check engine TOYOTA COROLLA VERSO 2004 Service Service Manual

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.

A62730
A62953
A62961
Continuity
A62962
No Continuity
A62963
± STARTING & CHARGINGSTARTER ASSY(2.0KW) (1CD±FTV)
19±11
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
9. REMOVE STARTER CLUTCH SUB±ASSY
(a) Using a screwdriver, tap in the stop collar towards the
starter clutch.
(b) Using a screwdriver, pry out the snap ring.
(c) Remove the stop collar from the shaft.
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.
(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.
(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.

A62964
A62965
A62966
A62967
Free
Lock 19±12
± STARTING & CHARGINGSTARTER ASSY(2.0KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(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.
(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.
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.
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
turns freely. Try to rotate the clutch pinion gear counter-
clockwise and check that it locks.
If necessary, replace the starter clutch.

A62968
Return
A63797
Terminal C Terminal 50
Continuity
A63798
Switch Body
Terminal 50
Continuity
A63799
Turn
± STARTING & CHARGINGSTARTER ASSY(2.0KW) (1CD±FTV)
19±13
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
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.
(b) Using an ohmmeter, check that there is continuity be-
tween terminals 50 and C.
If there is no continuity, replace the magnetic switch.
(c) Using an ohmmeter, check that there is continuity be-
tween terminal 50 and the switch body.
If there is no continuity, replace the magnet starter switch.
14. INSPECT PLANET CARRIER SHAFT SUB±ASSY
(a) Turn the shaft, and check that it is not rough or worn.
If it feels rough or worn, replace the planet carrier shaft.
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.

A63800
A63801
A63802
A63803
Knock
Pin Hole
Drive Housing
Knock Pin
Drive Lever
A63804
Rubber Cushion
19±14
± STARTING & CHARGINGSTARTER ASSY(2.0KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(b) Place the starter clutch and stop collar on the planet carri-
er shaft as shown in the illustration.
(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.
(f) Using a screwdriver, tap the stop collar to slide it onto the
snap ring.
17. INSTALL PLANET CARRIER SHAFT SUB±ASSY
(a) Set the planet carrier shaft and drive lever in position as
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.
(d) Install the rubber cushion.

A63810
A62724
A63811
A62722
19±16
±
STARTING & CHARGING STARTER ASSY(2.0KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
20. I N S TA L L S TA R T E R C O M M U TATO R E N D F R A M 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)
(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)
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.
(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)

A51182
A51183
A55637
A55638
A51186
± STARTING & CHARGINGSTARTER ASSY(2.2KW) (1CD±FTV)
19±19
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
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.
4. REMOVE STARTER ARMATURE ASSY
(a) Using a plastic±faced hammer, tap the yoke and remove
the armature.
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.
(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.)

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)