2004 TOYOTA COROLLA VERSO engine

A09512
Groove
A56048
A09497
A56046
A09506
Front Mark
(Arrow)
Front Mark
(Protrusion)
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±57
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Install the 2 thrust washers on the No. 3 bearing cap with
the oil grooves facing outward.
(d) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and a font mark.
(e) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(f) Install and uniformly tighten the 10 bolts of the main bear-
ing cap in several passes.
Torque: 115 N
m (1,173 kgf
cm, 85 ft
lbf)
(g) Check that the crankshaft turns smoothly.
28. INSTALL W/PIN PISTON SUB±ASSY
(a) Install a new snap ring on one side of the piston pin hole.
(b) Gradually heat the piston to 60
C (140
F).
(c) Coat the piston pin and piston hole of the piston with en-
gine oil.
(d) Align the front marks of the piston and connecting rod,
and push in the piston pin by hand.
(e) Install a new snap ring on the other side of the piston pin
hole.

A09508
A56047
Coil Joint
Oil Ring End
A09458
No.1
No.2Code Mark
Code Mark
A09507
Front
Mark
(Arrow)No.1
Compression
Ring
Oil Ring
No.2
Compression
Ring
Coil
14±58
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
29. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
30. INSTALL PISTON RING SET
(a) Install the coil by hand.
(b) Using a piston ring expander, install the oil ring.
HINT:
Face the end gap of the oil ring in the opposite direction coil
joint.
(c) Using a piston ring expander, install the No. 2 and No. 1
piston rings with the code mark facing upward.
Code mark:
No.11T
No.22T
NOTICE:
Make the expansion of the piston ring as small as neces-
sary.
(d) Position the piston rings so that the ring ends are as
shown.
31. INSTALL PISTON SUB±ASSY W/CONNECTING ROD
(a) Apply engine oil to the cylinder walls, pistons, and sur-
faces of connecting rod bearings.
(b) Check the position of the piston ring ends.

A09511
Front Mark
(Arrow)
Front
Push
A09514
Front Mark
(Protrusion)
A09493
90

90

A09490
Painted Mark
Front
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±59
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
(d) Match the numbered connecting rod cap with the con-
necting rod.
(e) Install the connecting rod cap with the front mark facing
forward.
(f) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(g) Install and alternately tighten the 2 cap bolts in several
passes.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
If any of the cap bolts does not meet the torque specification,
replace the connecting rod cap bolts.
(h) Mark the front of the cap bolt with the paint.
(i) Retighten the cap bolts 90
as shown.
(j) Check that the painted mark is now at a 90
angle to the
front.
(k) Check that the crankshaft turns smoothly.

1606V±02
A55603Drain Hole
Turn
± COOLINGWATER PUMP ASSY (1CD±FTV)
16±1
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
WATER PUMP ASSY (1CD±FTV)
INSPECTION
1. INSPECT WATER PUMP ASSY
(a) Visually check the drain hole for coolant leakage.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.

1704C±02
A55604
A55605
± LUBRICATIONOIL PUMP ASSY (1CD±FTV)
17±1
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OIL PUMP ASSY (1CD±FTV)
INSPECTION
1. INSPECT OIL PUMP ASSY
(a) Inspect the rotors for tip clearance.
(1) Using a feeler gauge, measure the clearance be-
tween the drive and driven rotor tips.
Standard tip clearance:
0.08 ± 0.16 mm (0.0031 ± 0.0063 in.)
Maximum tip clearance: 0.2 mm (0.0079 in.)
(b) Inspect the rotors for body clearance.
(1) Using a feeler gauge, measure the clearance be-
tween the driven rotor and body.
Standard body clearance:
0.1 ± 0.17 mm (0.0039 ± 0.0067 in.)
Maximum body clearance: 0.2 mm (0.0079 in.)

190AE±01
A62712
Starter Armature Assy
Starter Yoke Assy
Starter Brush Holder Assy
Rear End Frame Cover
Drive Housing
Starter Clutch Sub±Assy Ball
Spring
Magnetic Switch
N´m (kgf´cm, ft´lbf)
: Specified torque
5.9 (60, 52 in.´lbf)
5.9 (60, 52 in.´lbf)
5.9 (60, 52 in.´lbf)
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
19±1
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
STARTER ASSY(1.4KW) (1CD±FTV)
COMPONENTS

1906G±02
A55610
A55611
A55612
A55613
Magnetic Finger
19±2
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OVERHAUL
1. REMOVE STARTER YOKE ASSY
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
(b) Remove the 2 through bolts.
(c) Pull out the yoke together with the armature from the mag-
netic switch.
2. REMOVE STARTER CLUTCH SUB±ASSY
(a) Remove the 2 bolts and drive housing.
(b) Remove the clutch from the drive housing.
(c) Using a magnetic finger, remove the ball from the clutch
shaft hole.

A55614
A51226
A55615
A55616
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
19±3
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
3. REMOVE STARTER BRUSH HOLDER ASSY
(a) Remove the 2 screws and end frame from the yoke.
(b) Using a screwdriver, hold the spring back disconnect the
brush from the brush holder. Disconnect the 4 brushers
and remove the brush holder.
4. REMOVE STARTER ARMATURE ASSY
(a) Remove the armature from the yoke.
5. INSPECT STARTER ARMATURE ASSY
(a) Using an ohmmeter, check that there is continuity be-
tween the segments of the commutator.
(b) Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.