2004 TOYOTA COROLLA VERSO clutch

010BA±03
01±12
± INTRODUCTIONTERMS
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionTOYOTA Distributorless Ignition (TDI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)

± INTRODUCTIONTERMS
01±13
1CD±FTV ENGINE REPAIR MANUAL (RM927E) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module±
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel±Shutoff±
ISCIdle Speed Control±
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure±
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature±
MVZManifold Vacuum Zone±
NVRAMNon±Volatile Random Access Memory±
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn±Board DiagnosticOn±Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module±
PNPPark/Neutral Position±
PROMProgrammable Read Only Memory±
PSPPower Steering Pressure±
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module±
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE±ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter±
SRIService Reminder Indicator±
SRTSystem Readiness Test±
STScan Tool±
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter

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.

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