engine oil 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:

Illustration:
what to do and whereTask heading: what to do
Detailed text:
how to do task
Set part No.Component part No.
A59974
01±2
± INTRODUCTIONHOW TO USE THIS MANUAL
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(d) Tightening torque, oil applying position, and non±reusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc. are described in the illustration.
(e) Installing procedure of operation items is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a step±by±step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.
6. TERMS DEFINITION
CAUTIONIndicate the possibility of injury to you or other people.
NOTICEIndicate the possibility of damage to the components being repaired.
HINTProvide additional information to help you perform the repair efficiently.

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.

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)

0300O±05
03±6
± SERVICE SPECIFICATIONSENGINE MECHANICAL
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
ENGINE MECHANICAL
SERVICE DATA
Cylinder head
Warpage Cylinder brock side
Intake manifold side
Exhaust manifold side
0.08 mm (0.0031 in.)
0.20 mm (0.0079 in.)
0.20 mm (0.0079 in.)
Intake valve
Overall length Standard
Minimum
Valve stem diameter
Margin thickness Standard
Minimum
102.53 mm (4.0366in.)
102.10 mm (4.0197in.)
5.970 ± 5.985 mm (0.2350 ± 0.2356 in.)
0.9 (0.035 in.)
0.6 mm (0.0247 in.)
Exhaust valve
Overall length Standard
Minimum
Valve stem diameter
Margin thickness Standard
Minimum
101.97 mm (4.0146in.)
101.55 mm (3.9980 in.)
5.960 ± 5.975 mm (0.2346 ± 0.2352 in.)
0.9 mm (0.035 in.)
0.6 mm (0.024 in.)
Inner compression spring
Free length
Deviation Maximum
Installed tension at 31.1 mm (1.224 in.)
40.45 mm (1.5925 in.)
2.0 mm (0.079 in.)
177±195 N (18.0 ± 19.9 kgf, 39.7 ± 44.1 lbf)
Intake Valve guide bush
Bushing inside diameter
Oil clearance Standard
Maximum
Diameter
Protrusion height
6.010 ± 6.030 mm (0.2366 ± 0.2374 in.)
0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
0.08 mm (0.0031 in.)
10.985 ± 11.006 mm (0.4325 ± 0.4333 in.)
10.05 ± 10.45 mm (0.3957 ± 0.4114 in.)
Exhaust valve guide bush
Bushing inside diameter
Oil clearance Standard
Maximum
Diameter
Protrusion height
6.010 ± 6.030 mm (0.2366 ± 0.2374 in.)
0.035 ± 0.070 mm (0.0014 ± 0.0028 in.)
0.10 mm (0.0039 in.)
10.985 ± 11.006 mm (0.4325 ± 0.4333 in.)
9.65 ± 10.05 mm (0.3799 ± 0.3957 in.)
Valve lifter
Lifter diameter
Lifter bore diameter
Oil clearance Standard
Maximum
27.975 ± 27.985 mm (1.1014 ± 1.1018 in.)
28.010 ± 28.031 mm (1.1028 ± 1.1036 in.)
0.025 ± 0.056 mm (0.0010 ± 0.0022 in.)
0.08 mm (0.0031 in.)
Camshaft
Circle runout Maximum
Cam lobe height (No.1) Standard
Minimum
Cam lobe height (No.2) Standard
Minimum
Journal diameter
Thrust clearance
Oil clearance Standard
Minimum
Gear backlash Standard
Maximum
0.06 mm (0.0024 in.)
46.57 ± 46.67 mm (1.8335 ± 1.8374 in.)
46.10 mm (1.8150 in.)
47.52 ± 47.62 mm (1.8709 ± 1.8748 in.)
47.05 mm (1.8524 in.)
26.969 ± 26.985 mm (1.0618 ± 1.0624 in.)
0.035 ± 0.11 mm (0.0014 ± 0.0043 in.)
0.025 ± 0.062 mm (0.0010 ± 0.0024 in.)
0.08 mm (0.0031 in.)
0.014 ± 0.070 mm (0.0006 ± 0.0028 in.)
0.17 mm (0.0067 in.)
Connecting rod
Thrust clearance Standard
Maximum
Oil clearance Standard
Maximum
0.08 ± 0.30 mm (0.0031 ± 0.0118 in.)
0.40 mm (0.0157 in.)
0.038 ± 0.056 mm (0.0015 ± 0.0022 in.)
0.10 mm (0.0039 in.)

± SERVICE SPECIFICATIONSENGINE MECHANICAL
03±7
1CD±FTV ENGINE REPAIR MANUAL (RM927E) Cylinder block
Warpage Maximum
Bore diameter Standard
Maximum
0.05 mm (0.0020 in.)
82.200 ± 82.213 mm (3.2362 ± 3.2367 in.)
82.400 mm (3.2441 in.)
Piston
Piston diameter
Piston oil clearance Standard
Maximum
Bushing inside diameter
82.118 ± 82.132 mm (3.2330 ± 3.2335 in.)
0.068 ± 0.095 mm (0.0027 ± 0.0037 in.)
0.14 mm (0.0055 in.)
31.015 ± 31.027 mm (1.2211 ± 1.2215 in.)
Piston pin
Piston pin diameter
Oil clearance Standard
Maximum
31.000 ± 31.012 mm (1.2205 ± 1.2209 in.)
0.030 ± 0.027 mm (0.0001 ± 0.0011 in.)
0.025 mm (0.0010 in.)
Cylinder head set bolt
Out side diameter Standard
Minimum
10.75 ± 11.00 mm (0.4234 ± 0.4331 in.)
10.40 mm (0.4904 in.)
Connecting rod bolt
Diameter Standard
Minimum
8.2 ± 8.3 mm (0.323 ± 0.327 in.)
8.0 mm (0.315 in.)
Connecting rod
Out±of±alignment Maximum per 100 mm (3.94 in.)
Rod twist Maximum per 100 mm (3.94 in.)
0.05 mm (0.0020 in.)
0.15 mm (0.0059 in.)
Crankshaft
Thrust clearance Standard
Maximum
Circle runout Maximum
Crank pin taper and out± of ±round Maximum
Crank pin diameter
Main journal diameter
Oil clearance Standard
Maximum
0.040 ± 0.240 mm (0.0016 ± 0.0094 in.)
0.30 mm (0.0118 in.)
0.025 mm (0.0010 in.)
0.01 mm (0.0004 in.)
50.482 ± 50.500 mm (1.9875 ± 1.9882 in.)
56.992 ± 57.010 mm (2.2438 ± 2.2445 in.)
0.032 ± 0.050 mm (0.0013 ± 0.0020 in.)
0.10 mm (0.0039 in.)

0300P±05
03±8
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Cylinder block water drain cock x Cylinder block2929121
Oil check valve x Cylinder block3031022
Oil pump x Cylinder block3132023
Oil pan x Cylinder block For 10 mm head bolt and nut
For 12 mm head bolt
For 14 mm head bolt11
21
4211 2
210
4298.0 15
31
Oil strainer x Cylinder block For bolt For nut21
13210
13515
10
Oil pan No.2 x Cylinder block121209.0
Cylinder head x Cylinder block 1st 2nd3rd
4th45
Turn 90

Turn 90

Turn 90
460
Turn 90

Turn 90

Turn 90
33
Turn 90

Turn 90

Turn 90

Camshaft bearing cap x Cylinder head2020415
Water pump x Cylinder block3132023
Camshaft oil seal retainer x Cylinder head8.89078 in.
lbf
Timing belt idler Sub assy No.2 x Oil pump4747534
Timing belt idler No. 1 x Cylinder head3535025
Camshaft timing pulley x Camshaft8889965
Nozzle holder clamp x Cylinder head2727520
Nozzle leakage pipe x Cylinder head Hollow screw
Union bolt18
22184
22413
16
Over flow screw x Plug9.81007.0
Check valve x Cylinder head2121415
Cylinder head cover x Cylinder head1313510
Taper screw plug No.1 x Cylinder head2525518
Cylinder head stud bolt (See Page 14±23) Bolt A Bolt B
Bolt C8.8
12
8.890
120 9078 in.
lbf
9.0
78 in.
lbf
Connecting rod cap x Connecting rod 1st
2nd30
Turn 90
306
Turn 90
22
Turn 90

Crankshaft bearing cap x Cylinder block11 51,17385
Cylinder block oil orifice x Cylinder block9.09278 in.
lbf
Oil nozzle No.1 x Cylinder block7.47667 in.
lbf

0300L±04
± SERVICE SPECIFICATIONSLUBRICATION
03±9
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
LUBRICATION
SERVICE DATA
Oil pump
Tip clearance Standard
Maximum
Body clearance Standard
Maximum
0.080±0.160 mm (0.0031 ± 0.0063 in.)
0.2 mm (0.0079 in.)
0.100±0.170 mm (0.0039 ± 0.0067 in.)
0.2 mm (0.0079 in.)

0300Q±04
03±10
± SERVICE SPECIFICATIONSSTARTING & CHARGING
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
STARTING & CHARGING
SERVICE DATA
Starter assy (1.4kw)
Circle runout Maximum
Diameter Standard
Minimum
Undercut depth Standard
Minimum
Brush length Standard
Minimum
0.05 mm(0.0020 in.)
30 mm (1.18 in.)
29 mm (1.14 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
15.5 mm (0.61 in.)
8.5 mm (0.3346 in.)
Starter assy (2.0kw)
Circle runout Maximum
Diameter Standard
Minimum
Undercut depth Standard
Minimum
Brush length Standard
Minimum
0.03 mm (0.0012 in.)
32.3 mm (1.272 in.)
30.5 mm (1.201 in.)
0.9 mm (0.035 in.)
0.3 mm (0.012 in.)
14.5 mm (0.571 in.)
9.0 mm (0.354 in.)
Starter assy (2.2kw)
Circle runout Maximum
Diameter Standard
Minimum
Undercut depth Standard
Minimum
Brush length Standard
Minimum
0.05 mm(0.0020 in.)
35 mm (1.378 in.)
34 mm (1.3386 in.)
0.7 mm (0.0276 in.)
0.2 mm (0.079 in.)
16.5 mm (0.6496 in.)
9.0 mm (0.3543 in.)
Generator assy (90A)
Rotor coil resistance at 20
C (68
F)
Slip ring diameter Standard
Minimum
Brush exposed length Standard
Minimum
2.7 ± 3.1

14.2 ± 14.4 mm (0.559 ± 0.567 in.)
12.8 mm (0.504 in.)
9.5 ± 11.5 mm (0.374 ± 0.453 in.)
1.5 mm (0.059 in.)
Generator assy (130A)
Rotor coil resistance at 20
C (68
F)
Slip ring diameter Standard
Minimum
Brush exposed length Standard
Minimum
2.3 ± 2.7

14.2 ± 14.4 mm (0.559 ± 0.567 in.)
14 mm (0.551 in.)
10.5 mm (0.4134 in.)
4.5 mm (0.177 in.)

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)