also considered from a hardware aspect and efforts were made to ensure braking force. This included adopting ventilated front disc brakes in all vehicles, and in some models, adopting large diameter disc rotors and opposed piston brake calipers.
Other Technologies and Equipment
● Viscous LSD (Limited Slip Differential)
● Electric combination meters
● Seats made by Recaro
● 3-point seatbelts for the rear seat
● Projector fog lamps
● Flame retardant treatment of interior parts
---000---
Major Specifications
*The specifications listed here are for the displayed vehicle (shown in the photo on the left) at the Corolla 40 year anniversary event held in August 2006 in Tokyo, Japan.
Specifications of displayed vehicle : 7th generation
Model code : E-AE100-AEMEK
Grade : 1500SE-L sedan
Model year : 1991
Vehicle price (JPY) : 1,398,000
Vehicle weight (kg) : 1010
Minimum turning radius (m) : 4.8
Overall length (mm) : 4270
Overall width (mm) : 1685
Overall height (mm) : 1380
Wheelbase (mm) : 2465
Min. ground clearance (mm) : 150
Interior dimensions:
length (mm) : 1820
width (mm) : 1420
height (mm) : 1155
Passengers : 5
Engine type : 5A-FE
No. of cyls & arrangement : 4270
Fuel : Gasoline
Engine displacement (cc) : 1498
Fuel consumption (km/L) : -
60 km/h constant speed driving : 27.5
10 mode fuel efficiency : 16.4
10.15 mode driving : -
Transmission type : 5-speed manual
Drive train : FF
Max. output : 105PS / 6000rpm (NET)
Vehicle Diagram and Dimensions
Secret of COROLLA
COROLLA and the world's most famous super car
The Sports twin cam 4A-GE engine was modified for the 7th generation COROLLA to the point that it could be called a newly designed engine. The major characteristic of this engine was its valve mechanism of 5 valves per cylinder. This 5-valve configuration is rare even in present day performance cars, and certainly not found in family cars. For instance, Ferrari has adopted 5-valve engines in some of their super sports cars.
Corolla Generasi Ke-6
The 6th Generation COROLLA
A COROLLA beyond COROLLAs
"Higher levels demanded in an era of abundant prosperity."
Akihiko Saito,
Development Leader of the 6th Generation COROLLA
Production Period
1987 - 1991
*Production period in Japan. The period of introduction for this generation model may vary by region.
In May 1987, the COROLLA evolved into its 6th generation model. The catchphrase used in advertisements at that time was "A new tale in Japanese vehicles has begun. The birth of the all new COROLLA, a new grade Toyota sedan." As evident from this phrase, all areas of the new COROLLA were completely renovated to go beyond the norms of its class as the COROLLA entered the market armed with a sense of luxury and an even higher level of quality. Because of the rich economy in Japan, the customer needs were greatly changing from "satisfaction of ownership" to "what kind of life can be enjoyed with the use of possessions" and "how can items be put to use for personal lifestyle". In developing the 6th generation COROLLA, the development team recognized that the era had changed from focus on items to focus on things of the heart, and that customers sought self fulfillment in their cars as well. To comply with these types of needs, the design team embarked on developments with the idea of providing a vehicle that not merely functioned as a tool or means of transportation but that also provided passengers with "quality time and travel space". As a result, the team successfully achieved interior and exterior designs replete with a sense of luxury that challenged even higher grade vehicles as well as a high output engine with good fuel economy. The team also searched the range of sensitivity in areas of texture and tone in their pursuit for high levels of quality.
This 6th generation COROLLA was well received by many both in Japan and in overseas markets, and its popularity did not fade. In fact, in March 1989, three years after its release, the 6th generation COROLLA set a new record for monthly domestic sales in Japan of 44,000 units. In addition, the wagon and 4WD models gathered much attention, which has led to the current RV (Recreational Vehicle) boom in Japan, and achieved the highest monthly worldwide sales of 100,000 units.
The market in Japan at the time of the 6th generation COROLLA development was undergoing a change in its sense of values, shifting from an "era of enhancing items" to an "era of satisfying the heart and mind". With this occurring, the new model had to respond to the change by realizing a high level of quality that greatly exceeded the level sought by vehicles in this class. To achieve this, the development team targeted vehicle development based on a new sense of value that exceeded the boundaries of conventional family cars and compact cars. The team strived to develop a "car that would create new standards for the upcoming decade, the 1990s, as well as a global vehicle that exceeded its class."
Akihiko Saito, the Development leader, stated, "I believe that the COROLLA must erase the image of family cars of the past. Wouldn't it be nice if the quietness and riding comfort of the CROWN* and the attractive appearance of the MARK II (CRESSIDA) were achieved in a vehicle the size of the COROLLA?" To achieve this concept and development goal, Saito instructed the staff to create a car that provided "high quality time". The main point for materializing this concept was satisfying the customers by appealing to the five senses. For example, the importance of appearance ― a customer will not consider his or her time spent in the car as spending quality time, if the car he or she is driving appears shabby.
To materialize this "global vehicle that exceeded its class" and "quality time", the team focused on the following.
1. Provide a lineup of characteristic body styles to best fit the broad lifestyles of the customers.
2. Achieve a "Fun to Drive" vehicle through outstanding vehicle performance.
3. Realize high level aesthetic quality for the senses.
Rather than executing merely a model change, the team focused on these three points and embarked on developments with a spirit of introducing an entirely new vehicle for the market to judge.
A major feature of the 6th generation COROLLA was its engine, which adopted a newly developed double-overhead cam 4-valve mechanism called the "High-Mecha Twin Cam." At that time, while double-overhead cam 4-valve mechanisms enabled high speeds and high output, they were also expensive, and primarily mounted in sports cars and sporty models. Use in everyday family cars was not considered. However, the manager of the Engine Development Department declared, "When we pursued the ideal engine with both high performance and good fuel economy, we inevitably turned to this type of engine." With that, the team embarked on the development of a new double-overhead cam 4-valve mechanism for use in a family car ― with superior fundamental performance of output and fuel economy, whilst accomplishing excellent mass productivity and low production costs. However, there were many issues that had to be resolved in developments. For example, to determine the optimum cam drive method to open and close the valves, durability tests, lasting several hundred hours at 6000rpm, were repeated over and over using several types of prototype engines. As a result, an engine with high performance and fuel efficiency in the practical application range was completed with characteristics that appeal to the senses with comforting tones.
In the development of the 6th generation COROLLA, a project team was organized to increase overall quality. The team made over 2,000 proposals and cooperated with over 100 part manufacturers to improve quality in even areas that the customer would never see. Also, by ensuring high sensory qualities for higher levels of satisfaction, the development staff was confident that it had created a new standard for the appearance and finish of Toyota manufactured vehicles. With this level of quality, far beyond the boundaries of conventional family cars, the 6th generation COROLLA was well received by many and became a major hit model.
*CROWN: Introduced in 1955 and is now in its 12th generation as a large luxury passenger vehicle representative of Toyota.
At the time of its initial release, the 6th generation COROLLA was available in four body types including a 4-door sedan, a 2-door coupe, a 3-door hatchback, and a 5-door hatchback. In August 1987, the van and wagon models, which had been carried over from the 4th generation model without any model changes, underwent a conversion to FF drivetrain and joined the 6th generation lineup. When the model change was made for the 6th generation, the 3-door coupe and 5-door models were discontinued in Japan, but a 5-door liftback model was established for Europe.
Seven types of engines were available at the time of the initial release. This included the 1.3-liter OHC 2E engine, the newly developed High-mecha twin cam 1.5-liter 5A-F and 5A-FE engines, the 1.6-liter Sports twin cam 4A-GE and Supercharged 4A-GZE engines, and the 1.8-liter OHC 1C-II diesel engine. A 1.5-liter OHC 3E engine was also available exclusively for the van model.
In September 1987, the 1.6-liter High-mecha twin cam 4A-F engine was established exclusively for the 4WD model.
In May 1989, in the second half of the model period, the 5A-F and 4A-F engines were replaced by the EFI controlled 5A-FE and 4A-FE engines. In addition, the 5A-FHE was established for some grades of the coupe and hatchback models by further tuning the 5A-FE engine for improved output. Then in September of the same year, the 2.0-liter OHC 2C-III diesel engine was added to the lineup for 4WD models.
For the drivetrain, the front wheel drive was adopted from the time of the initial release for the sedan, coupe, and hatchback. In August, three months later, the van and wagon were converted to the FF drivetrain, and the conversion of all COROLLAs to FF, started on the 5th generation, was completed. Later, COROLLA's first full-time 4WD, based on the FF drivetrain, was established to further support the diversification of customer needs.
A wide & low theme was adopted for all body types, and a luxurious design was given to the 6th generation COROLLA. To achieve the exterior design, the COROLLA was designed like higher grade vehicles with well-proportioned style including a large, low form with a small cabin proportion and with rounded lines, which was the newest trend. Specifically, when seen from the side, the exterior design emphasized a carefree image with its straight horizontal lines that seemed to flow from the top of the fender to the rear trunk and with a cabin that appeared to be positioned on top. In addition, a visual effect was also incorporated by bringing the front pillar and rear pillar closer to the center pillar to achieve a well-proportioned style, and a delicately designed radiator grille was adopted to achieve a design that overflows with a sense of luxury.
As for the interior, the design team began by searching for which direction to take the design. To determine that direction, the designers, with the help of the sales staff, visited many customers at their homes to hear opinions. Also, to incorporate the trends of that time, the team began analyzing even songs that were popular at that time (in Japan) to determine what exactly it was that would be accepted by the people. From the analysis of popular songs and such and from listening to customers first hand, the team was guided in a design direction that led to luxury and freshness. Specifically, the seats adopted a velour knit fabric and a large, thick design to portray an image of luxuriousness. For the interior color, maroon (wine color), that had gained an excellent reputation in use in higher grade vehicles, was adopted. On the other hand, one area of focus to achieve the image of newness was the interior space, which was created by pursuing ergonomics. The shape of the meters, and the layout and grouping of the controls were designed by carefully examining visibility and operability.
Of the seven types of engines available at the initial release, the 1.5-liter DOHC 16-valve 5A-F and 5A-FE engines were newly developed to achieve high output, good fuel economy, high response, and ample torque characteristics in the practical application range. In addition, the engine sound was carefully tuned to achieve ear-pleasing tones. The characteristic feature of this engine was the High-mecha twin cam mechanism created from the concept of "make the ultimate twin cam mechanism a common device." While the conventional DOHC uses a timing belt to drive both camshafts, the lightweight and compact High-mecha twin cam drives one camshaft with a timing belt and the other camshaft with a scissors gear for high intake and exhaust efficiency. As a result, the 5A-F engine achieved a maximum output of 85ps / 6000rpm and a maximum torque of 12.5kg-m / 3600rpm, and the 5A-FE engine equipped with an EFI achieved a maximum output of 94ps / 6000rpm and a maximum torque of 13.1kg-m / 4400rpm. The level of confidence that the team had in these engines was apparent from advertisements in Japan that introduced the engines as "Engines that go beyond the boundaries of their class."
The sporty, 1.6-liter DOHC 4A-series engines included the 4A-GE engine that was refined based on the 5th generation 4A-GELU engine for increased power, and the 4A-GZE that was equipped with a supercharger. The 4A-GZE supercharger differed from conventional turbochargers because it gained its power from the crankshaft, so it had the merit of superior response. In addition, high power and high response in all speed ranges were achieved through various refinements. These included adopting an intercooler and forged pistons, as well as reinforcing the internal structure and components. The 4A-GE engine achieved a maximum output of 120ps / 6600rpm and a maximum torque of 14.5kg-m / 5200rpm, while the 4A-GZE engine provided a maximum output of 145ps / 6400rpm and a maximum torque of 19.0kg-m / 4400rpm.
On the other hand, changes were made to the ignition timing, engine mount, and fuel evaporative emission control system for the 1.3-liter OHC 12-valve 2E engine, which featured superior response and good fuel economy, to achieve a maximum output of 73ps / 6000rpm and a maximum torque of 10.3kg-m / 4000rpm. The 1.8-liter OHC 1C-II diesel engine with high economic efficiency and quietness was also continued from the 5th generation, but the injection nozzle was changed and the injection timing was optimized to comply with Japan's exhaust gas regulations, which were becoming increasingly stricter year by year. The maximum output of this engine was 64ps / 4700rpm and the maximum torque was 12.0kg-m / 2600rpm. Also, the newly developed, compact, lightweight 1.5-liter OHC 3E engine was adopted in the van model. This engine generated a maximum output of 79ps / 6000rpm and a maximum torque of 12.0kg-m / 4000rpm and focused on usability in the practical application range.
In September 1987, the 4A-F engine equipped with the High-mecha twin cam was adopted exclusively for 4WD models. This engine was developed based on the 5th generation 4A-ELU engine.
Then in May 1989, minor changes were made and the 5A-F and 4A-F engines were changed to the 5A-FE and 4A-FE engines with EFI control. In addition, efforts were made to improve the output of some grades of the coupe and hatchback models, and the 5A-FHE engine, which generates a maximum output of 105ps, was adopted. At that time, the 4A-GE, 4A-GZE, and 1C-II engines were also overhauled to improve output. Then in September of that year, the 2000cc 2C-III diesel engine was added to the lineup of the 4WD model to meet the needs for a diesel engine with high level startup characteristics in cold regions.
A strut type suspension similar to that of the 5th generation COROLLA was given to all four wheels. However, by updating the suspension geometry, shock absorber damping force, and component parts, etc., even more superior handling stability and riding comfort were achieved. Also, the TEMS (Toyota Electronic Modulated Suspension), an electronically controlled variable damping force damper, was made available in some of the higher grade models. This system allowed the driver to select the preferred damping force. The system featured an "AUTO Mode" in which the computer adjusted the damping force to either "SOFT" or "HARD" based on the driving conditions, and a "SPORT Mode" for a "HARD" damping force suited for sporty drives.
For the drivetrain, conversion to an FF design progressed from the 5th generation model, and in August 1987, the van and wagon underwent a full model change to a 6th generation and were converted to FF designs. With this, the entire COROLLA series featured an FF design. Then in October of that year, a 4WD model was added that exhibited superior driving performance in various road conditions to meet the needs of various customers. The 4WD system differed with each engine and transmission specifications. In manual transmission models with gasoline engines, full-time 4WD was adopted with a mechanical differential lock, while in automatic transmission models, electronically controlled hydraulic "High-matic" full-time 4WD was established. High-matic full time 4WD detected the throttle opening, vehicle speed, and such and used hydraulic pressure to control the center differential, thus making it easier to take off on slippery roads. This system also did not require any driver control, enabled an easy drive, and made the 4WD models more accessible. A full-time 4WD system with viscous coupling center differential was made available for the manual transmission model equipped with a diesel engine in the latter half of the model period.
In addition to equipping the 6th generation COROLLA with features that ensured a comfortable interior environment, the design team pursued comfort that satisfied even the human senses of touch and sound. A good example is that of details in the area of touch. Areas from the meter cluster to the instrument panel and door trim were wrapped with softer materials to achieve a pleasant texture. Meticulous attention was given to even the feel of switches. In the area of sound, penetrating road noise and wind noise were reduced, and engine sound was carefully tuned to create a pleasant tone. In addition, computer analysis was used to achieve a body structure that generated minimum noise and vibration, and as a result, a superior level of quietness was achieved. On the other hand, in the area of air conditioning, efforts were made to improve dynamic pressure ventilation performance, which played essential roles in maintaining the cabin air fresh.
Efforts were also made to enhance comfort and convenience equipment. The seats were available with a seat lifter, lumbar support, side support, and full-flat reclining. Rear seat types were available according to the body type and grade, including a 60:40 split retractable rear seat and a one-piece fixed rear seat. In addition, a countless number of comfort and convenience equipment was available such as centralized power windows switches, an air conditioning system that enabled rapid heating and cooling, sun visors with vanity mirrors, a power moonroof, 7-step adjustable tilt steering, and a rear window defogger with heater wires.
Numerous easy-to-use storage spaces were also provided including large door pockets, a front console tray, an glove box under tray, a console box with a cassette box, and a front seatback pocket. The van model was designed with a lower floor when converted to an FF design, and a class top level cargo area was ensured.
To accommodate the enhanced engine performance and drive power, disc brakes were adopted for the front brakes of all models, ensuring optimum braking force. In addition, a brake booster, that enabled a large braking force to be generated with only a light pedal pressure, and X-type dual circuit to handle the rare event of brake abnormalities were adopted. For models with sporty engines, ventilated disc brakes with superior anti-fade performance were adopted to ensure high braking force.
In terms of body rigidity, high levels were achieved by optimizing the frame structure and profile shape of the components. In addition, adjustable seatbelt anchors were adopted to ensure a comfortable fit by passenger of any physique. Other Technologies and Equipment
● Advanced panoramic digital meters with superior visibility
● Power adjustable and retracting outer mirrors
● Glare proof inner mirror that prevents glare from the lights of trailing vehicles
● Push button heater control panel and push button hazard lamp switch with superior operability
● Trunk room lamp
● Cup holders
● Fabric toned trunk mat
● Electronically controlled carburetor with a fuel cut off function to contribute to fuel economy performance
● Turnover type clutch pedal with reduced operation force
Major Specifications
*The specifications listed here are for the displayed vehicle (shown in the photo on the left) at the Corolla 40 year anniversary event held in August 2006 in Tokyo, Japan.
Specifications of displayed vehicle : 6th generation
Model code : E-AE91-AEMEK(S)
Grade : 1500SE Limited sedan
Model year : 1990
Vehicle price (JPY) : 1,172,000
Vehicle weight (kg) : 960
Minimum turning radius (m) : 4.9
Overall length (mm) : 4235
Overall width (mm) : 1655
Overall height (mm) : 1365
Wheelbase (mm) : 2430
Min. ground clearance (mm) : 155
Interior dimensions:
length (mm) : 1785
width (mm) : 1360
height (mm) : 1150
Passengers : 5
Engine type : 5A-FE
No. of cyls & arrangement : Water cooled, inline 4-cylinder DOHC
Fuel : Gasoline
Engine displacement (cc) : 1498
Fuel consumption (km/L) : -
60 km/h constant speed driving : 27.5
10 mode fuel efficiency : 16.4
10.15 mode driving : -
Transmission type : 5-speed manual
Drive train : FF
Max. output : 94PS / 6000rpm (NET)
Vehicle Diagram and Dimensions
Secret of COROLLA
Quietness of a higher grade
For the 6th generation COROLLA, efforts were made to reduce sounds that are compounded and felt in the interior such as engine noise, road noise, and wind noise, and to convert those noises into pleasing sounds. At the time, this was an uncultivated field with only a few examples of research documents, so the development team used the "Comprehensive Vibration Noise Analysis System" that had been only recently introduced in 1983. This system was formed by combining a large computer with the Fast Fourier Transform (FFT) device developed to analyze and identify submarine sounds (sound patterns). Using this system, the team could analyze and visualize eight types of sounds at the same time and could analyze the sound source in a short amount of time. Based on the analysis results, the team successfully reduced vibration from the engine, body, and such, changed the tone of noises, and created a comfortable interior environment.
A COROLLA beyond COROLLAs
"Higher levels demanded in an era of abundant prosperity."
Akihiko Saito,
Development Leader of the 6th Generation COROLLA
Production Period
1987 - 1991
*Production period in Japan. The period of introduction for this generation model may vary by region.
In May 1987, the COROLLA evolved into its 6th generation model. The catchphrase used in advertisements at that time was "A new tale in Japanese vehicles has begun. The birth of the all new COROLLA, a new grade Toyota sedan." As evident from this phrase, all areas of the new COROLLA were completely renovated to go beyond the norms of its class as the COROLLA entered the market armed with a sense of luxury and an even higher level of quality. Because of the rich economy in Japan, the customer needs were greatly changing from "satisfaction of ownership" to "what kind of life can be enjoyed with the use of possessions" and "how can items be put to use for personal lifestyle". In developing the 6th generation COROLLA, the development team recognized that the era had changed from focus on items to focus on things of the heart, and that customers sought self fulfillment in their cars as well. To comply with these types of needs, the design team embarked on developments with the idea of providing a vehicle that not merely functioned as a tool or means of transportation but that also provided passengers with "quality time and travel space". As a result, the team successfully achieved interior and exterior designs replete with a sense of luxury that challenged even higher grade vehicles as well as a high output engine with good fuel economy. The team also searched the range of sensitivity in areas of texture and tone in their pursuit for high levels of quality.
This 6th generation COROLLA was well received by many both in Japan and in overseas markets, and its popularity did not fade. In fact, in March 1989, three years after its release, the 6th generation COROLLA set a new record for monthly domestic sales in Japan of 44,000 units. In addition, the wagon and 4WD models gathered much attention, which has led to the current RV (Recreational Vehicle) boom in Japan, and achieved the highest monthly worldwide sales of 100,000 units.
The market in Japan at the time of the 6th generation COROLLA development was undergoing a change in its sense of values, shifting from an "era of enhancing items" to an "era of satisfying the heart and mind". With this occurring, the new model had to respond to the change by realizing a high level of quality that greatly exceeded the level sought by vehicles in this class. To achieve this, the development team targeted vehicle development based on a new sense of value that exceeded the boundaries of conventional family cars and compact cars. The team strived to develop a "car that would create new standards for the upcoming decade, the 1990s, as well as a global vehicle that exceeded its class."
Akihiko Saito, the Development leader, stated, "I believe that the COROLLA must erase the image of family cars of the past. Wouldn't it be nice if the quietness and riding comfort of the CROWN* and the attractive appearance of the MARK II (CRESSIDA) were achieved in a vehicle the size of the COROLLA?" To achieve this concept and development goal, Saito instructed the staff to create a car that provided "high quality time". The main point for materializing this concept was satisfying the customers by appealing to the five senses. For example, the importance of appearance ― a customer will not consider his or her time spent in the car as spending quality time, if the car he or she is driving appears shabby.
To materialize this "global vehicle that exceeded its class" and "quality time", the team focused on the following.
1. Provide a lineup of characteristic body styles to best fit the broad lifestyles of the customers.
2. Achieve a "Fun to Drive" vehicle through outstanding vehicle performance.
3. Realize high level aesthetic quality for the senses.
Rather than executing merely a model change, the team focused on these three points and embarked on developments with a spirit of introducing an entirely new vehicle for the market to judge.
A major feature of the 6th generation COROLLA was its engine, which adopted a newly developed double-overhead cam 4-valve mechanism called the "High-Mecha Twin Cam." At that time, while double-overhead cam 4-valve mechanisms enabled high speeds and high output, they were also expensive, and primarily mounted in sports cars and sporty models. Use in everyday family cars was not considered. However, the manager of the Engine Development Department declared, "When we pursued the ideal engine with both high performance and good fuel economy, we inevitably turned to this type of engine." With that, the team embarked on the development of a new double-overhead cam 4-valve mechanism for use in a family car ― with superior fundamental performance of output and fuel economy, whilst accomplishing excellent mass productivity and low production costs. However, there were many issues that had to be resolved in developments. For example, to determine the optimum cam drive method to open and close the valves, durability tests, lasting several hundred hours at 6000rpm, were repeated over and over using several types of prototype engines. As a result, an engine with high performance and fuel efficiency in the practical application range was completed with characteristics that appeal to the senses with comforting tones.
In the development of the 6th generation COROLLA, a project team was organized to increase overall quality. The team made over 2,000 proposals and cooperated with over 100 part manufacturers to improve quality in even areas that the customer would never see. Also, by ensuring high sensory qualities for higher levels of satisfaction, the development staff was confident that it had created a new standard for the appearance and finish of Toyota manufactured vehicles. With this level of quality, far beyond the boundaries of conventional family cars, the 6th generation COROLLA was well received by many and became a major hit model.
*CROWN: Introduced in 1955 and is now in its 12th generation as a large luxury passenger vehicle representative of Toyota.
At the time of its initial release, the 6th generation COROLLA was available in four body types including a 4-door sedan, a 2-door coupe, a 3-door hatchback, and a 5-door hatchback. In August 1987, the van and wagon models, which had been carried over from the 4th generation model without any model changes, underwent a conversion to FF drivetrain and joined the 6th generation lineup. When the model change was made for the 6th generation, the 3-door coupe and 5-door models were discontinued in Japan, but a 5-door liftback model was established for Europe.
Seven types of engines were available at the time of the initial release. This included the 1.3-liter OHC 2E engine, the newly developed High-mecha twin cam 1.5-liter 5A-F and 5A-FE engines, the 1.6-liter Sports twin cam 4A-GE and Supercharged 4A-GZE engines, and the 1.8-liter OHC 1C-II diesel engine. A 1.5-liter OHC 3E engine was also available exclusively for the van model.
In September 1987, the 1.6-liter High-mecha twin cam 4A-F engine was established exclusively for the 4WD model.
In May 1989, in the second half of the model period, the 5A-F and 4A-F engines were replaced by the EFI controlled 5A-FE and 4A-FE engines. In addition, the 5A-FHE was established for some grades of the coupe and hatchback models by further tuning the 5A-FE engine for improved output. Then in September of the same year, the 2.0-liter OHC 2C-III diesel engine was added to the lineup for 4WD models.
For the drivetrain, the front wheel drive was adopted from the time of the initial release for the sedan, coupe, and hatchback. In August, three months later, the van and wagon were converted to the FF drivetrain, and the conversion of all COROLLAs to FF, started on the 5th generation, was completed. Later, COROLLA's first full-time 4WD, based on the FF drivetrain, was established to further support the diversification of customer needs.
A wide & low theme was adopted for all body types, and a luxurious design was given to the 6th generation COROLLA. To achieve the exterior design, the COROLLA was designed like higher grade vehicles with well-proportioned style including a large, low form with a small cabin proportion and with rounded lines, which was the newest trend. Specifically, when seen from the side, the exterior design emphasized a carefree image with its straight horizontal lines that seemed to flow from the top of the fender to the rear trunk and with a cabin that appeared to be positioned on top. In addition, a visual effect was also incorporated by bringing the front pillar and rear pillar closer to the center pillar to achieve a well-proportioned style, and a delicately designed radiator grille was adopted to achieve a design that overflows with a sense of luxury.
As for the interior, the design team began by searching for which direction to take the design. To determine that direction, the designers, with the help of the sales staff, visited many customers at their homes to hear opinions. Also, to incorporate the trends of that time, the team began analyzing even songs that were popular at that time (in Japan) to determine what exactly it was that would be accepted by the people. From the analysis of popular songs and such and from listening to customers first hand, the team was guided in a design direction that led to luxury and freshness. Specifically, the seats adopted a velour knit fabric and a large, thick design to portray an image of luxuriousness. For the interior color, maroon (wine color), that had gained an excellent reputation in use in higher grade vehicles, was adopted. On the other hand, one area of focus to achieve the image of newness was the interior space, which was created by pursuing ergonomics. The shape of the meters, and the layout and grouping of the controls were designed by carefully examining visibility and operability.
Of the seven types of engines available at the initial release, the 1.5-liter DOHC 16-valve 5A-F and 5A-FE engines were newly developed to achieve high output, good fuel economy, high response, and ample torque characteristics in the practical application range. In addition, the engine sound was carefully tuned to achieve ear-pleasing tones. The characteristic feature of this engine was the High-mecha twin cam mechanism created from the concept of "make the ultimate twin cam mechanism a common device." While the conventional DOHC uses a timing belt to drive both camshafts, the lightweight and compact High-mecha twin cam drives one camshaft with a timing belt and the other camshaft with a scissors gear for high intake and exhaust efficiency. As a result, the 5A-F engine achieved a maximum output of 85ps / 6000rpm and a maximum torque of 12.5kg-m / 3600rpm, and the 5A-FE engine equipped with an EFI achieved a maximum output of 94ps / 6000rpm and a maximum torque of 13.1kg-m / 4400rpm. The level of confidence that the team had in these engines was apparent from advertisements in Japan that introduced the engines as "Engines that go beyond the boundaries of their class."
The sporty, 1.6-liter DOHC 4A-series engines included the 4A-GE engine that was refined based on the 5th generation 4A-GELU engine for increased power, and the 4A-GZE that was equipped with a supercharger. The 4A-GZE supercharger differed from conventional turbochargers because it gained its power from the crankshaft, so it had the merit of superior response. In addition, high power and high response in all speed ranges were achieved through various refinements. These included adopting an intercooler and forged pistons, as well as reinforcing the internal structure and components. The 4A-GE engine achieved a maximum output of 120ps / 6600rpm and a maximum torque of 14.5kg-m / 5200rpm, while the 4A-GZE engine provided a maximum output of 145ps / 6400rpm and a maximum torque of 19.0kg-m / 4400rpm.
On the other hand, changes were made to the ignition timing, engine mount, and fuel evaporative emission control system for the 1.3-liter OHC 12-valve 2E engine, which featured superior response and good fuel economy, to achieve a maximum output of 73ps / 6000rpm and a maximum torque of 10.3kg-m / 4000rpm. The 1.8-liter OHC 1C-II diesel engine with high economic efficiency and quietness was also continued from the 5th generation, but the injection nozzle was changed and the injection timing was optimized to comply with Japan's exhaust gas regulations, which were becoming increasingly stricter year by year. The maximum output of this engine was 64ps / 4700rpm and the maximum torque was 12.0kg-m / 2600rpm. Also, the newly developed, compact, lightweight 1.5-liter OHC 3E engine was adopted in the van model. This engine generated a maximum output of 79ps / 6000rpm and a maximum torque of 12.0kg-m / 4000rpm and focused on usability in the practical application range.
In September 1987, the 4A-F engine equipped with the High-mecha twin cam was adopted exclusively for 4WD models. This engine was developed based on the 5th generation 4A-ELU engine.
Then in May 1989, minor changes were made and the 5A-F and 4A-F engines were changed to the 5A-FE and 4A-FE engines with EFI control. In addition, efforts were made to improve the output of some grades of the coupe and hatchback models, and the 5A-FHE engine, which generates a maximum output of 105ps, was adopted. At that time, the 4A-GE, 4A-GZE, and 1C-II engines were also overhauled to improve output. Then in September of that year, the 2000cc 2C-III diesel engine was added to the lineup of the 4WD model to meet the needs for a diesel engine with high level startup characteristics in cold regions.
A strut type suspension similar to that of the 5th generation COROLLA was given to all four wheels. However, by updating the suspension geometry, shock absorber damping force, and component parts, etc., even more superior handling stability and riding comfort were achieved. Also, the TEMS (Toyota Electronic Modulated Suspension), an electronically controlled variable damping force damper, was made available in some of the higher grade models. This system allowed the driver to select the preferred damping force. The system featured an "AUTO Mode" in which the computer adjusted the damping force to either "SOFT" or "HARD" based on the driving conditions, and a "SPORT Mode" for a "HARD" damping force suited for sporty drives.
For the drivetrain, conversion to an FF design progressed from the 5th generation model, and in August 1987, the van and wagon underwent a full model change to a 6th generation and were converted to FF designs. With this, the entire COROLLA series featured an FF design. Then in October of that year, a 4WD model was added that exhibited superior driving performance in various road conditions to meet the needs of various customers. The 4WD system differed with each engine and transmission specifications. In manual transmission models with gasoline engines, full-time 4WD was adopted with a mechanical differential lock, while in automatic transmission models, electronically controlled hydraulic "High-matic" full-time 4WD was established. High-matic full time 4WD detected the throttle opening, vehicle speed, and such and used hydraulic pressure to control the center differential, thus making it easier to take off on slippery roads. This system also did not require any driver control, enabled an easy drive, and made the 4WD models more accessible. A full-time 4WD system with viscous coupling center differential was made available for the manual transmission model equipped with a diesel engine in the latter half of the model period.
In addition to equipping the 6th generation COROLLA with features that ensured a comfortable interior environment, the design team pursued comfort that satisfied even the human senses of touch and sound. A good example is that of details in the area of touch. Areas from the meter cluster to the instrument panel and door trim were wrapped with softer materials to achieve a pleasant texture. Meticulous attention was given to even the feel of switches. In the area of sound, penetrating road noise and wind noise were reduced, and engine sound was carefully tuned to create a pleasant tone. In addition, computer analysis was used to achieve a body structure that generated minimum noise and vibration, and as a result, a superior level of quietness was achieved. On the other hand, in the area of air conditioning, efforts were made to improve dynamic pressure ventilation performance, which played essential roles in maintaining the cabin air fresh.
Efforts were also made to enhance comfort and convenience equipment. The seats were available with a seat lifter, lumbar support, side support, and full-flat reclining. Rear seat types were available according to the body type and grade, including a 60:40 split retractable rear seat and a one-piece fixed rear seat. In addition, a countless number of comfort and convenience equipment was available such as centralized power windows switches, an air conditioning system that enabled rapid heating and cooling, sun visors with vanity mirrors, a power moonroof, 7-step adjustable tilt steering, and a rear window defogger with heater wires.
Numerous easy-to-use storage spaces were also provided including large door pockets, a front console tray, an glove box under tray, a console box with a cassette box, and a front seatback pocket. The van model was designed with a lower floor when converted to an FF design, and a class top level cargo area was ensured.
To accommodate the enhanced engine performance and drive power, disc brakes were adopted for the front brakes of all models, ensuring optimum braking force. In addition, a brake booster, that enabled a large braking force to be generated with only a light pedal pressure, and X-type dual circuit to handle the rare event of brake abnormalities were adopted. For models with sporty engines, ventilated disc brakes with superior anti-fade performance were adopted to ensure high braking force.
In terms of body rigidity, high levels were achieved by optimizing the frame structure and profile shape of the components. In addition, adjustable seatbelt anchors were adopted to ensure a comfortable fit by passenger of any physique. Other Technologies and Equipment
● Advanced panoramic digital meters with superior visibility
● Power adjustable and retracting outer mirrors
● Glare proof inner mirror that prevents glare from the lights of trailing vehicles
● Push button heater control panel and push button hazard lamp switch with superior operability
● Trunk room lamp
● Cup holders
● Fabric toned trunk mat
● Electronically controlled carburetor with a fuel cut off function to contribute to fuel economy performance
● Turnover type clutch pedal with reduced operation force
Major Specifications
*The specifications listed here are for the displayed vehicle (shown in the photo on the left) at the Corolla 40 year anniversary event held in August 2006 in Tokyo, Japan.
Specifications of displayed vehicle : 6th generation
Model code : E-AE91-AEMEK(S)
Grade : 1500SE Limited sedan
Model year : 1990
Vehicle price (JPY) : 1,172,000
Vehicle weight (kg) : 960
Minimum turning radius (m) : 4.9
Overall length (mm) : 4235
Overall width (mm) : 1655
Overall height (mm) : 1365
Wheelbase (mm) : 2430
Min. ground clearance (mm) : 155
Interior dimensions:
length (mm) : 1785
width (mm) : 1360
height (mm) : 1150
Passengers : 5
Engine type : 5A-FE
No. of cyls & arrangement : Water cooled, inline 4-cylinder DOHC
Fuel : Gasoline
Engine displacement (cc) : 1498
Fuel consumption (km/L) : -
60 km/h constant speed driving : 27.5
10 mode fuel efficiency : 16.4
10.15 mode driving : -
Transmission type : 5-speed manual
Drive train : FF
Max. output : 94PS / 6000rpm (NET)
Vehicle Diagram and Dimensions
Secret of COROLLA
Quietness of a higher grade
For the 6th generation COROLLA, efforts were made to reduce sounds that are compounded and felt in the interior such as engine noise, road noise, and wind noise, and to convert those noises into pleasing sounds. At the time, this was an uncultivated field with only a few examples of research documents, so the development team used the "Comprehensive Vibration Noise Analysis System" that had been only recently introduced in 1983. This system was formed by combining a large computer with the Fast Fourier Transform (FFT) device developed to analyze and identify submarine sounds (sound patterns). Using this system, the team could analyze and visualize eight types of sounds at the same time and could analyze the sound source in a short amount of time. Based on the analysis results, the team successfully reduced vibration from the engine, body, and such, changed the tone of noises, and created a comfortable interior environment.
Corolla Generasi Ke-5
The 5th Generation COROLLA
The front wheel drive COROLLA.
"A spacious interior in a compact sedan. Clearing the hurdles to meet world standards."
Fumio Agetsuma,
Development Leader of the 5th Generation COROLLA
Production Period (1983 - 1987)
*Production period in Japan. The period of introduction for this generation model may vary by region.
The 5th generation COROLLA was introduced on the market in May 1983, two months after the production total of COROLLAs reached the 10 million vehicles mark. Japan at that time was seeking a richer lifestyle, and preferences for high grade products were born. Individuals, particularly the younger generation, were exploring their own unique lifestyles, and their sense of values was diversifying. Providing an answer to this trend was the main issue for the 5th generation COROLLA. The key development themes for the new model were "follow the worldwide trend of technical innovations and convert the COROLLA into a front wheel drive passenger car," and "pursue ample room and styling favored by the younger generation."
The list of appealing features and new technology incorporated in the new model could go on and on. Examples include a gracefully curved silhouette emphasizing the trends of the new era, a sleek aerodynamic body, a choice of drivetrains ― front wheel drive for spacious interior and seating comfort / rear wheel drive for driving excitement and a sporty feel, a high performance engine with power and response, and a fine-tuned suspension and power train.
The 5th generation COROLLA was developed to further strengthen the dominance of the COROLLA as the best selling car in the world. And in the four years after its release, the 5th generation COROLLA successfully acquired the No. 1 position in domestic sales and also received favorable reputations overseas.
In March 1979, Fumio Agetsuma, who had served as Development leader of the previous generation, set forth policy to design the 5th generation COROLLA as an FF (front engine, front wheel drive) model. The world at that time was beginning to show signs of FF based passenger cars becoming the mainstream, and in 1978, Toyota released its first FF model. However, the idea of converting the COROLLA to an FF design was not readily approved. Because the COROLLA was a passenger car produced in record numbers, was loved by a wide range of users regardless of age or sex, and was being exported throughout the world, extreme caution was taken before making drastic changes.
In the first part of 1980 after the switch to an FF design had been approved, Agetsuma focused on the positioning of the 5th generation COROLLA and stressed the need to "strive to ensure its status as a worldwide strategic vehicle that is a high quality, high grade family car and to reinforce its international competitive strength." He also declared that this COROLLA "should be an innovative vehicle that incorporates new breakthroughs in every area," and thus launched the development policy for the new model.
Concerning the FF vehicle, Agetsuma stated at that time, "I believed that competitive family cars both from Japan and overseas would soon move towards FF designs to pursue the merits of straight line stability at high speeds, handling performance, and a spacious interior." Two hurdles stood before Agetsuma, who advocated an FF design for the COROLLA from this belief.
The first hurdle was a technical problem. FF designs use a complex mechanism to transmit drive power to the road surface while steering with the front wheels. Because of this complex mechanism, apprehensions existed concerning durability and repair serviceability after miles of use on rough roads. The COROLLA was being exported to many nations with poor road conditions and thus would be driven continuously for long periods of time on bad roads. In fact, around this time there was a European manufacturer that had catastrophic results in exporting FF vehicles to nations with poor road conditions.
The second hurdle was that of cost. In 1979, preliminary calculations showed that the investment needed to convert the FR COROLLA plant, producing 727,000 units per year, into a FF COROLLA plant would total 120 billion yen. This problem was solved with engineering technology that had made significant progress, and by producing the COROLLA in both the FF and FR drivetrains. By adopting the FF design for the sedan, which stressed seating comfort, and the FR design for the coupe, which stressed driving excitement, and by using existing equipment as much as possible, the team successfully reduced the equipment investment expense by almost half. In addition, to those within the company who were opposed to the switch to an FF design, Agetsuma enthusiastically explained the value demanded by the times and the importance of the FF design, and then finally in November 1979, the decision to convert to FF was official.
Computers were widely used to engineer the engine and design of the 5th generation COROLLA, and numerous world-first mechanisms were adopted in the newly developed engine. In addition, a truly innovative vehicle was developed with over 500 patent and utility model applications made during developments. On the other hand, Agetsuma stated the following concerning developments at that time. "The COROLLA has a continuous responsibility of being the 'bread and butter' for various people in nations throughout the world. We placed emphasis on the basic areas that have the greatest impact on passengers even though those areas may be low-key. For example, we used sound proofing and vibration proofing technology, and achieved an incredible level of quietness. Even when we drove the vehicle at 170km/h on the Autobahn in Germany, it provided a comfortable, secure feeling." He also stated, "When Ove Andersson, a professional rally car driver, and other European specialists praised the vehicle for being a step above European vehicles in the same class, it was more wonderful than someone praising my own son." This 5th generation COROLLA was created for the world market in May 1983.
The 5th generation COROLLA entered the market with five body types including the 4-door and 5-door (the former liftback) models in the sedan series, the 2-door and 3-door models in the coupe series, and the wagon. Later in October 1984, 3-door and 5-door model hatchbacks that focused on overseas strategy were added to the lineup. Furthermore, sales of the 4th generation wagon and van models continued without any model changes, and as a result, a total of nine body types were available during that time.
Gasoline engine variations for the sedan series included the newly adopted 1.3-liter OHC 2A-LU engine, the transversely mounted 1.5-liter OHC 3A-LU engine converted from the former 3A-U, and the newly developed 1.6-liter OHC 4A-ELU engine with an EFI system. The 1.8-liter 1C-L diesel engine, which switched the former 1C engine to a transverse mount, was also available.
In addition to offering the 1.5-liter OHC 3A-U II engine from the previous model for use in coupe models, which emphasized a sporty drive, the newly developed 1.6-liter DOHC 16-valve 4A-GEU engine was also made available.
In October 1984, the 4A-GELU engine, the L indicating that it was a converted version of the 4A-GEU to be mounted transversely, was offered in the sedan series and hatchback (COROLLA FX). Also, in May 1985 in the latter half of the model period, the 2A-LU engine was replaced by the newly developed 1.3-liter OHC 2E-LU engine.
The 5th generation COROLLA adopted the FF drivetrain in the sedan and hatchback models, and the FR drivetrain in the other models. To better emphasize a sporty image, all coupe models, which continued to use the FR drivetrain, were unified with the vehicle name "COROLLA Levin" regardless of the type of engine used.
The design concept adopted for the 5th generation COROLLA was "Let's return to the 1st generation COROLLA". The essence of this design concept was to create original style for the 5th generation with technological innovations such as conversion to FF, while achieving innovation like that of the 1st generation model. The major policy at the startup of design was to fully utilize the merits of the FF drivetrain and "create as spacious an interior as possible" and "adopt a style somewhat directed at the younger generation". The exterior, which was designed with awareness of the younger generation, featured a large slanted nose and rounded wedge shape that emphasized surface beauty. Concerning this style, Agetsuma stated, "I think that the gently curved silhouette will create a new trend in world car designs."
Concerning the interior, the development staff at that time stated, "We returned to ground zero and strived to create space for 5 adults." Specifically, the interior was expanded to the maximum limit through methods such as moving the steering wheel forward 5.5 centimeters, lowering the floor surface, and adopting a more vertical angle for the rear window. In this class, designers typically agonized over making millimeter increments, so this move to expand the space by several centimeters was truly revolutionary.
Looking at the exterior design by body type, the sedan adopted a clean, notchback style and expressed an airy image and ease of use. The 5-door model focused on aerodynamic characteristics and targeted a style that appeals to the younger generation as a vehicle featuring innovative style and function. While the coupe model was based on a design theme similar to that of the sedan series, it adopted a design with a carefree form typical of an FR vehicle, with the back end of the rear hatch pinched like a spoiler on the 3-door models.
Three types of engines were used in the sedan series including the 1.3-liter 2A-LU and 1.5-liter 3A-LU developed based on the 3A-U from the 4th generation, and the 1.6-liter 4A-ELU. The 2A-LU and 3A-LU engines strived to improve fuel economy and power performance by adopting the world's first SCV*1 to adjust combustion efficiency at medium and low speeds, a manifold converter, and the IIA*2. As a result, the 2A-LU engine achieved a maximum output of 74ps / 6000rpm and a maximum torque of 10.9kg-m / 3600rpm, and the 3A-LU engine achieved a maximum output of 83ps / 5600rpm and a maximum torque of 12.0kg-m / 3600rpm.
The 4A-ELU engine had increased engine displacement, EFI, and TCCS*3, while inheriting the compact, lightweight, good fuel economy, and low noise characteristics of the base 3A-U engine. This high performance engine generated a maximum output of 100ps / 5600rpm and a maximum torque of 14.0kg-m / rpm.
The 1.8-liter 1C diesel engine introduced in the final model period of the 4th generation was converted to a transverse mount and was offered on the 5th generation COROLLA as the 1C-L. To make compatible to the FF drivetrain, the flywheel was made lighter, and changes were made to the auxiliary equipment. However, there were no changes in performance, and a maximum output of 65ps / 4500rpm and a maximum torque of 11.5kg-m / 3000 rpm were generated.
On the other hand, the engines for the coupe series included the 1.5-liter 3A-U II continued from the 4th generation and the 1.6-liter 16-valve 4A-GEU. The 3A-U II engine strived for improvements in fuel economy and power performance by adopting a dual exhaust manifold and the IIA and such. The 4A-GEU engine, also based on the 3A-U, replaced the famed 2T-GEU. The 4A-GEU, initially developed as a single cam, 2 valves per cylinder engine, was converted into a double-overhead cam, 4-valve design after approximately a year and a half into development. This was done in favor of the higher output in the high speed range, increased combustion efficiency, and intake/exhaust efficiency that the new design offered. Along with this new generation DOHC design, the engine incorporated the latest technologies including an aluminum alloy cylinder head, forged crankshaft, Toyota-Variable Induction System, and higher compression ratio. As a result, a truly high power engine with high response was achieved that generated a maximum output of 130ps / 6600rpm and a maximum torque of 15.2kg-m / 5200rpm. The engine was given the name LASRE*4 like the other new generation Toyota engines, and was called the LASREα 4A-GEU engine.
In October 1984, the 4A-GELU engine, which was a converted version of the 4A-GEU engine for use in a FF drivetrain, was loaded in the sedan series and hatchback (COROLLA FX). Then in May 1985 in the latter half of the model period, the 2A-LU was replaced by the newly developed 1.3-liter OHC 2E-LU engine. This engine adopted SCV, cross flow type intake and exhaust ports, a 3-valve method, and a variable venturi carburetor and such to achieve good fuel economy and high power with a maximum output of 81ps / 6000rpm and a maximum torque of 11.0kg-m / 4400rpm. Furthermore, a Partial Lean System was adopted to stabilize lean air-fuel mixture combustion and conserve fuel through computer control of the air-fuel ratio, and this contributed to superior fuel economy performance.
*1: Swirl Control Valve *2: Integrated Ignition Assembly
*3: TOYOTA Computer Controlled System *4: Light-weight Advanced Super Response Engine
The 4-speed and 5-speed manual transmissions available for the sedan series were completely updated. The overall length was shortened to accommodate the transverse mounting of the engine due to the conversion to an FF drivetrain. In addition, a 3-speed automatic transmission (which was later replaced by a transmission with a lockup clutch) was available in models equipped with the 2A-LU and 3A-LU engines. Models equipped with the 1C-L engine featured a 3-speed automatic transmission with a lockup clutch that contributed to fuel economy performance. Models equipped with the 4A-ELU engine featured an electronically controlled 4-speed ETC-S automatic transmission. On-board computer was used to control this transmission in response to various road conditions such as departure from slippery road surfaces and driving on winding roads.
In February 1984, a 4-speed automatic transmission with a lockup clutch was added to each model equipped with the 2A-LU, 3A-LU and 1C-L engines, and fuel economy performance and quietness were improved by the OD (overdrive) mechanism.
On the other hand, coupe vehicles equipped with the 3A-U II engine were made available with a 4-speed automatic transmission with a lockup clutch from the time of its initial release. At the time, this was rare option in the 1.5-liter engine class vehicles and had a great impact. Models with the sporty 4A-GEU engine were initially only available with a 5-speed manual transmission, but later the electronically controlled 4-speed ETC-S automatic transmission was added to the lineup.
All suspensions for the sedan series were newly designed as a result of the conversion to the FF drivetrain. A MacPherson strut with an L-shaped lower arm was adopted for the front suspension, while a dual link strut with two lower arms was adopted for the rear suspension.
The suspension for the coupe series adopted the same proven layout of the 3rd generation COROLLA, with the front using a MacPherson strut, and the rear using a 4-link coil with a lateral rod. However, the suspension alignment and lateral rod positioning were reviewed to improve driving stability and riding comfort.
For the steering system, all models of the 5th generation COROLLA adopted rack & pinion steering, and the availability of power steering was expanded. However, to accommodate user needs and to expand their choices, a “-less” option (without power steering) was offered to customers not comfortable with the power steering.
The front seats featured fully reclining seatbacks, expanded slide range, and finer adjustment pitches to improve comfort and expand the freedom of driving postures. In addition, large fabric headrests were adopted in the sedan. For the rear, the availability of split folding seats was expanded in the sedan to enable various seating arrangements to match usage purposes. Distinctively designed lounge seats, appearing as if they are integrated with the trim, were given to the coupe model.
Efforts were also made to enhance equipment. Centralized door locks for convenience in getting in and out, intermittent wipers that reduce hassle in rainy weather, and an automatic air conditioner to maintain interior comfort were adopted. Other features included power door mirrors, power windows, power sunroof, and a multi-use tray and such.
Along with the many features and equipment, the expanded interior dimensions of the 5th generation COROLLA also contributed to providing comfort. With the adoption of a FF drivetrain, the sedan offered a roomy cabin with expanded head clearance and legroom.
In an effort to help enhance occupant protection, a crushable body structure was adopted. By allowing a portion of the body to crumple in a rare event of a collision, this revolutionary body structure efficiently absorbed and dispersed the impact load.
------000-----
Other Technologies and Equipment
● Bar type digital rev counter designed with consideration of innovation and visibility
● Mud guards to reduce dirt and scratching
● Lights left on notification buzzer to prevent the battery from draining because the driver forgot to turn off the lights
● Auto drive that enables low speed driving without having to press on the accelerator
● Digital quartz clock
● Power remote control door mirrors
---000---
Major Specifications
*The specifications listed here are for the displayed vehicle (shown in the photo on the left) at the Corolla 40 year anniversary event held in August 2006 in Tokyo, Japan.
Specifications of displayed vehicle
5th generation
Model code
E-AE81-EEMES
Grade
4-door 1500SE Saloon sedan
Model year
1985
Vehicle price (JPY)
1,201,000
Vehicle weight (kg)
890
Minimum turning radius (m)
4.7
Overall length (mm)
4185
Overall width (mm)
1635
Overall height (mm)
1385
Wheelbase (mm)
2430
Min. ground clearance (mm)
160
Interior dimensions
length (mm)
1810
width (mm)
1380
height (mm)
1160
Passengers
5
Engine type
3A-LU
No. of cyls & arrangement
Water cooled, inline 4-cylinder OHC
Fuel
Gasoline
Engine displacement (cc)
1452
Fuel consumption (km/L)
-
60 km/h constant speed driving
27.4
10 mode fuel efficiency
16.4
10・15 mode driving
-
Transmission type
5-speed manual
Drive train
FF
Max. output
83PS / 5600rpm
Vehicle Diagram and Dimensions
Secret of COROLLA
Continuously cherished "Hachi-roku"
The last COROLLA with a FR drivetrain was the coupe model "Levin" equipped with the 1.6-liter 16-valve 4A-GEU engine. From the vehicle code "AE86", this vehicle became known as the "86 (Hachi-roku) Levin", and even today is cherished by many fans. The proof of this is this model's continued service even today after 20 years since its release, the holding of one-make races by its fans, and its appearance in the popular TV animation, "Initial D" in Japan, the US, and Asia.
Introduction of the computer
While today computer technology is the obvious choice, the 5th generation COROLLA was a revolutionary car because computers were introduced for its exterior design and engine engineering. A CAD (Computer Aided Design) system just perfected in 1981 was introduced two years before the model's release to aid in design layout. With this system, the preparation of three-dimensional drawings from clay models, which normally took three experienced designers one full month, could be accurately and easily achieved. Full-scale introduction of computers in engine design began around 1980, making it possible to quickly find the most efficient shape by using a computer to handle complex computations such as rigidity calculations. Computers were also actively used in the development of electronically controlled systems, which were becoming more complex as the performance of engines increased. Today, designs that use computers have further expanded, and computers have become an essential element in vehicle development.
Pursuing passenger protection
Research has progressed on crushable body structures that absorb impact energy and protect passengers in a vehicle collision. The number of prototype vehicles manufactured to develop the 5th generation COROLLA totaled 600. Of these prototypes, approximately 100 were used in collision tests. In addition, computers were also used to analyze test results.
The front wheel drive COROLLA.
"A spacious interior in a compact sedan. Clearing the hurdles to meet world standards."
Fumio Agetsuma,
Development Leader of the 5th Generation COROLLA
Production Period (1983 - 1987)
*Production period in Japan. The period of introduction for this generation model may vary by region.
The 5th generation COROLLA was introduced on the market in May 1983, two months after the production total of COROLLAs reached the 10 million vehicles mark. Japan at that time was seeking a richer lifestyle, and preferences for high grade products were born. Individuals, particularly the younger generation, were exploring their own unique lifestyles, and their sense of values was diversifying. Providing an answer to this trend was the main issue for the 5th generation COROLLA. The key development themes for the new model were "follow the worldwide trend of technical innovations and convert the COROLLA into a front wheel drive passenger car," and "pursue ample room and styling favored by the younger generation."
The list of appealing features and new technology incorporated in the new model could go on and on. Examples include a gracefully curved silhouette emphasizing the trends of the new era, a sleek aerodynamic body, a choice of drivetrains ― front wheel drive for spacious interior and seating comfort / rear wheel drive for driving excitement and a sporty feel, a high performance engine with power and response, and a fine-tuned suspension and power train.
The 5th generation COROLLA was developed to further strengthen the dominance of the COROLLA as the best selling car in the world. And in the four years after its release, the 5th generation COROLLA successfully acquired the No. 1 position in domestic sales and also received favorable reputations overseas.
In March 1979, Fumio Agetsuma, who had served as Development leader of the previous generation, set forth policy to design the 5th generation COROLLA as an FF (front engine, front wheel drive) model. The world at that time was beginning to show signs of FF based passenger cars becoming the mainstream, and in 1978, Toyota released its first FF model. However, the idea of converting the COROLLA to an FF design was not readily approved. Because the COROLLA was a passenger car produced in record numbers, was loved by a wide range of users regardless of age or sex, and was being exported throughout the world, extreme caution was taken before making drastic changes.
In the first part of 1980 after the switch to an FF design had been approved, Agetsuma focused on the positioning of the 5th generation COROLLA and stressed the need to "strive to ensure its status as a worldwide strategic vehicle that is a high quality, high grade family car and to reinforce its international competitive strength." He also declared that this COROLLA "should be an innovative vehicle that incorporates new breakthroughs in every area," and thus launched the development policy for the new model.
Concerning the FF vehicle, Agetsuma stated at that time, "I believed that competitive family cars both from Japan and overseas would soon move towards FF designs to pursue the merits of straight line stability at high speeds, handling performance, and a spacious interior." Two hurdles stood before Agetsuma, who advocated an FF design for the COROLLA from this belief.
The first hurdle was a technical problem. FF designs use a complex mechanism to transmit drive power to the road surface while steering with the front wheels. Because of this complex mechanism, apprehensions existed concerning durability and repair serviceability after miles of use on rough roads. The COROLLA was being exported to many nations with poor road conditions and thus would be driven continuously for long periods of time on bad roads. In fact, around this time there was a European manufacturer that had catastrophic results in exporting FF vehicles to nations with poor road conditions.
The second hurdle was that of cost. In 1979, preliminary calculations showed that the investment needed to convert the FR COROLLA plant, producing 727,000 units per year, into a FF COROLLA plant would total 120 billion yen. This problem was solved with engineering technology that had made significant progress, and by producing the COROLLA in both the FF and FR drivetrains. By adopting the FF design for the sedan, which stressed seating comfort, and the FR design for the coupe, which stressed driving excitement, and by using existing equipment as much as possible, the team successfully reduced the equipment investment expense by almost half. In addition, to those within the company who were opposed to the switch to an FF design, Agetsuma enthusiastically explained the value demanded by the times and the importance of the FF design, and then finally in November 1979, the decision to convert to FF was official.
Computers were widely used to engineer the engine and design of the 5th generation COROLLA, and numerous world-first mechanisms were adopted in the newly developed engine. In addition, a truly innovative vehicle was developed with over 500 patent and utility model applications made during developments. On the other hand, Agetsuma stated the following concerning developments at that time. "The COROLLA has a continuous responsibility of being the 'bread and butter' for various people in nations throughout the world. We placed emphasis on the basic areas that have the greatest impact on passengers even though those areas may be low-key. For example, we used sound proofing and vibration proofing technology, and achieved an incredible level of quietness. Even when we drove the vehicle at 170km/h on the Autobahn in Germany, it provided a comfortable, secure feeling." He also stated, "When Ove Andersson, a professional rally car driver, and other European specialists praised the vehicle for being a step above European vehicles in the same class, it was more wonderful than someone praising my own son." This 5th generation COROLLA was created for the world market in May 1983.
The 5th generation COROLLA entered the market with five body types including the 4-door and 5-door (the former liftback) models in the sedan series, the 2-door and 3-door models in the coupe series, and the wagon. Later in October 1984, 3-door and 5-door model hatchbacks that focused on overseas strategy were added to the lineup. Furthermore, sales of the 4th generation wagon and van models continued without any model changes, and as a result, a total of nine body types were available during that time.
Gasoline engine variations for the sedan series included the newly adopted 1.3-liter OHC 2A-LU engine, the transversely mounted 1.5-liter OHC 3A-LU engine converted from the former 3A-U, and the newly developed 1.6-liter OHC 4A-ELU engine with an EFI system. The 1.8-liter 1C-L diesel engine, which switched the former 1C engine to a transverse mount, was also available.
In addition to offering the 1.5-liter OHC 3A-U II engine from the previous model for use in coupe models, which emphasized a sporty drive, the newly developed 1.6-liter DOHC 16-valve 4A-GEU engine was also made available.
In October 1984, the 4A-GELU engine, the L indicating that it was a converted version of the 4A-GEU to be mounted transversely, was offered in the sedan series and hatchback (COROLLA FX). Also, in May 1985 in the latter half of the model period, the 2A-LU engine was replaced by the newly developed 1.3-liter OHC 2E-LU engine.
The 5th generation COROLLA adopted the FF drivetrain in the sedan and hatchback models, and the FR drivetrain in the other models. To better emphasize a sporty image, all coupe models, which continued to use the FR drivetrain, were unified with the vehicle name "COROLLA Levin" regardless of the type of engine used.
The design concept adopted for the 5th generation COROLLA was "Let's return to the 1st generation COROLLA". The essence of this design concept was to create original style for the 5th generation with technological innovations such as conversion to FF, while achieving innovation like that of the 1st generation model. The major policy at the startup of design was to fully utilize the merits of the FF drivetrain and "create as spacious an interior as possible" and "adopt a style somewhat directed at the younger generation". The exterior, which was designed with awareness of the younger generation, featured a large slanted nose and rounded wedge shape that emphasized surface beauty. Concerning this style, Agetsuma stated, "I think that the gently curved silhouette will create a new trend in world car designs."
Concerning the interior, the development staff at that time stated, "We returned to ground zero and strived to create space for 5 adults." Specifically, the interior was expanded to the maximum limit through methods such as moving the steering wheel forward 5.5 centimeters, lowering the floor surface, and adopting a more vertical angle for the rear window. In this class, designers typically agonized over making millimeter increments, so this move to expand the space by several centimeters was truly revolutionary.
Looking at the exterior design by body type, the sedan adopted a clean, notchback style and expressed an airy image and ease of use. The 5-door model focused on aerodynamic characteristics and targeted a style that appeals to the younger generation as a vehicle featuring innovative style and function. While the coupe model was based on a design theme similar to that of the sedan series, it adopted a design with a carefree form typical of an FR vehicle, with the back end of the rear hatch pinched like a spoiler on the 3-door models.
Three types of engines were used in the sedan series including the 1.3-liter 2A-LU and 1.5-liter 3A-LU developed based on the 3A-U from the 4th generation, and the 1.6-liter 4A-ELU. The 2A-LU and 3A-LU engines strived to improve fuel economy and power performance by adopting the world's first SCV*1 to adjust combustion efficiency at medium and low speeds, a manifold converter, and the IIA*2. As a result, the 2A-LU engine achieved a maximum output of 74ps / 6000rpm and a maximum torque of 10.9kg-m / 3600rpm, and the 3A-LU engine achieved a maximum output of 83ps / 5600rpm and a maximum torque of 12.0kg-m / 3600rpm.
The 4A-ELU engine had increased engine displacement, EFI, and TCCS*3, while inheriting the compact, lightweight, good fuel economy, and low noise characteristics of the base 3A-U engine. This high performance engine generated a maximum output of 100ps / 5600rpm and a maximum torque of 14.0kg-m / rpm.
The 1.8-liter 1C diesel engine introduced in the final model period of the 4th generation was converted to a transverse mount and was offered on the 5th generation COROLLA as the 1C-L. To make compatible to the FF drivetrain, the flywheel was made lighter, and changes were made to the auxiliary equipment. However, there were no changes in performance, and a maximum output of 65ps / 4500rpm and a maximum torque of 11.5kg-m / 3000 rpm were generated.
On the other hand, the engines for the coupe series included the 1.5-liter 3A-U II continued from the 4th generation and the 1.6-liter 16-valve 4A-GEU. The 3A-U II engine strived for improvements in fuel economy and power performance by adopting a dual exhaust manifold and the IIA and such. The 4A-GEU engine, also based on the 3A-U, replaced the famed 2T-GEU. The 4A-GEU, initially developed as a single cam, 2 valves per cylinder engine, was converted into a double-overhead cam, 4-valve design after approximately a year and a half into development. This was done in favor of the higher output in the high speed range, increased combustion efficiency, and intake/exhaust efficiency that the new design offered. Along with this new generation DOHC design, the engine incorporated the latest technologies including an aluminum alloy cylinder head, forged crankshaft, Toyota-Variable Induction System, and higher compression ratio. As a result, a truly high power engine with high response was achieved that generated a maximum output of 130ps / 6600rpm and a maximum torque of 15.2kg-m / 5200rpm. The engine was given the name LASRE*4 like the other new generation Toyota engines, and was called the LASREα 4A-GEU engine.
In October 1984, the 4A-GELU engine, which was a converted version of the 4A-GEU engine for use in a FF drivetrain, was loaded in the sedan series and hatchback (COROLLA FX). Then in May 1985 in the latter half of the model period, the 2A-LU was replaced by the newly developed 1.3-liter OHC 2E-LU engine. This engine adopted SCV, cross flow type intake and exhaust ports, a 3-valve method, and a variable venturi carburetor and such to achieve good fuel economy and high power with a maximum output of 81ps / 6000rpm and a maximum torque of 11.0kg-m / 4400rpm. Furthermore, a Partial Lean System was adopted to stabilize lean air-fuel mixture combustion and conserve fuel through computer control of the air-fuel ratio, and this contributed to superior fuel economy performance.
*1: Swirl Control Valve *2: Integrated Ignition Assembly
*3: TOYOTA Computer Controlled System *4: Light-weight Advanced Super Response Engine
The 4-speed and 5-speed manual transmissions available for the sedan series were completely updated. The overall length was shortened to accommodate the transverse mounting of the engine due to the conversion to an FF drivetrain. In addition, a 3-speed automatic transmission (which was later replaced by a transmission with a lockup clutch) was available in models equipped with the 2A-LU and 3A-LU engines. Models equipped with the 1C-L engine featured a 3-speed automatic transmission with a lockup clutch that contributed to fuel economy performance. Models equipped with the 4A-ELU engine featured an electronically controlled 4-speed ETC-S automatic transmission. On-board computer was used to control this transmission in response to various road conditions such as departure from slippery road surfaces and driving on winding roads.
In February 1984, a 4-speed automatic transmission with a lockup clutch was added to each model equipped with the 2A-LU, 3A-LU and 1C-L engines, and fuel economy performance and quietness were improved by the OD (overdrive) mechanism.
On the other hand, coupe vehicles equipped with the 3A-U II engine were made available with a 4-speed automatic transmission with a lockup clutch from the time of its initial release. At the time, this was rare option in the 1.5-liter engine class vehicles and had a great impact. Models with the sporty 4A-GEU engine were initially only available with a 5-speed manual transmission, but later the electronically controlled 4-speed ETC-S automatic transmission was added to the lineup.
All suspensions for the sedan series were newly designed as a result of the conversion to the FF drivetrain. A MacPherson strut with an L-shaped lower arm was adopted for the front suspension, while a dual link strut with two lower arms was adopted for the rear suspension.
The suspension for the coupe series adopted the same proven layout of the 3rd generation COROLLA, with the front using a MacPherson strut, and the rear using a 4-link coil with a lateral rod. However, the suspension alignment and lateral rod positioning were reviewed to improve driving stability and riding comfort.
For the steering system, all models of the 5th generation COROLLA adopted rack & pinion steering, and the availability of power steering was expanded. However, to accommodate user needs and to expand their choices, a “-less” option (without power steering) was offered to customers not comfortable with the power steering.
The front seats featured fully reclining seatbacks, expanded slide range, and finer adjustment pitches to improve comfort and expand the freedom of driving postures. In addition, large fabric headrests were adopted in the sedan. For the rear, the availability of split folding seats was expanded in the sedan to enable various seating arrangements to match usage purposes. Distinctively designed lounge seats, appearing as if they are integrated with the trim, were given to the coupe model.
Efforts were also made to enhance equipment. Centralized door locks for convenience in getting in and out, intermittent wipers that reduce hassle in rainy weather, and an automatic air conditioner to maintain interior comfort were adopted. Other features included power door mirrors, power windows, power sunroof, and a multi-use tray and such.
Along with the many features and equipment, the expanded interior dimensions of the 5th generation COROLLA also contributed to providing comfort. With the adoption of a FF drivetrain, the sedan offered a roomy cabin with expanded head clearance and legroom.
In an effort to help enhance occupant protection, a crushable body structure was adopted. By allowing a portion of the body to crumple in a rare event of a collision, this revolutionary body structure efficiently absorbed and dispersed the impact load.
------000-----
Other Technologies and Equipment
● Bar type digital rev counter designed with consideration of innovation and visibility
● Mud guards to reduce dirt and scratching
● Lights left on notification buzzer to prevent the battery from draining because the driver forgot to turn off the lights
● Auto drive that enables low speed driving without having to press on the accelerator
● Digital quartz clock
● Power remote control door mirrors
---000---
Major Specifications
*The specifications listed here are for the displayed vehicle (shown in the photo on the left) at the Corolla 40 year anniversary event held in August 2006 in Tokyo, Japan.
Specifications of displayed vehicle
5th generation
Model code
E-AE81-EEMES
Grade
4-door 1500SE Saloon sedan
Model year
1985
Vehicle price (JPY)
1,201,000
Vehicle weight (kg)
890
Minimum turning radius (m)
4.7
Overall length (mm)
4185
Overall width (mm)
1635
Overall height (mm)
1385
Wheelbase (mm)
2430
Min. ground clearance (mm)
160
Interior dimensions
length (mm)
1810
width (mm)
1380
height (mm)
1160
Passengers
5
Engine type
3A-LU
No. of cyls & arrangement
Water cooled, inline 4-cylinder OHC
Fuel
Gasoline
Engine displacement (cc)
1452
Fuel consumption (km/L)
-
60 km/h constant speed driving
27.4
10 mode fuel efficiency
16.4
10・15 mode driving
-
Transmission type
5-speed manual
Drive train
FF
Max. output
83PS / 5600rpm
Vehicle Diagram and Dimensions
Secret of COROLLA
Continuously cherished "Hachi-roku"
The last COROLLA with a FR drivetrain was the coupe model "Levin" equipped with the 1.6-liter 16-valve 4A-GEU engine. From the vehicle code "AE86", this vehicle became known as the "86 (Hachi-roku) Levin", and even today is cherished by many fans. The proof of this is this model's continued service even today after 20 years since its release, the holding of one-make races by its fans, and its appearance in the popular TV animation, "Initial D" in Japan, the US, and Asia.
Introduction of the computer
While today computer technology is the obvious choice, the 5th generation COROLLA was a revolutionary car because computers were introduced for its exterior design and engine engineering. A CAD (Computer Aided Design) system just perfected in 1981 was introduced two years before the model's release to aid in design layout. With this system, the preparation of three-dimensional drawings from clay models, which normally took three experienced designers one full month, could be accurately and easily achieved. Full-scale introduction of computers in engine design began around 1980, making it possible to quickly find the most efficient shape by using a computer to handle complex computations such as rigidity calculations. Computers were also actively used in the development of electronically controlled systems, which were becoming more complex as the performance of engines increased. Today, designs that use computers have further expanded, and computers have become an essential element in vehicle development.
Pursuing passenger protection
Research has progressed on crushable body structures that absorb impact energy and protect passengers in a vehicle collision. The number of prototype vehicles manufactured to develop the 5th generation COROLLA totaled 600. Of these prototypes, approximately 100 were used in collision tests. In addition, computers were also used to analyze test results.
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