2004 TOYOTA COROLLA VERSO engine

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.

A62726
A62727
A62728
A62729
Rubber Cushion
19±10
± STARTING & CHARGINGSTARTER ASSY(2.0KW) (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
3. REMOVE STARTER YOKE ASSY
(a) Remove the 2 through bolts, and pull out the starter yoke
together with the armature.
4. REMOVE STARTER COMMUTATOR END FRAM ASSY
(a) Using a screwdriver, pry out the commutator end frame.
5. REMOVE STARTER ARMATURE ASSY
6. REMOVE STARTER BRUSH HOLDER ASSY
7. REMOVE PLANET CARRIER SHAFT SUB±ASSY
(a) Remove the rubber cushion.
(b) Remove the planet carrier shaft and starter clutch assem-
bly.
8. REMOVE STARTER PINION DRIVE LEVER

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.