2004 TOYOTA COROLLA VERSO engine

A09547
A09545
A09548
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±33
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(g) Measure the Plastigage at its widest point.
Standard oil clearance:
0.025 ± 0.062 mm (0.0010 ± 0.0024 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. if necessary, replace the bearing caps, camshaft carrier
and cylinder head as a set.
(h) Completely remove the Plastigage.
25. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshaft.
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.035 ± 0.110 mm (0.0014 ± 0.0043 in.)
If the thrust clearance is not as specified, replace the camshaft.
If necessary, replace the bearing caps, camshaft carrier and
cylinder head as a set.
26. INSPECT CAMSHAFT GEAR BACKLASH
(a) Install the camshafts.
(b) Using a dial indicator, measure the backlash.
Standard backlash:
0.014 ± 0.070 mm (0.0006 ± 0.0028 in.)
Maximum backlash: 0.17 mm (0.0067 in.)
If the backlash is greater then maximum, replace the cam-
shafts.

A56680
Intake Side:Cylinder Block Side:
Front Side: Rear Side:
1.5 mm 14±34
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
27. INSTALL TIGHT PLUG
(a) Apply adhesive around tight plugs.
Adhesive: Part No.08833 ± 00070, THREE BOND 1324
or equivalent
(b) Using SST, tap in the tight plugs as shown in the illustra-
tion.
SST 09950±60010 (09951±00210), 09950±70010
(09951±07100)

A56681
Intake Side: Upper Side:
Protrusion Height: 3 mm
11 m m8 mm
12.5 mm8 mmProtrusion Height: 3 mm
A56682
Upper Side:
11 m m Front Side:
16 mm
7 mm
7 mm
Protrusion Height: 11 mm Protrusion Height: 6 mm
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±35
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
28. INSTALL RING PIN
(a) Using a plastic±faced hammer, tap in new ring pins to the
specified protrusion height.
29. INSTALL STRAIGHT PIN
(a) Using a plastic±faced hammer, tap in the straight pin.

A56683
Intake Side: Rear Side:
Exhaust Side:A (M8)
B (M10)C (M8) 36 mm
64 mm34 mm
A62596
14±36
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
30. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
Torque:
Bolt A 8.8N
m (90 kgf
cm, 78 in.
lbf)
Bolt B 12N
m (120 kgf
cm, 9 ft
lbf)
Bolt C 8.8N
m (90 kgf
cm, 78 in.
lbf)
31. INSTALL W/HEAD TAPER SCREW PLUG NO.1
(a) Apply adhesive to the plugs end.
Adhesive: Part No. 08833 ± 00070, THREE BOND 1324 or equivalent
(b) Using a hexagon wrench (6 mm), install the 3 plugs.
Torque:25N
m (255 kgf
cm, 18 ft
lbf)
SST 99999±70037
32. INSTALL SEMICIRCULAR PLUG
(a) Apply seal packing to the semi±circular plug grooves.
Seal packing: Part No. 08826 ± 00080 or equivalent
(b) Install the semi±circular plug to the cylinder head.
33. INSTALL VALVE SPRING SEAT PLATE WASHER

A56032
A56684
A62597
SST
A62598
A62599
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±37
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
34. INSTALL VALVE STEM OIL O SEAL OR RING
(a) Apply a light coat of engine oil on the valve stem.
(b) Install a new oil seal on the valve guide bushing.
35. INSTALL INTAKE VALVE
(a) Install the valve, valve spring, and spring retainer.
(b) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202±70020 (09202±00010)
(c) Using a plastic±faced hammer and the valve stem (not in
use) tip wound with vinyl tape, lightly tap the valve stem
tip to ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
36. INSTALL EXHAUST VALVE
(a) Install the valve, valve spring, and spring retainer.

A56672
SST
A56685
14±38
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(b) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202±70020 (09202±00010)
(c) Using a plastic±faced hammer and the valve stem (not in
use) tip wound with vinyl tape, lightly tap the valve stem
tip to assure proper fit.
NOTICE:
Be careful not to damage the valve stem tip.

140L6±01
A62605
No.1 Piston Ring
No.2 Piston Ring
Oil Ring
Connecting Rod
Connecting Rod
Bearing Connecting
Rod Cap Cylinder Block
Upper Crankshaft
Thrust Washer Crankshaft
Lower Crankshaft
Thrust Washer
Main Bearing CapLower Main Bearing
Upper Main Bearing Coil

Non±reusable part
N´m (kgf´cm, ft´lbf)
Piston
: Specified torque
Connecting Rod
Bearing
See Page 14±40
1st 30 (306, 22)
2nd Turn 90



Snap Ring

Snap Ring
Cylinder Block
Oil Orifice
Sub±assy
Oil Nozzle No.1
115 (1,173, 85)
Piston Pin
9.0 (92, 78 in.´lbf)
7.4 (76, 67 in.´lbf)
±
ENGINE MECHANICAL CYLINDER BLOCK (1CD±FTV)
14±39
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
CYLINDER BLOCK (1CD±FTV)
COMPONENTS

140DS±02
A09477
A09488
A09492
A09494
Plastigage
14±40
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OVERHAUL
1. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.08 ± 0.30 mm (0.0031 ± 0.0118 in.)
Maximum thrust clearance: 0.40 mm (0.0157 in.)
If the thrust clearance is greater then maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Using 2 removed connecting rod cap bolts, remove the
connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pits and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
(f) Lay a strip of plastigage across the crank pin.