inter TOYOTA COROLLA VERSO 2004 Service Repair Manual

± INTRODUCTIONHOW TO USE THIS MANUAL
01±3
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N
m (310 kgf
cm, 22 ft
lbf)

± INTRODUCTIONTERMS
01±9
1CD±FTV ENGINE REPAIR MANUAL (RM927E)Abbreviations Meaning
HIDHigh Intensity Discharge (Head Lamp)
HPUHydrraulic Power Unit
HSGHousing
HTHard Top
HWSHeated Windshield System
IACIdel Air Control
ICIntegrated Circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
ISCIdle Speed Control
J/BJunction Block
J/CJunction Connector
KDKick±Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft±Hand
LHDLeft±Hand Drive
L/H/WLength, Height, Width
LLCLong±Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
M±FUSEMediam Current Fuse
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MG1Motor Generator No.1
MG2Motor Generator No.2
MPMultipurpose
MPIMultipoint Electronic Injection
MPXMultiplex Communication System
M/T, MTMManual Transmission
MTMount
MTGMounting
NNeutral
NANatural Aspiration
No.Number
O/DOverdrive

010BA±03
01±12
± INTRODUCTIONTERMS
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionTOYOTA Distributorless Ignition (TDI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)

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.

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)