torque TOYOTA COROLLA VERSO 2004 Service Owner's Manual

A56696
A56704
Seal Width
4 ± 7 mmBA
A
B
A56706
Front
Measuring Point
A57100
Measuring Tip
Protrusion 14±12
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
35. INSTALL OIL STRAINER SUB±ASSY
(a) Install a new gasket and the oil strainer with the 2 bolts
and 2 nuts.
Torque:
21 N
m (210 kgf
cm, 15 ft
lbf) for bolt
13 N
m (135 kgf
cm, 10 ft
lbf) for nut
36. INSTALL OIL PAN SUB±ASSY NO.2
(a) Apply a seal packing to the oil pan as shown in the illustra-
tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Install a nozzle that has been cut to a 4 ± 7 mm (0.16
± 0.28 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 pan with 16 bolts and 3 nuts. Uniformly tight-
en the bolts and nuts in several passes.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
37. INSTALL CYLINDER HEAD SUB±ASSY
(a) Check piston protrusions for each cylinder.
(1) Find where the piston head protrudes most by slow-
ly turning the crankshaft clockwise and counter-
clockwise.
(2) Measure each cylinder at 2 places as shown in the
illustration, marking a total of 8 measurements.
(3) For the piston protrusion valve of each cylinder, use
the average of the 2 measurements of each cylin-
der.
Protrusion: 0.165 ± 0.425 mm (0.0065 ± 0.0168 in.)

A
B
C
D
E
A09570
Front
A56055
A09564
1
18 2 3
4 56
78 9 (A)
10 11
12 1314
1516 17(B)
(A) (A) (A) (A)(A) (A)
(A)
(B) (B) (B) (B)
(B) (B) (B) (B) (B)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±13
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(b) Select a new cylinder head gasket.
HINT:
There are 5 sizes of new cylinder head gaskets, marked ºAº,
ºBº, ºCº, ºDº, or ºEº according.
New installed cylinder head gasket thickness:
A0.85 ± 0.95 mm (0.0335 ± 0.0374 in.)
B0.90 ± 1.00 mm (0.0354 ± 0.0394 in.)
C0.95 ± 1.05 mm (0.0374 ± 0.0413 in.)
D1.00 ± 1.10 mm (0.0394 ± 0.0433 in.)
E1.05 ± 1.15 mm (0.0413 ± 0.0453 in.)
(1) Select the largest piston protrusion value from the
measurements made, then select a new appropri-
ate gasket according to the table below.
Piston protrusion mm (in.)Gasket size
0.165 ± 0.220 (0.0065 ± 0.0087)Use A
0.220 ± 0.270 (0.0087 ± 0.0106)Use B
0.270 ± 0.320 (0.0106 ± 0.0126)Use C
0.320 ± 0.370 (0.0126 ± 0.0146)Use D
0.370 ± 0.425 (0.0146 ± 0.0167)Use E
(c) Place a new cylinder head gasket in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(d) Place the cylinder head in position on the cylinder head
gasket.
(e) Install the cylinder head bolts.
HINT:
The cylinder head bolts are tightened in 4 progressive steps
(steps (3), (5), (6) and (7)).
(1) Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts and plate
washers.
(2) Install the plate washer to the cylinder head bolt.
(3) Install and uniformly tighten the 18 cylinder head
bolts and plate washers in several passes in the se-
quence shown.
Torque: 45 N
m (460 kgf
cm, 33 ft
lbf)
HINT:
Each bolt length is indicated in the illustration.
Bolt length:
(A)160 mm (6.30 in.)
(B)104 mm (4.09 in.)
If any of the cylinder head bolt does not meet the torque specifi-
cation, replace the cylinder head bolts.

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.

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.

A57103
Plate Washer
Hexagon
Wrench
(8mm)
A62592
SST
B08252
B09792
Spring
Convex
14±18
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
46. INSTALL TIMING BELT IDLER SUB±ASSY NO.1
(a) Using an hexagon wrench (8mm), install the plate washer
and idler pulley with the idler pulley shaft.
Torque: 35 N
m (350 kgf
cm, 25 ft
lbf)
(b) Check that the pulley bracket moves smoothly.
47. INSTALL CAMSHAFT TIMING PULLEY
(a) Install the pulley set key to the key groove of the cam-
shaft.
(b) Align the pulley set key with the key groove of the timing
pulley, and slide on the timing pulley.
(c) Using SST, install the pulley bolt.
SST 09960±10010 (09962±01000, 09963±01000)
Torque: 88 N
m (899 kgf
cm, 65 ft
lbf)
48. INSTALL INJECTOR ASSY
(a) Install 4 new nozzle seats to the cylinder head.
(b) Set the spring to each injector.
NOTICE:
Be sure to make the opening direction of the spring and the
direction of the injector positioning convex meet.
(c) Install a new back±up ring and O±ring to each injector.
(d) Apply a light coat of oil onto O±ring for each injector.

B09793
Convex
Concave
B08249
Upward
B08253
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±19
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(e) Meet the injector positioning convex to the positioning
concave at the cylinder head side and install the injector
to the cylinder head.
NOTICE:

At this time, insert the injector until it touches the
nozzle sheet surface.

When installing the injector to the cylinder head and
in case that the injector comes to float up with the
reaction of O±ring, pull out the injector once, install
it again.

During the time after equipping the head cover and
before installing the injection pipe, install the irregu-
lar object prevention cover.

Do not exchange the injector cylinder.
(f) Place the 4 nozzle holder clamps to each injector.
49. INSTALL NOZZLE HOLDER CLAMP
(a) Set the washer on the nozzle holder clamp as shown in
the illustration.
(b) Tighten the bolts.
HINT:
Apply a light coat of engine oil on the threads and under the
heads of the nozzle holder clamp bolts.
Torque: 27 N
m (275 kgf
cm, 20 ft
lbf)
NOTICE:
At this time, the clamp has its cam cap bolt as a fulcrum and
clip the injector at the fork portion.

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.

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.

A56683
Intake Side: Rear Side:
Exhaust Side:A (M8)
B (M10)C (M8) 36 mm
64 mm34 mm
A62596
14±36
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
30. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
Torque:
Bolt A 8.8N
m (90 kgf
cm, 78 in.
lbf)
Bolt B 12N
m (120 kgf
cm, 9 ft
lbf)
Bolt C 8.8N
m (90 kgf
cm, 78 in.
lbf)
31. INSTALL W/HEAD TAPER SCREW PLUG NO.1
(a) Apply adhesive to the plugs end.
Adhesive: Part No. 08833 ± 00070, THREE BOND 1324 or equivalent
(b) Using a hexagon wrench (6 mm), install the 3 plugs.
Torque:25N
m (255 kgf
cm, 18 ft
lbf)
SST 99999±70037
32. INSTALL SEMICIRCULAR PLUG
(a) Apply seal packing to the semi±circular plug grooves.
Seal packing: Part No. 08826 ± 00080 or equivalent
(b) Install the semi±circular plug to the cylinder head.
33. INSTALL VALVE SPRING SEAT PLATE WASHER