check engine TOYOTA COROLLA VERSO 2004 Service Owner's Guide

A09514
Front Mark
(Protrusion)
A09493
90

90

A09490
Front
Painted Mark
A09495
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±41
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(g) Match the numbered connecting rod cap with the con-
necting rod.
(h) Install the connecting rod cap with the front mark facing
forward.
(i) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(j) 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.
(k) Mark the front of the cap bolt with the paint.
(l) Retighten the cap bolts 90
as shown.
(m) Check that the painted mark is now at a 90
angle to the
front.
NOTICE:
Do not turn the crankshaft.
(n) Remove the 2 bolts, connecting rod cap and lower bear-
ing.
(o) Measure the Plastigage at its widest point.
Standard oil clearance:
0.038 ± 0.056 mm (0.0015 ± 0.0022 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, replace the crankshaft.

Z00064
Z00065
A09462
110mm
A09464
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±47
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
14. INSPECT CONNECTING ROD SUB±ASSY
(a) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for out±of±alignment.
Maximum out±of alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out±of alignment is greater than maximum, replace the con-
necting rod assembly.
(2) Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
15. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between
new piston ring and wall of the ring groove.
Ring groove clearance:
No. 10.08 ± 0.12 mm (0.0031 ± 0.0047 in.)
No. 20.05 ± 0.09 mm (0.0020 ± 0.0035 in.)
Oil0.03 ± 0.07 mm (0.0012 ± 0.0028 in.)
If the clearance is not as specified, replace the piston.
16. INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 110 mm (4.33 in.) from the top of the
cylinder block.

A56041
A09474
A56038
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±49
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
56.992 ± 57.010 mm (2.2438 ± 2.2445 in.)
Crank pin diameter:
50.482 ± 50.500 mm (1.9875 ± 1.9882 in.)
If the diameter is not as specified, replace the crankshaft.
(d) Check each main journal and crank pin for taper and out±
of±round as shown.
Maximum taper and out±of±round:
0.01 mm (0.0004 in.)
If the taper and out±of±round is greater than maximum, replace
the crankshaft.
19. INSPECT CYLINDER BLOCK OIL ORIFICE
(a) Check the oil orifice for clogging.
If necessary, replace the oil orifice.
20. INSPECT CRANKSHAFT OIL CLEARANCE
(a) Clean each main journal and bearing.
(b) 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 clock, and push in the 5 upper bearings.

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.

A55614
A51226
A55615
A55616
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
19±3
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
3. REMOVE STARTER BRUSH HOLDER ASSY
(a) Remove the 2 screws and end frame from the yoke.
(b) Using a screwdriver, hold the spring back disconnect the
brush from the brush holder. Disconnect the 4 brushers
and remove the brush holder.
4. REMOVE STARTER ARMATURE ASSY
(a) Remove the armature from the yoke.
5. INSPECT STARTER ARMATURE ASSY
(a) Using an ohmmeter, check that there is continuity be-
tween the segments of the commutator.
(b) Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.

A55617
A55618
A51188
A55619
A55620
19±4
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Place the commutator on V±blocks.
(d) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.002 in.)
(e) Using vernier calipers, measure the commutator diame-
ter.
Standard diameter: 30 mm (1.1811 in.)
Minimum diameter: 29 mm (1.1417 in.)
(f) Check that the undercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
6. INSPECT STARTER YOKE ASSY
(a) Using an ohmmeter, check that there is continuity be-
tween the lead wire and field coil brush lead.
(b) Using an ohmmeter, check that there is no continuity be-
tween the field coil brush lead and yoke.

A55621
A55622
A55623
A55624
Free
Lock
A55625
Terminal 50 Terminal C
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
19±5
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Using vernier calipers, measure the brush length.
Standard length: 15.5 mm (0.6102 in.)
Minimum length: 8.5 mm (0.3346 in.)
7. INSPECT STARTER BRUSH HOLDER ASSY
(a) Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (±) brush holders.
(b) Using vernier calipers, measure the brush length.
Standard length: 15.5 mm (0.6102 in.)
Minimum length: 8.5 mm (0.3346 in.)
8. INSPECT STARTER CLUTCH SUB±ASSY
(a) Rotate the pinion gear clockwise, and check that it turns
freely. Try to rotate the pinion gear counterclockwise and
check that it locks.
9. INSPECT MAGNET STARTER SWITCH ASSY
(a) Using an ohmmeter, check that there is continuity be-
tween terminal 50 and C.