TOYOTA COROLLA VERSO 2004 Service Service Manual

140L3±01
A62602
Cylinder Head
Cover Sub±AssyGasket
Camshaft
Sub±Assy No.2
Camshaft
Sub±Assy No.1
18 (184, 13)
Camshaft Oil
Seal Retainer
 Nozzle Holder Seal
Nozzle Leakage
Pipe Assy
Nozzle Holder Clamp  O±Ring
 Injection Nozzle Seat
 Fuel Injector
Back±Up Ring No. 1
13 (135, 10)
Washer
Camshaft Carrier
Camshaft Bearing Cap
20 (204, 15)
Injector Assy
8.8 (90, 78 in.´lbf)
See page 14±3
1st 45 (460, 33)
2nd Turn 90

3rd Turn 90

4th Turn 90

22 (224, 16)
27 (275, 20)
 Gasket
 Gasket
20 (204, 15)
 Cylinder Head Gasket
 Oil Seal Plate Washer
x 18
Cylinder Head
Sub±Assy

Nozzle Holder Gasket
 Non±reusable partN´m (kgf´cm, ft´lbf)
: Specified torque
Oil Filler Cap Sub±Assy
Plate Washer
Camshaft Timing Pulley
88 (899, 65)
35 (357, 26)
Timing Belt Idler Sub±Assy No. 1
Timing Belt Idler Sub±Assy No. 2
47 (475, 34)
Crankshaft Timing Pulley
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±1
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
PARTIAL ENGINE ASSY (1CD±FTV)
COMPONENTS

A62603
Engine Rear Oil
Seal Retainer
Oil Check Valve
Sub±Assy
Cylinder Block Water
Drain Cock Sub±Assy
31 (320, 23)
Water Pump Assy
21 (209, 15)

Gasket
Gasket
x 6

Gasket

Oil Seal
Oil Pump Assy

Oil Seal31 (320, 23)
7.4 (75, 65 in.´lbf)
11 (112, 8)
21 (214, 15)
Oil Pan Sub±Assy
11 (112, 8)x 19
Oil Strainer Sub±Assy
13 (133, 10 )
34 (350, 25)
Drain Plug

Gasket
7.5 (77, 66 in.´lbf)
Oil Pan Insulator
Oil Pan Sub±Assy No. 2
12 (119, 9)

Non±reusable part
N´m (kgf´cm, ft´lbf)
: Specified torque
21 (214, 15)30 (310, 22)
14±2
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)

140L4±01
A56691
A62591
A56692
A56693
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±3
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OVERHAUL
1. REMOVE OIL FILLER CAP SUB±ASSY
2. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
3. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Remove the 10 bolts, cylinder head cover and gasket.
4. REMOVE NOZZLE LEAKAGE PIPE ASSY
(a) Using a hexagon wrench (6mm), remove 4 hollow screws.
(b) Remove the union bolt, nozzle leakage pipe and 5 gas-
kets from the cylinder head and injector.
5. REMOVE NOZZLE HOLDER CLAMP
(a) Remove the 4 bolts, 4 washers and 4 nozzle holder
clamps.

A56694
A62592
SST
A57095
Hexagon
Wrench
(8mm)
SST
A57096
14±4
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
6. REMOVE INJECTOR ASSY
(a) Remove the 4 injectors from the cylinder head.
HINT:
Arrange the injectors in correct order.
7. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the pulley bolt.
SST 09960±10010 (09962±01000, 09963±01000)
8. REMOVE TIMING BELT IDLER SUB±ASSY NO.1
(a) Using hexagon wrench (8mm), remove the idler pulley
shaft, idler pulley and plate washer.
9. REMOVE TIMING BELT IDLER SUB±ASSY NO.2
10. REMOVE CRANKSHAFT TIMING PULLEY
(a) If the pulley cannot be removed by hand, use SST to re-
move the timing pulley.
SST 09950±50013 (09951±05010, 09952±05010,
09953±05010, 09953±05020, 09954±05021)

A57097
A57098
A09650
1 3
24
576
8
9
10 11
12
13 14
15
A09624
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±5
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
11. REMOVE CAMSHAFT OIL SEAL RETAINER
(a) Remove the 4 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and camshaft
bearing cap.
12. REMOVE WATER PUMP ASSY
(a) Remove the 7 bolts, water pump and gasket.
13. REMOVE CAMSHAFT SUB±ASSY, NO.2
(a) Uniformly loosen and remove the 15 bearing cap bolts in
several passes in the sequence shown.
(b) Remove the 5 bearing caps.
(c) Remove the camshaft No. 2.
14. REMOVE CAMSHAFT SUB±ASSY, NO.1
(a) Remove the camshaft from the cylinder head.
(b) Remove the camshaft carrier from the cylinder head.

A09566
2
1 3
45
67 8
9
14 15 16
17 1211 1013
18
A09563
Pry
A56695
SSTSST
B08601
A56696
14±6
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
15. REMOVE CYLINDER HEAD SUB±ASSY
(a) Uniformly loosen the 18 cylinder head bolts in several
passes in the sequence shown. Remove the 18 cylinder
head bolts and plate washers.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a bench.
HINT:
If the cylinder head is lift off, pry between the cylinder head and
cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
16. REMOVE OIL PAN SUB±ASSY NO.2
(a) Remove the 16 bolts and 3 nuts.
(b) Insert the blade of SST between the No. 1 and No. 2 oil
pans, and cut off the applied seal and remove the No. 2
oil pan.
SST 09032±00100
NOTICE:
Be careful not to damage the contact surfaces of the No. 1
and No. 2 oil pans.
17. REMOVE OIL STRAINER SUB±ASSY
(a) Remove the 2 bolts, 2 nuts, oil strainer and gasket.

A56697
A56698
A56699
A09518
A09519
Hexagon
Wrench
(8mm)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±7
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
18. REMOVE OIL PAN SUB±ASSY
(a) Remove the 19 bolts and 3 nuts.
(b) Using a screwdriver, remove the oil pan by prying the por-
tions between the cylinder block and No. 1 oil pan.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and No. 1 oil pan.
19. REMOVE OIL PUMP ASSY
(a) Remove the 9 bolts.
(b) Remove the oil pump by prying a screwdriver between the
oil pump and main bearing cap.
(c) Remove the gasket.
20. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.
21. REMOVE OIL CHECK VALVE SUB±ASSY
(a) Using hexagon wrench (8mm), remove the pressure
valve and gasket.

A09619
SST
A09620
B07976
A56700
SST
14±8
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
22. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB±ASSY
23. REMOVE CAMSHAFT OIL SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
24. INSTALL CAMSHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the camshaft oil seal retainer edge.
SST 09223±46011
25. REMOVE CRANKSHAFT SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
26. INSTALL CRANKSHAFT SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump edge.
SST 09316±60011 (09316±00011, 09316±00021)

A09449
SST
A09451
A09555
Measuring Point
16 mm (0.63 in.)
P12477
Seal Packing
A09522
Upper
Front
60

± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±9
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
27. REMOVE ENGINE REAR OIL SEAL
(a) Using a screwdriver and a hammer, tap out the oil seal.
28. INSTALL ENGINE REAR OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the rear oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
29. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard outside diameter:
10.75 ± 11.00 mm (0.4232 ± 0.4331 in.)
Minimum outside diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
30. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB±ASSY
(a) Apply seal packing 2 or 3 threads.
Seal packing: Part No. 08826±00100 or equivalent
(b) Install the drain union.
Torque: 29 N
m (291 kgf
cm, 21 ft
lbf)
HINT:
After applying the specified torque, if the drain pipe of the drain
union is not at the position shown in the illustration, rotate the
drain union further clockwise and make the drain pipe face
downward.

A09519
Hexagon
Wrench
(8mm)
A09476
Seal Width
2 ± 3 mm
A56701
Seal Width
2 ± 4 mm
Seal
PackingNew Gasket
14±10
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
31. INSTALL OIL CHECK VALVE SUB±ASSY
(a) Using hexagon wrench (8mm), install a new gasket and
the pressure valve.
Torque: 30 N
m (310 kgf
cm, 22 ft
lbf)
32. INSTALL ENGINE REAR 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 ± 3 mm (0.08
± 0.12 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 6 bolts. Uniformly tighten
the bolt in several passes.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
33. INSTALL OIL PUMP ASSY
(a) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Avoid applying an excessive amount to the surface.

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 a new gasket to the oil pump.