check engine TOYOTA COROLLA VERSO 2004 Service Workshop Manual

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.

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.

A38025
SST 1 ± A
A38126
A38105
19±30
± STARTING & CHARGINGGENERATOR ASSY(90A) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Mount SST 2 in a vise.
(d) Insert SST 1 ± A, B into SST 2, and attach the pulley nut
to SST 2.
(e) Tighten the pulley nut, turn SST 1 ± A in the direction
shown in the illustration.
Torque: 111 N
m (1,125 kgf
cm, 81 ft
lbf)
(f) Remove the alternator form SST 2.
(g) Turn SST 1 ± B, and remove SST 1 ± A, B.
(h) Turn the pulley, and check that the pulley moves smooth-
ly.

A57794
SST (B)
Turn
A57795
A57796
SST
A57797
A57798
± STARTING & CHARGINGGENERATOR ASSY(130A) (1CD±FTV)
19±33
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(d) Insert the 3 tabs of SST (B) into the 3 holes on the pulley.
(e) To loosen the pulley, turn SST (B) in the direction shown
in the illustration.
(f) Remove the alternator from SST.
(g) Remove the pulley from the rotor shaft.
3. REMOVE GENERATOR ROTOR ASSY
(a) Remove the 4 through bolts.
(b) Using SST, remove the coil assembly.
SST 09950±40011 (09951±04020, 09952±04010,
09953±04020, 09954±04010, 09955±04071,
09958±04011)
(c) Remove the alternator washer.
(d) Remove the rotor from the drive end frame.
4. INSPECT GENERATOR ROTOR ASSY
(a) Using an ohmmeter, check that there is continuity be-
tween the slip rings.
Standard resistance: 2.3 ± 2.7
at 20
C (68
F)
(b) Using an ohmmeter, check that there is no continuity be-
tween the slip ring and rotor.

A57799
A57800
A57801
A57802
Socket
Wrench
(29 mm)
A57795
19±34
± STARTING & CHARGINGGENERATOR ASSY(130A) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Check that the slip rings are not rough or scored.
(d) Using vernier calipers, measure the slip ring diameter.
Standard diameter:
14.2 ± 14.4 mm (0.5591 ± 05669 in.)
Minimum diameter: 14.0 mm (0.551 in.)
5. INSPECT GENERATOR BRUSH HOLDER ASSY
(a) Using vernier calipers, measure the exposed brush
length.
Standard exposed length: 10.5 mm (0.4134 in.)
Minimum exposed length: 4.5 mm (0.177 in.)
HINT:
If the exposed length is less than minimum, replace the brush
holder.
6. INSTALL GENERATOR ROTOR ASSY
(a) Place the drive end frame.
(b) Install the rotor to the drive end frame.
(c) Place the alternator washer on the rear bearing.
(d) Using a socket wrench (29 mm)and press, slowly press
in the coil assembly.
(e) Install the 4 through bolts.
Torque: 5.8 N
m (59 kgf
cm, 51in.
lbf)