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1、190QO02A83797A84765Terminal CTerminal 50BatteryA84789DisconnectBatteryTerminal CA84790DisconnectBatterySTARTING & CHARGING STARTING SYSTEM (1ZZFE) (April, 2003)1911210Author : Date :2004 COROLLA (RM1037U)STARTING SYSTEM (1ZZFE) (April, 2003)INSPECTION1. INSPECT STARTER ASSYNOTICE:These tests must be
2、 performed within 3 to 5 seconds toprevent burnout of the coil.(a) Perform the pullin test.(1) Remove the nut, then disconnect the lead wire fromterminal C.(2) Connect the battery to the starter repair service kitas shown in the illustration. Check that the clutchpinion gear is extended.If the clutc
3、h pinion gear is not extended, replace the starter re-pair service kit.(b) Perform the holdin test.(1) Disconnect the negative () lead from terminal Cwith the lead wire disconnected from terminal C.Check that the clutch pinion gear remains ex-tended.If the clutch pinion gear returns, replace the sta
4、rter repair ser-vice kit.(c) Check the clutch pinion gear returns.(1) Disconnect the negative () lead from the starterbody. Check that the clutch pinion gear returns.If the clutch pinion gear does not return, replace the starter re-pair service kit.A83797A84791BatteryAmmeterTerminal 50Terminal 30A32
5、779192STARTING & CHARGING STARTING SYSTEM (1ZZFE) (April, 2003)1211Author : Date :2004 COROLLA (RM1037U)(d) Perform the noload 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)(2) Clamp the starter in a vi
6、se.(3) Connect the battery and an ammeter to the starteras shown in the illustration.(4) Check that the starter rotates smoothly and steadilywith the clutch pinion gear extended. Check that theammeter reads the specified current.Specified current: 90 A or less at 11.5 VIf the current is not as speci
7、fied, replace the starter repair ser-vice kit.2. INSPECT STARTER RELAY ASSY(a) Check the continuity.(1) Using an ohmmeter, check for continuity betweeneach terminal.Specified condition:Tester Connection Specified Condition1 2 Continuity3 5 No Continuity3 5Continuity(Apply battery voltage to terminal
8、s 1 and 2)If the result is not as specified, replace the starter relay.190QP02A84619Starter AssyStarter ConnectorStarter Wire9.8 (100, 7)37 (378, 27)6.0 (61, 53 in.lbf)x2Starter Commutator End Frame CoverSnap RingWasherStarter Commutator End Frame AssyStarter Yoke AssyStarter Armature AssyStarter Ar
9、mature PlatePlanetary GearStarter Center Bearing Clutch SubassyRepair Service Starter KitStarter Drive Lever Set PinStarter Drive Housing Assy10 (102, 7)7.5 (76, 66 in.lbf)x2Nonreusable partNm (kgfcm, ftlbf) : Specified torque37 (378, 27)STARTING & CHARGING STARTER ASSY (1ZZFE) (April, 2003)1931212A
10、uthor : Date :2004 COROLLA (RM1037U)STARTER ASSY (1ZZFE) (April, 2003)COMPONENTS190QQ02A51076(a)(c)(d)(d)Terminal Cover194STARTING & CHARGING STARTER ASSY (1ZZFE) (April, 2003)1213Author : Date :2004 COROLLA (RM1037U)REPLACEMENT1. DISCONNECT BATTERY NEGATIVE TERMINAL2. REMOVE ENGINE UNDER COVER RH3.
11、 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.4. INSTALL STARTER ASSYTorque: 37 Nm (378 kgfcm, 27 ftlbf) for bolt9.8 Nm (100 kgfcm, 7 ftlbf) for nut5. INSTALL E
12、NGINE UNDER COVER RH6. CONNECT BATTERY NEGATIVE TERMINALTorque: 5.4 Nm (55 kgfcm, 48 in.lbf)190QR03A83797A83798A83799A83800STARTING & CHARGING STARTER ASSY (1ZZFE) (April, 2003)1951214Author : Date :2004 COROLLA (RM1037U)OVERHAUL1. REMOVE REPAIR SERVICE STARTER KIT(a) Remove the nut, then disconnect
13、 the lead wire from termi-nal C.(b) Remove the 2 screws which are used to secure the repairservice starter kit to the starter drive housing.(c) Remove the repair service starter kit.(d) Remove the return spring and plunger from the starterdrive housing.2. REMOVE STARTER YOKE ASSY(a) Remove the 2 thr
14、ough bolts, then pull out the starter yoketogether with the starter commutator end frame.(b) Remove the starter yoke from the starter commutator endframe.A83803A83801A83802Snap Ring PliersA83804A83805196STARTING & CHARGING STARTER ASSY (1ZZFE) (April, 2003)1215Author : Date :2004 COROLLA (RM1037U)3.
15、 REMOVE STARTER ARMATURE PLATE(a) Remove the starter armature plate from the starter yoke.4. REMOVE STARTER COMMUTATOR END FRAMECOVER(a) Using a screwdriver, remove the starter commutator endframe cover.5. REMOVE STARTER ARMATURE ASSY(a) Using snap ring pliers, remove the snap ring.(b) Remove the wa
16、sher and starter armature from the startercommutator end frame.6. REMOVE PLANETARY GEAR(a) Remove the 3 planetary gears from the starter centerbearing clutch.7. REMOVE STARTER CENTER BEARING CLUTCHSUBASSY(a) Remove the starter center bearing clutch together withthe starter drive lever set pin from the starter drive hous-ing.A73990A58586A84614ContinuityTerminal CTerminal 50OhmmeterA84615ContinuityTerm
