TOYOTA COROLLA VERSO 2004 Service Owners Manual

A09497
A09500
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±51
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(h) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(i) Install and uniformly tighten the 10 bolts of the main bear-
ing cap in several passes.
Torque: 115 N
m (1,173 kgf
cm, 85 ft
lbf)
NOTICE:
Do not turn the crankshaft.
(j) Remove the bearing cap.
(k) Measure the Plastigage at its widest point.
Standard oil clearance:
0.026 ± 0.044 mm (0.0010 ± 0.0017 in.)
Maximum oil Clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater then maximum, replace the bear-
ings. If necessary, replace the crankshaft.

A09688
No.1No.2
No.3
No.4
No.5No.1No.2No.3 No.4No.5
Mark
1, 2 or 3
Mark
0, 1 or 2Mark
1, 2, 3, 4 or 5
14±52
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(l) If using a standard bearing, replace it with one having the
same number. If the number of the bearing cannot be de-
termined, select the correct bearing by adding together
the numbers imprinted on the cylinder block and crank-
shaft, then select the bearing with the same number as
the total. There are 5 sizes of standard bearings, marked
º1º, º2º, º3º, º4º and º5º accordingly.
Number Marked
Cylinder blockCrankshaftUse bearing
101
112
123
202
213
224
303
314
325
HINT:
EXAMPLE
Cylinder block º2º + Crankshaft º1º = Total number 3 (Use bear-
ing º3º)
Cylinder block main journal bore diameter:
Mark º1º61.000 ± 61.006 mm (2.4016 ± 2.4018 in.)
Mark º2º61.006 ± 61.012 mm (2.4018 ± 2.4020 in.)
Mark º3º61.012 ± 61.018 mm (2.4020 ± 2.4023 in.)
Crankshaft main journal diameter:
Mark º0º57.004 ± 57.010 mm (2.2442 ± 2.2445 in.)
Mark º1º56.998 ± 57.004 mm (2.2440 ± 2.2442 in.)
Mark º2º56.992 ± 56.998 mm (2.2438 ± 2.2440 in.)
Standard sized bearing center wall thickness:
Mark º1º1.976 ± 1.979 mm (0.0778 ± 0.0779 in.)
Mark º2º1.979 ± 1.982 mm (0.0779 ± 0.0780 in.)
Mark º3º1.982 ± 1.985 mm (0.0780 ± 0.0781 in.)
Mark º4º1.985 ± 1.988 mm (0.0781 ± 0.0783 in.)
Mark º5º1.988 ± 1.991 mm (0.0783 ± 0.0784 in.)
(m) Completely remove the Plastigage.

A59623
Intake Side:
Front Side:Exhaust Side:
Rear Side:
1.5 mm2.0 mm 2.0 mm
A
B
A 1.5 mm
B 2.0 mm
A
A
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±53
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
21. INSTALL TIGHT PLUG
(a) Apply adhesive around tight plugs.
Adhesive: Part No.08833 ± 00070, THREE BOND 1324
or equivalent.
(b) Using SST, tap to the tight plugs as shown tn the illustra-
tion.
SST 09950±60010 (09951±00350), 09950±70010
(09951±07100)
Standard depth:
Intake side: 2.0 mm (0.0787 in.)
Exhaust side: 2.0 mm (0.0787 in.)
Front side: 1.5 mm (0.0590 in.)
Rear side A: 1.5 mm (0.0590 in.)
B: 2.0 mm (0.0787 in.)

A56687
Cylinder Head Side: Lower Side:
Front Side:
A
B 11 m m20 mm
14 mm 8 mm
AAAA
B B
14±54
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
22. INSTALL RING PIN
(a) Using a plastic±faced hammer, tap in new ring pins to the
specified protrusion height.
Protrusion height:
A: 7.0 mm (0.2755 in.)
B: 13 mm (0.5118 in.)

A56688
10 mm
22 mm7 mm
14 mm
11 m m
ABRear Side: Exhaust Side:
7 mm
C
B
A
C
A56689
Rear Side: Lower Side:
A
B
23 mm
A (M6)
B (M6)28 mm
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±55
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
23. INSTALL STRAIGHT PIN
(a) Using a plastic±faced hammer, tap in the straight pin.
Standard protrusion:
A: 13 mm (0.5118 in.)
B: 7.0 mm (0.2755 in.)
C: 5.0 mm (0.1968 in.)
24. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.

A09473
Hexagon
Wrench (6 mm)
A09503
A56044
A56045
A09510Groove
14±56
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
25. INSTALL CYLINDER BLOCK OIL ORIFICE
(a) Using a hexagon wrench (6 mm), install the oil orifice.
Torque: 9.0 N
m (92 kgf
cm, 78 in.
lbf)
26. INSTALL SUB±ASSY OIL NOZZLE NO.1
(a) Install the oil nozzle with the bolt. Install the 4 oil nozzles.
Torque: 7.4 N
m (76 kgf
cm, 67 in.
lbf)
27. INSTALL CRANKSHAFT
(a) Install the bearing on the cylinder block and bearing cap.
HINT:
Upper bearings have an oil groove and oil holes; lower bearings
do not.
(1) Align the bearing claw with the claw groove of the
cylinder block, and push in the 5 upper bearings.
(2) Align the bearing claw with the claw groove of the
main bearing cap, and push in the 5 lower bearings.
(b) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.

A09512
Groove
A56048
A09497
A56046
A09506
Front Mark
(Arrow)
Front Mark
(Protrusion)
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±57
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Install the 2 thrust washers on the No. 3 bearing cap with
the oil grooves facing outward.
(d) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and a font mark.
(e) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(f) Install and uniformly tighten the 10 bolts of the main bear-
ing cap in several passes.
Torque: 115 N
m (1,173 kgf
cm, 85 ft
lbf)
(g) Check that the crankshaft turns smoothly.
28. INSTALL W/PIN PISTON SUB±ASSY
(a) Install a new snap ring on one side of the piston pin hole.
(b) Gradually heat the piston to 60
C (140
F).
(c) Coat the piston pin and piston hole of the piston with en-
gine oil.
(d) Align the front marks of the piston and connecting rod,
and push in the piston pin by hand.
(e) Install a new snap ring on the other side of the piston pin
hole.

A09508
A56047
Coil Joint
Oil Ring End
A09458
No.1
No.2Code Mark
Code Mark
A09507
Front
Mark
(Arrow)No.1
Compression
Ring
Oil Ring
No.2
Compression
Ring
Coil
14±58
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
29. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
30. INSTALL PISTON RING SET
(a) Install the coil by hand.
(b) Using a piston ring expander, install the oil ring.
HINT:
Face the end gap of the oil ring in the opposite direction coil
joint.
(c) Using a piston ring expander, install the No. 2 and No. 1
piston rings with the code mark facing upward.
Code mark:
No.11T
No.22T
NOTICE:
Make the expansion of the piston ring as small as neces-
sary.
(d) Position the piston rings so that the ring ends are as
shown.
31. INSTALL PISTON SUB±ASSY W/CONNECTING ROD
(a) Apply engine oil to the cylinder walls, pistons, and sur-
faces of connecting rod bearings.
(b) Check the position of the piston ring ends.

A09511
Front Mark
(Arrow)
Front
Push
A09514
Front Mark
(Protrusion)
A09493
90

90

A09490
Painted Mark
Front
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±59
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
(d) Match the numbered connecting rod cap with the con-
necting rod.
(e) Install the connecting rod cap with the front mark facing
forward.
(f) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(g) Install and alternately tighten the 2 cap bolts in several
passes.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
If any of the cap bolts does not meet the torque specification,
replace the connecting rod cap bolts.
(h) Mark the front of the cap bolt with the paint.
(i) Retighten the cap bolts 90
as shown.
(j) Check that the painted mark is now at a 90
angle to the
front.
(k) Check that the crankshaft turns smoothly.

1606V±02
A55603Drain Hole
Turn
± COOLINGWATER PUMP ASSY (1CD±FTV)
16±1
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
WATER PUMP ASSY (1CD±FTV)
INSPECTION
1. INSPECT WATER PUMP ASSY
(a) Visually check the drain hole for coolant leakage.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.