TOYOTA COROLLA VERSO 2004 Service Repair Manual

0106E±06
A54988
N´m (kgf´cm, ft´lbf) : Specified torque

Non±reusable partCamshaft Timing Tube AssyCamshaft Drive Gear
Seal Washer

Camshaft Setting Oil SealNo. 2 Camshaft,
No. 4 Camshaft Sub±assy
Wave WasherCamshaft Driven Main Gear
Snap RingCamshaft Timing Gear
Bolt Washer Screw Plug
78 (790, 58)
15 (150, 11)
7.5 (80, 66 in.´lbf)
Camshaft Sub Gear
Camshaft,
No. 3 Camshaft Sub±assy OVERHAUL
± INTRODUCTIONHOW TO USE THIS MANUAL
01±1
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explains ºRemoving and Installing, Replacing, Disassembling, Installing and Checking,
Adjustingº, but ºFinal Inspectionº is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the ºdisassembled parts drawingº so that it enables you
to understand the fitting condition of the components.
(c) Non±reusable parts, grease applied parts, precoated parts and tightening torque are specified in the
components drawing.
Example:

Illustration:
what to do and whereTask heading: what to do
Detailed text:
how to do task
Set part No.Component part No.
A59974
01±2
± INTRODUCTIONHOW TO USE THIS MANUAL
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(d) Tightening torque, oil applying position, and non±reusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc. are described in the illustration.
(e) Installing procedure of operation items is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a step±by±step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.
6. TERMS DEFINITION
CAUTIONIndicate the possibility of injury to you or other people.
NOTICEIndicate the possibility of damage to the components being repaired.
HINTProvide additional information to help you perform the repair efficiently.

± INTRODUCTIONHOW TO USE THIS MANUAL
01±3
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N
m (310 kgf
cm, 22 ft
lbf)

010BM±01
Z11554
Seal Lock Adhesive 01±4
± INTRODUCTIONREPAIR INSTRUCTION
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
REPAIR INSTRUCTION
PRECAUTION
1. TO PREVENT FROM ENTERING FOREIGN SUBSTANCES.
(a) When foreign substances such as dust, grain of sand or metallic dust enter inside of engine, it often
causes functional failure of the engine.
(1) Precaution before disassembly.

Remove adequately all sand and mud adhere to the outside of engine .
(2) Precaution at reassembly.

Protect disassembled parts from dust by using vinyl sheet to cover.
2. TO PREVENT SCRATCHES ON THE PARTS.
(a) The existence of scratches on the contact and revolving surfaces often causes oil leak and seisure.
(1) Precautions at disassembly and reassembly.

When disassemble the contact surface of the parts, use plastic hummer striking lightly. (Do
not pry out by screwdriver).

When fix the parts to the vise, do not directly catch it in the vise. Fix the parts through alumi-
num bar.
3. TO CLEAN AND WASH THE PARTS.
(a) Each parts needs to be well cleaned, washed, and dried by air, and apply specified oil before reas-
sembly.
(1) Cleaning and washing by alkaline solvent is prohibited:

Parts made of aluminum and rubber. (ex. cylinder head cover gasket etc.)
(2) Cleaning and washing by flushing oil (ex. kerosene, white gasoline etc.) is prohibited:

Parts made of rubber. (ex. cylinder head cover gasket etc.)
4. POSITION AND DIRECTION OF EACH PARTS.
(a) Each parts needs to be reassembled as the same position and direction as it disassembled.
(1) Precautions at disassembly and reassembly.

Follow the directions when the manual designates to mark the matchmark and/or direction
mark.

Disassembled parts needs to be put in order as disassembled, not to change position and/
or direction.

Follow the directions when the manual instructs the position and direction.
5. INSTALL ENGINE ASSEMBLY TO OVERHAUL STAND WHEN OVERHAUL THE ENGINE.
6. PUT THE DISASSEMBLED PARTS IN ORDER AS THEY DISASSEMBLED.
7. APPLY ENGINE OIL TO THE SLIDING AND ROTATING SURFACES.
8. NON±REUSABLE PARTS SUCH AS GASKET AND SEAL NEEDS TO BE CHANGED TO THE NEW
PARTS.
9. BASIC REPAIR HINT
(a) Precoated Parts:
(1) Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.

L1 L2
D02612
L2 L1
D01201
L2 L1
D01202
± INTRODUCTIONREPAIR INSTRUCTION
01±5
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets:
When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
(d) Torque When Using Extension Tool with Torque Wrench:
(1) In case of tightening by extending the entire length
of the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
mkgf
cmft
lbf
TTorque N
mkgf
cmft
lbf
L1Length of SST or tool (cm)
L2Length of torque wrench (cm)
10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) Place for Removing and Installing Fuel System Parts:
(1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, elec-
tric motor or stove in the surroundings.
(2) Never work in a place like a pit or nearby pit as there is a possibility that vaporized fuel fills those
places.
(b) Removing and Installing of Fuel System Parts:
(1) Prepare a fire extinguisher before starting the operation.
(2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank,
and do not spray much water so as to prevent slipping.

D01563
D25081
Flat Spring Clamp
Clamp Track 01±6
± INTRODUCTIONREPAIR INSTRUCTION
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(3) Never use any electric equipment like an electric motor or a working light as they may cause
spark or high temperature.
(4) Never use an iron hammer as it may cause spark.
(5) Dispose the shop lag separately from any fuel deposit.
11. REMOVAL AND INSTALLATION OF ENGINE INTAKE
PARTS
(a) If any metal tip is mixed in the inlet pass, that may give a
bad effect to the engine and turbo charger.
(b) When removing and installing of the inlet system parts,
close the opening of the removed inlet system parts and
the engine with a clean shop lag or gum tape.
(c) When installing the inlet system parts, check that there is
no mixing of a metal tip.
12. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the depth of inserting
portion and the clamp position to restore it surely.
(b) Change a deformed or dented into a new one.
(c) In case of reusing the hose, install the clamp on the hose
where it has a clamp track.
(d) For a flat spring type clamp, make it adjust by adding force
to the arrow mark direction after the installation.

010B9±02
± INTRODUCTIONTERMS
01±7
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
ASSYAssembly
A/T, ATMAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
Calif.California
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
DEFDefogger
DFLDeflector

01±8
± INTRODUCTIONTERMS
1CD±FTV ENGINE REPAIR MANUAL (RM927E)Abbreviations Meaning
DIFF.Differential
DIFF. LOCKDifferential Lock
D/INJDirect Injection
DLCData Link Connector
DLIDistributorless Ignition
DOHCDouble Overhead Cam
DPDash Pot
DSDead Soak
DSPDigital Signal Processor
DTCDiagnostic Trouble Code
DVDDigital Versatible Disc
EBDElectric Brake force Distribution
ECAMEngine Control And Measurement System
ECDElectronic Controlled Diesel
ECDYEddy Current Dynamometer
ECUElectronic Control Unit
EDElectro±Deposited Coating
EDUElectronic Driving Unit
EDICElectric Diesel Injection Control
EFIElectronic Fuel Injection
E/GEngine
EGRExhaust Gas Recirculation
EGR±VMEGR±Vacuum Modulator
ELREmergency Locking Retractor
EMPSElectric Motor Power Steering
ENGEngine
ESAElectronic Spark Advance
ETCS±iElectronic Throttle Control System±intelligent
EVAPEvaporative Emission Control
EVPEvaporator
E±VRVElectric Vacuum Regulating Valve
EX, EXHExhaust
FEFuel Economy
FFFront±Engine Front±Wheel±Drive
F/GFuel Gauge
FIPGFormed In Place Gasket
FLFusible Link
F/PFuel Pump
FPUFuel Pressure Up
FrFront
FRFront±Engine Rear±Wheel±Drive
F/WFlywheel
FW/DFlywheel Damper
FWDFront±Wheel±Drive
GASGasoline
GNDGround
GPSGlobal Positioning System
HACHigh Altitude Compensator
H/BHatchback
H±FUSEHigh Current Fuse
HIHigh

± INTRODUCTIONTERMS
01±9
1CD±FTV ENGINE REPAIR MANUAL (RM927E)Abbreviations Meaning
HIDHigh Intensity Discharge (Head Lamp)
HPUHydrraulic Power Unit
HSGHousing
HTHard Top
HWSHeated Windshield System
IACIdel Air Control
ICIntegrated Circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
ISCIdle Speed Control
J/BJunction Block
J/CJunction Connector
KDKick±Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft±Hand
LHDLeft±Hand Drive
L/H/WLength, Height, Width
LLCLong±Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
M±FUSEMediam Current Fuse
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MG1Motor Generator No.1
MG2Motor Generator No.2
MPMultipurpose
MPIMultipoint Electronic Injection
MPXMultiplex Communication System
M/T, MTMManual Transmission
MTMount
MTGMounting
NNeutral
NANatural Aspiration
No.Number
O/DOverdrive

01±10
± INTRODUCTIONTERMS
1CD±FTV ENGINE REPAIR MANUAL (RM927E)Abbreviations Meaning
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
ORVROn±board Refilling Vapor Recovery
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PSPower Steering
PTOPower Take±Off
P/WPower Window
R & PRack And Pinion
RAMRandom Access Memory
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight±Hand
RHDRight±Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRRear±Engine Rear±Wheel±Drive
RRSRigid Front Suspension
RWDRear±Wheel±Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold±Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
TCTurbocharger
TCCSTOYOTA Computer±Controlled System
TCVTiming Control Valve
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension