2004 TOYOTA COROLLA VERSO engine oil

A09497
A09500
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
14±51
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(h) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(i) 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)
NOTICE:
Do not turn the crankshaft.
(j) Remove the bearing cap.
(k) Measure the Plastigage at its widest point.
Standard oil clearance:
0.026 ± 0.044 mm (0.0010 ± 0.0017 in.)
Maximum oil Clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater then maximum, replace the bear-
ings. If necessary, replace the crankshaft.

A09473
Hexagon
Wrench (6 mm)
A09503
A56044
A56045
A09510Groove
14±56
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
25. INSTALL CYLINDER BLOCK OIL ORIFICE
(a) Using a hexagon wrench (6 mm), install the oil orifice.
Torque: 9.0 N
m (92 kgf
cm, 78 in.
lbf)
26. INSTALL SUB±ASSY OIL NOZZLE NO.1
(a) Install the oil nozzle with the bolt. Install the 4 oil nozzles.
Torque: 7.4 N
m (76 kgf
cm, 67 in.
lbf)
27. INSTALL CRANKSHAFT
(a) Install the bearing on the cylinder block and bearing cap.
HINT:
Upper bearings have an oil groove and oil holes; lower bearings
do not.
(1) Align the bearing claw with the claw groove of the
cylinder block, and push in the 5 upper bearings.
(2) Align the bearing claw with the claw groove of the
main bearing cap, and push in the 5 lower bearings.
(b) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.

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.

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.)

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.

A55617
A55618
A51188
A55619
A55620
19±4
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Place the commutator on V±blocks.
(d) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.002 in.)
(e) Using vernier calipers, measure the commutator diame-
ter.
Standard diameter: 30 mm (1.1811 in.)
Minimum diameter: 29 mm (1.1417 in.)
(f) Check that the undercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
6. INSPECT STARTER YOKE ASSY
(a) Using an ohmmeter, check that there is continuity be-
tween the lead wire and field coil brush lead.
(b) Using an ohmmeter, check that there is no continuity be-
tween the field coil brush lead and yoke.