Toyota 1CD-FTV Manuel utilisateur
010B2−19
A54988
N·m (kgf·cm, ft·lbf) : Specified torque
zNon−reusable part
Camshaft Timing Tube Assy
Camshaft Drive Gear
Seal Washer
zCamshaft Setting Oil Seal
No. 2 Camshaft,
No. 4 Camshaft Sub−assy
Wave Washer
Camshaft Driven Main Gear
Snap Ring
Camshaft Timing Gear
Bolt Washer
Screw Plug
78 (790, 58)
15 (150, 11)
7.5 (80, 66 in.·lbf)
Camshaft Sub Gear
Camshaft,
No. 3 Camshaft Sub−assy
OVERHAUL
−INTRODUCTION HOW TO USE THIS MANUAL
01−1
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
HOW TO USE THIS MANUAL
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 the 1st process of ”Diagnosis” (placed in the ”Diagnostics” section), the 2nd pro-
cess of ”Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting”, but
the 3rd process of ”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 under the title when necessary.
(b) Illustrations are placed as ”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:
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Illustration:
what to do and where
Task heading: what to do
Detailed text:
how to do task
Set part No. Component part No.
Illustration:
what to do and where
Task heading: what to do
Detailed text:
how to do task
Set part No. Component part No.
Illustration:
what to do and where
Task heading: what to do
Detailed text:
how to do task
Set part No. Component part No.
A59974
01−2
−INTRODUCTION HOW TO USE THIS MANUAL
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(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 removal, 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 the 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:
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 Indicates the possibility of injury to you or other people.
NOTICE Indicates the possibility of damage to the components being repaired.
HINT Provides additional information to help you to perform the repair efficiently.
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−INTRODUCTION HOW TO USE THIS MANUAL
01−3
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
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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010R3−01
Z11554
Seal Lock Adhesive
01−4
−INTRODUCTION REPAIR INSTRUCTION
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
REPAIR INSTRUCTION
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.
SRemove adequately all sand and mud adhere to the outside of engine .
(2) Precaution at reassembly.
SProtect 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.
SWhen disassemble the contact surface of the parts, use plastic hummer striking lightly. (Do
not pry out by screwdriver).
SWhen 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:
SParts 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:
SParts 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.
SFollow the directions when the manual designates to mark the matchmark and/or direction
mark.
SDisassembled parts needs to be put in order as disassembled, not to change position and/
or direction.
SFollow 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
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
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L1 L2L1 L2
D02612
L2L1 L2L1
D01201
L2L1 L2L1
D01202
−INTRODUCTION REPAIR INSTRUCTION
01−5
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets:
When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
(d) Torque When Using Extension Tool with Torque Wrench:
(1) In case of tightening by extending the entire length
of the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T’=T x L2/(L1 + L2)
T’ Reading of torque wrench {N×m(kgf×cm,ft×lbf)}
T Torque {N×m(kgf×cm,ft×lbf)}
L1 Length of SST or tool (cm)
L2 Length of torque wrench (cm)
10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) Place for Removing and Installing Fuel System Parts:
(1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, elec-
tric motor or stove in the surroundings.
(2) Never work in a place like a pit or nearby pit as there is a possibility that vaporized fuel fills those
places.
(b) Removing and Installing of Fuel System Parts:
(1) Prepare a fire extinguisher before starting the operation.
(2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank,
and do not spray much water so as to prevent slipping.
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D01563
D25081
Flat Spring Clamp
Clamp Track
01−6
−INTRODUCTION REPAIR INSTRUCTION
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(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
no mixing of a metal tip.
12. HANDLING OF HOSE CLAMPS
(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
to the arrow mark direction after the installation.
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010B9−17
−INTRODUCTION TERMS
01−7
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
TERMS
ABBREVIATIONS USED IN MANUAL
Abbreviations Meaning
ABS Anti−Lock Brake System
A/C Air Conditioner
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
CAN Controller Area Network
CB Circuit Breaker
CCo Catalytic Converter For Oxidation
CD Compact Disc
CF Cornering Force
CG Center Of Gravity
CH Channel
CKD Complete Knock Down
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
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01−8
−INTRODUCTION TERMS
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
Abbreviations Meaning
DEF Defogger
DFL Deflector
DIFF. Differential
DIFF. LOCK Differential Lock
D/INJ Direct Injection
DLC Data Link Connector
DLI Distributorless Ignition
DOHC Double Overhead Camshaft
DP Dash Pot
DS Dead Soak
DSP Digital Signal Processor
DTC Diagnostic Trouble Code
DVD Digital Versatile Disc
EBD Electric Brake Force Distribution
ECAM Engine Control And Measurement System
ECD Electronic Controlled Diesel
ECDY Eddy Current Dynamometer
ECT Electronic Control Transmission
ECU Electronic Control Unit
ED Electro−Deposited Coating
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 Exhaust
FE Fuel Economy
FF Front−Engine Front−Wheel−Drive
F/G Fuel Gauge
FIPG Formed In Place Gasket
FL Fusible Link
F/P Fuel Pump
FPU Fuel Pressure Up
Fr Front
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
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−INTRODUCTION TERMS
01−9
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
Abbreviations Meaning
H−FUSE High Current Fuse
HI High
HID High Intensity Discharge (Head Lamp)
HSG Housing
HT Hard Top
HWS Heated Windshield System
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
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 (Transaxle)
MT Mount
MTG Mounting
N Neutral
NA Natural Aspiration
No. Number
O2S Oxygen Sensor
O/D Overdrive
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01−10
−INTRODUCTION TERMS
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
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
PTC Positive Temperature Coefficient
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
RRS Rigid Rear 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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