TOYOTA COROLLA VERSO 2004 Service Repair Manual

1704C±02
A55604
A55605
± LUBRICATIONOIL PUMP ASSY (1CD±FTV)
17±1
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
OIL PUMP ASSY (1CD±FTV)
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.)
(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.)

190AE±01
A62712
Starter Armature Assy
Starter Yoke Assy
Starter Brush Holder Assy
Rear End Frame Cover
Drive Housing
Starter Clutch Sub±Assy Ball
Spring
Magnetic Switch
N´m (kgf´cm, ft´lbf)
: Specified torque
5.9 (60, 52 in.´lbf)
5.9 (60, 52 in.´lbf)
5.9 (60, 52 in.´lbf)
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
19±1
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
STARTER ASSY(1.4KW) (1CD±FTV)
COMPONENTS

1906G±02
A55610
A55611
A55612
A55613
Magnetic Finger
19±2
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
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.
2. REMOVE STARTER CLUTCH SUB±ASSY
(a) Remove the 2 bolts and drive housing.
(b) Remove the clutch from the drive housing.
(c) Using a magnetic finger, remove the ball from the clutch
shaft hole.

A55614
A51226
A55615
A55616
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
19±3
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
3. REMOVE STARTER BRUSH HOLDER ASSY
(a) Remove the 2 screws and end frame from the yoke.
(b) Using a screwdriver, hold the spring back disconnect the
brush from the brush holder. Disconnect the 4 brushers
and remove the brush holder.
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.
(b) Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.

A55617
A55618
A51188
A55619
A55620
19±4
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(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.)
(e) Using vernier calipers, measure the commutator diame-
ter.
Standard diameter: 30 mm (1.1811 in.)
Minimum diameter: 29 mm (1.1417 in.)
(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.)
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.

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

A55626
Terminal 50
Switch Body
A51226
A55614
A55627
19±6
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(b) Using an ohmmeter, check that there is continuity be-
tween terminal 50 and the switch body.
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.
(c) Install the end frame to the yoke with the 2 screws.
Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf)
12. INSTALL STARTER CLUTCH SUB±ASSY
(a) Apply grease to the ball.
(b) Insert the ball into the clutch shaft hole.

A55612
A55611
A55628
A55610
± STARTING & CHARGINGSTARTER ASSY(1.4KW) (1CD±FTV)
19±7
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Place the clutch on the drive housing.
(d) Install the drive housing to the magnetic switch with the
2 bolts.
Torque: 5.9 N
m (60 kgf
cm, 52 in.
lbf)
13. INSTALL STARTER YOKE ASSY
(a) Align the protrusion of the yoke with the cutout of the mag-
netic switch.
(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)

190AF±01
A62721
Return Spring
Plunger
Brush Retainer

Starter Drive Housing
Assy Planet Carrier Shaft
Sub±assy
Starter
Commutator
End Fram
CoverRubber Cushion
Magnet Stater
Switch AssyStarter Pinion Drive Lever
Stop Collar
Snap Ring Starter Clutch
Sub±assy
Starter Yoke
Assy
Starter Commutator
End Frame Assy
Brush HolderThrust Washer
Starter Armature
Assy Brush Spring Lock Plate

Non±reusable part
6.5 (66, 58 in.´lbf)
5.0 (51, 44 in.´lbf)
1.7 (17, 15 in.´lbf)
8.0 (82, 71 in.´lbf)
x 4
N´m (kgf´cm, ft´lbf) : Specified torque
19±8
± STARTING & CHARGINGSTARTER ASSY(2.0KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
STARTER ASSY(2.0KW) (1CD±FTV)
COMPONENTS

190AG±01
A62722
A62723
A62724
A62725
± STARTING & CHARGINGSTARTER ASSY(2.0KW) (1CD±FTV)
19±9
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
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.
(c) Pull the plunger, and disconnect the plunger hook from
the upper side of the drive lever.
2. REMOVE STARTER COMMUTATOR END FRAM
COVER
(a) Remove the 2 screws and end fram cover.
(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.