lock TOYOTA COROLLA VERSO 2004 Service Repair Manual

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.

L1 L2
D02612
L2 L1
D01201
L2 L1
D01202
± INTRODUCTIONREPAIR INSTRUCTION
01±5
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets:
When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
(d) Torque When Using Extension Tool with Torque Wrench:
(1) In case of tightening by extending the entire length
of the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
mkgf
cmft
lbf
TTorque N
mkgf
cmft
lbf
L1Length of SST or tool (cm)
L2Length of torque wrench (cm)
10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) Place for Removing and Installing Fuel System Parts:
(1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, elec-
tric motor or stove in the surroundings.
(2) Never work in a place like a pit or nearby pit as there is a possibility that vaporized fuel fills those
places.
(b) Removing and Installing of Fuel System Parts:
(1) Prepare a fire extinguisher before starting the operation.
(2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank,
and do not spray much water so as to prevent slipping.

010B9±02
± INTRODUCTIONTERMS
01±7
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
ASSYAssembly
A/T, ATMAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
Calif.California
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
DEFDefogger
DFLDeflector

01±8
± INTRODUCTIONTERMS
1CD±FTV ENGINE REPAIR MANUAL (RM927E)Abbreviations Meaning
DIFF.Differential
DIFF. LOCKDifferential Lock
D/INJDirect Injection
DLCData Link Connector
DLIDistributorless Ignition
DOHCDouble Overhead Cam
DPDash Pot
DSDead Soak
DSPDigital Signal Processor
DTCDiagnostic Trouble Code
DVDDigital Versatible Disc
EBDElectric Brake force Distribution
ECAMEngine Control And Measurement System
ECDElectronic Controlled Diesel
ECDYEddy Current Dynamometer
ECUElectronic Control Unit
EDElectro±Deposited Coating
EDUElectronic Driving Unit
EDICElectric Diesel Injection Control
EFIElectronic Fuel Injection
E/GEngine
EGRExhaust Gas Recirculation
EGR±VMEGR±Vacuum Modulator
ELREmergency Locking Retractor
EMPSElectric Motor Power Steering
ENGEngine
ESAElectronic Spark Advance
ETCS±iElectronic Throttle Control System±intelligent
EVAPEvaporative Emission Control
EVPEvaporator
E±VRVElectric Vacuum Regulating Valve
EX, EXHExhaust
FEFuel Economy
FFFront±Engine Front±Wheel±Drive
F/GFuel Gauge
FIPGFormed In Place Gasket
FLFusible Link
F/PFuel Pump
FPUFuel Pressure Up
FrFront
FRFront±Engine Rear±Wheel±Drive
F/WFlywheel
FW/DFlywheel Damper
FWDFront±Wheel±Drive
GASGasoline
GNDGround
GPSGlobal Positioning System
HACHigh Altitude Compensator
H/BHatchback
H±FUSEHigh Current Fuse
HIHigh

± 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

01±10
± INTRODUCTIONTERMS
1CD±FTV ENGINE REPAIR MANUAL (RM927E)Abbreviations Meaning
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
ORVROn±board Refilling Vapor Recovery
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PSPower Steering
PTOPower Take±Off
P/WPower Window
R & PRack And Pinion
RAMRandom Access Memory
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight±Hand
RHDRight±Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRRear±Engine Rear±Wheel±Drive
RRSRigid Front Suspension
RWDRear±Wheel±Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold±Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
TCTurbocharger
TCCSTOYOTA Computer±Controlled System
TCVTiming Control Valve
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension

± PREPARATIONENGINE MECHANICAL
02±3
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(09316±00021)Replacer ºAºPARTIAL ENGINE ASSY(1CD±FTV)
09950±50013Puller C SetPARTIAL ENGINE ASSY(1CD±FTV)
(09951±05010)Hanger 150PARTIAL ENGINE ASSY(1CD±FTV)
(09952±05010)Slide ArmPARTIAL ENGINE ASSY(1CD±FTV)
(09953±05010)Center Bolt 100PARTIAL ENGINE ASSY(1CD±FTV)
(09953±05020)Center Bolt 150PARTIAL ENGINE ASSY(1CD±FTV)
(09954±05021)Claw No.2PARTIAL ENGINE ASSY(1CD±FTV)
09950±60010Replacer SetCYLINDER HEAD ASSY(1CD±FTV)
CYLINDER BLOCK(1CD±FTV)
(09951±00210)Replacer 21CYLINDER HEAD ASSY(1CD±FTV)
(09951±00350)Replacer 35CYLINDER BLOCK(1CD±FTV)
09950±70010Handle SetCYLINDER HEAD ASSY(1CD±FTV)
CYLINDER BLOCK(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
(09951±07100)Handle 100CYLINDER HEAD ASSY(1CD±FTV)
CYLINDER BLOCK(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
09960±10010Variable Pin Wrench SetPARTIAL ENGINE ASSY(1CD±FTV)

02±4
± PREPARATIONENGINE MECHANICAL
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(09962±01000)Variable Pin Wrench Arm AssyPARTIAL ENGINE ASSY(1CD±FTV)
(09963±01000)Pin 10PARTIAL ENGINE ASSY(1CD±FTV)
09992±00242Turbocharger Pressure GaugePARTIAL ENGINE ASSY(1CD±FTV)
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)CYLINDER HEAD ASSY(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
08826±00100ºSeal Packing 1282B,º
THREE BOND 1282B or equivalent
(FIPG)PARTIAL ENGINE ASSY(1CD±FTV)
08833±00070ºAdhesive 1324,º
THREE BOND 1324 or equivalentCYLINDER HEAD ASSY(1CD±FTV)
CYLINDER BLOCK(1CD±FTV)
Equipment
V±block
Piston ring compressor
Piston ring expander
Valve seat cutter
Hexagon wrench (6 mm)
Hexagon wrench (8 mm)
Connecting rod aligner
Cylinder gauge
Dial indicator
Feeler gauge
Micrometer
Precision straight edge
Steel square
Torque wrench
Vernier calipers
Dial indicator with magnetic base
Slide calipers
Wooden block
Spring tester
Plastigage
Heater

± PREPARATIONSTARTING & CHARGING
02±7
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(09083±00350)AC/DC 400 A ProbeSTARTER ASSY(2.2KW)(1CD±FTV)
Equipment
V±block
Feeler gauge
Ohmmeter
Torque wrench
Vernier calipers
Dial indicator with magnetic base

± 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.)