2004 TOYOTA COROLLA VERSO engine

030KS±01
03±4
± SERVICE SPECIFICATIONSINTAKE
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
INTAKE
SERVICE DATA
TurbochargerActuator pressure
Turbine wheel axial play Maximum
Turbine wheel radial play Maximum129 ± 140 kPa (1.32 ± 1.43 kgf/cm2, 18.7 ± 20.3 psi)
0.09 mm (0.0035 in.) or less
0.16 mm (0.0063 in.) or less

030KT±01
± SERVICE SPECIFICATIONSINTAKE
03±5
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
V Band8.38574 in.´lbf
Compressor housing x Bearing housing4.74842 in.´lbf
Turbocharger actuator x Compressor housing7.88069 in.´lbf
Compressor inlet elbow x Compressor housing2323517

0300O±05
03±6
± SERVICE SPECIFICATIONSENGINE MECHANICAL
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
ENGINE MECHANICAL
SERVICE DATA
Cylinder head
Warpage Cylinder brock side
Intake manifold side
Exhaust manifold side
0.08 mm (0.0031 in.)
0.20 mm (0.0079 in.)
0.20 mm (0.0079 in.)
Intake valve
Overall length Standard
Minimum
Valve stem diameter
Margin thickness Standard
Minimum
102.53 mm (4.0366in.)
102.10 mm (4.0197in.)
5.970 ± 5.985 mm (0.2350 ± 0.2356 in.)
0.9 (0.035 in.)
0.6 mm (0.0247 in.)
Exhaust valve
Overall length Standard
Minimum
Valve stem diameter
Margin thickness Standard
Minimum
101.97 mm (4.0146in.)
101.55 mm (3.9980 in.)
5.960 ± 5.975 mm (0.2346 ± 0.2352 in.)
0.9 mm (0.035 in.)
0.6 mm (0.024 in.)
Inner compression spring
Free length
Deviation Maximum
Installed tension at 31.1 mm (1.224 in.)
40.45 mm (1.5925 in.)
2.0 mm (0.079 in.)
177±195 N (18.0 ± 19.9 kgf, 39.7 ± 44.1 lbf)
Intake Valve guide bush
Bushing inside diameter
Oil clearance Standard
Maximum
Diameter
Protrusion height
6.010 ± 6.030 mm (0.2366 ± 0.2374 in.)
0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
0.08 mm (0.0031 in.)
10.985 ± 11.006 mm (0.4325 ± 0.4333 in.)
10.05 ± 10.45 mm (0.3957 ± 0.4114 in.)
Exhaust valve guide bush
Bushing inside diameter
Oil clearance Standard
Maximum
Diameter
Protrusion height
6.010 ± 6.030 mm (0.2366 ± 0.2374 in.)
0.035 ± 0.070 mm (0.0014 ± 0.0028 in.)
0.10 mm (0.0039 in.)
10.985 ± 11.006 mm (0.4325 ± 0.4333 in.)
9.65 ± 10.05 mm (0.3799 ± 0.3957 in.)
Valve lifter
Lifter diameter
Lifter bore diameter
Oil clearance Standard
Maximum
27.975 ± 27.985 mm (1.1014 ± 1.1018 in.)
28.010 ± 28.031 mm (1.1028 ± 1.1036 in.)
0.025 ± 0.056 mm (0.0010 ± 0.0022 in.)
0.08 mm (0.0031 in.)
Camshaft
Circle runout Maximum
Cam lobe height (No.1) Standard
Minimum
Cam lobe height (No.2) Standard
Minimum
Journal diameter
Thrust clearance
Oil clearance Standard
Minimum
Gear backlash Standard
Maximum
0.06 mm (0.0024 in.)
46.57 ± 46.67 mm (1.8335 ± 1.8374 in.)
46.10 mm (1.8150 in.)
47.52 ± 47.62 mm (1.8709 ± 1.8748 in.)
47.05 mm (1.8524 in.)
26.969 ± 26.985 mm (1.0618 ± 1.0624 in.)
0.035 ± 0.11 mm (0.0014 ± 0.0043 in.)
0.025 ± 0.062 mm (0.0010 ± 0.0024 in.)
0.08 mm (0.0031 in.)
0.014 ± 0.070 mm (0.0006 ± 0.0028 in.)
0.17 mm (0.0067 in.)
Connecting rod
Thrust clearance Standard
Maximum
Oil clearance Standard
Maximum
0.08 ± 0.30 mm (0.0031 ± 0.0118 in.)
0.40 mm (0.0157 in.)
0.038 ± 0.056 mm (0.0015 ± 0.0022 in.)
0.10 mm (0.0039 in.)

± 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.)

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

0300L±04
± SERVICE SPECIFICATIONSLUBRICATION
03±9
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
LUBRICATION
SERVICE DATA
Oil pump
Tip clearance Standard
Maximum
Body clearance Standard
Maximum
0.080±0.160 mm (0.0031 ± 0.0063 in.)
0.2 mm (0.0079 in.)
0.100±0.170 mm (0.0039 ± 0.0067 in.)
0.2 mm (0.0079 in.)

0300Q±04
03±10
± SERVICE SPECIFICATIONSSTARTING & CHARGING
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
STARTING & CHARGING
SERVICE DATA
Starter assy (1.4kw)
Circle runout Maximum
Diameter Standard
Minimum
Undercut depth Standard
Minimum
Brush length Standard
Minimum
0.05 mm(0.0020 in.)
30 mm (1.18 in.)
29 mm (1.14 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
15.5 mm (0.61 in.)
8.5 mm (0.3346 in.)
Starter assy (2.0kw)
Circle runout Maximum
Diameter Standard
Minimum
Undercut depth Standard
Minimum
Brush length Standard
Minimum
0.03 mm (0.0012 in.)
32.3 mm (1.272 in.)
30.5 mm (1.201 in.)
0.9 mm (0.035 in.)
0.3 mm (0.012 in.)
14.5 mm (0.571 in.)
9.0 mm (0.354 in.)
Starter assy (2.2kw)
Circle runout Maximum
Diameter Standard
Minimum
Undercut depth Standard
Minimum
Brush length Standard
Minimum
0.05 mm(0.0020 in.)
35 mm (1.378 in.)
34 mm (1.3386 in.)
0.7 mm (0.0276 in.)
0.2 mm (0.079 in.)
16.5 mm (0.6496 in.)
9.0 mm (0.3543 in.)
Generator assy (90A)
Rotor coil resistance at 20
C (68
F)
Slip ring diameter Standard
Minimum
Brush exposed length Standard
Minimum
2.7 ± 3.1

14.2 ± 14.4 mm (0.559 ± 0.567 in.)
12.8 mm (0.504 in.)
9.5 ± 11.5 mm (0.374 ± 0.453 in.)
1.5 mm (0.059 in.)
Generator assy (130A)
Rotor coil resistance at 20
C (68
F)
Slip ring diameter Standard
Minimum
Brush exposed length Standard
Minimum
2.3 ± 2.7

14.2 ± 14.4 mm (0.559 ± 0.567 in.)
14 mm (0.551 in.)
10.5 mm (0.4134 in.)
4.5 mm (0.177 in.)

0300R±04
± SERVICE SPECIFICATIONSSTARTING & CHARGING
03±11
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Starter assy (1.4kw)
Commutator end frame assy x Starter yoke
Starter housing x Magnetic switch
Filed frame x Armature assembly
Lead wire x Terminal C of starter
1.5
5.9
5.9
5.915
60
60
6013 in.
lbf
52 in.
lbf
52 in.
lbf
52 in.
lbf
Starter assy (2.0kw)
Commutator end frame assy x Starter housing
Commutator end frame cover x Commutator end frame assy
Starter housing x Magnet Starter Switch
Lead wire x Terminal C of starter
6.5
1.7
5.0
8.066
17
51
8258 in.
lbf
15 in.
lbf
44 in.
lbf
71 in.
lbf
Starter assy (2.2kw)
Starter housing x Magnetic switch
Filed frame x Armature assembly
Lead wire x Terminal C of starter
9.3
12.7
5.995
130
6082 in.
lbf
9.0
52 in.
lbf
Generator (90A)
Rectifire end frame x Drive end frame Nut A
Nut B
Rectifire holder x Rectifire end frame
Voltage regulator x Rectifire holder
Brush holder x Rectifier holder
Rear end cover x Rectifier end frame Nut
Bolt
Generator pulley x Rotor
4.5
5.4
2.9
3.9
2.0
4.4
3.9
11146
55
30
40
20
45
39
1,13339 in.
lbf
47 in.
lbf
26 in.
lbf
35 in.
lbf
18 in.
lbf
39 in.
lbf
35 in.
lbf
82
Generator assy (130 A)
Rectifire end frame x Drive end frame
Generator pulley x Rotor
Brush holder x Rectifire end frame
Rear end cover x Rectifire holder
5.8
111
1.8
4.659
1,133
18
4751 in.
lbf
82
16 in.
lbf
41 in.
lbf