19 - Starting and Charging.pdf

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19–1
STARTING & CHARGING
–
STARTING SYSTEM (1ZZ–FE) (April, 2003)
STARTING SYSTEM (1ZZ–FE) (April, 2003)
INSPECTION
190QO–02
1. INSPECT STARTER ASSY
NOTICE:
These tests must be performed within 3 to 5 seconds to
prevent burnout of the coil.
(a) Perform the pull–in test.
(1) Remove the nut, then disconnect the lead wire from
terminal C.
A83797
(2) Connect the battery to the starter repair service kit
as shown in the illustration. Check that the clutch
pinion gear is extended.
If the clutch pinion gear is not extended, replace the starter re-
pair service kit.
Terminal C
Terminal 50
Battery
A84765
Disconnect
(b) Perform the hold–in test.
(1) Disconnect the negative (–) lead from terminal C
with the lead wire disconnected from terminal C.
Check that the clutch pinion gear remains ex-
tended.
If the clutch pinion gear returns, replace the starter repair ser-
vice kit.
Terminal C
Battery
A84789
Disconnect
(c) Check the clutch pinion gear returns.
(1) Disconnect the negative (–) lead from the starter
body. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return, replace the starter re-
pair service kit.
Battery
A84790
2004 COROLLA (RM1037U)
Author:
Date:
1210
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19–2
STARTING & CHARGING
–
STARTING SYSTEM (1ZZ–FE) (April, 2003)
(d) Perform the no–load performance test.
(1) Connect the lead wire to terminal C with the nut.
Make sure that the lead is not grounded.
Torque: 10 N
m (102 kgf
V
cm, 7 ft
V
lbf)
A83797
Terminal 30
(2) Clamp the starter in a vise.
(3) Connect the battery and an ammeter to the starter
as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily
with the clutch pinion gear extended. Check that the
ammeter reads the specified current.
Specified current: 90 A or less at 11.5 V
If the current is not as specified, replace the starter repair ser-
vice kit.
Terminal 50
Ammeter
Battery
2. INSPECT STARTER RELAY ASSY
(a) Check the continuity.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Tester Connection
Specified Condition
1 – 2
Continuity
3 – 5
No Continuity
A32779
Continuity
(Apply battery voltage to terminals 1 and 2)
If the result is not as specified, replace the starter relay.
3 – 5
2004 COROLLA (RM1037U)
Author:
Date:
1211
V
A84791
256353444.007.png
19–3
STARTING & CHARGING
–
STARTER ASSY (1ZZ–FE) (April, 2003)
STARTER ASSY (1ZZ–FE) (April, 2003)
COMPONENTS
190QP–02
37 (378, 27)
Starter Assy
37 (378, 27)
Starter Connector
Starter Center Bearing
Clutch Sub–assy
Planetary Gear
Starter Armature Plate
Starter Wire
9.8 (100, 7)
Starter Yoke Assy
Starter Armature Assy
Starter Commutator
End Frame Assy
6.0 (61, 53 in. V lbf)
7.5 (76, 66 in.
lbf)
x2
x2
Washer
Repair Service Starter Kit
Snap Ring
Starter Commutator
End Frame Cover
10 (102, 7)
Starter Drive Lever
Set Pin
Starter Drive Housing
Assy
N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part
A84619
2004 COROLLA (RM1037U)
Author:
Date:
1212
V
256353444.008.png 256353444.009.png 256353444.001.png 256353444.002.png 256353444.003.png
19–4
STARTING & CHARGING
–
STARTER ASSY (1ZZ–FE) (April, 2003)
REPLACEMENT
1.
190QQ–02
DISCONNECT BATTERY NEGATIVE TERMINAL
2.
REMOVE ENGINE UNDER COVER RH
Terminal Cover
3. REMOVE STARTER ASSY
(a) Disconnect the starter connector.
(b) Open the terminal cover.
(c) Remove the nut, then disconnect the starter wire.
(d) Remove the 2 bolts, then remove the starter.
(d)
(c)
(a)
(d)
A51076
4.
INSTALL STARTER ASSY
Torque:
37 N
V
m (378 kgf
V
cm, 27 ft
lbf) for bolt
9.8 N
V
m (100 kgf
V
cm, 7 ft
V
lbf) for nut
5.
INSTALL ENGINE UNDER COVER RH
6.
CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 N
m (55 kgf
V
cm, 48 in.
lbf)
2004 COROLLA (RM1037U)
Author:
Date:
1213
V
V
V
256353444.004.png
19–5
STARTING & CHARGING
–
STARTER ASSY (1ZZ–FE) (April, 2003)
OVERHAUL
190QR–03
1. REMOVE REPAIR SERVICE STARTER KIT
(a) Remove the nut, then disconnect the lead wire from termi-
nal C.
A83797
(b) Remove the 2 screws which are used to secure the repair
service starter kit to the starter drive housing.
(c) Remove the repair service starter kit.
(d) Remove the return spring and plunger from the starter
drive housing.
A83798
2. REMOVE STARTER YOKE ASSY
(a) Remove the 2 through bolts, then pull out the starter yoke
together with the starter commutator end frame.
A83799
(b) Remove the starter yoke from the starter commutator end
frame.
A83800
2004 COROLLA (RM1037U)
Author:
Date:
1214
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