2004 TOYOTA COROLLA VERSO length

L1 L2
D02612
L2 L1
D01201
L2 L1
D01202
± INTRODUCTIONREPAIR INSTRUCTION
01±5
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets:
When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
(d) Torque When Using Extension Tool with Torque Wrench:
(1) In case of tightening by extending the entire length
of the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
mkgf
cmft
lbf
TTorque N
mkgf
cmft
lbf
L1Length of SST or tool (cm)
L2Length of torque wrench (cm)
10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) Place for Removing and Installing Fuel System Parts:
(1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, elec-
tric motor or stove in the surroundings.
(2) Never work in a place like a pit or nearby pit as there is a possibility that vaporized fuel fills those
places.
(b) Removing and Installing of Fuel System Parts:
(1) Prepare a fire extinguisher before starting the operation.
(2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank,
and do not spray much water so as to prevent slipping.

± 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.)

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.)

A
B
C
D
E
A09570
Front
A56055
A09564
1
18 2 3
4 56
78 9 (A)
10 11
12 1314
1516 17(B)
(A) (A) (A) (A)(A) (A)
(A)
(B) (B) (B) (B)
(B) (B) (B) (B) (B)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±13
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(b) Select a new cylinder head gasket.
HINT:
There are 5 sizes of new cylinder head gaskets, marked ºAº,
ºBº, ºCº, ºDº, or ºEº according.
New installed cylinder head gasket thickness:
A0.85 ± 0.95 mm (0.0335 ± 0.0374 in.)
B0.90 ± 1.00 mm (0.0354 ± 0.0394 in.)
C0.95 ± 1.05 mm (0.0374 ± 0.0413 in.)
D1.00 ± 1.10 mm (0.0394 ± 0.0433 in.)
E1.05 ± 1.15 mm (0.0413 ± 0.0453 in.)
(1) Select the largest piston protrusion value from the
measurements made, then select a new appropri-
ate gasket according to the table below.
Piston protrusion mm (in.)Gasket size
0.165 ± 0.220 (0.0065 ± 0.0087)Use A
0.220 ± 0.270 (0.0087 ± 0.0106)Use B
0.270 ± 0.320 (0.0106 ± 0.0126)Use C
0.320 ± 0.370 (0.0126 ± 0.0146)Use D
0.370 ± 0.425 (0.0146 ± 0.0167)Use E
(c) Place a new cylinder head gasket in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(d) Place the cylinder head in position on the cylinder head
gasket.
(e) Install the cylinder head bolts.
HINT:
The cylinder head bolts are tightened in 4 progressive steps
(steps (3), (5), (6) and (7)).
(1) Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts and plate
washers.
(2) Install the plate washer to the cylinder head bolt.
(3) Install and uniformly tighten the 18 cylinder head
bolts and plate washers in several passes in the se-
quence shown.
Torque: 45 N
m (460 kgf
cm, 33 ft
lbf)
HINT:
Each bolt length is indicated in the illustration.
Bolt length:
(A)160 mm (6.30 in.)
(B)104 mm (4.09 in.)
If any of the cylinder head bolt does not meet the torque specifi-
cation, replace the cylinder head bolts.

EM2534
Z00052
A56051
Margin
Thickness
EM2534
Z00052
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±25
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
10. INSPECT INTAKE VALVE
(a) Check the valve overall length.
Standard overall length: 102.53 mm (4.0366 in.)
Minimum overall length: 102.10 mm (4.0197 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
5.970 ± 5.985 mm (0.2350 ± 0.2356 in.)
(c) Check the valve head margin thickness.
Standard margin thickness: 0.9 mm (0.035 in.)
Minimum margin thickness: 0.6 mm (0.0247 in.)
11. INSPECT EXHAUST VALVE
(a) Check the valve overall length.
Standard overall length: 101.97 mm (4.0146 in.)
Minimum overall length: 101.55 mm (3.9980 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
5.960 ± 5.975 mm (0.2346 ± 0.2352 in.)

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.)

A55621
A55622
A55623
A55624
Free
Lock
A55625
Terminal 50 Terminal C
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
19±5
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Using vernier calipers, measure the brush length.
Standard length: 15.5 mm (0.6102 in.)
Minimum length: 8.5 mm (0.3346 in.)
7. INSPECT STARTER BRUSH HOLDER ASSY
(a) Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (±) brush holders.
(b) Using vernier calipers, measure the brush length.
Standard length: 15.5 mm (0.6102 in.)
Minimum length: 8.5 mm (0.3346 in.)
8. INSPECT STARTER CLUTCH SUB±ASSY
(a) Rotate the pinion gear clockwise, and check that it turns
freely. Try to rotate the pinion gear counterclockwise and
check that it locks.
9. INSPECT MAGNET STARTER SWITCH ASSY
(a) Using an ohmmeter, check that there is continuity be-
tween terminal 50 and C.