Remove TOYOTA COROLLA VERSO 2004 Service Owner's Manual

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A09565
Front
Painted
Mark
A09624
A09625
A09626
Alignment Mark
A09601
Seal Packing
14±14
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(4) Mark the front of the cylinder head bolt with paint.
(5) Retighten the cylinder head bolts additional 90
in
the numerical order shown.
(6) Retighten the cylinder head bolts additional 90
in
the numerical order shown.
(7) Retighten the cylinder head bolts additional 90
in
the numerical order shown.
(8) Check that the painted mark is at the intake man-
ifold side now.
38. INSTALL CAMSHAFT SUB±ASSY, NO.1
(a) Place the camshaft carrier in position on the cylinder
head.
(b) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(c) Place the intake camshaft on top of the camshaft carrier
as shown in the illustration so that the No. 3 and No. 4 of
cylinder cam lobes face downward.
39. INSTALL CAMSHAFT SUB±ASSY, NO.2
(a) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(b) Engage the exhaust camshaft gear to the intake cam-
shaft gear by matching the alignment marks on each
gear.
(c) Roll down the exhaust camshaft onto the bearing journals
while engaging gears with each other.
(d) Install the camshaft bearing caps.
(1) Remove any old packing (FIPG) material from the
No.5 camshaft bearing cap.
(2) Apply seal packing to the No. 5 camshaft bearing
cap as shown in the illustration.
Seal packing: Part No. 08826±00080 or equivalent

A09627
A09650
6 10
1 2
3 7 89 511
412
1314
15
A09687
Upward
Cam Lobe
Clearance
A09617
Upward
Notch
Cam Lobe
Intake
Manifold
Side
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±15
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(3) Place the 5 bearing caps in their proper locations.
(4) Install and uniformly tighten the 15 bearing cap
bolts in several passes and in the sequence shown.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
40. INSPECT VALVE CLEARANCE
(a) Turn the crankshaft so that the cam lobe of the camshaft
on the inspecting valve points upward.
(b) Using a feeler gauge, measure the clearance between
the valve lifter and the camshaft.
(c) Measure the clearance at 16 places.
(d) Record the out±of±specification valve clearance mea-
surements. They will be used later to determine the re-
quired replacement adjusting shim.
Valve clearance (Cold) :
Intake0.20 ± 0.30 mm (0.008 ± 0.012 in.)
Exhaust0.35 ± 0.45 mm (0.014 ± 0.018 in.)
41. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
(1) Turn the crankshaft so that the cam lobe of the cam-
shaft on the adjusting valve points upward.
(2) Position the notch of the valve lifter facing the intake
manifold side.

A62959
SST (B)SST (A)
A09615
Magnetic
Finger
A54826
SST (A)
SST (B)
A09686
14±16
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(3) Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter. Re-
move SST (A).
SST 09248±55050 (09248±05510, 09248±05520)
HINT:
Apply SST (B) on the side marked with º11º.
(4) Remove the adjusting shim with a small screwdriver
and magnetic finger.
(b) Determine the replacement adjusting shim size by follow-
ing the formula:
(1) Using a micrometer, measure the thickness of the
removed shim.
(2) Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
HINT:

T ........... Thickness of removed adjusting shim

A ........... Measured valve clearance

N ........... Thickness of new adjusting shim

Intake: N = T + (A ± 0.25 mm (0.010 in.))

Exhaust: N = T + (A ± 0.40 mm (0.016 in.))
(3) Select a new shim with a thickness as close as pos-
sible to the calculated value.
HINT:
Shims are available in 17 sizes in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
(c) Install a new adjusting shim.
(1) Place a new adjusting shim on the valve lifter.
(2) Using SST (A), press down the valve lifter and re-
move SST (B).
SST 09248±55050 (09248±05510, 09248±05520)
(d) Recheck the valve clearance.

A57098
A09600
Seal Width
2 ± 4 mm
Seal Packing
SST
A57101
Inward
Angle Sensor
A57102
Turn
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±17
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
42. INSTALL WATER PUMP ASSY
(a) Install a new gasket and the water pump with the 7bolts.
Torque: 31 N
m (320 kgf
cm, 23 ft
lbf)
43. INSTALL CAMSHAFT OIL SEAL RETAINER
(a) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Install a nozzle that has been cut to a 2 ± 4 mm (0.08
± 0.16 in.) opening.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil seal retainer with 4 bolts. Uniformly tighten
the 4 bolts in several passes.
Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
44. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the pulley set key with the key groove of the timing
pulley.
(b) Using SST and a hammer, tap in the timing pulley, facing
the angle sensor inward.
SST 09223±46011
45. INSTALL TIMING BELT IDLER SUB±ASSY NO.2
(a) Install the idler pulley with the bolt.
Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
(b) Check that the idler pulley moves smoothly.

90

180

B08307
B08311
B08312
Plug
GasketOverflow Screw
Ball Spring 14±20
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
50. INSTALL NOZZLE LEAKAGE PIPE ASSY
(a) Place the leakage pipe and 5 new gaskets.
NOTICE:
Do the installation of the gasket craw within the angle
range shown in the illustration.
(b) Apply a light coat of oil onto 4 hollow screws and union
bolt.
(c) Tighten the 4 hollow screws and union bolt by hand.
(d) Tighten the 4 hollow screws and union bolt.
Torque:
Hollow screw 18 N
m (184 kgf
cm, 13 ft
lbf)
Union bolt 22 N
m (224 kgf
cm, 16 ft
lbf)
(e) Check that there is no leak from nozzle leakage pipe con-
nection.
(1) Disconnect the fuel hose, and remove the check
valve, No. 2 nozzle leakage pipe and gasket.
(2) Purchase a new check valve.
HINT:
Part No. 23122±27010
(3) Remove the plug, gasket, spring and ball.
(4) Install the plug with the gasket to the overflow
screw.
Torque: 9.8 N
m (100 kgf
cm, 7 ft.
lbf)
(5) Install the No. 2 nozzle leakage pipe and gasket
with the check valve to the cylinder head.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(6) Apply a light coat of soapy water (any fluid to detect
fuel leakage) on the nozzle leakage pipe connec-
tion.

A56050
New Gasket
Union Bolt
Hollow
Screw
SST
No. 2 Nozzle
Leakage Pipe
Check
Valve
New Gasket
B08328
Check
ValveNo. 2 Nozzle
Leakage Pipe
New Gasket
A09663
: Seal Packing
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±21
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(7) Using SST (turbocharger pressure gauge), apply
the SST to the fuel return side of the No. 2 nozzle
leakage pipe, and maintain 100 kPa (1 kgf/cm
2,
14.5 psi) of pressure for 600 seconds to check that
there are no bubbles from the soap±applied places.
SST 09992±00242
(8) After checking fuel leaks, wipe off soapy water from
nozzle leakage pipe connection.
(9) Remove SST, check valve, No. 2 nozzle leakage
pipe and gasket.
(10) Reinstall the No. 2 nozzle leakage pipe and a new
gasket with the check valve.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
HINT:
Never reinstall the disassembled check valve on the engine.
(11) Reconnect the fuel hose to the No. 2 nozzle leak-
age pipe.
51. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head.
Seal packing: Part No. 08826±00080 or equivalent
(c) Install the gasket to the head cover.
(d) Install the cylinder head cover with 10 bolts.
Torque: 13 N
m (135 kgf
cm, 10 ft
lbf)
(e) Install 4 new nozzle holder seals.

140DR±03
A56671
SST
A62594
SST
A09561
A09676
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±23
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OVERHAUL
1. REMOVE VALVE LIFTER
HINT:
Arrange the valve lifters in the correct order.
2. REMOVE INTAKE VALVE
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202±70020 (09202±00010)
(b) Remove the spring retainer, valve spring and valve.
3. REMOVE EXHAUST VALVE
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202±70020 (09202±00010)
(b) Remove the spring retainer, valve spring and valve.
4. REMOVE VALVE STEM OIL O SEAL OR RING
(a) Using needle±nose pliers, remove the oil seal.
5. REMOVE VALVE SPRING SEAT PLATE WASHER
(a) Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in the correct order.

A62595
A56049
Cylinder Block Side
Intake Manifold Side
Exhaust Manifold Side
A09534
14±24
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
6. REMOVE SEMICIRCULAR PLUG
7. REMOVE W/HEAD TAPER SCREW PLUG NO.1
(a) Using a hexagon wrench (6mm), remove the 3 plugs.
SST 99999±70037
8. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side0.08mm (0.0031in.)
Intake manifold side0.20mm (0.0079in.)
Exhaust manifold side0.20mm (0.0079in.)
9. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using dye penetrant, check the intake ports, exhaust
ports and cylinder block contact surface for cracks.

A56674
SST
A56675
SST
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±27
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(b) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
Intake0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
Exhaust0.035 ± 0.070 mm (0.0014 ± 0.0028 in.)
Maximum oil clearance:
Intake0.08 mm (0.0031 in.)
Exhaust0.10 mm (0.0039 in.)
14. REMOVE INTAKE VALVE GUIDE BUSH
(a) Heat the cylinder head to 80 ± 100
C (176 ± 212
F).
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201±10000 (09201±01060), 09950±70010
(09951±07100)
15. REMOVE EXHAUST VALVE GUIDE BUSH
(a) Heat the cylinder head to 80 ± 100
C (176 ± 212
F).
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201±10000 (09201±01060), 09950±70010
(09951±07100)

A09550
A09551
A09552
A09546
Plastigage
A09557
14±32
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
23. INSPECT CAMSHAFT
(a) Inspect the circle runout.
(1) Place the camshaft on V±blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater then maximum, replace the cam-
shaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake46.57 ± 46.67 mm (1.8335 ± 1.8374 in.)
Exhaust47.52 ± 47.62 mm (1.8709 ± 1.8748 in.)
Minimum cam lobe height:
Intake46.10 mm (1.8150 in.)
Exhaust47.05 mm (1.8524 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
(c) Using a micrometer, measure the journal diameter.
Journal diameter:
26.969 ± 26.985 mm (1.0618 ± 1.0624 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
24. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the bearing caps and camshaft carrier.
(b) Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps, cam-
shaft carrier and cylinder head as a set.
(c) Place the camshaft carrier and camshafts on the cylinder
head.
(d) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(e) Install the bearing caps.
Torque: 20 N
m (200 kgf
cm, 15 ft
lbf)
NOTICE:
Do not turn the camshaft.
(f) Remove the bearing caps.