TOYOTA COROLLA VERSO 2004 Service Repair Manual

A51187
A51188
A55639
A55640
A55641
19±20
± STARTING & CHARGINGSTARTER ASSY(2.2KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(e) Using vernier calipers, measure the commutator diame-
ter.
Standard diameter: 35 mm (1.378 in.)
Minimum diameter: 34 mm (1.3386 in.)
(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.)
6. INSPECT STARTER YOKE ASSY
(a) Using an ohmmeter, check that there is continuity be-
tween the lead wire and field coil brush lead.
(b) Using an ohmmeter, check that there is no continuity be-
tween the field coil brush lead and yoke.
(c) Using vernier calipers, measure the brush length.
Standard length: 16.5 mm (0.6496 in.)
Minimum length: 9 mm (0.3543 in.)

A55642
A55643
A55624
Free
Lock
B55687
Terminal 50
Terminal C
B55691
Terminal 50
Switch Body
± STARTING & CHARGINGSTARTER ASSY(2.2KW) (1CD±FTV)
19±21
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
7. INSPECT STARTER BRUSH HOLDER ASSY
(a) Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (±) brush holders.
(b) Using vernier calipers, measure the brush length.
Standard length: 16.5 mm (0.6496 in.)
Minimum length: 9 mm (0.3543 in.)
8. INSPECT STARTER CLUTCH SUB±ASSY
(a) Rotate the pinion gear clockwise, and check that it turns
freely. Try to rotate the pinion gear counterclockwise and
check that it locks.
9. INSPECT MAGNET STARTER SWITCH ASSY
(a) Using an ohmmeter, check that there is continuity be-
tween terminals 50 and C.
(b) Using an ohmmeter, check that there is continuity be-
tween terminal 50 and the switch body.

A51212
A55483
A55646
A55635
B13607
19±22
± STARTING & CHARGINGSTARTER ASSY(2.2KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
10. INSTALL STARTER ARMATURE ASSY
(a) Apply grease to the armature bearings.
(b) Using a press, press in armature.
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.
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.
(c) Place the clutch on the drive housing.
(d) Install the drive housing to the magnetic switch with the
2 bolts.
Torque: 9.3 N
m (95 kgf
cm, 82 in.
lbf)

A55647
A55633
± STARTING & CHARGINGSTARTER ASSY(2.2KW) (1CD±FTV)
19±23
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
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.
(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)

19094±02
A59147
PulleyDrive End FrameRotor
Alternator Washer
Rectifier End Frame
Voltage Regulator Brush Holder Cover
Brush HolderRear End Cover
N´m (kgf´cm, ft´lbf)
: Specified torque
111 (1125, 81)
Rectifier Holder
19±24
± STARTING & CHARGINGGENERATOR ASSY(90A) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
GENERATOR ASSY(90A) (1CD±FTV)
COMPONENTS

19095±02
A38024
A38025
SST 1 ± A
A38104
A38105
± STARTING & CHARGINGGENERATOR ASSY(90A) (1CD±FTV)
19±25
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OVERHAUL
1. REMOVE GENERATOR PULLEY
SST 09820±63010 (09820±06010, 09820±06020)
HINT:
SST1 ± A, B09820±06010
SST209820±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.
(b) Mount SST 2 in a vise.
(c) Insert SST 1 ± A, B into SST 2, and attach the pulley nut
to SST 2.
(d) To loosen the pulley nut, turn SST 1 ± A in the direction
shown in the illustration.
NOTICE:
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.
(f) Turn SST 1 ± B, and remove SST 1 ± A, B.
(g) Remove the pulley nut and pulley.

SST
Wooden block
A51918
A59143
F
B
Ohmmeter 19±26
± STARTING & CHARGINGGENERATOR ASSY(90A) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
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.
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.
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-
nals F and B 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-
tor.

A59144
E
F
Ohmmeter
A38108
A38109
A38110


B
P
1
P2P3
P4
EP
4P2P1
B
A36999
± STARTING & CHARGINGGENERATOR ASSY(90A) (1CD±FTV)
19±27
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(b) Using an ohmmeter, check the continuity between termi-
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-
tor.
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.
(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.
(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.
9. INSPECT GENERATOR HOLDER W/RECTIFIER
(a) Using an ohmmeter, connect one tester probe to the B or
E terminal and the other to each rectifier terminal.
(b) Reverse the polarity of the tester probes and repeat step
(a).
(c) Check that one shows continuity and the other shows no
continuity.

Length
P13535
17 mm
Socket
Wrench
A51920
Cord ClipA
B
A A
A64533
Inside
A51921
19±28
± STARTING & CHARGINGGENERATOR ASSY(90A) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
10. INSPECT BRUSH
(a) Using vernier calipers, measure the exposed brush
length.
Standard exposed 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.
11. INSTALL GENERATOR ROTOR ASSY
(a) Install the generator rotor.
(b) Install the alternator washer to the rotor.
12. INSTALL ALTERNATOR RECTIFIRE END FRAME
(a) Using a 17 mm socket wrench and press, slowly press in
the rectifier end frame.
(b) Install the cord clip and 4 nuts.
Torque:
Nut A 4.5 N
m (46 kgf
cm, 39 in.
lbf)
Nut B 5.4 N
m (55 kgf
cm, 47 in.
lbf)
(c) Install the seal plate on the rectifier end frame.
(d) Install the 4 rubber insulators on the lead wires.
NOTICE:
Be careful of the rubber insulators installation direction.
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)

Upward
A51919
A38024
± STARTING & CHARGINGGENERATOR ASSY(90A) (1CD±FTV)
19±29
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
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
(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.
(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, B09820±06010
SST209820±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.