Toyota Corolla (2004+). Manual - part 13

 

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Toyota Corolla (2004+). Manual - part 13

 

 

19-17
STARTING & CHARGING
- GENERATOR ASSY
190CB-01
COMPONENTS
Drive End Frame
Pulley
F Front Bearing
3.0 (31, 27 in.·lbf)
Rotor
111 (1,132, 82)
F Rear Bearing
4.5 (46, 40 in.·lbf)
Washer
2.9 (30, 26 in.·lbf)
Terminal Insulator
Bearing Retainer Plate
Rectifier Holder
Bearing Cover
2.0 (20, 18 in.·lbf)
Brush Cover
Plate Seal
2.0 (20, 18 in.·lbf)
Rectifier
Terminal Plate
End Frame
Cord Clip
Regulator
Brush Holder
5.4 (55, 48 in.·lbf)
4.1 (42, 36 in.·lbf)
Terminal Insulator
4.4 (45, 39 in.·lbf)
Rear End Cover
3.9 (40, 35 in.·lbf)
N m (kgf·cm, ft·lbf)
: Specified torque
F Non-reusable part
A65928
19-18
STARTING & CHARGING
- GENERATOR ASSY
190CC-01
OVERHAUL
1.
REMOVE GENERATOR PULLEY
SST
SST
SST
09820-63010 (09820-06010, 09820-06020)
1 - B
1 - A
HINT:
SST1 - A, B
09820-06010
SST2
09820-06020
(a) Hold SST 1 - A with a torque wrench, and tighten SST 1
- B clockwise to the specified torque.
Torque: 39 Nm (398 kgfcm, 29 ftlbf)
A62753
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.
SST 2
A62754
(d) To loosen the pulley nut, turn SST 1 - A in the direction
shown in the illustration.
NOTICE:
SST
To prevent damage to the rotor shaft, do not loosen the
1 - A
pulley nut more than one-half of a turn.
(e) Remove the alternator form SST 2.
A62755
SST
(f)
Turn SST 1 - B, and remove SST 1 - A, B.
1 - A
(g) Remove the pulley nut and pulley.
SST
1 - B
A62756
19-19
STARTING & CHARGING
- GENERATOR ASSY
2.
REMOVE GENERATOR BRUSH HOLDER ASSY
(a) Remove the nut and terminal insulator.
(b) Remove the screw, nut and terminal plate.
(c)
Remove the 2 nuts and rear end cover.
(d) Remove the brush cover from the brush holder.
(e) Remove the 2 screw and brush holder.
(f)
Remove the plate seal.
3.
REMOVE GENERATOR REGULATOR ASSY
(a) Remove the 3 screws and regulator.
4.
REMOVE GENERATOR HOLDER W/RECTIFIER
(a) Remove the 4 screws and holder w/ rectifier.
5.
REMOVE GENERATOR RECTIFIER END FRAME
(a) Remove the plate seal from the rectifier end frame.
SST
(b) Remove the 4 terminal insulator, 4 nuts and cord clip.
(c)
Using SST, remove the rectifier end frame.
SST
09286-46011
A62757
6.
REMOVE GENERATOR ROTOR ASSY
(a) Remove the washer from the rotor.
(b) Remove the rotor from drive end frame.
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-
F
nals F and B are exchanged, there is continuity in one
way but no continuity in another way.
B
A62881
(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
E
way but no continuity in another way.
F
A62882
19-20
STARTING & CHARGING
- GENERATOR ASSY
8.
INSPECT GENERATOR REGULATOR ASSY
(a) Using an ohmmeter, check that there is continuity be-
Slip Ring
tween the slip rings.
Standard resistance: 2.1 - 2.5
W at 20FC (68FF)
A62758
(b) Using an ohmmeter, check that there is no continuity be-
Rotor
tween the slip ring and rotor.
Slip Ring
A62759
(c)
Using a vernier calipers, measure the slip ring diameter.
Standard diameter: 14.2 - 14.4 mm (0.559 - 0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
A62760
9.
INSPECT BRUSH
(a) Using a vernier calipers, measure the exposed brush
length.
Standard exposed length:
9.5 - 11.5 mm (0.374 - 0.453 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
A62762
10. INSTALL GENERATOR ROTOR ASSY
(a) Install the rotor to the drive end frame.
(b) Install the washer on the rotor.
B00219
19-21
STARTING & CHARGING
- GENERATOR ASSY
(c)
Using a socket wrench 29 and press, slowly press in the
Socket Wrench
rectifier end frame.
29
B00211
(d) Install the cord clip and 4 nuts.
B
A
Torque:
Nut A 4.5 Nm (46 kgfcm, 40 in.lbf)
Nut B 5.4 Nm (55 kgfcm, 48 in.lbf)
Cord Clip
A
A
A62763
11. INSTALL GENERATOR HOLDER W/RECTIFIER
(a) Install the holder w/ rectifier with 4 screws.
Torque: 2.9 Nm (30 kgfcm, 26 in.lbf)
12. INSTALL GENERATOR REGULATOR ASSY
(a) Install the regulator with the 3 screw.
Torque: 2.0 Nm (20 kgfcm, 18 in.lbf)
13. INSTALL GENERATOR BRUSH HOLDER ASSY
(a) Place the plate seal on the brush holder.
(b) Install the brush holder with the 2 screws.
Torque: 2.0 Nm (20 kgfcm, 18 in.lbf)
NOTICE:
Pay attention to the holder installation direction.
(c)
Place the brush cover on the brush holder.
(d) Install the rear end cover with the 2 nuts.
Protrusion
A62764
Torque: 4.4 Nm (45 kgfcm, 39 in.lbf)
(e) Install the terminal plate with the screw and nut.
Torque:
Bolt 3.9 Nm (40 kgfcm, 35 in.lbf)
Nut 4.4 Nm (45 kgfcm, 39 in.lbf)
(f)
Install the terminal insulator withe the nut.
Torque: 4.1 Nm (42 kgfcm, 36 in.lbf)
19-22
STARTING & CHARGING
- GENERATOR ASSY
14. INSTALL GENERATOR PULLEY
SST
SST
SST
09820-63010 (09820-06010, 09820-06020)
1 - B
1 - A
HINT:
SST1 - A, B
09820-06010
SST2
09820-06020
(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
A62753
- B clockwise to the specified torque.
Torque: 39 Nm (398 kgfcm, 29 ftlbf)
NOTICE:
Check that SST is secured to the pulley shaft.
(c)
Mount SST 2 in a vise.
(d) Insert SST 1 - A, B into SST 2, and attach the pulley nut
to SST 2.
SST 2
A62754
(e) Tighten the pulley nut, turn SST 1 - A in the direction
shown in the illustration.
Torque: 111 Nm (1,132 kgfcm, 82 ftlbf)
SST
(f)
Remove the alternator form SST 2.
1 - A
A62765
SST
(g) Turn SST 1 - B, and remove SST 1 - A, B.
1 - A
(h) Turn the pulley, and check that the pulley moves smooth-
ly.
SST
1 - B
A62756
19-16
STARTING & CHARGING
- GENERATOR ASSY
GENERATOR ASSY
190CA-01
REPLACEMENT
1.
REMOVE ENGINE UNDER COVER RH
2.
REMOVE FAN AND GENERATOR V BELT
(See page 14-4)
B00145
3.
REMOVE GENERATOR ASSY
(a) Disconnect the wire clamp from the wire clip on the recti-
fire end frame.
(b) Remove the rubber cap and nut, and disconnect the alter-
nator wire.
(c)
Disconnect the alternator connector.
A65924
(d) Remove the 2 bolts and alternator.
A65925
4.
INSTALL GENERATOR ASSY
Torque:
12 mm head 25 Nm (250 kgfcm, 18 ftlbf)
14 mm head 54 Nm (550 kgfcm, 39 ftlbf)
A65925
19-1
STARTING & CHARGING
- STARTING SYSTEM (1ZZ-FE) (April, 2003)
STARTING SYSTEM (1ZZ-FE) (April, 2003)
190QO-02
INSPECTION
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
(b) Perform the hold-in test.
Disconnect
(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
(c)
Check the clutch pinion gear returns.
(1)
Disconnect the negative (-) lead from the starter
Disconnect
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
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 Nm (102 kgfcm, 7 ftlbf)
A83797
(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.
Terminal 30
Specified current: 90 A or less at 11.5 V
Terminal 50
If the current is not as specified, replace the starter repair ser-
Ammeter
Battery
A84791
vice kit.
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
3 - 5
(Apply battery voltage to terminals 1 and 2)
If the result is not as specified, replace the starter relay.
19-13
STARTING & CHARGING
- CHARGING SYSTEM
190C9-01
ON-VEHICLE INSPECTION
1.
CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell (Maintenance-Free Battery).
(1)
If under the lower level, replace the battery (or add distilled water if possible) and check the charg-
ing system.
(b) Check the electrolyte quantity of each cell (Except Maintenance-Free Battery).
(1)
If under the lower level, add distilled water.
2.
CHECK BATTERY SPECIFIC GRAVITY
(Except Maintenance-Free Battery)
(a) Check the specific gravity of each cell.
Standard specific gravity: 1.25 - 1.29 at 20
_C (68_F)
HINT:
If the specific gravity is less than specification, charge the bat-
tery.
A01259
3.
CHECK BATTERY VOLTAGE
(a) After having driven the vehicle and in the case that 20
minutes have not passed after having stopped the en-
gine, turn the ignition switch ON and turn on the electrical
system (headlight, blower motor, rear defogger etc.) for
60 seconds to remove the surface charge.
(b) Turn the ignition switch OFF and turn off the electrical sys-
tems.
A01260
(c)
Measure the battery voltage between the negative (-)
and positive (+) terminals of the battery.
Standard voltage: 12.5 - 12.9 V at 20
_C (68_F)
HINT:
If the voltage is less than specification, charge the battery.
(d) Check the indicator as shown in the illustration.
HINT:
Blue
White
Red
F
Blue: OK
F
White: Charging Necessary
F
Red: Insufficient Water
Z11580
4.
CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Check that the battery terminals are not loose or corroded.
(b) Check the fusible link, H-fuses and fuses for continuity.
19-14
STARTING & CHARGING
- CHARGING SYSTEM
5.
INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:
F
If any defect has been found, replace the drive belt.
F
Cracks on the rib side of a belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be
replaced.
B00543
(b) Check that it fits properly in the ribbed grooves.
HINT:
Check with your hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.
B00540
6.
VISUALLY CHECK ALTERNATOR WIRING
(a) Check that the wiring is in good condition.
7.
LISTEN FOR ABNORMAL NOISES FROM ALTERNATOR
(a) Check that there is no abnormal noise from the alternator while the engine is running.
8.
INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge warning light comes on.
(b) Start the engine. Check that the light goes off.
HINT:
If the light does not operate as specified, troubleshoot the charge warning light circuit.
9.
INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) If a battery/alternator tester is available, connect the tes-
ter to the charging circuit as permanufacturer’s instruc-
tions.
Ammeter
(b) If a tester is not available, connect a voltmeter to the
Disconnect Wire
charging circuit as follows.
from Terminal B
(1)
Disconnect to the wire from terminal B of the alter-
nator and connect it to the negative (-) lead of the
Battery
ammeter.
(2)
Connect the positive (+) lead of the ammeter to ter-
Alternator
minal B of the alternator.
Voltmeter
(3)
Connect the positive (+) lead of the voltmeter to ter-
CH0732
minal B of the alternator.
(4)
Ground the negative (-) lead of the voltmeter.
19-15
STARTING & CHARGING
-
CHARGING SYSTEM
(c)
Check the charging circuit (DENSO made).
(1)
With the engine running from idle to 2,000 rpm,
check the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 12.9 - 14.9 V
10. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower
switch at ”HI”.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
HINT:
F
If the ammeter reading is less than standard amperage, repair the alternator.
F
If the battery is fully charged, the indication will sometimes be less than standard amperage.
19-12
STARTING & CHARGING
- CHARGING SYSTEM
CHARGING SYSTEM
190C8-01
PRECAUTION
1.
Check that the battery cables are connected to the correct terminals.
2.
Disconnect the battery cables when the battery is given a quick charge.
3.
Do not perform tests with a high voltage insulation resistance tester.
4.
Never disconnect the battery while the engine is running.
5.
Check that the charging cable is tightened on terminal B of the alternator and the fuse box.
6.
Do not check whether the alternator generates or not with connecting terminal F to other termi-
nal.
19-3
STARTING & CHARGING
- STARTER ASSY (1ZZ-FE) (April, 2003)
STARTER ASSY (1ZZ-FE) (April, 2003)
190QP-02
COMPONENTS
37 (378, 27)
Starter Assy
37 (378, 27)
Starter Connector
Starter Center Bearing
Clutch Sub-assy
Planetary Gear
Starter Armature Plate
Starter Yoke Assy
Starter Wire
9.8 (100, 7)
Starter Armature Assy
Starter Commutator
End Frame Assy
6.0 (61, 53 in.lbf)
7.5 (76, 66 in.lbf)
x2
x2
Washer
Repair Service Starter Kit
F Snap Ring
Starter Commutator
End Frame Cover
Starter Drive Housing
10 (102, 7)
Starter Drive Lever
Assy
Set Pin
N·m (kgf·cm, ft·lbf)
: Specified torque
F Non-reusable part
A84619
19-5
STARTING & CHARGING
- STARTER ASSY (1ZZ-FE) (April, 2003)
190QR-03
OVERHAUL
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

 

 

 

 

 

 

 

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