TOYOTA COROLLA VERSO 2004 Service Owner's Manual

± PREPARATIONSTARTING & CHARGING
02±7
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(09083±00350)AC/DC 400 A ProbeSTARTER ASSY(2.2KW)(1CD±FTV)
Equipment
V±block
Feeler gauge
Ohmmeter
Torque wrench
Vernier calipers
Dial indicator with magnetic base

030KP±01
4
5
6
7
8
9
10
11
B06431
Bolt Type
Hexagon Head Bolt
Normal Recess Bolt Deep Recess BoltStud Bolt Weld BoltClass
4T
5T
6T
7T
8T
9T
10T
11 T
No Mark
w/ WasherNo MarkNo Mark
w/ Washer
± SERVICE SPECIFICATIONSSTANDARD BOLT
03±1
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH

030KQ±01
03±2
± SERVICE SPECIFICATIONSSTANDARD BOLT
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
ClassDiameter
mm
Pitch
mmHexagon head boltHexagon flange boltmmmmN´mkgf´cmft´lbfN´mkgf´cmft´lbf
4T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.55
12.5
26
47
74
11 555
130
260
480
760
1,15048 in.´lbf
9
19
35
55
836
14
29
53
84
±60
145
290
540
850
±52 in.´lbf
10
21
39
61
±
5T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.56.5
15.5
32
59
91
14065
160
330
600
930
1,40056 in.´lbf
12
24
43
67
1017.5
17.5
36
65
100
±75
175
360
670
1,050
±65 in.´lbf
13
26
48
76
±
6T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.58
19
39
71
11 0
17080
195
400
730
1,100
1,75069 in.´lbf
14
29
53
80
1279
21
44
80
125
±90
210
440
810
1,250
±78 in.´lbf
15
32
59
90
±
7T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.510.5
25
52
95
145
23011 0
260
530
970
1,500
2,3008
19
38
70
108
16612
28
58
105
165
±120
290
590
1,050
1,700
±9
21
43
76
123
±
8T
8
10
121.25
1.25
1.2529
61
11 0300
620
1,10022
45
8033
68
120330
690
1,25024
50
90
9T
8
10
121.25
1.25
1.2534
70
125340
710
1,30025
51
9437
78
140380
790
1,45027
57
105
10T
8
10
121.25
1.25
1.2538
78
140390
800
1,45028
58
10542
88
155430
890
1,60031
64
11 6
11 T
8
10
121.25
1.25
1.2542
87
155430
890
1,60031
64
11 647
97
175480
990
1,80035
72
130

030KR±01
6N
8N
10N
11 N
12N
B06432
Nut Type
Present Standard
Hexagon Nut
Cold Forging Nut Cutting Processed NutClass
4N
5N (4T)
6N
7N (5T)
8N
10N (7T)
11 N
12N Old Standard Hexagon Nut
No Mark (w/ Washer)No Mark
*
No Mark (w/ Washer)
No Mark
No Mark
*: Nut with 1 or more marks on one side surface of the nut.
± SERVICE SPECIFICATIONSSTANDARD BOLT
03±3
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
HOW TO DETERMINE NUT STRENGTH
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more

030KS±01
03±4
± SERVICE SPECIFICATIONSINTAKE
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
INTAKE
SERVICE DATA
TurbochargerActuator pressure
Turbine wheel axial play Maximum
Turbine wheel radial play Maximum129 ± 140 kPa (1.32 ± 1.43 kgf/cm2, 18.7 ± 20.3 psi)
0.09 mm (0.0035 in.) or less
0.16 mm (0.0063 in.) or less

030KT±01
± SERVICE SPECIFICATIONSINTAKE
03±5
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
V Band8.38574 in.´lbf
Compressor housing x Bearing housing4.74842 in.´lbf
Turbocharger actuator x Compressor housing7.88069 in.´lbf
Compressor inlet elbow x Compressor housing2323517

0300O±05
03±6
± SERVICE SPECIFICATIONSENGINE MECHANICAL
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
ENGINE MECHANICAL
SERVICE DATA
Cylinder head
Warpage Cylinder brock side
Intake manifold side
Exhaust manifold side
0.08 mm (0.0031 in.)
0.20 mm (0.0079 in.)
0.20 mm (0.0079 in.)
Intake valve
Overall length Standard
Minimum
Valve stem diameter
Margin thickness Standard
Minimum
102.53 mm (4.0366in.)
102.10 mm (4.0197in.)
5.970 ± 5.985 mm (0.2350 ± 0.2356 in.)
0.9 (0.035 in.)
0.6 mm (0.0247 in.)
Exhaust valve
Overall length Standard
Minimum
Valve stem diameter
Margin thickness Standard
Minimum
101.97 mm (4.0146in.)
101.55 mm (3.9980 in.)
5.960 ± 5.975 mm (0.2346 ± 0.2352 in.)
0.9 mm (0.035 in.)
0.6 mm (0.024 in.)
Inner compression spring
Free length
Deviation Maximum
Installed tension at 31.1 mm (1.224 in.)
40.45 mm (1.5925 in.)
2.0 mm (0.079 in.)
177±195 N (18.0 ± 19.9 kgf, 39.7 ± 44.1 lbf)
Intake Valve guide bush
Bushing inside diameter
Oil clearance Standard
Maximum
Diameter
Protrusion height
6.010 ± 6.030 mm (0.2366 ± 0.2374 in.)
0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
0.08 mm (0.0031 in.)
10.985 ± 11.006 mm (0.4325 ± 0.4333 in.)
10.05 ± 10.45 mm (0.3957 ± 0.4114 in.)
Exhaust valve guide bush
Bushing inside diameter
Oil clearance Standard
Maximum
Diameter
Protrusion height
6.010 ± 6.030 mm (0.2366 ± 0.2374 in.)
0.035 ± 0.070 mm (0.0014 ± 0.0028 in.)
0.10 mm (0.0039 in.)
10.985 ± 11.006 mm (0.4325 ± 0.4333 in.)
9.65 ± 10.05 mm (0.3799 ± 0.3957 in.)
Valve lifter
Lifter diameter
Lifter bore diameter
Oil clearance Standard
Maximum
27.975 ± 27.985 mm (1.1014 ± 1.1018 in.)
28.010 ± 28.031 mm (1.1028 ± 1.1036 in.)
0.025 ± 0.056 mm (0.0010 ± 0.0022 in.)
0.08 mm (0.0031 in.)
Camshaft
Circle runout Maximum
Cam lobe height (No.1) Standard
Minimum
Cam lobe height (No.2) Standard
Minimum
Journal diameter
Thrust clearance
Oil clearance Standard
Minimum
Gear backlash Standard
Maximum
0.06 mm (0.0024 in.)
46.57 ± 46.67 mm (1.8335 ± 1.8374 in.)
46.10 mm (1.8150 in.)
47.52 ± 47.62 mm (1.8709 ± 1.8748 in.)
47.05 mm (1.8524 in.)
26.969 ± 26.985 mm (1.0618 ± 1.0624 in.)
0.035 ± 0.11 mm (0.0014 ± 0.0043 in.)
0.025 ± 0.062 mm (0.0010 ± 0.0024 in.)
0.08 mm (0.0031 in.)
0.014 ± 0.070 mm (0.0006 ± 0.0028 in.)
0.17 mm (0.0067 in.)
Connecting rod
Thrust clearance Standard
Maximum
Oil clearance Standard
Maximum
0.08 ± 0.30 mm (0.0031 ± 0.0118 in.)
0.40 mm (0.0157 in.)
0.038 ± 0.056 mm (0.0015 ± 0.0022 in.)
0.10 mm (0.0039 in.)

± SERVICE SPECIFICATIONSENGINE MECHANICAL
03±7
1CD±FTV ENGINE REPAIR MANUAL (RM927E) Cylinder block
Warpage Maximum
Bore diameter Standard
Maximum
0.05 mm (0.0020 in.)
82.200 ± 82.213 mm (3.2362 ± 3.2367 in.)
82.400 mm (3.2441 in.)
Piston
Piston diameter
Piston oil clearance Standard
Maximum
Bushing inside diameter
82.118 ± 82.132 mm (3.2330 ± 3.2335 in.)
0.068 ± 0.095 mm (0.0027 ± 0.0037 in.)
0.14 mm (0.0055 in.)
31.015 ± 31.027 mm (1.2211 ± 1.2215 in.)
Piston pin
Piston pin diameter
Oil clearance Standard
Maximum
31.000 ± 31.012 mm (1.2205 ± 1.2209 in.)
0.030 ± 0.027 mm (0.0001 ± 0.0011 in.)
0.025 mm (0.0010 in.)
Cylinder head set bolt
Out side diameter Standard
Minimum
10.75 ± 11.00 mm (0.4234 ± 0.4331 in.)
10.40 mm (0.4904 in.)
Connecting rod bolt
Diameter Standard
Minimum
8.2 ± 8.3 mm (0.323 ± 0.327 in.)
8.0 mm (0.315 in.)
Connecting rod
Out±of±alignment Maximum per 100 mm (3.94 in.)
Rod twist Maximum per 100 mm (3.94 in.)
0.05 mm (0.0020 in.)
0.15 mm (0.0059 in.)
Crankshaft
Thrust clearance Standard
Maximum
Circle runout Maximum
Crank pin taper and out± of ±round Maximum
Crank pin diameter
Main journal diameter
Oil clearance Standard
Maximum
0.040 ± 0.240 mm (0.0016 ± 0.0094 in.)
0.30 mm (0.0118 in.)
0.025 mm (0.0010 in.)
0.01 mm (0.0004 in.)
50.482 ± 50.500 mm (1.9875 ± 1.9882 in.)
56.992 ± 57.010 mm (2.2438 ± 2.2445 in.)
0.032 ± 0.050 mm (0.0013 ± 0.0020 in.)
0.10 mm (0.0039 in.)

0300P±05
03±8
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Cylinder block water drain cock x Cylinder block2929121
Oil check valve x Cylinder block3031022
Oil pump x Cylinder block3132023
Oil pan x Cylinder block For 10 mm head bolt and nut
For 12 mm head bolt
For 14 mm head bolt11
21
4211 2
210
4298.0 15
31
Oil strainer x Cylinder block For bolt For nut21
13210
13515
10
Oil pan No.2 x Cylinder block121209.0
Cylinder head x Cylinder block 1st 2nd3rd
4th45
Turn 90

Turn 90

Turn 90
460
Turn 90

Turn 90

Turn 90
33
Turn 90

Turn 90

Turn 90

Camshaft bearing cap x Cylinder head2020415
Water pump x Cylinder block3132023
Camshaft oil seal retainer x Cylinder head8.89078 in.
lbf
Timing belt idler Sub assy No.2 x Oil pump4747534
Timing belt idler No. 1 x Cylinder head3535025
Camshaft timing pulley x Camshaft8889965
Nozzle holder clamp x Cylinder head2727520
Nozzle leakage pipe x Cylinder head Hollow screw
Union bolt18
22184
22413
16
Over flow screw x Plug9.81007.0
Check valve x Cylinder head2121415
Cylinder head cover x Cylinder head1313510
Taper screw plug No.1 x Cylinder head2525518
Cylinder head stud bolt (See Page 14±23) Bolt A Bolt B
Bolt C8.8
12
8.890
120 9078 in.
lbf
9.0
78 in.
lbf
Connecting rod cap x Connecting rod 1st
2nd30
Turn 90
306
Turn 90
22
Turn 90

Crankshaft bearing cap x Cylinder block11 51,17385
Cylinder block oil orifice x Cylinder block9.09278 in.
lbf
Oil nozzle No.1 x Cylinder block7.47667 in.
lbf

0300L±04
± SERVICE SPECIFICATIONSLUBRICATION
03±9
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
LUBRICATION
SERVICE DATA
Oil pump
Tip clearance Standard
Maximum
Body clearance Standard
Maximum
0.080±0.160 mm (0.0031 ± 0.0063 in.)
0.2 mm (0.0079 in.)
0.100±0.170 mm (0.0039 ± 0.0067 in.)
0.2 mm (0.0079 in.)