2004 TOYOTA COROLLA VERSO engine oil

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.

B09793
Convex
Concave
B08249
Upward
B08253
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±19
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(e) Meet the injector positioning convex to the positioning
concave at the cylinder head side and install the injector
to the cylinder head.
NOTICE:

At this time, insert the injector until it touches the
nozzle sheet surface.

When installing the injector to the cylinder head and
in case that the injector comes to float up with the
reaction of O±ring, pull out the injector once, install
it again.

During the time after equipping the head cover and
before installing the injection pipe, install the irregu-
lar object prevention cover.

Do not exchange the injector cylinder.
(f) Place the 4 nozzle holder clamps to each injector.
49. INSTALL NOZZLE HOLDER CLAMP
(a) Set the washer on the nozzle holder clamp as shown in
the illustration.
(b) Tighten the bolts.
HINT:
Apply a light coat of engine oil on the threads and under the
heads of the nozzle holder clamp bolts.
Torque: 27 N
m (275 kgf
cm, 20 ft
lbf)
NOTICE:
At this time, the clamp has its cam cap bolt as a fulcrum and
clip the injector at the fork portion.

90

180

B08307
B08311
B08312
Plug
GasketOverflow Screw
Ball Spring 14±20
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
50. INSTALL NOZZLE LEAKAGE PIPE ASSY
(a) Place the leakage pipe and 5 new gaskets.
NOTICE:
Do the installation of the gasket craw within the angle
range shown in the illustration.
(b) Apply a light coat of oil onto 4 hollow screws and union
bolt.
(c) Tighten the 4 hollow screws and union bolt by hand.
(d) Tighten the 4 hollow screws and union bolt.
Torque:
Hollow screw 18 N
m (184 kgf
cm, 13 ft
lbf)
Union bolt 22 N
m (224 kgf
cm, 16 ft
lbf)
(e) Check that there is no leak from nozzle leakage pipe con-
nection.
(1) Disconnect the fuel hose, and remove the check
valve, No. 2 nozzle leakage pipe and gasket.
(2) Purchase a new check valve.
HINT:
Part No. 23122±27010
(3) Remove the plug, gasket, spring and ball.
(4) Install the plug with the gasket to the overflow
screw.
Torque: 9.8 N
m (100 kgf
cm, 7 ft.
lbf)
(5) Install the No. 2 nozzle leakage pipe and gasket
with the check valve to the cylinder head.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(6) Apply a light coat of soapy water (any fluid to detect
fuel leakage) on the nozzle leakage pipe connec-
tion.

140L5±01
A62604
Non±reusable part
Valve Stem Oil
O Seal or RingValve Adusting Shim
Valve Lifter
Valve Spring Retainer
Valve Spring Retainer Lock
Inner Compression Spring
Valve Spring Seat
Plate Washer

Valve Guide Bushing
Exhaust Valve
Semicircular Plug

Valve Stem Oil O Seal or Ring Valve Adusting Shim
Valve Lifter
Valve Spring RetainerValve Spring Retainer Lock
Inner Compression Spring
Valve Spring Seat Plate Washer

Valve Guide Bushing
Intake Valve
14±22
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
CYLINDER HEAD ASSY (1CD±FTV)
COMPONENTS

140DR±03
A56671
SST
A62594
SST
A09561
A09676
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±23
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OVERHAUL
1. REMOVE VALVE LIFTER
HINT:
Arrange the valve lifters in the correct order.
2. REMOVE INTAKE VALVE
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202±70020 (09202±00010)
(b) Remove the spring retainer, valve spring and valve.
3. REMOVE EXHAUST VALVE
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202±70020 (09202±00010)
(b) Remove the spring retainer, valve spring and valve.
4. REMOVE VALVE STEM OIL O SEAL OR RING
(a) Using needle±nose pliers, remove the oil seal.
5. REMOVE VALVE SPRING SEAT PLATE WASHER
(a) Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in the correct order.

A56051
Margin
Thickness
EM0801
A56052
Deviation
EM0281
A09539
14±26
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Check the valve head margin thickness.
Standard margin thickness: 0.9 mm (0.035 in.)
Minimum margin thickness: 0.6 mm (0.024 in.)
12. INSPECT INNER COMPRESSION SPRING
(a) Using vernier calipers, measure the free length of the
valve spring.
Free length: 40.45 mm (1.5925 in.)
(b) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
177 ± 195 N (18.0 ± 19.9 kgf, 39.7 ± 44.1 lbf) at 31.1 mm
(1.224 in.)
If the installed tension is not as specified, replace the valve
spring.
13. INSPECT VALVE GUIDE BUSHING OIL CLEARANCE
(a) using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
6.010 ± 6.030 mm (0.2366 ± 0.2374 in.)

A56674
SST
A56675
SST
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±27
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(b) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
Intake0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
Exhaust0.035 ± 0.070 mm (0.0014 ± 0.0028 in.)
Maximum oil clearance:
Intake0.08 mm (0.0031 in.)
Exhaust0.10 mm (0.0039 in.)
14. REMOVE INTAKE VALVE GUIDE BUSH
(a) Heat the cylinder head to 80 ± 100
C (176 ± 212
F).
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201±10000 (09201±01060), 09950±70010
(09951±07100)
15. REMOVE EXHAUST VALVE GUIDE BUSH
(a) Heat the cylinder head to 80 ± 100
C (176 ± 212
F).
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201±10000 (09201±01060), 09950±70010
(09951±07100)