Remove TOYOTA COROLLA VERSO 2004 Service Repair Manual

0106E±06
A54988
N´m (kgf´cm, ft´lbf) : Specified torque

Non±reusable partCamshaft Timing Tube AssyCamshaft Drive Gear
Seal Washer

Camshaft Setting Oil SealNo. 2 Camshaft,
No. 4 Camshaft Sub±assy
Wave WasherCamshaft Driven Main Gear
Snap RingCamshaft Timing Gear
Bolt Washer Screw Plug
78 (790, 58)
15 (150, 11)
7.5 (80, 66 in.´lbf)
Camshaft Sub Gear
Camshaft,
No. 3 Camshaft Sub±assy OVERHAUL
± INTRODUCTIONHOW TO USE THIS MANUAL
01±1
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explains ºRemoving and Installing, Replacing, Disassembling, Installing and Checking,
Adjustingº, but ºFinal Inspectionº is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the ºdisassembled parts drawingº so that it enables you
to understand the fitting condition of the components.
(c) Non±reusable parts, grease applied parts, precoated parts and tightening torque are specified in the
components drawing.
Example:

010BM±01
Z11554
Seal Lock Adhesive 01±4
± INTRODUCTIONREPAIR INSTRUCTION
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
REPAIR INSTRUCTION
PRECAUTION
1. TO PREVENT FROM ENTERING FOREIGN SUBSTANCES.
(a) When foreign substances such as dust, grain of sand or metallic dust enter inside of engine, it often
causes functional failure of the engine.
(1) Precaution before disassembly.

Remove adequately all sand and mud adhere to the outside of engine .
(2) Precaution at reassembly.

Protect disassembled parts from dust by using vinyl sheet to cover.
2. TO PREVENT SCRATCHES ON THE PARTS.
(a) The existence of scratches on the contact and revolving surfaces often causes oil leak and seisure.
(1) Precautions at disassembly and reassembly.

When disassemble the contact surface of the parts, use plastic hummer striking lightly. (Do
not pry out by screwdriver).

When fix the parts to the vise, do not directly catch it in the vise. Fix the parts through alumi-
num bar.
3. TO CLEAN AND WASH THE PARTS.
(a) Each parts needs to be well cleaned, washed, and dried by air, and apply specified oil before reas-
sembly.
(1) Cleaning and washing by alkaline solvent is prohibited:

Parts made of aluminum and rubber. (ex. cylinder head cover gasket etc.)
(2) Cleaning and washing by flushing oil (ex. kerosene, white gasoline etc.) is prohibited:

Parts made of rubber. (ex. cylinder head cover gasket etc.)
4. POSITION AND DIRECTION OF EACH PARTS.
(a) Each parts needs to be reassembled as the same position and direction as it disassembled.
(1) Precautions at disassembly and reassembly.

Follow the directions when the manual designates to mark the matchmark and/or direction
mark.

Disassembled parts needs to be put in order as disassembled, not to change position and/
or direction.

Follow the directions when the manual instructs the position and direction.
5. INSTALL ENGINE ASSEMBLY TO OVERHAUL STAND WHEN OVERHAUL THE ENGINE.
6. PUT THE DISASSEMBLED PARTS IN ORDER AS THEY DISASSEMBLED.
7. APPLY ENGINE OIL TO THE SLIDING AND ROTATING SURFACES.
8. NON±REUSABLE PARTS SUCH AS GASKET AND SEAL NEEDS TO BE CHANGED TO THE NEW
PARTS.
9. BASIC REPAIR HINT
(a) Precoated Parts:
(1) Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.

D01563
D25081
Flat Spring Clamp
Clamp Track 01±6
± INTRODUCTIONREPAIR INSTRUCTION
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(3) Never use any electric equipment like an electric motor or a working light as they may cause
spark or high temperature.
(4) Never use an iron hammer as it may cause spark.
(5) Dispose the shop lag separately from any fuel deposit.
11. REMOVAL AND INSTALLATION OF ENGINE INTAKE
PARTS
(a) If any metal tip is mixed in the inlet pass, that may give a
bad effect to the engine and turbo charger.
(b) When removing and installing of the inlet system parts,
close the opening of the removed inlet system parts and
the engine with a clean shop lag or gum tape.
(c) When installing the inlet system parts, check that there is
no mixing of a metal tip.
12. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the depth of inserting
portion and the clamp position to restore it surely.
(b) Change a deformed or dented into a new one.
(c) In case of reusing the hose, install the clamp on the hose
where it has a clamp track.
(d) For a flat spring type clamp, make it adjust by adding force
to the arrow mark direction after the installation.

0214S±01
02±2
± PREPARATIONENGINE MECHANICAL
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
ENGINE MECHANICAL
PREPARATION
SST
09032±00100Oil Pan Seal CutterPARTIAL ENGINE ASSY(1CD±FTV)
09201±10000Valve Guide Bushing Remover &
Replacer SetCYLINDER HEAD ASSY(1CD±FTV)
(09201±01060)Valve Guide Bushing Remover &
Replacer 6CYLINDER HEAD ASSY(1CD±FTV)
09202±70020Valve Spring CompressorCYLINDER HEAD ASSY(1CD±FTV)
(09202±00010)AttachmentCYLINDER HEAD ASSY(1CD±FTV)
09223±15030Oil Seal & Bearing ReplacerPARTIAL ENGINE ASSY(1CD±FTV)
09223±46011Crankshaft Front Oil Seal
ReplacerPARTIAL ENGINE ASSY(1CD±FTV)
09248±55050Valve Clearance Adjust Tool SetPARTIAL ENGINE ASSY(1CD±FTV)
(09248±05510)Valve Lifter PressPARTIAL ENGINE ASSY(1CD±FTV)
(09248±05520)Valve Lifter StopperPARTIAL ENGINE ASSY(1CD±FTV)
09316±60011Transmission & Transfer Bearing
ReplacerPARTIAL ENGINE ASSY(1CD±FTV)
(09316±00011)Replacer PipePARTIAL ENGINE ASSY(1CD±FTV)

13035±01
B08025
Turn
A62443
Move
SST
B08048
Move
A62444
Open
SST
2mm 13±2
± INTAKETURBOCHARGER ASSEMBLY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OVERHAUL
1. REMOVE COMPRESSOR INLET ELBOW
(a) Remove 2 bolts and the compressor inlet elbow.
2. INSPECT TURBOCHARGER SUB±ASSY
(a) Inspect turbine shaft rotation
(1) Grasp the edge of the turbine shaft, and turn it.
(2) Check that the turbine shaft turns smoothly.
If the turbine shaft turns remarkably heavily or stuck, replace
the bearing housing. At that time, check also the interference
with the turbine housing and compressor housing.
(b) Inspect axial play of turbine shaft
(1) Using a dial indicator, insert the needle of the dial in-
dicator into the exhaust side.
(2) Move the turbine shaft in an axial direction, mea-
sure the axial play of the turbine shaft.
Maximum oil clearance: 0.09 mm (0.0035 in.) or less
If the axial play is greater than maximum, replace the bearing
housing. At that time, check also the interference with the tur-
bine housing and compressor housing.
(c) Inspect radial play of turbine shaft
(1) Using SST and a dial indicator, insert the needle of
the dial indicator into the oil outlet hole, and set it in
the center of the turbine shaft.
SST 09992±00600
(2) Move the turbine shaft in a radial direction, measure
the radial play of the turbine shaft.
Maximum oil clearance: 0.16 mm (0.0063 in.) or less
If the radial play is greater than maximum, replace the bearing
housing. At that time, check also the interference with the tur-
bine housing and compressor housing.
(d) Inspect actuator and waste gate valve operation.
(1) Disconnect the actuator hose from the compressor
housing.
(2) Using SST and a dial indicator, read the graduation
of SST when the actuator push rod moved 2 mm
(0.079 in.).
SST 09992±00242
Standard pressure:
129 ± 140 kPa (1.32 ± 1.43 kgf/cm
2, 18.7 ± 20.3 psi)

A62445
Torx Socket Wrench
A62446
Matchmarks
A62447
A62448
Matchmarks
± INTAKETURBOCHARGER ASSEMBLY (1CD±FTV)
13±3
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(e) Move the actuator push rod, and check that the waste
gate valve is open.
If operation is not as specified, replace the actuator and/or tur-
bine housing.
NOTICE:
Never apply more than 161 kPa (1.64 kgf/cm
2, 28.5 psi) of
pressure on the actuator.
(f) Reconnect the actuator hose to the compressor housing.
3. REMOVE W/BRACKET ACTUATOR ASSY
(a) Remove the actuator hose.
(b) Using a torx socket wrench (T30), remove the 2 screws
holding the actuator to the compressor housing.
(c) Remove the E±ring holding the actuator push rod to the
waste gate valve link, and remove the actuator w/ brack-
et.
4. REMOVE COMPRESSOR HOUSING SUB±ASSY
(a) Place the matchmarks on the compressor housing and
the bearing housing.
(b) Remove the 5 bolts and 5 clamp plates.
(c) Using a plastic±faced hammer, tap out the compressor
housing.
NOTICE:
Remove the compressor housing as straight as possible
and do not make the impeller wheel interfere with the com-
pressor housing.
5. REMOVE BEARING HOUSING SUB±ASSY
(a) Place the matchmarks on the V band, turbine housing
and bearing housing.
(b) Remove the flat head square neck bolt, nut and V band.

B08059
B08067
B08068
Seal Surface
Shroud Section
B08065
Inside Diameter Section
B08066
13±4
± INTAKETURBOCHARGER ASSEMBLY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Using a plastic±faced hammer, tap out the bearing hous-
ing.
NOTICE:
Remove the bearing housing as straight as possible and do
not make the turbine wheel interfere with the turbine hous-
ing.
6. CLEAN TURBINE HOUSING
(a) Spray the engine conditioner to the section where the car-
bon dirt is adhered.
NOTICE:
Be careful not to erase the matchmark of the turbine hous-
ing.
(b) Using a wire brush, remove all the carbon dirt inside the
turbine housing.
NOTICE:
Clean the seal surface and shroud section shown in the il-
lustration sufficiently. And clean the waste gate valve seat
sufficiently, too.
HINT:
When the carbon dirt is heavily adhered, remove it using the
screwdriver and the like.
(c) Clean the inside diameter section with a sandpaper (No.
100) until the metal surface can be seen.
NOTICE:
If the cleaning is not enough, installation of the bearing
housing becomes harder, so clean it sufficiently.
(d) Wash with compressed air or a steam cleaner.
NOTICE:
Wash sufficiently without leaving any irregular objects.

B08064
Seal Surface
Shroud Section
B08069
A62449
A62450
± INTAKETURBOCHARGER ASSEMBLY (1CD±FTV)
13±5
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(e) Check that there is no severe damage on the seal surface
with the bearing housing.
(f) Check that there is no bore made by the interference with
the turbine wheel in the shroud section.
If the turbine housing is having remarkable damage or bore, re-
place the turbine housing and bearing housing.
(g) Move the waste gate valve link and check that it runs
smoothly without sticking.
If the link is bad running, clean again. If it is bad running, even
after cleaning, replace the turbine housing.
7. CLEAN COMPRESSOR HOUSING SUB±ASSY
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the compres-
sor housing and bearing housing.
(1) Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Using a non±residue solvent, clean both sealing
surfaces.
(b) Wipe off the dirt from the inside of the housing with a shop
rag.
(c) Check that there is no severe interference with the impel-
ler wheel.
If it is having bur made by a slight interference damage, remove
it with a sandpaper (No. 400) and blow with compressed air.
8. INSTALL BEARING HOUSING SUB±ASSY
(a) Align the pin of the turbine housing with the pin hole of the
bearing housing.

A62448
Matchmarks
B08239
Approx. 38

A62453
603 4 5
2
1 60
A62454
Seal Width
0.1 ± 0.2 mmSeal
Packing
± INTAKETURBOCHARGER ASSEMBLY (1CD±FTV)
13±7
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(e) Align the matchmarks on the new V band, turbine housing
and bearing housing, and temporarily torque with a new
bolt and nut.
Torque: 8.3 N
m (85 kgf
cm, 74 in.
lbf)
HINT:
When the marks are erased, make the matching openings meet
at the position shown in the illustration.
(f) Using a brass bar and hammer, hit 2 or 3 times lightly at
each place in order of 1 through 5.
(g) Torque the bolt and nut more.
Torque: 8.3 N
m (85 kgf
cm, 74 in.
lbf)
(h) Using a brass bar and hammer, hit 2 or 3 times lightly at
each place of 1 and 4.
(i) Torque the bolt and nut completely.
Torque: 8.3 N
m (85 kgf
cm, 74 in.
lbf)
9. INSTALL COMPRESSOR HOUSING SUB±ASSY
(a) In case of reusing the compressor housing and bearing
housing:
(1) Apply seal packing to the compressor housing as
shown in the illustration.
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 0.1 ± 0.2
mm (0.004 ± 0.008 in.) opening.

Parts must be assembled within 7 minutes of
application. Otherwise the material must be
removed and reapplied.

Immediately remove nozzle from the tube
and reinstall the cap.

A62455
Matchmarks
A62456
Cut
Protractor
Steel Square49
A62457
SST
13±8
± INTAKETURBOCHARGER ASSEMBLY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(2) Align the matchmarks on the compressor housing
and bearing housing, and install them.
NOTICE:

Do not make the impeller wheel interfere with the
compressor housing.

Check that the turbine shaft turns smoothly.
(3) Using a steel square and protractor, check the
installation angle of the outlet port of the compres-
sor housing shown in the illustration.
(4) Install the 5 clamp plates and bolts.
Torque: 4.7 N
m (48 kgf
cm, 42 in.
lbf)
(b) In case of using a new compressor housing and/or bear-
ing housing :
(1) Temporally install the compressor housing on the
bearing housing, make the installation angle of the
outlet port of the compressor housing meet at the
position shown in the illustration, and place the
matchmarks.
(2) Remove the compressor housing.
(3) The following procedure is the same as that of reus-
ing the compressor housing and/or bearing hous-
ing.
10. INSTALL W/BRACKET ACTUATOR ASSY
(a) Using a torx wrench (T30), install the actuator w/ bracket
to the compressor housing with the 2 screws.
Torque: 7.8 N
m (80 kgf
cm, 69 in.
lbf)
(b) Using SST, move the actuator push rod.
SST 09992±00242
NOTICE:
Never apply more than 197 kPa (2.01 kgf/cm
2, 28.5 psi) of
pressure on the actuator.
(c) Connect the actuator push rod to the waste gate valve link
with a new E±ring.
NOTICE:
Do not use a hammer, etc. to force the actuator push rod
onto the waste gate valve link.
(d) Remove the SST.
(e) Connect the actuator hose.
11. INSTALL COMPRESSOR INLET ELBOW
Torque: 23 N
m (235 kgf
cm, 17 ft
lbf)