timing belt TOYOTA COROLLA VERSO 2004 Service Repair Manual

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

140L3±01
A62602
Cylinder Head
Cover Sub±AssyGasket
Camshaft
Sub±Assy No.2
Camshaft
Sub±Assy No.1
18 (184, 13)
Camshaft Oil
Seal Retainer
 Nozzle Holder Seal
Nozzle Leakage
Pipe Assy
Nozzle Holder Clamp  O±Ring
 Injection Nozzle Seat
 Fuel Injector
Back±Up Ring No. 1
13 (135, 10)
Washer
Camshaft Carrier
Camshaft Bearing Cap
20 (204, 15)
Injector Assy
8.8 (90, 78 in.´lbf)
See page 14±3
1st 45 (460, 33)
2nd Turn 90

3rd Turn 90

4th Turn 90

22 (224, 16)
27 (275, 20)
 Gasket
 Gasket
20 (204, 15)
 Cylinder Head Gasket
 Oil Seal Plate Washer
x 18
Cylinder Head
Sub±Assy

Nozzle Holder Gasket
 Non±reusable partN´m (kgf´cm, ft´lbf)
: Specified torque
Oil Filler Cap Sub±Assy
Plate Washer
Camshaft Timing Pulley
88 (899, 65)
35 (357, 26)
Timing Belt Idler Sub±Assy No. 1
Timing Belt Idler Sub±Assy No. 2
47 (475, 34)
Crankshaft Timing Pulley
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±1
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
PARTIAL ENGINE ASSY (1CD±FTV)
COMPONENTS

A56694
A62592
SST
A57095
Hexagon
Wrench
(8mm)
SST
A57096
14±4
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
6. REMOVE INJECTOR ASSY
(a) Remove the 4 injectors from the cylinder head.
HINT:
Arrange the injectors in correct order.
7. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the pulley bolt.
SST 09960±10010 (09962±01000, 09963±01000)
8. REMOVE TIMING BELT IDLER SUB±ASSY NO.1
(a) Using hexagon wrench (8mm), remove the idler pulley
shaft, idler pulley and plate washer.
9. REMOVE TIMING BELT IDLER SUB±ASSY NO.2
10. REMOVE CRANKSHAFT TIMING PULLEY
(a) If the pulley cannot be removed by hand, use SST to re-
move the timing pulley.
SST 09950±50013 (09951±05010, 09952±05010,
09953±05010, 09953±05020, 09954±05021)

A57098
A09600
Seal Width
2 ± 4 mm
Seal Packing
SST
A57101
Inward
Angle Sensor
A57102
Turn
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±17
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
42. INSTALL WATER PUMP ASSY
(a) Install a new gasket and the water pump with the 7bolts.
Torque: 31 N
m (320 kgf
cm, 23 ft
lbf)
43. INSTALL CAMSHAFT OIL SEAL RETAINER
(a) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Install a nozzle that has been cut to a 2 ± 4 mm (0.08
± 0.16 in.) opening.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil seal retainer with 4 bolts. Uniformly tighten
the 4 bolts in several passes.
Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
44. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the pulley set key with the key groove of the timing
pulley.
(b) Using SST and a hammer, tap in the timing pulley, facing
the angle sensor inward.
SST 09223±46011
45. INSTALL TIMING BELT IDLER SUB±ASSY NO.2
(a) Install the idler pulley with the bolt.
Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
(b) Check that the idler pulley moves smoothly.

A57103
Plate Washer
Hexagon
Wrench
(8mm)
A62592
SST
B08252
B09792
Spring
Convex
14±18
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
46. INSTALL TIMING BELT IDLER SUB±ASSY NO.1
(a) Using an hexagon wrench (8mm), install the plate washer
and idler pulley with the idler pulley shaft.
Torque: 35 N
m (350 kgf
cm, 25 ft
lbf)
(b) Check that the pulley bracket moves smoothly.
47. INSTALL CAMSHAFT TIMING PULLEY
(a) Install the pulley set key to the key groove of the cam-
shaft.
(b) Align the pulley set key with the key groove of the timing
pulley, and slide on the timing pulley.
(c) Using SST, install the pulley bolt.
SST 09960±10010 (09962±01000, 09963±01000)
Torque: 88 N
m (899 kgf
cm, 65 ft
lbf)
48. INSTALL INJECTOR ASSY
(a) Install 4 new nozzle seats to the cylinder head.
(b) Set the spring to each injector.
NOTICE:
Be sure to make the opening direction of the spring and the
direction of the injector positioning convex meet.
(c) Install a new back±up ring and O±ring to each injector.
(d) Apply a light coat of oil onto O±ring for each injector.