TOYOTA COROLLA VERSO 2004 Service Manual PDF

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.

140L5±01
A62604
Non±reusable part
Valve Stem Oil
O Seal or RingValve Adusting Shim
Valve Lifter
Valve Spring Retainer
Valve Spring Retainer Lock
Inner Compression Spring
Valve Spring Seat
Plate Washer

Valve Guide Bushing
Exhaust Valve
Semicircular Plug

Valve Stem Oil O Seal or Ring Valve Adusting Shim
Valve Lifter
Valve Spring RetainerValve Spring Retainer Lock
Inner Compression Spring
Valve Spring Seat Plate Washer

Valve Guide Bushing
Intake Valve
14±22
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
CYLINDER HEAD ASSY (1CD±FTV)
COMPONENTS

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.

EM2534
Z00052
A56051
Margin
Thickness
EM2534
Z00052
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±25
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
10. INSPECT INTAKE VALVE
(a) Check the valve overall length.
Standard overall length: 102.53 mm (4.0366 in.)
Minimum overall length: 102.10 mm (4.0197 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
5.970 ± 5.985 mm (0.2350 ± 0.2356 in.)
(c) Check the valve head margin thickness.
Standard margin thickness: 0.9 mm (0.035 in.)
Minimum margin thickness: 0.6 mm (0.0247 in.)
11. INSPECT EXHAUST VALVE
(a) Check the valve overall length.
Standard overall length: 101.97 mm (4.0146 in.)
Minimum overall length: 101.55 mm (3.9980 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
5.960 ± 5.975 mm (0.2346 ± 0.2352 in.)

A56051
Margin
Thickness
EM0801
A56052
Deviation
EM0281
A09539
14±26
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Check the valve head margin thickness.
Standard margin thickness: 0.9 mm (0.035 in.)
Minimum margin thickness: 0.6 mm (0.024 in.)
12. INSPECT INNER COMPRESSION SPRING
(a) Using vernier calipers, measure the free length of the
valve spring.
Free length: 40.45 mm (1.5925 in.)
(b) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
177 ± 195 N (18.0 ± 19.9 kgf, 39.7 ± 44.1 lbf) at 31.1 mm
(1.224 in.)
If the installed tension is not as specified, replace the valve
spring.
13. INSPECT VALVE GUIDE BUSHING OIL CLEARANCE
(a) using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
6.010 ± 6.030 mm (0.2366 ± 0.2374 in.)

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)

A09543
SSTSST
A09541
A09540
Sharp 6 mm
Reamer 14±28
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
16. INSTALL INTAKE VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
Diameter: 10.985 ± 11.006 mm (0.4325 ± 0.4333 in.)
If the bushing bore diameter of the cylinder head is greater then
11.006 mm (0.4333 in.), machine the bushing bore to the di-
mension of 11.035 ± 11.056 mm (0.4344 ± 0.4353 in.).
HINT:
Bushing sizeBushing bore diameter
mm (in.)
Use STD10.985 ± 11.006
(0.4325 ± 0.4333)
Use O/S 0.0511.035 ± 11.056
(0.4344 ± 0.4353)
(b) Heat the cylinder head to 80 ± 100
C. (176 ± 212
F)
(c) Using SST and a hammer, top in a new guide bushing to
the specified protrusion height.
SST 09201±10000 (09201±01060), 09950±70010
(09951±07100)
Protrusion height:
10.05 ± 10.45 mm (0.3957 ± 0.4114 in.)
(d) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance between the
guide bushing and valve stem.
Standard oil clearance:
0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)

A56676
A56677
SST
A56678
Sharp 6 mm
Reamer
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±29
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
17. INSTALL EXHAUST VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
Diameter: 10.985 ± 11.006 mm (0.4325 ± 0.4333 in.)
If the bushing bore diameter of the cylinder head is greater then
11.006 mm (0.4333 in.), machine the bushing bore to the di-
mension of 11.035 ± 11.056 mm (0.4344 ± 0.4353 in.).
HINT:
Bushing sizeBushing bore diameter
mm (in.)
Use STD10.985 ± 11.006
(0.4325 ± 0.4333)
Use O/S 0.0511.035 ± 11.056
(0.4344 ± 0.4353)
(b) Heat the cylinder head to 80 ± 100
C. (176 ± 212
F)
(c) Using SST and a hammer, tap in a new guide bushing to
the specified protrusion height.
SST 09201±10000 (09201±01060), 09950±70010
(09951±07100)
Protrusion height:
9.65 ± 10.05 mm (0.3799 ± 0.3957 in.)
(d) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance between the
guide bushing and valve stem.
Standard oil clearance:
0.035 ± 0.070 mm (0.0014 ± 0.0028 in.)
18. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.

A56053
Width
45
25

Z03988
45

70

A57105Contacting Width
A09537
14±30
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360
around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360
around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the following width.
Intake1.2 ± 1.6 mm (0.047 ± 0.063 in.)
Exhaust1.6 ± 2.0 mm (0.063 ± 0.079 in.)
19. REPAIR INTAKE VALVE SEATS
NOTICE:
Take off a cutter gradually to make smooth valve seats.
(a) If the seating is too high on the valve face, use 25
and
45
cutters to correct the seat.
(b) If the seating is too low on the valve face, use 70
and
45
cutters to correct the seat.
(c) Hand±lap the valve and valve seat with an abrasive com-
pound.
(d) Check the valve seating position.
SST 99999±60014