2004 TOYOTA COROLLA VERSO Remove

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.

A63805
SST
A63806
SST
A63807
SST
A63808
A63809
± STARTING & CHARGINGSTARTER ASSY(2.0KW) (1CD±FTV)
19±15
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
18. INSTALL STARTER BRUSH HOLDER ASSY
(a) Install the 4 brush retainers and 4 brush springs to the
brush holder.
(b) Using SST, install the 4 brushes to the brush holder.
SST 09950±60010 (09951±00340)
(c) Attach the brush holder to the armature.
(d) Push the armature, and remove the SST.
19. INSTALL STARTER YOKE ASSY
(a) Align the cushion rubber on the starter drive housing with
the cutout of the starter yoke.
(b) Install the starter yoke and armature assembly.
(c) Align the commutator end frame with the brush holder
rubber part as shown in the illustration.
(d) Install the commutator end frame with the 2 through bolts.
6.5 N´m (66 kgf´cm, 58 in.´lbf)

1906H±02
A55633
B13607
A55635
A55636
Magnetic Finger
19±18
± STARTING & CHARGINGSTARTER ASSY(2.2KW) (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.

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.)

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.