2004 TOYOTA COROLLA VERSO height

010B9±02
± INTRODUCTIONTERMS
01±7
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
ASSYAssembly
A/T, ATMAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
Calif.California
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
DEFDefogger
DFLDeflector

± INTRODUCTIONTERMS
01±9
1CD±FTV ENGINE REPAIR MANUAL (RM927E)Abbreviations Meaning
HIDHigh Intensity Discharge (Head Lamp)
HPUHydrraulic Power Unit
HSGHousing
HTHard Top
HWSHeated Windshield System
IACIdel Air Control
ICIntegrated Circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
ISCIdle Speed Control
J/BJunction Block
J/CJunction Connector
KDKick±Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft±Hand
LHDLeft±Hand Drive
L/H/WLength, Height, Width
LLCLong±Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
M±FUSEMediam Current Fuse
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MG1Motor Generator No.1
MG2Motor Generator No.2
MPMultipurpose
MPIMultipoint Electronic Injection
MPXMultiplex Communication System
M/T, MTMManual Transmission
MTMount
MTGMounting
NNeutral
NANatural Aspiration
No.Number
O/DOverdrive

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.)

A09543
SSTSST
A09541
A09540
Sharp 6 mm
Reamer 14±28
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
16. INSTALL INTAKE VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
Diameter: 10.985 ± 11.006 mm (0.4325 ± 0.4333 in.)
If the bushing bore diameter of the cylinder head is greater then
11.006 mm (0.4333 in.), machine the bushing bore to the di-
mension of 11.035 ± 11.056 mm (0.4344 ± 0.4353 in.).
HINT:
Bushing sizeBushing bore diameter
mm (in.)
Use STD10.985 ± 11.006
(0.4325 ± 0.4333)
Use O/S 0.0511.035 ± 11.056
(0.4344 ± 0.4353)
(b) Heat the cylinder head to 80 ± 100
C. (176 ± 212
F)
(c) Using SST and a hammer, top in a new guide bushing to
the specified protrusion height.
SST 09201±10000 (09201±01060), 09950±70010
(09951±07100)
Protrusion height:
10.05 ± 10.45 mm (0.3957 ± 0.4114 in.)
(d) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance between the
guide bushing and valve stem.
Standard oil clearance:
0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)

A56676
A56677
SST
A56678
Sharp 6 mm
Reamer
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±29
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
17. INSTALL EXHAUST VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
Diameter: 10.985 ± 11.006 mm (0.4325 ± 0.4333 in.)
If the bushing bore diameter of the cylinder head is greater then
11.006 mm (0.4333 in.), machine the bushing bore to the di-
mension of 11.035 ± 11.056 mm (0.4344 ± 0.4353 in.).
HINT:
Bushing sizeBushing bore diameter
mm (in.)
Use STD10.985 ± 11.006
(0.4325 ± 0.4333)
Use O/S 0.0511.035 ± 11.056
(0.4344 ± 0.4353)
(b) Heat the cylinder head to 80 ± 100
C. (176 ± 212
F)
(c) Using SST and a hammer, tap in a new guide bushing to
the specified protrusion height.
SST 09201±10000 (09201±01060), 09950±70010
(09951±07100)
Protrusion height:
9.65 ± 10.05 mm (0.3799 ± 0.3957 in.)
(d) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance between the
guide bushing and valve stem.
Standard oil clearance:
0.035 ± 0.070 mm (0.0014 ± 0.0028 in.)
18. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.

A09550
A09551
A09552
A09546
Plastigage
A09557
14±32
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
23. INSPECT CAMSHAFT
(a) Inspect the circle runout.
(1) Place the camshaft on V±blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater then maximum, replace the cam-
shaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake46.57 ± 46.67 mm (1.8335 ± 1.8374 in.)
Exhaust47.52 ± 47.62 mm (1.8709 ± 1.8748 in.)
Minimum cam lobe height:
Intake46.10 mm (1.8150 in.)
Exhaust47.05 mm (1.8524 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
(c) Using a micrometer, measure the journal diameter.
Journal diameter:
26.969 ± 26.985 mm (1.0618 ± 1.0624 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
24. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the bearing caps and camshaft carrier.
(b) Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps, cam-
shaft carrier and cylinder head as a set.
(c) Place the camshaft carrier and camshafts on the cylinder
head.
(d) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(e) Install the bearing caps.
Torque: 20 N
m (200 kgf
cm, 15 ft
lbf)
NOTICE:
Do not turn the camshaft.
(f) Remove the bearing caps.

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.

A56687
Cylinder Head Side: Lower Side:
Front Side:
A
B 11 m m20 mm
14 mm 8 mm
AAAA
B B
14±54
± ENGINE MECHANICALCYLINDER BLOCK (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
22. INSTALL RING PIN
(a) Using a plastic±faced hammer, tap in new ring pins to the
specified protrusion height.
Protrusion height:
A: 7.0 mm (0.2755 in.)
B: 13 mm (0.5118 in.)