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Toyota 1CD-FTV User Manual

Toyota 1CD-FTV
81 pages
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010B219
A54988
N·m (kgf·cm, ft·lbf) : Specified torque
z Nonreusable part
Camshaft Timing Tube Assy
Camshaft Drive Gear
Seal Washer
z Camshaft Setting Oil Seal
No. 2 Camshaft,
No. 4 Camshaft Subassy
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 Subassy
OVERHAUL
INTRODUCTION HOW TO USE THIS MANUAL
011
1CDFTV 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) Nonreusable parts, grease applied parts, precoated parts and tightening torque are specified in the
components drawing.
Example:
ProCarManuals.com

Table of Contents

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Toyota 1CD-FTV Specifications

General IconGeneral
BrandToyota
Model1CD-FTV
CategoryEngine
LanguageEnglish

Summary

How To Use This Manual

How To Use This Manual: General Information

Manual's structure, description, index, preparation, and repair procedures overview.

How To Use This Manual: Repair Procedures

Explains component drawings, disassembled parts, non-reusable parts, and torque.

How To Use This Manual: Procedure Format and Service Specifications

Procedure format, service specifications, terms definitions, and SI units.

How To Use This Manual: SI Unit Convention

Explains units are primarily SI, with metric and English alternatives.

Repair Instruction

Repair Instruction: Preventing Contamination and Scratches

Precautions for preventing foreign substances and scratches.

Repair Instruction: Part Cleaning and Reassembly

Instructions for cleaning parts, position/direction, and basic repair hints.

Repair Instruction: Safety and Hints

Safety for fuel parts, intake parts, hose clamps, and repair hints.

Manual Terminology

Manual Terminology: Abbreviations Used

Lists abbreviations and their meanings.

Manual Terminology: SAE and Toyota Terms Glossary

Lists SAE and Toyota terms and abbreviations.

Preparation and Special Tools

Preparation: Intake System and SST

Lists Special Service Tool for Turbocharger Pressure Gauge.

Preparation: Engine Mechanical Tools and SSTs

Lists various Special Service Tools (SSTs) for engine mechanical work.

Preparation: Starting & Charging Tools and SSTs

Lists Special Service Tools (SSTs) for starting and charging systems.

Standard Bolt Specifications

Standard Bolt Specifications: Determining Bolt Strength

Explains how to determine bolt strength based on markings.

Standard Bolt Specifications: Torque Values

Provides specified torque values for standard bolts.

Standard Bolt Specifications: Determining Nut Strength

Explains how to determine nut strength based on markings.

Service Data and Specifications

Service Data: Intake System

Provides service data for intake components.

Service Data: Engine Mechanical

Lists service data for various engine mechanical components.

Service Data: Engine Mechanical Torque

Provides torque specifications for engine mechanical parts.

Service Data: Lubrication System

Provides service data for lubrication components.

Service Data: Starting & Charging System

Lists service data for starting and charging components.

Service Data: Starting & Charging Torque

Provides torque specifications for starting and charging components.

Turbocharger Sub-Assy Inspection

Turbocharger Inspection: Turbine Shaft

Describes how to inspect the turbocharger turbine shaft.

Turbocharger Inspection: Actuator Operation

Describes how to inspect the turbocharger actuator operation.

Partial Engine Assembly Procedures

Partial Engine Assembly: Components Overview

Lists components of the partial engine assembly.

Partial Engine Assembly Overhaul: Oil Filler Cap and Nozzle Holder Seal Removal

Steps to remove oil filler cap and nozzle holder seals.

Partial Engine Assembly Overhaul: Cylinder Head Cover and Pipe Removal

Steps to remove cylinder head cover, leakage pipe, and clamps.

Partial Engine Assembly Overhaul: Injector and Timing Pulley Removal

Steps to remove injectors, exhaust injector, and camshaft timing pulley.

Partial Engine Assembly Overhaul: Crankshaft Pulley and Camshaft Seal Removal

Steps to remove crankshaft timing pulley and camshaft oil seal retainer.

Partial Engine Assembly Overhaul: Water Pump and Camshaft Removal

Steps to remove water pump assembly and camshafts.

Partial Engine Assembly Overhaul: Cylinder Head Removal

Steps to remove cylinder head sub-assembly.

Partial Engine Assembly Overhaul: Oil Pan and Strainer Removal

Steps to remove oil pan sub-assemblies and oil strainer.

Partial Engine Assembly Overhaul: Oil Regulator and Pump Removal

Steps to remove oil regulator and oil pump assemblies.

Partial Engine Assembly Overhaul: Rear Seal Retainer and Check Valve Removal

Steps to remove rear oil seal retainer and check valve.

Partial Engine Assembly Overhaul: Cylinder Head Set Bolt Inspection

Measures the tension portion diameter of the set bolt.

Partial Engine Assembly Overhaul: Drain Cock and Check Valve Installation

Installs drain cock and oil check valve sub-assemblies.

Partial Engine Assembly Overhaul: Oil Pump Assembly Installation

Applies seal packing, installs gasket, and oils pump components.

Partial Engine Assembly Overhaul: Oil Pan Sub-Assembly Installation

Applies seal packing and installs oil pan with bolts.

Partial Engine Assembly Overhaul: Cylinder Head Sub-Assembly Installation

Measures piston protrusion height for gasket selection.

Partial Engine Assembly Overhaul: Cylinder Head Gasket Procedures

Selects and places cylinder head gasket and cylinder head.

Partial Engine Assembly Overhaul: Cylinder Head Bolt Installation

Installs and tightens cylinder head bolts in sequence.

Partial Engine Assembly Overhaul: Camshaft Installation

Places camshaft carrier and installs camshaft.

Partial Engine Assembly Overhaul: No.2 Camshaft Installation

Installs No. 2 camshaft and bearing caps.

Partial Engine Assembly: Valve Clearance Inspection

Measures valve clearance at 16 places.

Partial Engine Assembly: Valve Clearance Adjustment

Adjusts valve clearance by removing and installing shims.

Partial Engine Assembly: Shim Selection Charts and Examples

Charts and examples for selecting adjusting shims for valve clearance.

Cylinder Block Assembly Procedures

Cylinder Block Assembly: Components Overview

Lists components of the cylinder block assembly.

Cylinder Block Assembly: Rod and Crankshaft Procedures

Inspection, measurement, and installation of rods and crankshaft.

Cylinder Block Assembly: Piston and Ring Procedures

Inspection and installation of pistons, rings, and related parts.

Cylinder Block Assembly: Block Inspection

Inspection of cylinder block flatness and bore diameter.

System Inspections and Components

System Inspections: Water Pump Assembly

Inspects water pump for coolant leaks and bearing condition.

System Inspections: Oil Pump Assembly

Measures oil pump tip and body clearance.

System Inspections: Starter Assembly Components

Lists components of the starter assembly.

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