01–1

INTRODUCTION – HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

0106E–06

GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explains ”Removing and Installing, Replacing, Disassembling, Installing and Checking,
Adjusting”, but ”Final Inspection” is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the ”disassembled parts drawing” so that it enables you
to understand the fitting condition of the components.
(c) Non–reusable parts, grease applied parts, precoated parts and tightening torque are specified in the
components drawing.
Example:
OVERHAUL Camshaft,
No. 3 Camshaft Sub–assy

Camshaft Drive Gear

Camshaft Timing Tube Assy

7.5 (80, 66 in.·lbf)

No. 2 Camshaft,
Seal Washer No. 4 Camshaft Sub–assy

Camshaft Setting Oil Seal Camshaft Driven Main Gear

Screw Plug
78 (790, 58)

15 (150, 11) Wave Washer Camshaft Timing Gear

Bolt Washer
Camshaft Sub Gear
N·m (kgf·cm, ft·lbf) : Specified torque Snap Ring

Non–reusable part A54988

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(d) Tightening torque, oil applying position, and non–reusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc. are described in the illustration.
(e) Installing procedure of operation items is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a step–by–step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:

Illustration: Task heading: what to do

what to do and where

Detailed text:
Set part No. Component part No. how to do task

A59974

HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.

5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.

6. TERMS DEFINITION
CAUTION Indicate the possibility of injury to you or other people.
NOTICE Indicate the possibility of damage to the components being repaired.
HINT Provide additional information to help you perform the repair efficiently.

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7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N
m (310 kgf
cm, 22 ft
lbf)

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INTRODUCTION – REPAIR INSTRUCTION

REPAIR INSTRUCTION
010BM–01

PRECAUTION
1. TO PREVENT FROM ENTERING FOREIGN SUBSTANCES.
(a) When foreign substances such as dust, grain of sand or metallic dust enter inside of engine, it often
causes functional failure of the engine.
(1) Precaution before disassembly.

Remove adequately all sand and mud adhere to the outside of engine .
(2) Precaution at reassembly.

Protect disassembled parts from dust by using vinyl sheet to cover.
2. TO PREVENT SCRATCHES ON THE PARTS.
(a) The existence of scratches on the contact and revolving surfaces often causes oil leak and seisure.
(1) Precautions at disassembly and reassembly.

When disassemble the contact surface of the parts, use plastic hummer striking lightly. (Do
not pry out by screwdriver).

When fix the parts to the vise, do not directly catch it in the vise. Fix the parts through alumi-
num bar.
3. TO CLEAN AND WASH THE PARTS.
(a) Each parts needs to be well cleaned, washed, and dried by air, and apply specified oil before reas-
sembly.
(1) Cleaning and washing by alkaline solvent is prohibited:

Parts made of aluminum and rubber. (ex. cylinder head cover gasket etc.)
(2) Cleaning and washing by flushing oil (ex. kerosene, white gasoline etc.) is prohibited:

Parts made of rubber. (ex. cylinder head cover gasket etc.)
4. POSITION AND DIRECTION OF EACH PARTS.
(a) Each parts needs to be reassembled as the same position and direction as it disassembled.
(1) Precautions at disassembly and reassembly.

Follow the directions when the manual designates to mark the matchmark and/or direction
mark.

Disassembled parts needs to be put in order as disassembled, not to change position and/
or direction.

Follow the directions when the manual instructs the position and direction.
5. INSTALL ENGINE ASSEMBLY TO OVERHAUL STAND WHEN OVERHAUL THE ENGINE.
6. PUT THE DISASSEMBLED PARTS IN ORDER AS THEY DISASSEMBLED.
7. APPLY ENGINE OIL TO THE SLIDING AND ROTATING SURFACES.
8. NON–REUSABLE PARTS SUCH AS GASKET AND SEAL NEEDS TO BE CHANGED TO THE NEW
PARTS.
9. BASIC REPAIR HINT

(a) Precoated Parts:

(1) Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
Seal Lock Adhesive
adhesive and dry with compressed air. Then apply
Z11554 the specified seal lock adhesive to the bolt, nut or
threads.
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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
L1 L2 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-
D02612 ing of the torque wrench by the formula.
(3) Formula T’=T x L2/(L1 + L2)
T’ Reading of torque wrench N
m kgf
cm ft
lbf
L1 L2 T Torque N
m kgf
cm ft
lbf
L1 Length of SST or tool (cm)
L2 Length of torque wrench (cm)

D01201

L1 L2

D01202

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.
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(3) Never use any electric equipment like an electric motor or a working light as they may cause
spark or high temperature.
(4) Never use an iron hammer as it may cause spark.
(5) Dispose the shop lag separately from any fuel deposit.

11. REMOVAL AND INSTALLATION OF ENGINE INTAKE

PARTS
(a) If any metal tip is mixed in the inlet pass, that may give a
bad effect to the engine and turbo charger.
(b) When removing and installing of the inlet system parts,
close the opening of the removed inlet system parts and
the engine with a clean shop lag or gum tape.
(c) When installing the inlet system parts, check that there is
D01563 no mixing of a metal tip.

12. HANDLING OF HOSE CLAMPS

Flat Spring Clamp
(a) Before removing the hose, check the depth of inserting
portion and the clamp position to restore it surely.
(b) Change a deformed or dented into a new one.
(c) In case of reusing the hose, install the clamp on the hose
where it has a clamp track.
(d) For a flat spring type clamp, make it adjust by adding force
Clamp Track to the arrow mark direction after the installation.
D25081

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INTRODUCTION – TERMS

TERMS
010B9–02

ABBREVIATIONS USED IN THIS MANUAL

Abbreviations Meaning
ABS Anti–Lock Brake System
AC Alternating Current
ACC Accessory
ACIS Acoustic Control Induction System
ACSD Automatic Cold Start Device
A.D.D. Automatic Disconnecting Differential
A/F Air–Fuel Ratio
AHC Active Height Control Suspension
ALR Automatic Locking Retractor
ALT Alternator
AMP Amplifier
ANT Antenna
APPROX. Approximately
ASSY Assembly
A/T, ATM Automatic Transmission (Transaxle)
ATF Automatic Transmission Fluid
AUTO Automatic
AUX Auxiliary
AVG Average
AVS Adaptive Variable Suspension
B+ Battery Voltage
BA Brake Assist
BACS Boost Altitude Compensation System
BAT Battery
BDC Bottom Dead Center
B/L Bi–Level
B/S Bore–Stroke Ratio
BTDC Before Top Dead Center
BVSV Bimetallic Vacuum Switching Valve
Calif. California
CB Circuit Breaker
CCo Catalytic Converter For Oxidation
CD Compact Disc
CF Cornering Force
CG Center Of Gravity
CH Channel
COMB. Combination
CPE Coupe
CPS Combustion Pressure Sensor
CPU Central Processing Unit
CRS Child Restraint System
CTR Center
C/V Check Valve
CV Control Valve
CW Curb Weight
DC Direct Current
DEF Defogger
DFL Deflector

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Abbreviations Meaning
DIFF. Differential
DIFF. LOCK Differential Lock
D/INJ Direct Injection
DLC Data Link Connector
DLI Distributorless Ignition
DOHC Double Overhead Cam
DP Dash Pot
DS Dead Soak
DSP Digital Signal Processor
DTC Diagnostic Trouble Code
DVD Digital Versatible Disc
EBD Electric Brake force Distribution
ECAM Engine Control And Measurement System
ECD Electronic Controlled Diesel
ECDY Eddy Current Dynamometer
ECU Electronic Control Unit
ED Electro–DepositedCoating
EDU Electronic Driving Unit
EDIC Electric Diesel Injection Control
EFI Electronic Fuel Injection
E/G Engine
EGR Exhaust Gas Recirculation
EGR–VM EGR–Vacuum Modulator
ELR Emergency Locking Retractor
EMPS Electric Motor Power Steering
ENG Engine
ESA Electronic Spark Advance
ETCS–i Electronic Throttle Control System–intelligent
EVAP Evaporative Emission Control
EVP Evaporator
E–VRV Electric Vacuum Regulating Valve
EX, EXH Exhaust
FE Fuel Economy
FF Front–EngineFront–Wheel–Drive
F/G Fuel Gauge
FIPG Formed In Place Gasket
FL Fusible Link
F/P Fuel Pump
FPU Fuel Pressure Up
Fr Front
FR Front–EngineRear–Wheel–Drive
F/W Flywheel
FW/D Flywheel Damper
FWD Front–Wheel–Drive
GAS Gasoline
GND Ground
GPS Global Positioning System
HAC High Altitude Compensator
H/B Hatchback
H–FUSE High Current Fuse
HI High

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INTRODUCTION – TERMS

Abbreviations Meaning
HID High Intensity Discharge (Head Lamp)
HPU Hydrraulic Power Unit
HSG Housing
HT Hard Top
HWS Heated Windshield System
IAC Idel Air Control
IC Integrated Circuit
IDI Indirect Diesel Injection
IFS Independent Front Suspension
IG Ignition
IIA Integrated Ignition Assembly
IN Intake (Manifold, Valve)
INT Intermittent
I/P Instrument Panel
IRS Independent Rear Suspension
ISC Idle Speed Control
J/B Junction Block
J/C Junction Connector
KD Kick–Down
LAN Local Area Network
LB Liftback
LCD Liquid Crystal Display
LED Light Emitting Diode
LH Left–Hand
LHD Left–Hand Drive
L/H/W Length, Height, Width
LLC Long–Life Coolant
LNG Liquified Natural Gas
LO Low
LPG Liquified Petroleum Gas
LSD Limited Slip Differential
LSP & PV Load Sensing Proportioning And Bypass Valve
LSPV Load Sensing Proportioning Valve
MAP Manifold Absolute Pressure
MAX. Maximum
M–FUSE Mediam Current Fuse
MIC Microphone
MIL Malfunction Indicator Lamp
MIN. Minimum
MG1 Motor Generator No.1
MG2 Motor Generator No.2
MP Multipurpose
MPI Multipoint Electronic Injection
MPX Multiplex Communication System
M/T, MTM Manual Transmission
MT Mount
MTG Mounting
N Neutral
NA Natural Aspiration
No. Number
O/D Overdrive

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INTRODUCTION – TERMS

Abbreviations Meaning
OEM Original Equipment Manufacturing
OHC Overhead Camshaft
OHV Overhead Valve
OPT Option
ORVR On–board Refilling Vapor Recovery
O/S Oversize
P & BV Proportioning And Bypass Valve
PCS Power Control System
PCV Positive Crankcase Ventilation
PKB Parking Brake
PPS Progressive Power Steering
PS Power Steering
PTO Power Take–Off
P/W Power Window
R&P Rack And Pinion
RAM Random Access Memory
R/B Relay Block
RBS Recirculating Ball Type Steering
R/F Reinforcement
RFS Rigid Front Suspension
RH Right–Hand
RHD Right–Hand Drive
RLY Relay
ROM Read Only Memory
Rr Rear
RR Rear–EngineRear–Wheel–Drive
RRS Rigid Front Suspension
RWD Rear–Wheel–Drive
SDN Sedan
SEN Sensor
SICS Starting Injection Control System
SOC State Of Charge
SOHC Single Overhead Camshaft
SPEC Specification
SPI Single Point Injection
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
STD Standard
STJ Cold–Start Fuel Injection
SW Switch
SYS System
T/A Transaxle
TACH Tachometer
TBI Throttle Body Electronic Fuel Injection
TC Turbocharger
TCCS TOYOTA Computer–Controlled System
TCV Timing Control Valve
TDC Top Dead Center
TEMP. Temperature
TEMS TOYOTA Electronic Modulated Suspension

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INTRODUCTION – TERMS

Abbreviations Meaning
TFT Toyota Free–Tronic
TIS Total Information System For Vehicle Development
T/M Transmission
TMC TOYOTA Motor Corporation
TMMK TOYOTA Motor Manufacturing Kentucky, Inc.
TRC Traction Control System
TURBO Turbocharge
TWC Three–Way Catalyst
U/D Underdrive
U/S Undersize
VCV Vacuum Control Valve
VENT Ventilator
VIN Vehicle Identification Number
VPS Variable Power Steering
VSC Vehicle Stability Control
VSV Vacuum Switching Valve
VTV Vacuum Transmitting Valve
VVT–i Variable Valve Timing–intelligent
w/ With
WGN Wagon
W/H Wire Harness
w/o Without
WU–TWC Warm Up Three–way Catalytic Converter
WU–OC Warm Up Oxidation Catalytic Converter
1st First
2nd Second
2WD Two Wheel Drive Vehicle (4 x 2)
3rd Third
4th Fourth
4WD Four Wheel Drive Vehicle (4 x 4)
4WS Four Wheel Steering System
5th Fifth

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INTRODUCTION – TERMS
010BA–03

GLOSSARY OF SAE AND TOYOTA TERMS

This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE TOYOTA TERMS
SAE TERMS
ABBREVIATIONS ( )––ABBREVIATIONS

A/C Air Conditioning Air Conditioner

ACL Air Cleaner Air Cleaner, A/CL
AIR Secondary Air Injection Air Injection (AI)
AP Accelerator Pedal –
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure HAC
CAC Charge Air Cooler Intercooler
CARB Carburetor Carburetor
CFI Continuous Fuel Injection –
CKP Crankshaft Position Crank Angle
CL Closed Loop Closed Loop
CMP Camshaft Position Cam Angle
CPP Clutch Pedal Position –
CTOX Continuous Trap Oxidizer –
CTP Closed Throttle Position LL ON, Idle ON
DFI Direct Fuel Injection (Diesel) Direct Injection (DI)
DI Distributor Ignition –
DLC1 Data Link Connector 1 1: Check Connector
DLC2 Data Link Connector 2 2: Total Diagnosis Comunication Link (TDCL)
DLC3 Data Link Connector 3 3: OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Code
DTM Diagnostic Test Mode –
ECL Engine Control Level –
ECM Engine Control Module Engine ECU (Electronic Control Unit)
ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only Memory
EEPROM Electrically Erasable Programmable Read Only Memory (EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition TOYOTA Distributorless Ignition (TDI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control –
Flash Electrically Erasable Programmable
FEEPROM –
Read Only Memory

FEPROM Flash Erasable Programmable Read Only Memory –

FF Flexible Fuel –
FP Fuel Pump Fuel Pump
GEN Generator Alternator
GND Ground Ground (GND)
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INTRODUCTION – TERMS

HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)

IAC Idle Air Control Idle Speed Control (ISC)
IAT Intake Air Temperature Intake or Inlet Air Temperature
ICM Ignition Control Module –
IFI Indirect Fuel Injection Indirect Injection (IDL)
IFS Inertia Fuel–Shutoff –
ISC Idle Speed Control –
KS Knock Sensor Knock Sensor
MAF Mass Air Flow Air Flow Meter
Manifold Pressure
MAP Manifold Absolute Pressure
Intake Vacuum
Electric Bleed Air Control Valve (EBCV)
MC Mixture Control Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDP Manifold Differential Pressure –
MFI Multiport Fuel Injection Electronic Fuel Injection (EFI)
MIL Malfunction Indicator Lamp Check Engine Lamp
MST Manifold Surface Temperature –
MVZ Manifold Vacuum Zone –
NVRAM Non–Volatile Random Access Memory –
O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S)
OBD On–Board Diagnostic On–Board Diagnostic System (OBD)
OC Oxidation Catalytic Converter Oxidation Catalyst Convert (OC), CCo
OP Open Loop Open Loop
PAIR Pulsed Secondary Air Injection Air Suction (AS)
PCM Powertrain Control Module –
PNP Park/Neutral Position –
PROM Programmable Read Only Memory –
PSP Power Steering Pressure –
Diesel Particulate Filter (DPF)
PTOX Periodic Trap Oxidizer
Diesel Particulate Trap (DPT)

RAM Random Access Memory Random Access Memory (RAM)

RM Relay Module –
ROM Read Only Memory Read Only Memory (ROM)
RPM Engine Speed Engine Speed
SC Supercharger Supercharger
SCB Supercharger Bypass E–ABV
SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection
SPL Smoke Puff Limiter –
SRI Service Reminder Indicator –
SRT System Readiness Test –
ST Scan Tool –
TB Throttle Body Throttle Body
Single Point Injection
TBI Throttle Body Fuel Injection
Central Fuel Injection (Ci)

TC Turbocharger Turbocharger
TCC Torque Converter Clutch Torque Converter
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INTRODUCTION – TERMS

TCM Transmission Control Module Transmission ECU, ECT ECU

TP Throttle Position Throttle Position
TR Transmission Range –
Bimetallic Vacuum Switching Valve (BVSV)
TVV Thermal Vacuum Valve
Thermostatic Vacuum Switching Valve (TVSV)

Three–Way Catalytic (TWC)

TWC Three–Way Catalytic Converter Manifold Converter
CCRO
TWC+OC Three–Way + Oxidation Catalytic Converter CCR + CCo
VAF Volume Air Flow Air Flow Meter
VR Voltage Regulator Voltage Regulator
VSS Vehicle Speed Sensor Vehicle Speed Sensor
WOT Wide Open Throttle Full Throttle
WU–OC Warm Up Oxidation Catalytic Converter –
WU–TWC Warm Up Three–Way Catalytic Converter –
3GR Third Gear –
4GR Fourth Gear –

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PREPARATION – INTAKE

INTAKE
0214R–01

PREPARATION
SST
09350–32014 TOYOTA Automatic Transmission TURBOCHARGER
Tool Set ASSEMBLY(1CD–FTV)

(09351–32070) No.2 Piston Spring Compressor TURBOCHARGER

ASSEMBLY(1CD–FTV)

09992–00242 Turbocharger Pressure Gauge TURBOCHARGER

ASSEMBLY(1CD–FTV)

09992–00600 Crank Type Spindle TURBOCHARGER

ASSEMBLY(1CD–FTV)

Recomended Tools
09042–00010 Torx Socket T30 TURBOCHARGER
ASSEMBLY(1CD–FTV)

SSM
08826–00080 Seal Packing Black or equivalent TURBOCHARGER
(FIPG) ASSEMBLY(1CD–FTV)

Equipment
Dial indicator
Torque wrench
Protractor
Steel square

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PREPARATION – ENGINE MECHANICAL

ENGINE MECHANICAL
0214S–01

PREPARATION
SST
09032–00100 Oil Pan Seal Cutter PARTIAL ENGINE ASSY(1CD–FTV)

09201–10000 Valve Guide Bushing Remover & CYLINDER HEAD ASSY(1CD–FTV)

Replacer Set

(09201–01060) Valve Guide Bushing Remover & CYLINDER HEAD ASSY(1CD–FTV)

Replacer 6

09202–70020 Valve Spring Compressor CYLINDER HEAD ASSY(1CD–FTV)

(09202–00010) Attachment CYLINDER HEAD ASSY(1CD–FTV)

09223–15030 Oil Seal & Bearing Replacer PARTIAL ENGINE ASSY(1CD–FTV)

09223–46011 Crankshaft Front Oil Seal PARTIAL ENGINE ASSY(1CD–FTV)

Replacer

09248–55050 Valve Clearance Adjust Tool Set PARTIAL ENGINE ASSY(1CD–FTV)

(09248–05510) Valve Lifter Press PARTIAL ENGINE ASSY(1CD–FTV)

(09248–05520) Valve Lifter Stopper PARTIAL ENGINE ASSY(1CD–FTV)

09316–60011 Transmission & Transfer Bearing PARTIAL ENGINE ASSY(1CD–FTV)

Replacer

(09316–00011) Replacer Pipe PARTIAL ENGINE ASSY(1CD–FTV)

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PREPARATION – ENGINE MECHANICAL

(09316–00021) Replacer ”A” PARTIAL ENGINE ASSY(1CD–FTV)

09950–50013 Puller C Set PARTIAL ENGINE ASSY(1CD–FTV)

(09951–05010) Hanger 150 PARTIAL ENGINE ASSY(1CD–FTV)

(09952–05010) Slide Arm PARTIAL ENGINE ASSY(1CD–FTV)

(09953–05010) Center Bolt 100 PARTIAL ENGINE ASSY(1CD–FTV)

(09953–05020) Center Bolt 150 PARTIAL ENGINE ASSY(1CD–FTV)

(09954–05021) Claw No.2 PARTIAL ENGINE ASSY(1CD–FTV)

09950–60010 Replacer Set CYLINDER HEAD ASSY(1CD–FTV)

CYLINDER BLOCK(1CD–FTV)

(09951–00210) Replacer 21 CYLINDER HEAD ASSY(1CD–FTV)

(09951–00350) Replacer 35 CYLINDER BLOCK(1CD–FTV)

09950–70010 Handle Set CYLINDER HEAD ASSY(1CD–FTV)

CYLINDER BLOCK(1CD–FTV)
PARTIAL ENGINE ASSY(1CD–FTV)

(09951–07100) Handle 100 CYLINDER HEAD ASSY(1CD–FTV)

CYLINDER BLOCK(1CD–FTV)
PARTIAL ENGINE ASSY(1CD–FTV)

09960–10010 Variable Pin Wrench Set PARTIAL ENGINE ASSY(1CD–FTV)

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PREPARATION – ENGINE MECHANICAL

(09962–01000) Variable Pin Wrench Arm Assy PARTIAL ENGINE ASSY(1CD–FTV)

(09963–01000) Pin 10 PARTIAL ENGINE ASSY(1CD–FTV)

09992–00242 Turbocharger Pressure Gauge PARTIAL ENGINE ASSY(1CD–FTV)

SSM
08826–00080 Seal Packing Black or equivalent CYLINDER HEAD ASSY(1CD–FTV)
(FIPG) PARTIAL ENGINE ASSY(1CD–FTV)

08826–00100 ”Seal Packing 1282B,” PARTIAL ENGINE ASSY(1CD–FTV)

THREE BOND 1282B or equivalent
(FIPG)

08833–00070 ”Adhesive 1324,” CYLINDER HEAD ASSY(1CD–FTV)

THREE BOND 1324 or equivalent CYLINDER BLOCK(1CD–FTV)

Equipment
V–block
Piston ring compressor
Piston ring expander
Valve seat cutter
Hexagon wrench (6 mm)
Hexagon wrench (8 mm)
Connecting rod aligner
Cylinder gauge
Dial indicator
Feeler gauge
Micrometer
Precision straight edge
Steel square
Torque wrench
Vernier calipers
Dial indicator with magnetic base
Slide calipers
Wooden block
Spring tester
Plastigage
Heater

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PREPARATION – LUBRICATION

LUBRICATION
0214T–01

PREPARATION
Equipment
Feeler gauge

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

02–6
PREPARATION – STARTING & CHARGING

STARTING & CHARGING

0214U–01

PREPARATION
SST
09820–63020 Alternator Pulley Wrench Set GENERATOR
ASSY(130A)(1CD–FTV)

09950–40011 Puller B Set GENERATOR

ASSY(130A)(1CD–FTV)

(09951–04020) Hanger 200 GENERATOR

ASSY(130A)(1CD–FTV)

(09952–04010) Slide Arm GENERATOR

ASSY(130A)(1CD–FTV)

(09953–04020) Center Bolt 150 GENERATOR

ASSY(130A)(1CD–FTV)

(09954–04010) Arm 25 GENERATOR

ASSY(130A)(1CD–FTV)

(09955–04071) Claw No.7 GENERATOR

ASSY(130A)(1CD–FTV)

(09958–04011) Holder GENERATOR

ASSY(130A)(1CD–FTV)

09950–60010 Replacer Set STARTER ASSY(2.0KW)(1CD–FTV)

(09951–00340) Replacer 34 STARTER ASSY(2.0KW)(1CD–FTV)

Recomended Tools
09082–00040 TOYOTA Electrical Tester STARTER ASSY(1.4KW)(1CD–FTV)
STARTER ASSY(2.2KW)(1CD–FTV)
GENERATOR
ASSY(130A)(1CD–FTV)

(09083–00150) Test Lead Set STARTER ASSY(1.4KW)(1CD–FTV)

STARTER ASSY(2.2KW)(1CD–FTV)
GENERATOR ASSY(90A)(1CD–FTV)
GENERATOR
ASSY(130A)(1CD–FTV)
1CD–FTV ENGINE REPAIR MANUAL (RM927E)
 02–7
PREPARATION – STARTING & CHARGING

(09083–00350) AC/DC 400 A Probe STARTER ASSY(2.2KW)(1CD–FTV)

Equipment
V–block
Feeler gauge
Ohmmeter
Torque wrench
Vernier calipers
Dial indicator with magnetic base

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 03–1
SERVICE SPECIFICATIONS – STANDARD BOLT

STANDARD BOLT
030KP–01

HOW TO DETERMINE BOLT STRENGTH

Bolt Type
Hexagon Head Bolt Class
Stud Bolt Weld Bolt
Normal Recess Bolt Deep Recess Bolt

4 4T

No Mark No Mark No Mark

5 5T

6 6T

w/ Washer w/ Washer

7 7T

8 8T

9 9T

10 10T

11 11T

B06431

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

03–2
SERVICE SPECIFICATIONS – STANDARD BOLT
030KQ–01

SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Diameter Pitch
Class Hexagon head bolt Hexagon flange bolt
mm mm
N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf
6 1 5 55 48 in.·lbf 6 60 52 in.·lbf
8 1.25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,150 83 – – –

6 1 6.5 65 56 in.·lbf 7.5 75 65 in.·lbf

8 1.25 15.5 160 12 17.5 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1,050 76
16 1.5 140 1,400 101 – – –

6 1 8 80 69 in.·lbf 9 90 78 in.·lbf
8 1.25 19 195 14 21 210 15
10 1.25 39 400 29 44 440 32
6T
12 1.25 71 730 53 80 810 59
14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 127 – – –

6 1 10.5 110 8 12 120 9

8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 105 1,050 76
14 1.5 145 1,500 108 165 1,700 123
16 1.5 230 2,300 166 – – –

8 1.25 29 300 22 33 330 24

8T 10 1.25 61 620 45 68 690 50
12 1.25 110 1,100 80 120 1,250 90
8 1.25 34 340 25 37 380 27
9T 10 1.25 70 710 51 78 790 57
12 1.25 125 1,300 94 140 1,450 105
8 1.25 38 390 28 42 430 31
10T 10 1.25 78 800 58 88 890 64
12 1.25 140 1,450 105 155 1,600 116
8 1.25 42 430 31 47 480 35
11T 10 1.25 87 890 64 97 990 72
12 1.25 155 1,600 116 175 1,800 130

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 03–3
SERVICE SPECIFICATIONS – STANDARD BOLT
030KR–01

HOW TO DETERMINE NUT STRENGTH

Nut Type
Present Standard Old Standard Hexagon Nut Class
Hexagon Nut Cold Forging Nut Cutting Processed Nut

4N

No Mark

5N (4T)

No Mark (w/ Washer) No Mark (w/ Washer) No Mark

6N
6N

7N (5T)

8N
8N

10N (7T)
10N

No Mark

11N
11N

12N
12N

*: Nut with 1 or more marks on one side surface of the nut.

B06432
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
1CD–FTV ENGINE REPAIR MANUAL (RM927E)
03–4
SERVICE SPECIFICATIONS – INTAKE

INTAKE
030KS–01

SERVICE DATA
Turbocharger Actuator pressure 129 – 140 kPa (1.32 – 1.43 kgf/cm2, 18.7 – 20.3 psi)
Turbine wheel axial play Maximum 0.09 mm (0.0035 in.) or less
Turbine wheel radial play Maximum 0.16 mm (0.0063 in.) or less

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 03–5
SERVICE SPECIFICATIONS – INTAKE
030KT–01

TORQUE SPECIFICATION
Part tightened N·m kgf·cm ft·lbf
V Band 8.3 85 74 in.·lbf
Compressor housing x Bearing housing 4.7 48 42 in.·lbf
Turbocharger actuator x Compressor housing 7.8 80 69 in.·lbf
Compressor inlet elbow x Compressor housing 23 235 17

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

03–6
SERVICE SPECIFICATIONS – ENGINE MECHANICAL

ENGINE MECHANICAL
0300O–05

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

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 03–7
SERVICE SPECIFICATIONS – ENGINE MECHANICAL

Cylinder block
Warpage Maximum 0.05 mm (0.0020 in.)
Bore diameter Standard 82.200 – 82.213 mm (3.2362 – 3.2367 in.)
Maximum 82.400 mm (3.2441 in.)
Piston
Piston diameter 82.118 – 82.132 mm (3.2330 – 3.2335 in.)
Piston oil clearance Standard 0.068 – 0.095 mm (0.0027 – 0.0037 in.)
Maximum 0.14 mm (0.0055 in.)
Bushing inside diameter 31.015 – 31.027 mm (1.2211 – 1.2215 in.)
Piston pin
Piston pin diameter 31.000 – 31.012 mm (1.2205 – 1.2209 in.)
Oil clearance Standard 0.030 – 0.027 mm (0.0001 – 0.0011 in.)
Maximum 0.025 mm (0.0010 in.)
Cylinder head set bolt
Out side diameter Standard 10.75 – 11.00 mm (0.4234 – 0.4331 in.)
Minimum 10.40 mm (0.4904 in.)
Connecting rod bolt
Diameter Standard 8.2 – 8.3 mm (0.323 – 0.327 in.)
Minimum 8.0 mm (0.315 in.)
Connecting rod
Out–of–alignment Maximum per 100 mm (3.94 in.) 0.05 mm (0.0020 in.)
Rod twist Maximum per 100 mm (3.94 in.) 0.15 mm (0.0059 in.)
Crankshaft
Thrust clearance Standard 0.040 – 0.240 mm (0.0016 – 0.0094 in.)
Maximum 0.30 mm (0.0118 in.)
Circle runout Maximum 0.025 mm (0.0010 in.)
Crank pin taper and out– of –round Maximum 0.01 mm (0.0004 in.)
Crank pin diameter 50.482 – 50.500 mm (1.9875 – 1.9882 in.)
Main journal diameter 56.992 – 57.010 mm (2.2438 – 2.2445 in.)
Oil clearance Standard 0.032 – 0.050 mm (0.0013 – 0.0020 in.)
Maximum 0.10 mm (0.0039 in.)

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

03–8
SERVICE SPECIFICATIONS – ENGINE MECHANICAL
0300P–05

TORQUE SPECIFICATION
Part Tightened N
m kgf
cm ft
lbf
Cylinder block water drain cock x Cylinder block 29 291 21
Oil check valve x Cylinder block 30 310 22
Oil pump x Cylinder block 31 320 23
Oil pan x Cylinder block For 10 mm head bolt and nut 11 112 8.0
For 12 mm head bolt 21 210 15
For 14 mm head bolt 42 429 31
Oil strainer x Cylinder block For bolt 21 210 15
For nut 13 135 10
Oil pan No.2 x Cylinder block 12 120 9.0
Cylinder head x Cylinder block 1st 45 460 33
2nd Turn 90
Turn 90
Turn 90

3rd Turn 90
Turn 90
Turn 90

4th Turn 90
Turn 90
Turn 90

Camshaft bearing cap x Cylinder head 20 204 15
Water pump x Cylinder block 31 320 23
Camshaft oil seal retainer x Cylinder head 8.8 90 78 in.
lbf
Timing belt idler Sub assy No.2 x Oil pump 47 475 34
Timing belt idler No. 1 x Cylinder head 35 350 25
Camshaft timing pulley x Camshaft 88 899 65
Nozzle holder clamp x Cylinder head 27 275 20
Nozzle leakage pipe x Cylinder head Hollow screw 18 184 13
Union bolt 22 224 16
Over flow screw x Plug 9.8 100 7.0
Check valve x Cylinder head 21 214 15
Cylinder head cover x Cylinder head 13 135 10
Taper screw plug No.1 x Cylinder head 25 255 18
Cylinder head stud bolt (See Page 14–23) Bolt A 8.8 90 78 in.
lbf
Bolt B 12 120 9.0
Bolt C 8.8 90 78 in.
lbf
Connecting rod cap x Connecting rod 1st 30 306 22
2nd Turn 90
Turn 90
Turn 90

Crankshaft bearing cap x Cylinder block 115 1,173 85
Cylinder block oil orifice x Cylinder block 9.0 92 78 in.
lbf
Oil nozzle No.1 x Cylinder block 7.4 76 67 in.
lbf

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 03–9
SERVICE SPECIFICATIONS – LUBRICATION

LUBRICATION
0300L–04

SERVICE DATA
Oil pump
Tip clearance Standard 0.080–0.160 mm (0.0031 – 0.0063 in.)
Maximum 0.2 mm (0.0079 in.)
Body clearance Standard 0.100–0.170 mm (0.0039 – 0.0067 in.)
Maximum 0.2 mm (0.0079 in.)

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

03–10
SERVICE SPECIFICATIONS – STARTING & CHARGING

STARTING & CHARGING

0300Q–04

SERVICE DATA
Starter assy (1.4kw)
Circle runout Maximum 0.05 mm(0.0020 in.)
Diameter Standard 30 mm (1.18 in.)
Minimum 29 mm (1.14 in.)
Undercut depth Standard 0.6 mm (0.024 in.)
Minimum 0.2 mm (0.008 in.)
Brush length Standard 15.5 mm (0.61 in.)
Minimum 8.5 mm (0.3346 in.)
Starter assy (2.0kw)
Circle runout Maximum 0.03 mm (0.0012 in.)
Diameter Standard 32.3 mm (1.272 in.)
Minimum 30.5 mm (1.201 in.)
Undercut depth Standard 0.9 mm (0.035 in.)
Minimum 0.3 mm (0.012 in.)
Brush length Standard 14.5 mm (0.571 in.)
Minimum 9.0 mm (0.354 in.)
Starter assy (2.2kw)
Circle runout Maximum 0.05 mm(0.0020 in.)
Diameter Standard 35 mm (1.378 in.)
Minimum 34 mm (1.3386 in.)
Undercut depth Standard 0.7 mm (0.0276 in.)
Minimum 0.2 mm (0.079 in.)
Brush length Standard 16.5 mm (0.6496 in.)
Minimum 9.0 mm (0.3543 in.)
Generator assy (90A)
Rotor coil resistance at 20
C (68
F) 2.7 – 3.1

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

Slip ring diameter Standard 14.2 – 14.4 mm (0.559 – 0.567 in.)
Minimum 14 mm (0.551 in.)
Brush exposed length Standard 10.5 mm (0.4134 in.)
Minimum 4.5 mm (0.177 in.)

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 03–11
SERVICE SPECIFICATIONS – STARTING & CHARGING
0300R–04

TORQUE SPECIFICATION
Part Tightened N
m kgf
cm ft
lbf
Starter assy (1.4kw)
Commutator end frame assy x Starter yoke 1.5 15 13 in.
lbf
Starter housing x Magnetic switch 5.9 60 52 in.
lbf
Filed frame x Armature assembly 5.9 60 52 in.
lbf
Lead wire x Terminal C of starter 5.9 60 52 in.
lbf
Starter assy (2.0kw)
Commutator end frame assy x Starter housing 6.5 66 58 in.
lbf
Commutator end frame cover x Commutator end frame assy 1.7 17 15 in.
lbf
Starter housing x Magnet Starter Switch 5.0 51 44 in.
lbf
Lead wire x Terminal C of starter 8.0 82 71 in.
lbf
Starter assy (2.2kw)
Starter housing x Magnetic switch 9.3 95 82 in.
lbf
Filed frame x Armature assembly 12.7 130 9.0
Lead wire x Terminal C of starter 5.9 60 52 in.
lbf
Generator (90A)
Rectifire end frame x Drive end frame Nut A 4.5 46 39 in.
lbf
Nut B 5.4 55 47 in.
lbf
Rectifire holder x Rectifire end frame 2.9 30 26 in.
lbf
Voltage regulator x Rectifire holder 3.9 40 35 in.
lbf
Brush holder x Rectifier holder 2.0 20 18 in.
lbf
Rear end cover x Rectifier end frame Nut 4.4 45 39 in.
lbf
Bolt 3.9 39 35 in.
lbf
Generator pulley x Rotor 111 1,133 82
Generator assy (130 A)
Rectifire end frame x Drive end frame 5.8 59 51 in.
lbf
Generator pulley x Rotor 111 1,133 82
Brush holder x Rectifire end frame 1.8 18 16 in.
lbf
Rear end cover x Rectifire holder 4.6 47 41 in.
lbf

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 13–1
INTAKE – TURBOCHARGER ASSEMBLY (1CD–FTV)

TURBOCHARGER ASSEMBLY (1CD–FTV)

13034–01

COMPONENTS

Compressor Housing Sub–Assy

Compressor Inlet Elbow
Clamp Plate
23 (235, 17)

Gasket
4.7 (48, 42 in.·lbf) Actuator
Hose
Bearing Housing
Sub–Assy

Turbine Housing


Clip

8.3 (85, 74 in.·lbf)

V Band

7.8 (80, 69 in.·lbf)

w/ Bracket Actuator Assy

E–Ring

N·m (kgf·cm, ft·lbf) : Specified torque

Non–reusable part
A62601

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

13–2
INTAKE – TURBOCHARGER ASSEMBLY (1CD–FTV)
13035–01

OVERHAUL
1. REMOVE COMPRESSOR INLET ELBOW

(a) Remove 2 bolts and the compressor inlet elbow.

2. INSPECT TURBOCHARGER SUB–ASSY

Turn
(a) Inspect turbine shaft rotation
(1) Grasp the edge of the turbine shaft, and turn it.
(2) Check that the turbine shaft turns smoothly.
If the turbine shaft turns remarkably heavily or stuck, replace
the bearing housing. At that time, check also the interference
with the turbine housing and compressor housing.

B08025

(b) Inspect axial play of turbine shaft

(1) Using a dial indicator, insert the needle of the dial in-
dicator into the exhaust side.
(2) Move the turbine shaft in an axial direction, mea-
sure the axial play of the turbine shaft.
Move
Maximum oil clearance: 0.09 mm (0.0035 in.) or less
If the axial play is greater than maximum, replace the bearing
housing. At that time, check also the interference with the tur-
A62443 bine housing and compressor housing.

(c) Inspect radial play of turbine shaft

(1) Using SST and a dial indicator, insert the needle of
the dial indicator into the oil outlet hole, and set it in
SST the center of the turbine shaft.
SST 09992–00600
(2) Move the turbine shaft in a radial direction, measure
Move the radial play of the turbine shaft.
Maximum oil clearance: 0.16 mm (0.0063 in.) or less
B08048 If the radial play is greater than maximum, replace the bearing
housing. At that time, check also the interference with the tur-
bine housing and compressor housing.

(d) Inspect actuator and waste gate valve operation.

Open (1) Disconnect the actuator hose from the compressor
housing.
SST
(2) Using SST and a dial indicator, read the graduation
of SST when the actuator push rod moved 2 mm
(0.079 in.).
SST 09992–00242
Standard pressure:
2mm 129 – 140 kPa (1.32 – 1.43 kgf/cm2, 18.7 – 20.3 psi)
A62444

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 13–3
INTAKE – TURBOCHARGER ASSEMBLY (1CD–FTV)

(e) Move the actuator push rod, and check that the waste
gate valve is open.
If operation is not as specified, replace the actuator and/or tur-
bine housing.
NOTICE:
Never apply more than 161 kPa (1.64 kgf/cm2, 28.5 psi) of
pressure on the actuator.
(f) Reconnect the actuator hose to the compressor housing.

3. REMOVE W/BRACKET ACTUATOR ASSY

Torx Socket Wrench
(a) Remove the actuator hose.
(b) Using a torx socket wrench (T30), remove the 2 screws
holding the actuator to the compressor housing.
(c) Remove the E–ring holding the actuator push rod to the
waste gate valve link, and remove the actuator w/ brack-
et.

A62445

4. REMOVE COMPRESSOR HOUSING SUB–ASSY

(a) Place the matchmarks on the compressor housing and
the bearing housing.
(b) Remove the 5 bolts and 5 clamp plates.

Matchmarks
A62446

(c) Using a plastic–faced hammer, tap out the compressor

housing.
NOTICE:
Remove the compressor housing as straight as possible
and do not make the impeller wheel interfere with the com-
pressor housing.

A62447

5. REMOVE BEARING HOUSING SUB–ASSY

(a) Place the matchmarks on the V band, turbine housing
and bearing housing.
(b) Remove the flat head square neck bolt, nut and V band.

Matchmarks

A62448

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

13–4
INTAKE – TURBOCHARGER ASSEMBLY (1CD–FTV)

(c) Using a plastic–faced hammer, tap out the bearing hous-

ing.
NOTICE:
Remove the bearing housing as straight as possible and do
not make the turbine wheel interfere with the turbine hous-
ing.

B08059

6. CLEAN TURBINE HOUSING

(a) Spray the engine conditioner to the section where the car-
bon dirt is adhered.
NOTICE:
Be careful not to erase the matchmark of the turbine hous-
ing.

B08067

Seal Surface Shroud Section

(b) Using a wire brush, remove all the carbon dirt inside the
turbine housing.
NOTICE:
Clean the seal surface and shroud section shown in the il-
lustration sufficiently. And clean the waste gate valve seat
sufficiently, too.
HINT:
When the carbon dirt is heavily adhered, remove it using the
B08068 screwdriver and the like.

Inside Diameter Section (c) Clean the inside diameter section with a sandpaper (No.
100) until the metal surface can be seen.
NOTICE:
If the cleaning is not enough, installation of the bearing
housing becomes harder, so clean it sufficiently.

B08065

(d) Wash with compressed air or a steam cleaner.

NOTICE:
Wash sufficiently without leaving any irregular objects.

B08066

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 13–5
INTAKE – TURBOCHARGER ASSEMBLY (1CD–FTV)

(e) Check that there is no severe damage on the seal surface

Seal Surface
with the bearing housing.
(f) Check that there is no bore made by the interference with
the turbine wheel in the shroud section.
If the turbine housing is having remarkable damage or bore, re-
place the turbine housing and bearing housing.

Shroud Section
B08064

(g) Move the waste gate valve link and check that it runs
smoothly without sticking.
If the link is bad running, clean again. If it is bad running, even
after cleaning, replace the turbine housing.

B08069

7. CLEAN COMPRESSOR HOUSING SUB–ASSY

(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the compres-
sor housing and bearing housing.
(1) Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces.
(2) Thoroughly clean all components to remove all the
A62449 loose material.
(3) Using a non–residue solvent, clean both sealing
surfaces.
(b) Wipe off the dirt from the inside of the housing with a shop
rag.
(c) Check that there is no severe interference with the impel-
ler wheel.
If it is having bur made by a slight interference damage, remove
it with a sandpaper (No. 400) and blow with compressed air.

8. INSTALL BEARING HOUSING SUB–ASSY

(a) Align the pin of the turbine housing with the pin hole of the
bearing housing.

A62450

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

13–6
INTAKE – TURBOCHARGER ASSEMBLY (1CD–FTV)

(b) Install the bearing housing to the turbine housing.

NOTICE:

Install the bearing housing straight, and be careful
not to damage the turbine wheel.

In case of having difficulty of pressing in the bearing
housing to install with a hand due to hard engage-
ment, apply the procedure (c).
HINT:
A62451 Apply a little penetrate rust prevention lubricant onto the en-
gagement section to make installation easier.
(c) In case that the engagement of the bearing housing is
hard, using SST and a press, install the bearing housing
while checking the smooth rotation of the impeller wheel.
SST 09350–32014 (09351–32070)
NOTICE:

Do not hold the turbine housing with the stud bolts.

Be sure to install the bearing housing straight without
tilting as the shaft may bent and cause the irregular
A62452 noise.

Press in the bearing housing slowly. When the rota-
tion of the impeller wheel becomes heavy, return the
press immediately and do the operation again.

After installation, check that the turbine shaft turns
smoothly.

(d) Place a new and old (used) V bands in line, then reprint
Old V Band the matchmark position on the old V band to the new one.

New V Band
Matchmark
A62960

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 13–7
INTAKE – TURBOCHARGER ASSEMBLY (1CD–FTV)

(e) Align the matchmarks on the new V band, turbine housing

and bearing housing, and temporarily torque with a new
bolt and nut.
Torque: 8.3 N
m (85 kgf
cm, 74 in.
lbf)
HINT:
When the marks are erased, make the matching openings meet
at the position shown in the illustration.
Matchmarks
A62448

Approx. 38

B08239

(f) Using a brass bar and hammer, hit 2 or 3 times lightly at

each place in order of 1 through 5.
(g) Torque the bolt and nut more.
5 Torque: 8.3 N
m (85 kgf
cm, 74 in.
lbf)
4 (h) Using a brass bar and hammer, hit 2 or 3 times lightly at
2 each place of 1 and 4.
60_ 3
(i) Torque the bolt and nut completely.
1 60_ Torque: 8.3 N
m (85 kgf
cm, 74 in.
lbf)
A62453

Seal 9. INSTALL COMPRESSOR HOUSING SUB–ASSY

Seal Width
Packing (a) In case of reusing the compressor housing and bearing
0.1 – 0.2 mm
housing:
(1) Apply seal packing to the compressor housing as
shown in the illustration.
Seal packing: Part No. 08826–00080 or equivalent
NOTICE:
Avoid applying an excessive amount to the surface.
A62454 S Install a nozzle that has been cut to a 0.1 – 0.2
mm (0.004 – 0.008 in.) opening.
S Parts must be assembled within 7 minutes of
application. Otherwise the material must be
removed and reapplied.
S Immediately remove nozzle from the tube
and reinstall the cap.

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

13–8
INTAKE – TURBOCHARGER ASSEMBLY (1CD–FTV)

Matchmarks (2) Align the matchmarks on the compressor housing

and bearing housing, and install them.
NOTICE:
S Do not make the impeller wheel interfere with the
compressor housing.
S Check that the turbine shaft turns smoothly.

A62455

(3) Using a steel square and protractor, check the

49_
installation angle of the outlet port of the compres-
sor housing shown in the illustration.
Cut (4) Install the 5 clamp plates and bolts.
Torque: 4.7 N
m (48 kgf
cm, 42 in.
lbf)
Protractor
(b) In case of using a new compressor housing and/or bear-
Steel Square ing housing :
(1) Temporally install the compressor housing on the
A62456 bearing housing, make the installation angle of the
outlet port of the compressor housing meet at the
position shown in the illustration, and place the
matchmarks.
(2) Remove the compressor housing.
(3) The following procedure is the same as that of reus-
ing the compressor housing and/or bearing hous-
ing.

10. INSTALL W/BRACKET ACTUATOR ASSY

(a) Using a torx wrench (T30), install the actuator w/ bracket
SST to the compressor housing with the 2 screws.
Torque: 7.8 N
m (80 kgf
cm, 69 in.
lbf)
(b) Using SST, move the actuator push rod.
SST 09992–00242
NOTICE:
Never apply more than 197 kPa (2.01 kgf/cm2, 28.5 psi) of
A62457 pressure on the actuator.
(c) Connect the actuator push rod to the waste gate valve link
with a new E–ring.
NOTICE:
Do not use a hammer, etc. to force the actuator push rod
onto the waste gate valve link.
(d) Remove the SST.
(e) Connect the actuator hose.
11. INSTALL COMPRESSOR INLET ELBOW

Torque: 23 N
m (235 kgf
cm, 17 ft
lbf)

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–1
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

PARTIAL ENGINE ASSY (1CD–FTV)

140L3–01

COMPONENTS

 Gasket Oil Filler Cap Sub–Assy

18 (184, 13) 22 (224, 16)  Nozzle Holder Seal
Nozzle Leakage 13 (135, 10)
Pipe Assy
Cylinder Head
Cover Sub–Assy
27 (275, 20)
 Gasket  Nozzle Holder Gasket
Washer
Injector Assy
Gasket
Nozzle Holder Clamp  Fuel Injector
Back–Up Ring No. 1
 O–Ring 20 (204, 15)
 Injection Nozzle Seat
20 (204, 15)

Camshaft Bearing Cap

See page 14–3 Camshaft

Sub–Assy No.2
1st 45 (460, 33)
2nd Turn 90
Camshaft
3rd Turn 90
Sub–Assy No.1
x 18
4th Turn 90

Plate Washer Camshaft Carrier

8.8 (90, 78 in.·lbf)

Cylinder Head
Camshaft Timing Pulley Sub–Assy
 Oil Seal

 Cylinder Head Gasket

88 (899, 65)

Plate Washer
Camshaft Oil
Seal Retainer
35 (357, 26)

Timing Belt Idler Sub–Assy No. 1

Timing Belt Idler Sub–Assy No. 2

47 (475, 34)

Crankshaft Timing Pulley

N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part A62602

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–2
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

Gasket
Water Pump Assy
Cylinder Block Water
Drain Cock Sub–Assy
Engine Rear Oil
Seal Retainer

Oil Seal

31 (320, 23)

Gasket
Oil Pump Assy
x6

7.4 (75, 65 in.·lbf)

30 (310, 22)
21 (214, 15)
Oil Check Valve
Oil Pan Sub–Assy Sub–Assy

Oil Seal 31 (320, 23)
11 (112, 8)

x 19
11 (112, 8)
21 (214, 15)

Gasket
Oil Strainer Sub–Assy
Oil Pan Insulator
13 (133, 10 )
7.5 (77, 66 in.·lbf)

21 (209, 15)

Gasket

Drain Plug Oil Pan Sub–Assy No. 2

34 (350, 25)

12 (119, 9)
N·m (kgf·cm, ft·lbf) : Specified torque

Non–reusable part A62603

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–3
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)
140L4–01

OVERHAUL
1. REMOVE OIL FILLER CAP SUB–ASSY

2. REMOVE NOZZLE HOLDER SEAL

(a) Using a screwdriver, pry out the 4 nozzle holder seals.

A56691

3. REMOVE CYLINDER HEAD COVER SUB–ASSY

(a) Remove the 10 bolts, cylinder head cover and gasket.

A62591

4. REMOVE NOZZLE LEAKAGE PIPE ASSY

(a) Using a hexagon wrench (6mm), remove 4 hollow screws.

(b) Remove the union bolt, nozzle leakage pipe and 5 gas-
kets from the cylinder head and injector.

A56692

5. REMOVE NOZZLE HOLDER CLAMP

(a) Remove the 4 bolts, 4 washers and 4 nozzle holder

clamps.

A56693

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–4
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

6. REMOVE INJECTOR ASSY

(a) Remove the 4 injectors from the cylinder head.

HINT:
Arrange the injectors in correct order.

A56694

7. REMOVE CAMSHAFT TIMING PULLEY

(a) Using SST, remove the pulley bolt.

SST 09960–10010 (09962–01000, 09963–01000)

SST

A62592

Hexagon 8. REMOVE TIMING BELT IDLER SUB–ASSY NO.1

Wrench
(8mm) (a) Using hexagon wrench (8mm), remove the idler pulley
shaft, idler pulley and plate washer.

A57095

9. REMOVE TIMING BELT IDLER SUB–ASSY NO.2

10. REMOVE CRANKSHAFT TIMING PULLEY

(a) If the pulley cannot be removed by hand, use SST to re-

move the timing pulley.
SST 09950–50013 (09951–05010, 09952–05010,
SST 09953–05010, 09953–05020, 09954–05021)

A57096

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–5
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

11. REMOVE CAMSHAFT OIL SEAL RETAINER

(a) Remove the 4 bolts.

(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and camshaft
bearing cap.

A57097

12. REMOVE WATER PUMP ASSY

(a) Remove the 7 bolts, water pump and gasket.

A57098

13. REMOVE CAMSHAFT SUB–ASSY, NO.2

4 6
11 5 (a) Uniformly loosen and remove the 15 bearing cap bolts in
12
14
15 several passes in the sequence shown.
8
9 (b) Remove the 5 bearing caps.
3 10
7 (c) Remove the camshaft No. 2.
2 13
1

A09650

14. REMOVE CAMSHAFT SUB–ASSY, NO.1

(a) Remove the camshaft from the cylinder head.

(b) Remove the camshaft carrier from the cylinder head.

A09624

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–6
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

15. REMOVE CYLINDER HEAD SUB–ASSY

8 16 13 5
2 10 18 11 3
(a) Uniformly loosen the 18 cylinder head bolts in several
passes in the sequence shown. Remove the 18 cylinder
head bolts and plate washers.
NOTICE:
Cylinder head warpage or cracking could result from re-
4 12 17 9 1 moving bolts in incorrect order.
6 14 15 7
A09566

(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a bench.
HINT:
Pry If the cylinder head is lift off, pry between the cylinder head and
cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
A09563 der head and cylinder block.

16. REMOVE OIL PAN SUB–ASSY NO.2

(a) Remove the 16 bolts and 3 nuts.

A56695

(b) Insert the blade of SST between the No. 1 and No. 2 oil
pans, and cut off the applied seal and remove the No. 2
oil pan.
SST 09032–00100
NOTICE:
SST Be careful not to damage the contact surfaces of the No. 1
SST and No. 2 oil pans.

B08601

17. REMOVE OIL STRAINER SUB–ASSY

(a) Remove the 2 bolts, 2 nuts, oil strainer and gasket.

A56696

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–7
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

18. REMOVE OIL PAN SUB–ASSY

(a) Remove the 19 bolts and 3 nuts.

A56697

(b) Using a screwdriver, remove the oil pan by prying the por-
tions between the cylinder block and No. 1 oil pan.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and No. 1 oil pan.

A56698

19. REMOVE OIL PUMP ASSY

(a) Remove the 9 bolts.

(b) Remove the oil pump by prying a screwdriver between the
oil pump and main bearing cap.
(c) Remove the gasket.

A56699

20. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 6 bolts.

(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.

A09518

21. REMOVE OIL CHECK VALVE SUB–ASSY

(a) Using hexagon wrench (8mm), remove the pressure

valve and gasket.
Hexagon
Wrench
(8mm)

A09519

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–8
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

22. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB–ASSY

23. REMOVE CAMSHAFT OIL SEAL

(a) Using a screwdriver and a hammer, tap out the oil seal.

A09619

24. INSTALL CAMSHAFT OIL SEAL

SST
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the camshaft oil seal retainer edge.
SST 09223–46011

A09620

25. REMOVE CRANKSHAFT SEAL

(a) Using a screwdriver and a hammer, tap out the oil seal.

B07976

26. INSTALL CRANKSHAFT SEAL

SST
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump edge.
SST 09316–60011 (09316–00011, 09316–00021)

A56700

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–9
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

27. REMOVE ENGINE REAR OIL SEAL

(a) Using a screwdriver and a hammer, tap out the oil seal.

A09449

28. INSTALL ENGINE REAR OIL SEAL

SST
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the rear oil seal retainer edge.
SST 09223–15030, 09950–70010 (09951–07100)

A09451

29. INSPECT CYLINDER HEAD SET BOLT

(a) Using vernier calipers, measure the tension portion diam-

eter of the bolt.
Standard outside diameter:
10.75 – 11.00 mm (0.4232 – 0.4331 in.)
Minimum outside diameter: 10.40 mm (0.4094 in.)
Measuring Point If the diameter is less than minimum, replace the bolt.
16 mm (0.63 in.) A09555

Seal Packing
30. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB–ASSY

(a) Apply seal packing 2 or 3 threads.

Seal packing: Part No. 08826–00100 or equivalent

P12477

(b) Install the drain union.

Torque: 29 N
m (291 kgf
cm, 21 ft
lbf)
HINT:
Upper After applying the specified torque, if the drain pipe of the drain
Front union is not at the position shown in the illustration, rotate the
drain union further clockwise and make the drain pipe face
downward.
60

A09522

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–10
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

31. INSTALL OIL CHECK VALVE SUB–ASSY

(a) Using hexagon wrench (8mm), install a new gasket and

the pressure valve.
Torque: 30 N
m (310 kgf
cm, 22 ft
lbf)
Hexagon
Wrench
(8mm)

A09519

32. INSTALL ENGINE REAR OIL SEAL RETAINER

(a) Apply seal packing to the oil seal retainer as shown in the
Seal Width illustration.
2 – 3 mm
Seal packing: Part No. 08826–00080 or equivalent
NOTICE:
S Install a nozzle that has been cut to a 2 – 3 mm (0.08
– 0.12 in.) opening.
A09476 S Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
S Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil seal retainer with 6 bolts. Uniformly tighten
the bolt in several passes.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)

New Gasket 33. INSTALL OIL PUMP ASSY

Seal Width
2 – 4 mm
(a) Apply seal packing to the oil pump as shown in the illustra-
Seal tion.
Packing Seal packing: Part No. 08826–00080 or equivalent
NOTICE:
S Avoid applying an excessive amount to the surface.
S Install a nozzle that has been cut to a 2 – 4 mm (0.08
A56701 – 0.16 in.) opening
S Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
S Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install a new gasket to the oil pump.

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–11
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

(c) Pour in 0.5 cm3 (0.03 cu in.) or more of engine oil into the
bushing of the cylinder block.
(d) Apply engine oil to the cylinder block side where it con-
tacts with the oil pump driven rotor.

B08024

(e) Install the oil pump with the 9 bolts.

Torque: 31 N
m (320 kgf
cm, 23 ft
lbf)

A57099

(f) Measure the oil pump rotating torque

(1) Check that the pump rotates smoothly without ab-
normal noise.
(2) Using a torque wrench, check the pump rotating
torque.
Rotating torque: 3.0 N
m (30 kgf
cm, 26 in.
lbf) or less

A56702

34. INSTALL OIL PAN SUB–ASSY

B (a) Apply seal packing to the No. 1 oil pan as shown in the
illustration.
A Seal packing: Part No. 08826–00080 or equivalent
NOTICE:
Seal Width
S Install a nozzle that has been cut to a 4 – 7 mm (0.16
4 – 7 mm
– 0.28 in.) opening.
S Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
A B S Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil pan with 19 bolts and 3 nuts.
Torque:
11 N
m (112 kgf
cm, 8 ft
lbf) for 10 mm head bolt and
nut
21 N
m (210 kgf
cm, 15 ft
lbf) for 12 mm head bolt
A56703 42 N
m (429 kgf
cm, 31 ft
lbf) for 14 mm head bolt

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–12
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

35. INSTALL OIL STRAINER SUB–ASSY

(a) Install a new gasket and the oil strainer with the 2 bolts
and 2 nuts.
Torque:
21 N
m (210 kgf
cm, 15 ft
lbf) for bolt
13 N
m (135 kgf
cm, 10 ft
lbf) for nut

A56696

36. INSTALL OIL PAN SUB–ASSY NO.2

A
A (a) Apply a seal packing to the oil pan as shown in the illustra-
tion.
Seal Width
B Seal packing: Part No. 08826–00080 or equivalent
4 – 7 mm
B
NOTICE:
S Install a nozzle that has been cut to a 4 – 7 mm (0.16
– 0.28 in.) opening.
A56704 S Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
S Immediately remove nozzle from the tube and rein-
stall the cap.
(b) Install the oil pan with 16 bolts and 3 nuts. Uniformly tight-
en the bolts and nuts in several passes.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)

Measuring Tip 37. INSTALL CYLINDER HEAD SUB–ASSY

(a) Check piston protrusions for each cylinder.

(1) Find where the piston head protrudes most by slow-
ly turning the crankshaft clockwise and counter-
Protrusion clockwise.
(2) Measure each cylinder at 2 places as shown in the
illustration, marking a total of 8 measurements.
A57100 (3) For the piston protrusion valve of each cylinder, use
the average of the 2 measurements of each cylin-
der.
Front
Protrusion: 0.165 – 0.425 mm (0.0065 – 0.0168 in.)

Measuring Point
A56706

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–13
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

(b) Select a new cylinder head gasket.

HINT:
A There are 5 sizes of new cylinder head gaskets, marked ”A”,
B ”B”, ”C”, ”D”, or ”E” according.
New installed cylinder head gasket thickness:
C
A 0.85 – 0.95 mm (0.0335 – 0.0374 in.)
Front D
B 0.90 – 1.00 mm (0.0354 – 0.0394 in.)
E C 0.95 – 1.05 mm (0.0374 – 0.0413 in.)
A09570 D 1.00 – 1.10 mm (0.0394 – 0.0433 in.)
E 1.05 – 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.

A56055

(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-
(A) (A) (A) (A) quence shown.
(B) 11 (B) 3 (B) 6 (B) 14 (B)
17 9 1 8 16 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.)
15 7 2 10 18
(B) 13 (B) 5 (B) 4 (B) 12 (B) If any of the cylinder head bolt does not meet the torque specifi-
(A) (A) (A) (A) A09564 cation, replace the cylinder head bolts.

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–14
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

90
(4) Mark the front of the cylinder head bolt with paint.
90

90
(5) Retighten the cylinder head bolts additional 90
in
90
90

90
the numerical order shown.
(6) Retighten the cylinder head bolts additional 90
in
Front
the numerical order shown.
Painted (7) Retighten the cylinder head bolts additional 90
in
Mark the numerical order shown.
(8) Check that the painted mark is at the intake man-
A09565 ifold side now.

38. INSTALL CAMSHAFT SUB–ASSY, NO.1

(a) Place the camshaft carrier in position on the cylinder
head.

A09624

(b) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(c) Place the intake camshaft on top of the camshaft carrier
as shown in the illustration so that the No. 3 and No. 4 of
cylinder cam lobes face downward.

A09625

Alignment Mark 39. INSTALL CAMSHAFT SUB–ASSY, NO.2

(a) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(b) Engage the exhaust camshaft gear to the intake cam-
shaft gear by matching the alignment marks on each
gear.
(c) Roll down the exhaust camshaft onto the bearing journals
while engaging gears with each other.
A09626

(d) Install the camshaft bearing caps.

Seal Packing
(1) Remove any old packing (FIPG) material from the
No.5 camshaft bearing cap.
(2) Apply seal packing to the No. 5 camshaft bearing
cap as shown in the illustration.
Seal packing: Part No. 08826–00080 or equivalent

A09601

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–15
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

(3) Place the 5 bearing caps in their proper locations.

A09627

(4) Install and uniformly tighten the 15 bearing cap

11 10
5 12 bolts in several passes and in the sequence shown.
4
2
1 Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
8
7
13 6
9 3
14
15

A09650

Upward 40. INSPECT VALVE CLEARANCE

Cam Lobe (a) Turn the crankshaft so that the cam lobe of the camshaft
on the inspecting valve points upward.
(b) Using a feeler gauge, measure the clearance between
the valve lifter and the camshaft.
(c) Measure the clearance at 16 places.
Clearance (d) Record the out–of–specification valve clearance mea-
surements. They will be used later to determine the re-
A09687 quired replacement adjusting shim.
Valve clearance (Cold) :
Intake 0.20 – 0.30 mm (0.008 – 0.012 in.)
Exhaust 0.35 – 0.45 mm (0.014 – 0.018 in.)

Upward 41. ADJUST VALVE CLEARANCE

Cam Lobe (a) Remove the adjusting shim.
(1) Turn the crankshaft so that the cam lobe of the cam-
shaft on the adjusting valve points upward.
(2) Position the notch of the valve lifter facing the intake
manifold side.
Intake
Manifold
Notch Side
A09617

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–16
ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

(3)Using SST (A), press down the valve lifter and place
SST (A)
SST (B) between the camshaft and valve lifter. Re-
SST (B) move SST (A).
SST 09248–55050 (09248–05510, 09248–05520)
HINT:
Apply SST (B) on the side marked with ”11”.

A62959

(4) Remove the adjusting shim with a small screwdriver

and magnetic finger.

Magnetic
Finger

A09615

(b) Determine the replacement adjusting shim size by follow-

ing the formula:
(1) Using a micrometer, measure the thickness of the
removed shim.
(2) Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
HINT:
S T ........... Thickness of removed adjusting shim
A54826 S A ........... Measured valve clearance
S N ........... Thickness of new adjusting shim
S Intake: N = T + (A – 0.25 mm (0.010 in.))
S Exhaust: N = T + (A – 0.40 mm (0.016 in.))
(3) Select a new shim with a thickness as close as pos-
sible to the calculated value.
HINT:
Shims are available in 17 sizes in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).

(c) Install a new adjusting shim.

SST (A) (1) Place a new adjusting shim on the valve lifter.
(2) Using SST (A), press down the valve lifter and re-
SST (B)
move SST (B).
SST 09248–55050 (09248–05510, 09248–05520)
(d) Recheck the valve clearance.

A09686

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

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)

A57098

43. INSTALL CAMSHAFT OIL SEAL RETAINER

Seal Width
2 – 4 mm
(a) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826–00080 or equivalent
NOTICE:
S Install a nozzle that has been cut to a 2 – 4 mm (0.08
Seal Packing – 0.16 in.) opening.
A09600 S Parts must be assembled within 15 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
S 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

Inward
(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
Angle Sensor the angle sensor inward.
SST 09223–46011
SST

A57101

45. INSTALL TIMING BELT IDLER SUB–ASSY NO.2

(a) Install the idler pulley with the bolt.

Turn
Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
(b) Check that the idler pulley moves smoothly.

A57102

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

Hexagon 46. INSTALL TIMING BELT IDLER SUB–ASSY NO.1

Wrench
(8mm) (a) Using an hexagon wrench (8mm), install the plate washer
and idler pulley with the idler pulley shaft.
Plate Washer
Torque: 35 N
m (350 kgf
cm, 25 ft
lbf)
(b) Check that the pulley bracket moves smoothly.

A57103

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.
SST (c) Using SST, install the pulley bolt.
SST 09960–10010 (09962–01000, 09963–01000)
A62592 Torque: 88 N
m (899 kgf
cm, 65 ft
lbf)

48. INSTALL INJECTOR ASSY

(a) Install 4 new nozzle seats to the cylinder head.

B08252

Spring (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.

Convex

B09792

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

(e) Meet the injector positioning convex to the positioning

concave at the cylinder head side and install the injector
to the cylinder head.
NOTICE:
S At this time, insert the injector until it touches the
nozzle sheet surface.
Convex
S 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.
S During the time after equipping the head cover and
before installing the injection pipe, install the irregu-
lar object prevention cover.
S Do not exchange the injector cylinder.
(f) Place the 4 nozzle holder clamps to each injector.

Concave

B09793

49. INSTALL NOZZLE HOLDER CLAMP

Upward

(a) Set the washer on the nozzle holder clamp as shown in

the illustration.

B08249

(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.
B08253

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

50. INSTALL NOZZLE LEAKAGE PIPE ASSY

90

(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)
180
(e) Check that there is no leak from nozzle leakage pipe con-
nection.

B08307

(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

B08311

(3) Remove the plug, gasket, spring and ball.

Overflow Screw
(4) Install the plug with the gasket to the overflow
Spring screw.
Plug 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.
Ball Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
Gasket (6) Apply a light coat of soapy water (any fluid to detect
B08312 fuel leakage) on the nozzle leakage pipe connec-
tion.

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ENGINE MECHANICAL – PARTIAL ENGINE ASSY (1CD–FTV)

New Gasket (7) Using SST (turbocharger pressure gauge), apply

Union Bolt the SST to the fuel return side of the No. 2 nozzle
leakage pipe, and maintain 100 kPa (1 kgf/cm2,
14.5 psi) of pressure for 600 seconds to check that
there are no bubbles from the soap–applied places.
SST 09992–00242
Hollow (8) After checking fuel leaks, wipe off soapy water from
Screw nozzle leakage pipe connection.
(9) Remove SST, check valve, No. 2 nozzle leakage
pipe and gasket.

SST
No. 2 Nozzle
Check Leakage Pipe
Valve

New Gasket
A56050

Check No. 2 Nozzle (10) Reinstall the No. 2 nozzle leakage pipe and a new
Valve Leakage Pipe gasket with the check valve.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
HINT:
Never reinstall the disassembled check valve on the engine.
(11) Reconnect the fuel hose to the No. 2 nozzle leak-
age pipe.

New Gasket
B08328

: Seal Packing 51. INSTALL CYLINDER HEAD COVER SUB–ASSY

(a) Remove any old packing (FIPG) material.

(b) Apply seal packing to the cylinder head.
Seal packing: Part No. 08826–00080 or equivalent
(c) Install the gasket to the head cover.
(d) Install the cylinder head cover with 10 bolts.
Torque: 13 N
m (135 kgf
cm, 10 ft
lbf)
A09663 (e) Install 4 new nozzle holder seals.

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

CYLINDER HEAD ASSY (1CD–FTV)

140L5–01

COMPONENTS

Valve Adusting Shim

Valve Lifter
Valve Adusting Shim
Valve Spring Retainer Lock
Valve Lifter
Valve Spring Retainer
Valve Spring Retainer Lock
Inner Compression Spring
Valve Spring Retainer
Inner Compression Spring
Valve Stem Oil O Seal or Ring

Valve Stem Oil
O Seal or Ring Valve Spring Seat Plate Washer
Valve Spring Seat
Plate Washer
Semicircular Plug

Valve Guide Bushing

Valve Guide Bushing

Intake Valve

Exhaust Valve

Non–reusable part
A62604

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)
140DR–03

OVERHAUL
1. REMOVE VALVE LIFTER

HINT:
Arrange the valve lifters in the correct order.

2. REMOVE INTAKE VALVE

SST
(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.

A56671

3. REMOVE EXHAUST VALVE

(a) Using SST, compress the valve spring and remove the 2
SST
keepers.
SST 09202–70020 (09202–00010)
(b) Remove the spring retainer, valve spring and valve.

A62594

4. REMOVE VALVE STEM OIL O SEAL OR RING

(a) Using needle–nose pliers, remove the oil seal.

A09561

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.

A09676

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

6. REMOVE SEMICIRCULAR PLUG

A62595

7. REMOVE W/HEAD TAPER SCREW PLUG NO.1

(a) Using a hexagon wrench (6mm), remove the 3 plugs.

SST 99999–70037

8. INSPECT CYLINDER HEAD FOR FLATNESS

(a) Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side 0.08mm (0.0031in.)
Cylinder Block Side Intake manifold side 0.20mm (0.0079in.)
Exhaust manifold side 0.20mm (0.0079in.)

Intake Manifold Side

Exhaust Manifold Side

A56049

9. INSPECT CYLINDER HEAD FOR CRACKS

(a) Using dye penetrant, check the intake ports, exhaust
ports and cylinder block contact surface for cracks.

A09534

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

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.)

EM2534

(b) Using a micrometer, measure the diameter of the valve

stem.
Valve stem diameter:
5.970 – 5.985 mm (0.2350 – 0.2356 in.)

Z00052

(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.)

Margin
Thickness

A56051

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.)

EM2534

(b) Using a micrometer, measure the diameter of the valve

stem.
Valve stem diameter:
5.960 – 5.975 mm (0.2346 – 0.2352 in.)

Z00052

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

(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.)

Margin
Thickness

A56051

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.)

EM0801

(b) Using a steel square, measure the deviation of the valve

Deviation spring.
Maximum deviation: 2.0 mm (0.079 in.)

A56052

(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.

EM0281

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.)

A09539

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

(b) Subtract the valve stem diameter measurement from the

guide bushing inside diameter measurement.
Standard oil clearance:
Intake 0.025 – 0.060 mm (0.0010 – 0.0024 in.)
Exhaust 0.035 – 0.070 mm (0.0014 – 0.0028 in.)

Maximum oil clearance:

Intake 0.08 mm (0.0031 in.)
Exhaust 0.10 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)

SST
A56674

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)

SST

A56675

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

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.).
A09543 HINT:
Bushing bore diameter
Bushing size
mm (in.)
10.985 – 11.006
Use STD
(0.4325 – 0.4333)
11.035 – 11.056
Use O/S 0.05
(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
SST
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.)

SST
A09541

(d) Using a sharp 6 mm reamer, ream the guide bushing to

Sharp 6 mm
obtain the standard specified clearance between the
Reamer
guide bushing and valve stem.
Standard oil clearance:
0.025 – 0.060 mm (0.0010 – 0.0024 in.)

A09540

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

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.).
A56676 HINT:
Bushing bore diameter
Bushing size
mm (in.)
10.985 – 11.006
Use STD
(0.4325 – 0.4333)
11.035 – 11.056
Use O/S 0.05
(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 SST 09201–10000 (09201–01060), 09950–70010
(09951–07100)
Protrusion height:
9.65 – 10.05 mm (0.3799 – 0.3957 in.)

A56677

Sharp 6 mm (d) Using a sharp 6 mm reamer, ream the guide bushing to

Reamer 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.)

A56678

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.

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360
around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360
around the valve seat, the
Width
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
A56053 valve face with the following width.
Intake 1.2 – 1.6 mm (0.047 – 0.063 in.)
Exhaust 1.6 – 2.0 mm (0.063 – 0.079 in.)

19. REPAIR INTAKE VALVE SEATS

NOTICE:
25
Take off a cutter gradually to make smooth valve seats.
45

(a) If the seating is too high on the valve face, use 25
and
45
cutters to correct the seat.

Z03988

(b) If the seating is too low on the valve face, use 70
and
45
cutters to correct the seat.
45

70

Contacting Width
A57105

(c) Hand–lap the valve and valve seat with an abrasive com-
pound.
(d) Check the valve seating position.
SST 99999–60014

A09537

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

20. REPAIR EXHAUST VALVE SEATS

NOTICE:
25
Take off a cutter gradually to make smooth valve seats.
45

(a) If the seating is too high on the valve face, use 25
and
45
cutters to correct the seat.

Z03988

(b) If the seating is too low on the valve face, use 65
and 45

45
cutters to correct the seat.
65

A57106

(c) Hand–lap the valve and valve seat with an abrasive com-
pound.
(d) Check the valve seating position.

A56679

21. INSPECT VALVE LIFTER

(a) Using a micrometer, measure the lifter diameter.

Lifter diameter:
27.975 – 27.985 mm (1.1014 – 1.1018 in.)

EM2196

22. INSPECT VALVE LIFTER OIL CLEARANCE

(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter diameter:
28.010 – 28.031 mm (1.1028 – 1.1036 in.)
(b) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
A09544 0.025 – 0.056 mm (0.0010 – 0.0022 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

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.
A09550

(b) Using a micrometer, measure the cam lobe height.

Standard cam lobe height:
Intake 46.57 – 46.67 mm (1.8335 – 1.8374 in.)
Exhaust 47.52 – 47.62 mm (1.8709 – 1.8748 in.)

Minimum cam lobe height:

Intake 46.10 mm (1.8150 in.)
Exhaust 47.05 mm (1.8524 in.)
If the cam lobe height is less than minimum, replace the cam-
A09551
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.

A09552

24. INSPECT CAMSHAFT OIL CLEARANCE

Plastigage (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-
A09546 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.

A09557

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

(g) Measure the Plastigage at its widest point.

Standard oil clearance:
0.025 – 0.062 mm (0.0010 – 0.0024 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. if necessary, replace the bearing caps, camshaft carrier
and cylinder head as a set.
(h) Completely remove the Plastigage.
A09547

25. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Install the camshaft.
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.035 – 0.110 mm (0.0014 – 0.0043 in.)
If the thrust clearance is not as specified, replace the camshaft.
If necessary, replace the bearing caps, camshaft carrier and
A09545 cylinder head as a set.

26. INSPECT CAMSHAFT GEAR BACKLASH

(a) Install the camshafts.
(b) Using a dial indicator, measure the backlash.
Standard backlash:
0.014 – 0.070 mm (0.0006 – 0.0028 in.)
Maximum backlash: 0.17 mm (0.0067 in.)
If the backlash is greater then maximum, replace the cam-
shafts.
A09548

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

27. INSTALL TIGHT PLUG

(a) Apply adhesive around tight plugs.
Adhesive: Part No.08833 – 00070, THREE BOND 1324
or equivalent
(b) Using SST, tap in the tight plugs as shown in the illustra-
tion.
SST 09950–60010 (09951–00210), 09950–70010
(09951–07100)

Cylinder Block Side:

Intake Side:

Front Side: Rear Side:

1.5 mm

A56680

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

28. INSTALL RING PIN

(a) Using a plastic–faced hammer, tap in new ring pins to the
specified protrusion height.

Upper Side:

8 mm Protrusion Height: 3 mm

11 mm

Intake Side:

8 mm Protrusion Height: 3 mm

12.5 mm

A56681

29. INSTALL STRAIGHT PIN

(a) Using a plastic–faced hammer, tap in the straight pin.

Front Side: Upper Side:

11 mm 16 mm

7 mm 7 mm

Protrusion Height: 6 mm Protrusion Height: 11 mm

A56682

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

30. INSTALL STUD BOLT

(a) Install the stud bolts as shown in the illustration.
Torque:
Bolt A 8.8N
m (90 kgf
cm, 78 in.
lbf)
Bolt B 12N
m (120 kgf
cm, 9 ft
lbf)
Bolt C 8.8N
m (90 kgf
cm, 78 in.
lbf)

Intake Side: Rear Side:

36 mm 34 mm

A (M8) C (M8)
Exhaust Side:

64 mm

B (M10)

A56683

31. INSTALL W/HEAD TAPER SCREW PLUG NO.1

(a) Apply adhesive to the plugs end.

Adhesive: Part No. 08833 – 00070, THREE BOND 1324 or equivalent
(b) Using a hexagon wrench (6 mm), install the 3 plugs.
Torque:25N
m (255 kgf
cm, 18 ft
lbf)
SST 99999–70037

32. INSTALL SEMICIRCULAR PLUG

(a) Apply seal packing to the semi–circular plug grooves.

Seal packing: Part No. 08826 – 00080 or equivalent
(b) Install the semi–circular plug to the cylinder head.

A62596

33. INSTALL VALVE SPRING SEAT PLATE WASHER

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

34. INSTALL VALVE STEM OIL O SEAL OR RING

(a) Apply a light coat of engine oil on the valve stem.

(b) Install a new oil seal on the valve guide bushing.

A56032

35. INSTALL INTAKE VALVE

(a) Install the valve, valve spring, and spring retainer.

A56684

(b) Using SST, compress the valve spring and place the 2
SST
keepers around the valve stem.
SST 09202–70020 (09202–00010)

A62597

(c) Using a plastic–faced hammer and the valve stem (not in

use) tip wound with vinyl tape, lightly tap the valve stem
tip to ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.

A62598

36. INSTALL EXHAUST VALVE

(a) Install the valve, valve spring, and spring retainer.

A62599

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ENGINE MECHANICAL – CYLINDER HEAD ASSY (1CD–FTV)

(b) Using SST, compress the valve spring and place the 2
SST
keepers around the valve stem.
SST 09202–70020 (09202–00010)

A56672

(c) Using a plastic–faced hammer and the valve stem (not in

use) tip wound with vinyl tape, lightly tap the valve stem
tip to assure proper fit.
NOTICE:
Be careful not to damage the valve stem tip.

A56685

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ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

CYLINDER BLOCK (1CD–FTV)

140L6–01

COMPONENTS

No.1 Piston Ring

No.2 Piston Ring
Oil Ring
Coil

Piston
Snap Ring

Piston Pin

Snap Ring

Connecting Rod

9.0 (92, 78 in.·lbf)

Cylinder Block
Oil Orifice

Cylinder Block

Sub–assy
Upper Main Bearing
Oil Nozzle No.1
Upper Crankshaft 7.4 (76, 67 in.·lbf)
Thrust Washer
Connecting Rod
Bearing Crankshaft

Connecting Rod Lower Main Bearing

Bearing

Connecting Lower Crankshaft

Rod Cap Thrust Washer
Main Bearing Cap
See Page 14–40
1st 30 (306, 22)
2nd Turn 90

115 (1,173, 85)

N·m (kgf·cm, ft·lbf) : Specified torque

Non–reusable part A62605

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–40
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)
140DS–02

OVERHAUL

1. INSPECT CONNECTING ROD THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.08 – 0.30 mm (0.0031 – 0.0118 in.)
Maximum thrust clearance: 0.40 mm (0.0157 in.)
If the thrust clearance is greater then maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
A09477 shaft.

2. INSPECT CONNECTING ROD OIL CLEARANCE

(a) Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.

A09488

(c) Using 2 removed connecting rod cap bolts, remove the

connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT:
Keep the lower bearing inserted with the connecting rod cap.

A09492

(d) Clean the crank pin and bearing.

Plastigage
(e) Check the crank pin and bearing for pits and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
(f) Lay a strip of plastigage across the crank pin.

A09494

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ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

(g) Match the numbered connecting rod cap with the con-
Front Mark necting rod.
(Protrusion)
(h) Install the connecting rod cap with the front mark facing
forward.
(i) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.

A09514

(j) 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.

A09493

(k) Mark the front of the cap bolt with the paint.
90
90
(l) Retighten the cap bolts 90
as shown.
(m) Check that the painted mark is now at a 90
angle to the
Front front.
Painted Mark NOTICE:
Do not turn the crankshaft.
(n) Remove the 2 bolts, connecting rod cap and lower bear-
ing.
A09490

(o) Measure the Plastigage at its widest point.

Standard oil clearance:
0.038 – 0.056 mm (0.0015 – 0.0022 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, replace the crankshaft.

A09495

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ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

(p) If using a standard bearing, replace it with one having the

same number. If the number of the bearing cannot be de-
termined, select the correct bearing by adding together
the numbers imprinted on the crankshaft and connecting
rod cap, then select the bearing with the same number as
No.1 the total. There are 5 sizes of standard bearings, marked
No.2 Mark ”1”, ”2”, ”3”, ”4” and ”5” accordingly.
1, 2 or 3 Connecting rod cap Crankshaft Use bearing
No.3
1 0 1
No.4
1 1 2
1 2 3
2 0 2
2 1 3
2 2 4
3 0 3
3 1 4
Mark Mark 3 2 5
0,1 or 2 1, 2, 3, 4 or 5 HINT:
A09472
EXAMPLE: Connecting rod cap ”2” + Crankshaft ”1”
= total number 3 (Use bearing ”3”)
Connecting rod big end inside diameter:
Mark ”1” 53.500 – 53.506 mm (2.1063 – 2.1065 in.)
Mark ”2” 53.506 – 53.512 mm (2.1065 – 2.1068 in.)
Mark ”3” 53.512 – 53.518 mm (2.1068 – 2.1070 in.)
Crankshaft crank pin diameter:
Mark ”0” 50.494 – 50.500 mm (1.9880 – 1.9882 in.)
Mark ”1” 50.488 – 50.494 mm (1.9877 – 1.9880 in.)
Mark ”2” 50.482 – 50.488 mm (1.9875 – 1.9877 in.)
Standard sized bearing center wall thickness:
Mark ”1” 1.478 – 1.481 mm (0.0582 – 0.0583 in.)
Mark ”2” 1.481 – 1.484 mm (0.0583 – 0.0584 in.)
Mark ”3” 1.484 – 1.487 mm (0.0584 – 0.0585 in.)
Mark ”4” 1.487 – 1.490 mm (0.0585 – 0.0587 in.)
Mark ”5” 1.490 – 1.493 mm (0.0587 – 0.0588 in.)

(q) Completely remove the Plastigage.

3. REMOVE PISTON SUB–ASSY W/CONNECTING ROD
Ridge reamer
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
S Keep the bearing, connecting rod and cap together.
S Arrange the piston and connecting rod assemblies in the
A56037 correct order.

4. REMOVE CONNECTING ROD BEARING

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ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

5. INSPECT CRANKSHAFT THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.040 – 0.240 mm (0.0016 – 0.0009 in.)
Maximum thrust clearance: 0.30 mm(0.0118 in.)
If the thrust clearance is greater then maximum, replace the
thrust washer as a set.
A09496 Thrust washer thickness:
STD 2.680 – 2.730 mm (0.1055 – 0.1075 in.)
O/S 0.125 2.743 – 2.793 mm (0.1080 – 0.1100 in.)
O/S 0.250 2.805 – 2.855 mm (0.1104 – 0.1124 in.)

6. REMOVE CRANKSHAFT

(a) Uniformly loosen and remove the 10 main bearing cap

bolts.

A09497

(b) Using the removed main bearing cap bolts, wiggle the cap
back and forth, and remove the 5 main bearing caps, 5
lower bearings and 2 lower thrust washers (No. 3 main
bearing cap only).
HINT:
S Keep the lower bearing and main bearing cap together.
S Arrange the main bearing caps and lower thrust washers
in the correct order.
A08026 (c) Lift out the crankshaft.
HINT:
Keep the upper bearing and upper thrust washers together with
the cylinder block.

7. REMOVE SUB–ASSY OIL NOZZLE NO.1

(a) Remove the bolt and 4 oil nozzles.

A09503

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

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ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

8. REMOVE CYLINDER BLOCK OIL ORIFICE

(a) Using a hexagon wrench (6 mm), remove the oil orifice.

Hexagon
Wrench (6 mm)
A09473

9. REMOVE PISTON RING SET

(a) Using a piston ring expander, remove the No. 1 piston

ring, No. 2 piston ring and oil ring.
NOTICE:
Make the expansion of the piston ring as small as neces-
sary.
(b) Remove the coil by hand.
A09457 HINT:
Arrange the piston rings in correct order.
10. REMOVE W/PIN PISTON SUB–ASSY

(a) Using a small screwdriver, pry off the snap rings from the
piston.
(b) Gradually heat the piston to approx. 60_C (140_F).

A09502

(c) Using a plastic–faced hammer and brass bar, lightly tap

out the piston pin and remove the connecting rod.
HINT:
S The piston and pin are a matched set.
S Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.

A09501

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

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ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

11. INSPECT CYLINDER BLOCK FOR FLATNESS

(a) Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head gasket for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.

A09453

12. INSPECT CYLINDER BORE

Thrust
1 (a) Using a cylinder gauge, measure the cylinder bore diame-
1 Direction
Front Axial ter at the positions A, B and C in the thrust and axial direc-
2 2
Direction tions.
Standard diameter:
10mm 82.200 – 82.213 mm (3.2362 – 3.2367 in.)
A
(0.39 in) Maximum diameter: 82.400 mm (3.2441 in.)
B If the diameter is greater than maximum, replace the cylinder
10mm
block.
C
(0.39 in)

A09455

13. INSPECT W/PIN PISTON SUB–ASSY

(a) Using a micrometer, measure the piston diameter at a

right angles to the piston pin center line, 14 mm (0.55 in.)
below the skirt bottom edge.
Piston diameter:
82.118 – 82.132 mm (3.2330 – 3.2335 in.)
14mm
A09465

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–46
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

(b) Subtract the piston diameter measurement from the cylin-

der bore diameter measurement.
Standard oil clearance:
0.068 – 0.095 mm (0.0027 – 0.0037 in.)
Maximum oil clearance: 0.14 mm (0.0055 in.)
If the oil clearance is greater than maximum, replace all the 4
pistons. If necessary, replace the cylinder block.

(c) Using a caliper gauge, measure the inside diameter of the

connecting rod bushing.
Bushing inside diameter:
31.015 – 31.027 mm (1.2211 – 1.2215 in.)

A09693

(d) Using a micrometer, measure the piston pin diameter.

Piston pin diameter:
31.000 – 31.012 mm (1.2205 – 1.2209 in.)

EM0227

(e) Subtract the piston pin diameter measurement from the

bushing inside diameter measurement.
Standard oil clearance:
0.003 – 0.027 mm (0.0001 – 0.0011 in.)
Maximum oil clearance: 0.025 mm (0.0010 in.)
If the oil clearance is greater than maximum, replace the con-
necting rod. If necessary, replace the piston and piston pin as
a set.

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

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ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

14. INSPECT CONNECTING ROD SUB–ASSY

(a) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.

(1) Check for out–of–alignment.

Maximum out–of alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out–of alignment is greater than maximum, replace the con-
necting rod assembly.

Z00064

(2) Check for twist.

Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.

Z00065

15. INSPECT RING GROOVE CLEARANCE

(a) Using a feeler gauge, measure the clearance between
new piston ring and wall of the ring groove.
Ring groove clearance:
No. 1 0.08 – 0.12 mm (0.0031 – 0.0047 in.)
No. 2 0.05 – 0.09 mm (0.0020 – 0.0035 in.)
Oil 0.03 – 0.07 mm (0.0012 – 0.0028 in.)
If the clearance is not as specified, replace the piston.
A09462

16. INSPECT PISTON RING END GAP

(a) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 110 mm (4.33 in.) from the top of the
cylinder block.

110mm

A09464

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

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ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

(b) Using a feeler gauge, measure the end gap.

Standard end gap:
No. 1 0.27 – 0.43 mm (0.0106 – 0.0169 in.)
No. 2 0.39 – 0.58 mm (0.0154 – 0.0228 in.)
Oil 0.20 – 0.44 mm (0.0079 – 0.0173 in.)
Maximum end gap:
No. 1 0.82 mm (0.0323 in.)
No. 2 1.00 mm (0.0394 in.)
EM7639 Oil 0.90 mm (0.0354 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, replace the cylinder block.

17. INSPECT CONNECTING ROD BOLT

20 mm (0.79 in.)
(a) Using vernier calipers, measure the tension portion diam-
eter.
Standard diameter:
8.2 – 8.3 mm (0.323 – 0.327 in.)
Minimum diameter: 8.0 mm (0.315 in.)
If the diameter is less than minimum, replace the connecting rod
A09491 bolt.

18. INSPECT CRANKSHAFT

(a) Place the crankshaft on V–blocks.

(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.025 mm (0.0010 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
A56040

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–49
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

(c) Using a micrometer, measure the diameter of each main

journal and crank pin.
Main journal diameter:
56.992 – 57.010 mm (2.2438 – 2.2445 in.)
Crank pin diameter:
50.482 – 50.500 mm (1.9875 – 1.9882 in.)
If the diameter is not as specified, replace the crankshaft.
(d) Check each main journal and crank pin for taper and out–
of–round as shown.
Maximum taper and out–of–round:
0.01 mm (0.0004 in.)
If the taper and out–of–round is greater than maximum, replace
the crankshaft.

A56041

19. INSPECT CYLINDER BLOCK OIL ORIFICE

(a) Check the oil orifice for clogging.

If necessary, replace the oil orifice.

A09474

20. INSPECT CRANKSHAFT OIL CLEARANCE

(a) Clean each main journal and bearing.

(b) 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 clock, and push in the 5 upper bearings.

A56038

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–50
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

(2) Align the bearing claw with the claw groove of the
main bearing cap, and push in the 5 lower bearings.

A56042

(c) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.

Groove A56039

(d) Install the 2 thrust washers on the No. 3 bearing cap with
the oil grooves facing outward.
(e) Place the crankshaft on the cylinder block.

Groove
A09512

(f) Lay a strip of Plastigage across each journal.

Plastigage

A09499

(g) Install the 5 main bearing caps in their proper locations.

HINT:
Each bearing cap has a number and a front mark.

A56043

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–51
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

(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.
A09497

(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.

A09500

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–52
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

(l) If using a standard bearing, replace it with one having the

same number. If the number of the bearing cannot be de-
No.5 termined, select the correct bearing by adding together
No.4 the numbers imprinted on the cylinder block and crank-
shaft, then select the bearing with the same number as
the total. There are 5 sizes of standard bearings, marked
Mark
”1”, ”2”, ”3”, ”4” and ”5” accordingly.
1, 2 or 3
No.3 Number Marked
No.2 No.3 No.2
No.4 No.1 Cylinder block Crankshaft Use bearing

No.5 1 0 1
1 1 2
No.1 1 2 3
2 0 2
2 1 3
2 2 4
3 0 3
Mark 3 1 4
Mark
1, 2, 3, 4 or 5 3 2 5
0, 1 or 2
A09688
HINT:
EXAMPLE
Cylinder block ”2” + Crankshaft ”1” = Total number 3 (Use bear-
ing ”3”)
Cylinder block main journal bore diameter:
Mark ”1” 61.000 – 61.006 mm (2.4016 – 2.4018 in.)
Mark ”2” 61.006 – 61.012 mm (2.4018 – 2.4020 in.)
Mark ”3” 61.012 – 61.018 mm (2.4020 – 2.4023 in.)
Crankshaft main journal diameter:
Mark ”0” 57.004 – 57.010 mm (2.2442 – 2.2445 in.)
Mark ”1” 56.998 – 57.004 mm (2.2440 – 2.2442 in.)
Mark ”2” 56.992 – 56.998 mm (2.2438 – 2.2440 in.)

Standard sized bearing center wall thickness:

Mark ”1” 1.976 – 1.979 mm (0.0778 – 0.0779 in.)
Mark ”2” 1.979 – 1.982 mm (0.0779 – 0.0780 in.)
Mark ”3” 1.982 – 1.985 mm (0.0780 – 0.0781 in.)
Mark ”4” 1.985 – 1.988 mm (0.0781 – 0.0783 in.)
Mark ”5” 1.988 – 1.991 mm (0.0783 – 0.0784 in.)
(m) Completely remove the Plastigage.

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–53
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

21. INSTALL TIGHT PLUG

(a) Apply adhesive around tight plugs.
Adhesive: Part No.08833 – 00070, THREE BOND 1324
or equivalent.
(b) Using SST, tap to the tight plugs as shown tn the illustra-
tion.
SST 09950–60010 (09951–00350), 09950–70010
(09951–07100)
Standard depth:
Intake side: 2.0 mm (0.0787 in.)
Exhaust side: 2.0 mm (0.0787 in.)
Front side: 1.5 mm (0.0590 in.)
Rear side A: 1.5 mm (0.0590 in.)
B: 2.0 mm (0.0787 in.)

Intake Side: Exhaust Side:

2.0 mm 2.0 mm

Rear Side:
Front Side:
B
A 1.5 mm
1.5 mm A B 2.0 mm

A
A

A59623

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–54
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

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.)

Cylinder Head Side: Lower Side:

A
B B

Front Side:

A
8 mm 20 mm

11 mm
14 mm
A
B

A
A
A56687

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–55
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

23. INSTALL STRAIGHT PIN

(a) Using a plastic–faced hammer, tap in the straight pin.
Standard protrusion:
A: 13 mm (0.5118 in.)
B: 7.0 mm (0.2755 in.)
C: 5.0 mm (0.1968 in.)

Rear Side: Exhaust Side:

B
10 mm
7 mm
7 mm

22 mm
14 mm 11 mm
A B C A56688

24. INSTALL STUD BOLT

(a) Install the stud bolts as shown in the illustration.

Rear Side: Lower Side:

23 mm 28 mm

A (M6)
B (M6)

B A56689

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

14–56
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

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)

Hexagon
Wrench (6 mm)
A09473

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)

A09503

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.
A56044

(2) Align the bearing claw with the claw groove of the
main bearing cap, and push in the 5 lower bearings.

A56045

(b) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.

Groove
A09510

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–57
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

(c) Install the 2 thrust washers on the No. 3 bearing cap with
the oil grooves facing outward.

Groove
A09512

(d) Install the 5 main bearing caps in their proper locations.

HINT:
Each bearing cap has a number and a font mark.

A56048

(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.

A09497

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.

A56046

(d) Align the front marks of the piston and connecting rod,
Front Mark
(Arrow) and push in the piston pin by hand.
(e) Install a new snap ring on the other side of the piston pin
hole.

Front Mark
(Protrusion)
A09506

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14–58
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

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.

A09508

30. INSTALL PISTON RING SET

(a) Install the coil by hand.

(b) Using a piston ring expander, install the oil ring.

HINT:
Coil Joint Face the end gap of the oil ring in the opposite direction coil
joint.

Oil Ring End A56047

(c) Using a piston ring expander, install the No. 2 and No. 1
Code Mark piston rings with the code mark facing upward.
No.1 Code mark:
No.1 1T
No.2 2T
NOTICE:
No.2
Make the expansion of the piston ring as small as neces-
Code Mark sary.
A09458

No.1 (d) Position the piston rings so that the ring ends are as
Front
Compression shown.
Mark
(Arrow) Ring
Oil Ring

No.2
Compression
Ring
Coil A09507

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.

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 14–59
ENGINE MECHANICAL – CYLINDER BLOCK (1CD–FTV)

(c) Using a piston ring compressor, push the correctly num-

Front Mark
(Arrow) bered piston and connecting rod assemblies into each
Push cylinder with the front mark of the piston facing forward.

Front

A09511

(d) Match the numbered connecting rod cap with the con-
Front Mark
necting rod.
(Protrusion)
(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.

A09514

(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.

A09493

(h) Mark the front of the cap bolt with the paint.
90
90
(i) Retighten the cap bolts 90
as shown.
(j) Check that the painted mark is now at a 90
angle to the
Front front.
Painted Mark (k) Check that the crankshaft turns smoothly.

A09490

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 16–1
COOLING – WATER PUMP ASSY (1CD–FTV)

WATER PUMP ASSY (1CD–FTV)

1606V–02

INSPECTION

1. INSPECT WATER PUMP ASSY

Turn (a) Visually check the drain hole for coolant leakage.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.

Drain Hole A55603

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 17–1
LUBRICATION – OIL PUMP ASSY (1CD–FTV)

OIL PUMP ASSY (1CD–FTV)

1704C–02

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.)
A55604

(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.)

A55605

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–1
STARTING & CHARGING – STARTER ASSY(1.4KW) (1CD–FTV)

STARTER ASSY(1.4KW) (1CD–FTV)

190AE–01

COMPONENTS

Starter Armature Assy

Starter Yoke Assy

Starter Brush Holder Assy

5.9 (60, 52 in.·lbf)

Rear End Frame Cover

5.9 (60, 52 in.·lbf)

Ball

5.9 (60, 52 in.·lbf)

Drive Housing

Spring Starter Clutch Sub–Assy

Magnetic Switch

N·m (kgf·cm, ft·lbf) : Specified torque

A62712

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–2
STARTING & CHARGING – STARTER ASSY(1.4KW) (1CD–FTV)
1906G–02

OVERHAUL

1. REMOVE STARTER YOKE ASSY

(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
(b) Remove the 2 through bolts.
(c) Pull out the yoke together with the armature from the mag-
netic switch.

A55610

2. REMOVE STARTER CLUTCH SUB–ASSY

(a) Remove the 2 bolts and drive housing.

A55611

(b) Remove the clutch from the drive housing.

A55612

Magnetic Finger (c) Using a magnetic finger, remove the ball from the clutch
shaft hole.

A55613

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–3
STARTING & CHARGING – STARTER ASSY(1.4KW) (1CD–FTV)

3. REMOVE STARTER BRUSH HOLDER ASSY

(a) Remove the 2 screws and end frame from the yoke.

A55614

(b) Using a screwdriver, hold the spring back disconnect the

brush from the brush holder. Disconnect the 4 brushers
and remove the brush holder.

A51226

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.

A55615

(b) Using an ohmmeter, check that there is no continuity be-

tween the commutator and armature coil core.

A55616

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–4
STARTING & CHARGING – STARTER ASSY(1.4KW) (1CD–FTV)

(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.)

A55617

(e) Using vernier calipers, measure the commutator diame-

ter.
Standard diameter: 30 mm (1.1811 in.)
Minimum diameter: 29 mm (1.1417 in.)

A55618

(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.)

A51188

6. INSPECT STARTER YOKE ASSY

(a) Using an ohmmeter, check that there is continuity be-

tween the lead wire and field coil brush lead.

A55619

(b) Using an ohmmeter, check that there is no continuity be-

tween the field coil brush lead and yoke.

A55620

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–5
STARTING & CHARGING – STARTER ASSY(1.4KW) (1CD–FTV)

(c) Using vernier calipers, measure the brush length.

Standard length: 15.5 mm (0.6102 in.)
Minimum length: 8.5 mm (0.3346 in.)

A55621

7. INSPECT STARTER BRUSH HOLDER ASSY

(a) Using an ohmmeter, check that there is no continuity be-

tween the positive (+) and negative (–) brush holders.

A55622

(b) Using vernier calipers, measure the brush length.

Standard length: 15.5 mm (0.6102 in.)
Minimum length: 8.5 mm (0.3346 in.)

A55623

8. INSPECT STARTER CLUTCH SUB–ASSY

Free (a) Rotate the pinion gear clockwise, and check that it turns
freely. Try to rotate the pinion gear counterclockwise and
Lock check that it locks.

A55624

9. INSPECT MAGNET STARTER SWITCH ASSY

(a) Using an ohmmeter, check that there is continuity be-

tween terminal 50 and C.
Terminal C Terminal 50

A55625

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–6
STARTING & CHARGING – STARTER ASSY(1.4KW) (1CD–FTV)

(b) Using an ohmmeter, check that there is continuity be-

tween terminal 50 and the switch body.

Terminal 50

Switch Body A55626

10. INSTALL STARTER ARMATURE ASSY

(a) Apply grease to the armature bearings and insert the armature into the yoke.

11. INSTALL STARTER BRUSH HOLDER ASSY

(a) Place the brush holder on the armature.

(b) Using a screwdriver, hold the brush spring back and con-
nect the brush into the brush holder. Connect the 4
brushes.
NOTICE:
Check that the positive (+) lead wires are not grounded.
A51226

(c) Install the end frame to the yoke with the 2 screws.
Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf)

A55614

12. INSTALL STARTER CLUTCH SUB–ASSY

(a) Apply grease to the ball.

(b) Insert the ball into the clutch shaft hole.

A55627

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–7
STARTING & CHARGING – STARTER ASSY(1.4KW) (1CD–FTV)

(c) Place the clutch on the drive housing.

A55612

(d) Install the drive housing to the magnetic switch with the
2 bolts.
Torque: 5.9 N
m (60 kgf
cm, 52 in.
lbf)

A55611

13. INSTALL STARTER YOKE ASSY

(a) Align the protrusion of the yoke with the cutout of the mag-
netic switch.

A55628

(b) Install the yoke and armature with the 2 through bolts.
Torque: 5.9 N
m (60 kgf
cm, 52 in.
lbf)
(c) Connect the lead wire to terminal C with the nut.
Torque: 5.9 N
m (60 kgf
cm, 52 in.
lbf)

A55610

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–8
STARTING & CHARGING – STARTER ASSY(2.0KW) (1CD–FTV)

STARTER ASSY(2.0KW) (1CD–FTV)

190AF–01

COMPONENTS

8.0 (82, 71 in.·lbf) Return Spring

Plunger

Rubber Cushion

Magnet Stater Starter Pinion Drive Lever

Switch Assy

Planet Carrier Shaft

Sub–assy

5.0 (51, 44 in.·lbf)

Stop Collar

Starter Clutch
Sub–assy
1.7 (17, 15 in.·lbf)

Snap Ring

Starter Thrust Washer

Commutator
End Fram
Cover Starter Drive Housing
Lock Plate Assy
Starter Yoke
Assy
6.5 (66, 58 in.·lbf)

Starter Commutator
End Frame Assy x4

Brush Holder
Brush Retainer
Brush Spring

Starter Armature
Assy
N·m (kgf·cm, ft·lbf) : Specified torque

Non–reusable part A62721

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–9
STARTING & CHARGING – STARTER ASSY(2.0KW) (1CD–FTV)
190AG–01

OVERHAUL

1. REMOVE MAGNET STARTER SWITCH ASSY

(a) Remove the nut, and disconnect lead wire from the mag-
net starter switch terminal.
(b) Remove the 3 screws, magnet starter switch and return
spring.

A62722

(c) Pull the plunger, and disconnect the plunger hook from
the upper side of the drive lever.

A62723

2. REMOVE STARTER COMMUTATOR END FRAM

COVER
(a) Remove the 2 screws and end fram cover.

A62724

(b) Using a feeler gauge, measure the armature thrust clear-

ance between the lock plate and end frame.
Standard thrust clearance: 0.3 mm (0.012 in.)
Maximum thrust clearance: 0.6 mm (0.024 in.)
If the thrust clearance is greater the than maximum, replace the
thrust washer.
(c) Remove the lock plate and thrust washer.

A62725

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–10
STARTING & CHARGING – STARTER ASSY(2.0KW) (1CD–FTV)

3. REMOVE STARTER YOKE ASSY

(a) Remove the 2 through bolts, and pull out the starter yoke
together with the armature.

A62726

4. REMOVE STARTER COMMUTATOR END FRAM ASSY

(a) Using a screwdriver, pry out the commutator end frame.

A62727

5. REMOVE STARTER ARMATURE ASSY

A62728

6. REMOVE STARTER BRUSH HOLDER ASSY

7. REMOVE PLANET CARRIER SHAFT SUB–ASSY

Rubber Cushion
(a) Remove the rubber cushion.
(b) Remove the planet carrier shaft and starter clutch assem-
bly.

A62729

8. REMOVE STARTER PINION DRIVE LEVER

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–11
STARTING & CHARGING – STARTER ASSY(2.0KW) (1CD–FTV)

9. REMOVE STARTER CLUTCH SUB–ASSY

(a) Using a screwdriver, tap in the stop collar towards the
starter clutch.

A62730

(b) Using a screwdriver, pry out the snap ring.

(c) Remove the stop collar from the shaft.

A62953

Continuity 10. INSPECT STARTER ARMATURE ASSY

(a) Using an ohmmeter, check that there is continuity be-
tween the segments of the commutator.
If there is no continuity between any segments, replace the ar-
mature.

A62961

No Continuity (b) Using an ohmmeter, check that there is no continuity be-

tween the commutator and armature coil core.
If there is continuity, replace the armature.
(c) Check the commutator for the dirty and burnt surface.
If the surface is dirty or burnt, correct with sandpaper (No.400)
or a lathe.

A62962

(d) Place the commutator on V–blocks.

(e) Using a dial indicator, measure the circle runout.
Maximum circle runout: 0.03 mm (0.0012 in.)
If the circle runout is greater than maximum, correct it on a lathe.

A62963

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–12
STARTING & CHARGING – STARTER ASSY(2.0KW) (1CD–FTV)

(f) Using vernier calipers, measure the commutator diame-

ter.
Standard diameter: 32.3 mm (1.272 in.)
Minimum diameter: 30.5 mm (1.201 in.)
If the diameter is less than minimum, replace the armature.

A62964

(g) Check that the undercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth: 0.9 mm (0.035 in.)
Minimum undercut depth: 0.3 mm (0.012 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

A62965

11. INSPECT STARTER BRUSH HOLDER ASSY

(a) Using vernier calipers, measure the brush length.
Standard length: 14.5 mm (0.571 in.)
Minimum length: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the brush holder.

A62966

12. INSPECT STARTER CLUTCH SUB–ASSY

(a) Check the gear teeth on the starter clutch for wear or dam-
age.
If the gear is damaged, replace it.
If damaged, replace the clutch assembly. If damaged, also
check the drive plate ring gear for wear or damage.

(b) Rotate the clutch pinion gear clockwise and check that it
Free turns freely. Try to rotate the clutch pinion gear counter-
Lock clockwise and check that it locks.
If necessary, replace the starter clutch.

A62967

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–13
STARTING & CHARGING – STARTER ASSY(2.0KW) (1CD–FTV)

13. INSPECT MAGNET STARTER SWITCH ASSY

(a) Push in the plunger and check that it returns quickly to its
original position.
If necessary, replace the magnetic switch.

Return

A62968

Terminal 50 (b) Using an ohmmeter, check that there is continuity be-

tween terminals 50 and C.
If there is no continuity, replace the magnetic switch.

Terminal C
Continuity

A63797

(c) Using an ohmmeter, check that there is continuity be-

Terminal 50 Switch Body
tween terminal 50 and the switch body.
If there is no continuity, replace the magnet starter switch.

Continuity
A63798

14. INSPECT PLANET CARRIER SHAFT SUB–ASSY

(a) Turn the shaft, and check that it is not rough or worn.
Turn If it feels rough or worn, replace the planet carrier shaft.

A63799

15. INSTALL STARTER PINION DRIVE LEVER

16. INSTALL STARTER CLUTCH SUB–ASSY

(a) Apply grease to the bushing and spline of the starter

clutch and planet carrier shaft.

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–14
STARTING & CHARGING – STARTER ASSY(2.0KW) (1CD–FTV)

(b) Place the starter clutch and stop collar on the planet carri-
er shaft as shown in the illustration.

A63800

(c) Install a new snap ring to the planet carrier shaft groove.
(d) Using a vise, compress the snap ring.
(e) Check that the snap ring fits correctly.

A63801

(f) Using a screwdriver, tap the stop collar to slide it onto the
snap ring.

A63802

17. INSTALL PLANET CARRIER SHAFT SUB–ASSY

Drive Lever
Knock
(a) Set the planet carrier shaft and drive lever in position as
Pin Hole shown in the illustration.
(b) Align the holes of the drive housing with the knock pins.
(c) Install the planet carrier shaft and starter clutch to the
drive housing.

Drive Housing Knock Pin A63803

(d) Install the rubber cushion.

Rubber Cushion

A63804

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–15
STARTING & CHARGING – STARTER ASSY(2.0KW) (1CD–FTV)

SST 18. INSTALL STARTER BRUSH HOLDER ASSY

(a) Install the 4 brush retainers and 4 brush springs to the
brush holder.
(b) Using SST, install the 4 brushes to the brush holder.
SST 09950–60010 (09951–00340)

A63805

(c) Attach the brush holder to the armature.

SST

A63806

(d) Push the armature, and remove the SST.

SST

A63807

19. INSTALL STARTER YOKE ASSY

(a) Align the cushion rubber on the starter drive housing with
the cutout of the starter yoke.
(b) Install the starter yoke and armature assembly.

A63808

(c) Align the commutator end frame with the brush holder
rubber part as shown in the illustration.
(d) Install the commutator end frame with the 2 through bolts.
6.5 N·m (66 kgf·cm, 58 in.·lbf)

A63809

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–16
STARTING & CHARGING – STARTER ASSY(2.0KW) (1CD–FTV)

20. INSTALL STARTER COMMUTATOR END FRAM

COVER
(a) Install the thrust washer and lock plate.
(b) Check the armature thrust clearance between the lock
plate and the end frame cover. (See page 19–9)

A63810

(c) Pack grease to the commutator end cover.

(d) Install the commutator end fram cover with the 2 screws.
1.7 N·m (17 kgf·cm, 15 in.·lbf)

A62724

21. INSTALL MAGNET STARTER SWITCH ASSY

(a) Hang the plunger hook to the upper side of the drive lever.
(b) Install the return spring into the plunger.

A63811

(c) Install the return spring and magnet sarter switch with the
3 screws.
5.0 N·m (51 kgf·cm, 44 in.·lbf)
(d) Connect the lead wire to the magnet starter switch termi-
nal with the nut.
8.0 N·m (82 kgf·cm, 71 in.·lbf)

A62722

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–17
STARTING & CHARGING – STARTER ASSY(2.2KW) (1CD–FTV)

STARTER ASSY(2.2KW) (1CD–FTV)

190AH–01

COMPONENTS

Starter Armature Assy

Starter Yoke Assy

Starter Brush Holder Assy

12.7 (130, 9.0 )

9.3 (95, 82 in.·lbf)

12.7 (130, 9.0 )

Ball

5.9 (60, 52 in.·lbf)

Spring

9.3 (95, 82 in.·lbf)

Drive Housing
Starter Clutch Sub–Assy

Magnetic Switch

N·m (kgf·cm, ft·lbf) : Specified torque

A62713

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–18
STARTING & CHARGING – STARTER ASSY(2.2KW) (1CD–FTV)
1906H–02

OVERHAUL

1. REMOVE STARTER YOKE ASSY

(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
(b) Remove the 2 through bolts.
(c) Pull out the yoke together with the armature from the mag-
netic switch.

A55633

2. REMOVE STARTER CLUTCH SUB–ASSY

(a) Remove the 2 bolts and drive housing.

B13607

(b) Remove the clutch from the drive housing

A55635

(c) Using a magnetic finger, remove the ball from the clutch
Magnetic Finger
shaft hole.

A55636

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–19
STARTING & CHARGING – STARTER ASSY(2.2KW) (1CD–FTV)

3. REMOVE STARTER BRUSH HOLDER ASSY

(a) Using a screwdriver, hold the spring back disconnect the

brush from the brush holder. Disconnect the 4 brushers
and remove the brush holder.

A51182

4. REMOVE STARTER ARMATURE ASSY

(a) Using a plastic–faced hammer, tap the yoke and remove

the armature.

A51183

5. INSPECT STARTER ARMATURE ASSY

(a) Using an ohmmeter, check that there is continuity be-

tween the segments of the commutator.

A55637

(b) Using an ohmmeter, check that there is no continuity be-

tween the commutator and armature coil core.

A55638

(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.)

A51186

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–20
STARTING & CHARGING – STARTER ASSY(2.2KW) (1CD–FTV)

(e) Using vernier calipers, measure the commutator diame-

ter.
Standard diameter: 35 mm (1.378 in.)
Minimum diameter: 34 mm (1.3386 in.)

A51187

(f) Check that the undercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth: 0.7 mm (0.0276 in.)
Minimum undercut depth: 0.2 mm (0.079 in.)

A51188

6. INSPECT STARTER YOKE ASSY

(a) Using an ohmmeter, check that there is continuity be-

tween the lead wire and field coil brush lead.

A55639

(b) Using an ohmmeter, check that there is no continuity be-

tween the field coil brush lead and yoke.

A55640

(c) Using vernier calipers, measure the brush length.

Standard length: 16.5 mm (0.6496 in.)
Minimum length: 9 mm (0.3543 in.)

A55641

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–21
STARTING & CHARGING – STARTER ASSY(2.2KW) (1CD–FTV)

7. INSPECT STARTER BRUSH HOLDER ASSY

(a) Using an ohmmeter, check that there is no continuity be-

tween the positive (+) and negative (–) brush holders.

A55642

(b) Using vernier calipers, measure the brush length.

Standard length: 16.5 mm (0.6496 in.)
Minimum length: 9 mm (0.3543 in.)

A55643

8. INSPECT STARTER CLUTCH SUB–ASSY

Free (a) Rotate the pinion gear clockwise, and check that it turns
freely. Try to rotate the pinion gear counterclockwise and
Lock check that it locks.

A55624

9. INSPECT MAGNET STARTER SWITCH ASSY

(a) Using an ohmmeter, check that there is continuity be-

Terminal 50 tween terminals 50 and C.

Terminal C
B55687

(b) Using an ohmmeter, check that there is continuity be-

tween terminal 50 and the switch body.
Terminal 50

Switch Body
B55691

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–22
STARTING & CHARGING – STARTER ASSY(2.2KW) (1CD–FTV)

10. INSTALL STARTER ARMATURE ASSY

(a) Apply grease to the armature bearings.

(b) Using a press, press in armature.

A51212

11. INSTALL STARTER BRUSH HOLDER ASSY

(a) Align the claw of the brush holder with the claw groove of
the yoke.
(b) Place the brush on the yoke.
(c) Using a screwdriver, hold the brush spring back and con-
nect the brush into the brush holder. Connect the 4
brushes.
A55483 NOTICE:
Check that the positive (+) lead wires are not grounded.
12. INSTALL STARTER CLUTCH SUB–ASSY

(a) Apply grease to the ball.

(b) Insert the ball into the clutch shaft hole.

A55646

(c) Place the clutch on the drive housing.

A55635

(d) Install the drive housing to the magnetic switch with the
2 bolts.
Torque: 9.3 N
m (95 kgf
cm, 82 in.
lbf)

B13607

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–23
STARTING & CHARGING – STARTER ASSY(2.2KW) (1CD–FTV)

13. INSTALL STARTER YOKE ASSY

(a) Align the claws of the brush holder with the grooves of the
magnetic switch, and install the yoke and armature.
(b) Align the punch mark of the yoke with the line of the mag-
netic switch.

A55647

(c) Install the yoke and armature with the 2 through bolts.
Torque: 12.7 N
m (130 kgf
cm, 9 ft
lbf)
(d) Connect the lead wire to terminal C with the nut.
Torque: 5.9 N
m (60 kgf
cm, 52 in.
lbf)

A55633

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–24
STARTING & CHARGING – GENERATOR ASSY(90A) (1CD–FTV)

GENERATOR ASSY(90A) (1CD–FTV)

19094–02

COMPONENTS
Rotor
Drive End Frame

Pulley

Alternator Washer

111 (1125, 81) Rear End Cover

Brush Holder Cover

Brush Holder

Rectifier End Frame

Voltage Regulator

Rectifier Holder

N·m (kgf·cm, ft·lbf) : Specified torque

A59147

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–25
STARTING & CHARGING – GENERATOR ASSY(90A) (1CD–FTV)
19095–02

OVERHAUL
1. REMOVE GENERATOR PULLEY

SST 09820–63010 (09820–06010, 09820–06020)

HINT:
SST1 – A, B 09820–06010
SST2 09820–06020

(a) Hold SST 1 – A with a torque wrench, and tighten SST 1

– B clockwise to the specified torque.
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
NOTICE:
Check that SST is secured to the rotor shaft.

A38024

(b) Mount SST 2 in a vise.

(c) Insert SST 1 – A, B into SST 2, and attach the pulley nut
to SST 2.

A38025

(d) To loosen the pulley nut, turn SST 1 – A in the direction

shown in the illustration.
NOTICE:
SST 1 – A To prevent damage to the rotor shaft, do not loosen the
pulley nut more than one–half of a turn.
(e) Remove the alternator form SST 2.

A38104

(f) Turn SST 1 – B, and remove SST 1 – A, B.

(g) Remove the pulley nut and pulley.

A38105

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–26
STARTING & CHARGING – GENERATOR ASSY(90A) (1CD–FTV)

2. REMOVE GENERATOR BRUSH HOLDER ASSY

(a) Remove the nut and terminal insulator.

(b) Remove the bolt, 3 nuts, plate terminal and end cover.
(c) Remove the brush cover.
(d) Remove the 2 screws and brush holder.
3. REMOVE GENERATOR REGULATOR ASSY

(a) Remove the 3 screws and voltage regulator.

4. REMOVE GENERATOR HOLDER W/RECTIFIER

(a) Remove the 4 screws and rectifier holder.

5. REMOVE ALTERNATOR RECTIFIRE END FRAME
(a) Remove the rubber insulator.
(b) Remove the seal plate.
(c) Remove the 4 nuts.

(d) Using bearing puller set, remove the rectifier end frame.
SST

Wooden block A51918

6. REMOVE GENERATOR ROTOR ASSY

(a) Remove the alternator washer from the rotor.

(b) Remove the rotor from drive end frame.
NOTICE:
Do not drop the rotor.

Ohmmeter 7. INSPECT GENERATOR REGULATOR ASSY

(a) Using an ohmmeter, check the continuity between termi-

nals F and B.
Standard:
When the positive and negative poles between termi-
F
nals F and B are exchanged, there is continuity in one
B
way but no continuity in another way.
A59143 If the continuity is not as specified, replace the voltage regula-
tor.
1CD–FTV ENGINE REPAIR MANUAL (RM927E)
 19–27
STARTING & CHARGING – GENERATOR ASSY(90A) (1CD–FTV)

Ohmmeter (b) Using an ohmmeter, check the continuity between termi-

E nals F and E.
Standard:
When the positive and negative poles between termi-
nals F and E are exchanged, there is continuity in one
way but no continuity in another way.
If the continuity is not as specified, replace the voltage regula-
F
tor.
A59144

8. INSPECT GENERATOR ROTOR ASSY

(a) Inspect rotor for open circuit.

(1) Using an ohmmeter, check that there is continuity
between the slip rings.
Standard resistance: 2.7 – 3.1
at 20
C (68
F)
If there is no continuity, replace the rotor.

A38108

(b) Inspect rotor for ground.

(1) Using an ohmmeter, check that there is no continu-
ity between the slip ring and rotor.
If there is continuity, replace the rotor.

A38109

(c) Inspect slip rings.

(1) Using vernier calipers, measure the slip ring diame-
ter.
Standard diameter: 14.2 – 14.4 mm (0.559 – 0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.

A38110

B 9. INSPECT GENERATOR HOLDER W/RECTIFIER

P1 P2 P4 (a) Using an ohmmeter, connect one tester probe to the B or

B E terminal and the other to each rectifier terminal.
E

(b) Reverse the polarity of the tester probes and repeat step
(a).
P1 P4
(c) Check that one shows continuity and the other shows no
continuity.
P2
P3 A36999

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–28
STARTING & CHARGING – GENERATOR ASSY(90A) (1CD–FTV)

10. INSPECT BRUSH

(a) Using vernier calipers, measure the exposed brush
length.
Standard exposed length:
Length
9.5 – 11.5 mm (0.374 – 0.453 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brush
holder assembly.
P13535

11. INSTALL GENERATOR ROTOR ASSY

(a) Install the generator rotor.

(b) Install the alternator washer to the rotor.

12. INSTALL ALTERNATOR RECTIFIRE END FRAME

17 mm
(a) Using a 17 mm socket wrench and press, slowly press in
Socket
the rectifier end frame.
Wrench

A51920

(b) Install the cord clip and 4 nuts.

A Torque:
B Nut A 4.5 N
m (46 kgf
cm, 39 in.
lbf)
Nut B 5.4 N
m (55 kgf
cm, 47 in.
lbf)
Cord Clip (c) Install the seal plate on the rectifier end frame.

A A64533

(d) Install the 4 rubber insulators on the lead wires.

Inside NOTICE:
Be careful of the rubber insulators installation direction.

A51921

13. INSTALL GENERATOR HOLDER W/RECTIFIER

(a) Install the rectifier holder while pushing it with the 4 screws.
Torque: 2.9 N
m (30 kgf
cm, 26 in.
lbf)

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–29
STARTING & CHARGING – GENERATOR ASSY(90A) (1CD–FTV)

14. INSTALL GENERATOR REGULATOR ASSY

(a) Install the 3 screws and voltage regulator.

Torque: 3.9 N
m (40 kgf
cm, 35 in.
lbf)

15. INSTALL GENERATOR BRUSH HOLDER ASSY

Upward

(a) Install the 2 screws and brush holder.

Torque: 2.0 N
m (20 kgf
cm, 18 in.
lbf)
NOTICE:
Be careful of the holder installation direction.

A51919

(b) Install the brush cover.

(c) Install the end cover and plate terminal with the bolt and
3 nuts.
Torque:
Nut 4.4 N
m (45 kgf
cm, 39 in.
lbf)
Bolt 3.9 N
m (39 kgf
cm, 35 in.
lbf)
(d) Install the terminal insulator with the nut.
Torque: 4.1 N
m (42 kgf
cm, 36 in.
lbf)
16. INSTALL GENERATOR PULLEY

SST 09820–63010 (09820–06010, 09820–06020)

HINT:
SST1 – A, B 09820–06010
SST2 09820–06020
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.

(b) Hold SST 1 – A with a torque wrench, and tighten SST 1

– B clockwise to the specified to torque.
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
NOTICE:
Check that SST is secured to the pulley shaft.

A38024

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–30
STARTING & CHARGING – GENERATOR ASSY(90A) (1CD–FTV)

(c) Mount SST 2 in a vise.

(d) Insert SST 1 – A, B into SST 2, and attach the pulley nut
to SST 2.

A38025

(e) Tighten the pulley nut, turn SST 1 – A in the direction

shown in the illustration.
Torque: 111 N
m (1,125 kgf
cm, 81 ft
lbf)
SST 1 – A (f) Remove the alternator form SST 2.

A38126

(g) Turn SST 1 – B, and remove SST 1 – A, B.

(h) Turn the pulley, and check that the pulley moves smooth-
ly.

A38105

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–31
STARTING & CHARGING – GENERATOR ASSY(130A) (1CD–FTV)

GENERATOR ASSY(130A) (1CD–FTV)

190AI–01

COMPONENTS

Generator Rotor Assy

Generator w/ Clutch Pulley

Drive End Frame Assy

4.6 (47, 41 in.·lbf)

Rear Seal Plate

Generator Brush
Holder Assy
Alternator Pulley Cap
Front Seal
Plate

1.8 (18, 16 in.·lbf)

Rear End Cover

Sub–Assy
5.8 (59, 51 in.·lbf)

Alternator Coil Assy

N·m (kgf·cm, ft·lbf) : Specified torque

A62720

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–32
STARTING & CHARGING – GENERATOR ASSY(130A) (1CD–FTV)
190AJ–01

OVERHAUL

1. REMOVE GENERATOR BRUSH HOLDER ASSY

(a) Remove the 3 nuts and rear end cover.

(b) Remove the B terminal insulator.

A55648

(c) Remove the rear plate seal from the brush holder.
(d) Remove the 2 screws and brush holder.
(e) Remove the front seal plate from the rear frame.

A55649

2. REMOVE GENERATOR W/CLUTCH PULLEY

SST (A) (a) Set SST (A) and (B).

SST 09820–63020

SST (B)
A55650

(b) Mount SST (A) in a vise.

Rotor Shaft
(c) Set the alternator to SST.
NOTICE:
At this time, make sure that the alternator and SST are per-
pendicular to one another.

SST (A)
A55651

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–33
STARTING & CHARGING – GENERATOR ASSY(130A) (1CD–FTV)

(d) Insert the 3 tabs of SST (B) into the 3 holes on the pulley.
(e) To loosen the pulley, turn SST (B) in the direction shown
in the illustration.
SST (B)
(f) Remove the alternator from SST.
(g) Remove the pulley from the rotor shaft.
Turn

A57794

3. REMOVE GENERATOR ROTOR ASSY

(a) Remove the 4 through bolts.

A57795

(b) Using SST, remove the coil assembly.

SST
SST 09950–40011 (09951–04020, 09952–04010,
09953–04020, 09954–04010, 09955–04071,
09958–04011)
(c) Remove the alternator washer.
(d) Remove the rotor from the drive end frame.

A57796

4. INSPECT GENERATOR ROTOR ASSY

(a) Using an ohmmeter, check that there is continuity be-

tween the slip rings.
Standard resistance: 2.3 – 2.7
at 20
C (68
F)

A57797

(b) Using an ohmmeter, check that there is no continuity be-

tween the slip ring and rotor.

A57798

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

19–34
STARTING & CHARGING – GENERATOR ASSY(130A) (1CD–FTV)

(c) Check that the slip rings are not rough or scored.
(d) Using vernier calipers, measure the slip ring diameter.
Standard diameter:
14.2 – 14.4 mm (0.5591 – 05669 in.)
Minimum diameter: 14.0 mm (0.551 in.)

A57799

5. INSPECT GENERATOR BRUSH HOLDER ASSY

(a) Using vernier calipers, measure the exposed brush

length.
Standard exposed length: 10.5 mm (0.4134 in.)
Minimum exposed length: 4.5 mm (0.177 in.)
HINT:
If the exposed length is less than minimum, replace the brush
A57800 holder.

6. INSTALL GENERATOR ROTOR ASSY

(a) Place the drive end frame.

(b) Install the rotor to the drive end frame.
(c) Place the alternator washer on the rear bearing.

A57801

(d) Using a socket wrench (29 mm)and press, slowly press

Socket in the coil assembly.
Wrench
(29 mm)

A57802

(e) Install the 4 through bolts.

Torque: 5.8 N
m (59 kgf
cm, 51in.
lbf)

A57795

1CD–FTV ENGINE REPAIR MANUAL (RM927E)

 19–35
STARTING & CHARGING – GENERATOR ASSY(130A) (1CD–FTV)

7. INSTALL GENERATOR W/CLUTCH PULLEY

SST (A) (a) Temporarily install the pulley to the rotor shaft.
(b) Set SST (A) and (B).
SST 09820–63020

SST (B)
A55650

(c) Mount SST (A) in a vise.

Rotor Shaft
(d) Set the alternator to SST.
NOTICE:
At this time, make sure that the alternator and SST are per-
pendicular to one another.

SST (A)
A55651

(e) Insert the 3 tabs of SST (B) into the 3 holes on the pulley.
(f) To torque the pulley, turn SST (B) in the direction shown
SST (B) in the illustration.
Torque: 111 N
m (1132 kgf
cm, 82 ft
lbf) for using SST
HINT:
Use a torque wrench with a fulcrum length of 50 cm (19.69 in.).
(g) Remove the alternator from SST.
Turn
(h) Install a new alternator pulley cap.
A57803

8. INSTALL GENERATOR BRUSH HOLDER ASSY

Upward

(a) Place the front seal plate to the coil assembly.

(b) Install the brush holder with the 2 screws.
Torque: 1.8 N
m (18 kgf
cm, 16 in.
lbf)
NOTICE:
Be careful of the holder installation direction.
(c) Place the plate seal on the brush holder.
A57804

(d) Install the rear end cover with the 3 nuts.

Torque: 4.6 N
m (47 kgf
cm, 41 in.
lbf)

A55648

1CD–FTV ENGINE REPAIR MANUAL (RM927E)