Toyota Corrolla 2005 - 2006 Sistema de Arranque y Carga

2005 Toyota Corolla LE
2005-06 ENGINE Starting & Charging - Corolla
2005-06 ENGINE
Starting & Charging - Corolla
STARTING SYSTEM (1ZZ-FE/2ZZ-GE)

INSPECTION
1. INSPECT STARTER ASSY
NOTE: 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.
Fig. 1: Disconnecting Lead Wire From Terminal C
martes, 9 de junio de 2020 15:49:59

15:49:46 Page 1 © 2011 Mitchell Repair Information Company, LLC.
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2. Connect the battery to the starter repair service kit as shown. Check that the clutch pinion
gear is extended.
If the clutch pinion gear is not extended, replace the magnet switch.
Fig. 2: Connecting Battery To Starter

b. Perform the hold-in test.

1. Disconnect the negative (-) lead from terminal C.Check that the clutch pinion gear remains
extended.
If the clutch pinion gear returns, replace the magnet switch body.
martes, 9 de junio de 2020 15:49:46 Page 2 © 2011 Mitchell Repair Information Company, LLC.
Fig. 3: Disconnecting Negative (-) Lead From Terminal

c. Check the operation.

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 magnet switch.
Fig. 4: Disconnecting Negative (-) Lead From Starter Body

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.cm, 7 ft.lbf)
Fig. 5: Connecting Lead Wire To Terminal C With Nut

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 magnet switch.
Fig. 6: Checking Starter Rotates Smoothly And Steadily With Clutch Pinion Gear Extended
2. INSPECT STARTER RELAY ASSY

a. Check the resistance.
1. Using an ohmmeter, measure the resistance between the terminals.
Standard:
TESTER CONNECTION - SPECIFIED CONDITION

Tester Connection Specified Condition
3-5 10ohms or higher
3-5 Below 1 ohms (Apply battery voltage to terminals 1 and 2)
If the resistance is not as specified, replace the starter relay.
Fig. 7: Measuring Resistance Between Terminals Using Ohmmeter

3. INSPECT IGNITION OR STARTER SWITCH ASSY

a. Measure the ignition starter switch resistance.
Standard:
TESTER CONNECTION - SPECIFIED CONDITION

Switch Position TeSter Connection Specified Condition
Lock - 10ohms or higher
ACC 1-3 Below 1 ohms
ON 1 - 2 -3 5 - 6 Below 1 ohms
START 1 - 2 -4 5 - 6 Below 1 ohms
If the resistance is not as specified, replace the ignition starter switch.
Fig. 8: Measuring Ignition Starter Switch Resistance

IGNITION OR STARTER SWITCH ASSY (1ZZ-FE/2ZZ-GE)

REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL

2. REMOVE STEERING COLUMN COVER LWR
a. Remove the 3 screws, then remove the steering column cover LWR.
Fig. 9: Removing Steering Column Cover LWR

3. REMOVE IGNITION OR STARTER SWITCH ASSY

a. Disconnect the ignition switch connector and unlock the warning switch connector.
Fig. 10: Disconnecting Ignition Switch Connector And Unlock Warning Switch Connector
b. Disconnect the unlock warning switch connector from the ignition switch assy.
Fig. 11: Disconnecting Unlock Warning Switch Connector From Ignition Switch Assy
c. Disconnect the wire harness from the steering assy.
Fig. 12: Disconnecting Wire Harness From Steering Assy

d. Remove the 2 screws, then remove the ignition switch assy.
Fig. 13: Removing Ignition Switch Assy

4. INSTALL IGNITION OR STARTER SWITCH ASSY

a. Install the ignition switch assy with the 2 screws.
Fig. 14: Installing Ignition Switch Assy With Screws

b. Connect the wire harness to the steering assy.
Fig. 15: Connecting Wire Harness To Steering Assy

c. Connect the unlock warning switch connector to the ignition switch assy.
Fig. 16: Connecting Unlock Warning Switch Connector To Ignition Switch Assy
d. Connect the ignition switch connector and unlock warning switch connector.
Fig. 17: Connecting Ignition Switch Connector And Unlock Warning Switch Connector
5. INSTALL STEERING COLUMN COVER LWR

a. Install the steering column cover LWR with the 3 screws.
Fig. 18: Installing Steering Column Cover LWR With Screws

6. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 N.m (55 kgf.cm, 48 in. bf)
STARTER ASSY (1ZZ-FE/2ZZ-GE)

COMPONENTS
Fig. 19: Identifying Starter Assy (1ZZ-FE/2ZZ-GE) Components

REPLACEMENT

2. REMOVE ENGINE UNDER COVER RH
3. REMOVE ENGINE UNDER COVER LH

4. REMOVE STARTER ASSY
a. Disconnect the starter connector.
b. Open the terminal cover.
c. Remove the nut, then remove the starter wire.
Fig. 20: Removing Starter Wires

d. Remove the 2 bolts, then remove the starter.
Fig. 21: Removing Starter

5. INSTALL STARTER ASSY

a. Install the starter assy with the 2 bolts.
Fig. 22: Installing Starter Assembly

b. Install the starter wire with the nut.
Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf)
c. Put the terminal cover.

d. Connect the starter connector.
Fig. 23: Connecting Starter Connector

6. INSTALL ENGINE UNDER COVER LH

7. INSTALL ENGINE UNDER COVER RH
Torque: 5.4 N.m (55 kgf.cm, 48in..lbf)
OVERHAUL
1. REMOVE MAGNET SWITCH BODY

a. Remove the nut, then disconnect the lead wire from the magnet switch.
Fig. 24: Disconnecting Lead Wire From Magnet Switch

b. Remove the 2 screws which are used to secure the magnet switch to the starter drive housing.
c. Remove the magnet switch.
d. Remove the return spring and plunger from the starter drive housing.
Fig. 25: Removing Magnet Switch From The Starter Drive Housing
2. REMOVE STARTER YOKE ASSY

a. Remove the 2 through bolts, then pull out the starter yoke together with the starter commutator end
frame.
Fig. 26: Pulling Out Starter Yoke Together With Starter Commutator End Frame
b. Remove the starter yoke from the starter commutator end frame.
Fig. 27: Removing Starter Yoke From Starter Commutator End Frame
3. REMOVE STARTER ARMATURE PLATE

a. Remove the starter armature plate from the starter yoke.
Fig. 28: Removing Starter Armature Plate From Starter Yoke

4. REMOVE STARTER COMMUTATOR END FRAME COVER

a. Using a screwdriver, remove the starter commutator end frame cover.
Fig. 29: Removing Starter Commutator End Frame Cover Using Screwdriver
5. REMOVE STARTER ARMATURE ASSY

a. Using snap ring pliers, remove the snap ring.
b. Remove the washer and the starter armature from the starter commutator end frame.
Fig. 30: Removing Snap Ring Using Snap Ring Pliers

6. REMOVE PLANETARY GEAR

a. Remove the 3 planetary gears from the starter center bearing clutch.
Fig. 31: Removing Planetary Gears From Starter Center Bearing Clutch
7. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSY

a. Remove the starter center bearing clutch together with the starter drive lever set pin from the starter
drive housing.
Fig. 32: Removing Starter Center Bearing Clutch Sub-Assy

8. REMOVE STARTER DRIVE LEVER SET PIN

a. Remove the starter drive lever set pin from the starter center bearing clutch.
Fig. 33: Removing Starter Drive Lever Set Pin From Starter Center Bearing Clutch
9. INSPECT MAGNET SWITCH BODY

a. Check the operation.
1. Push in the plunger, then check that it returns quickly to its original position.
If necessary, replace the magnet switch body.
Fig. 34: Checking Plunger Returns Quickly To Its Original Position

b. Check the resistance.

1. Using an ohmmeter, check that there is resistance between terminals 50 and C.
Standard: 1ohms or lower
If the resistance is not specified, replace the magnet switch body.
Fig. 35: Checking Resistance Between Terminals 50 And C Using Ohmmeter

2. Using an ohmmeter, check that there is resistance between terminal 50 and the switch body.
Standard: 2ohms or lower
If the resistance is not specified, replace the magnet switch body.
Fig. 36: Checking Resistance Between Terminal 50 And Switch Body Using Ohmmeter
10. INSPECT STARTER ARMATURE ASSY

1. Using an ohmmeter, check that there is resistance between the segments of the commutator.
Standard: 1 ohms or lower
If the resistance is not specified, replace the starter armature.
Fig. 37: Checking Resistance Between Segments Of Commutator Using Ohmmeter

2. Using an ohmmeter, check that there is no resistance between the commutator and armature
coil core.
Standard: 10 kohms or higher
If the standard is not specified, replace the starter armature.
b. Check the commutator surface for dirt and burn.
If the surface is dirty and burnt, smooth the surface with 400-grit sandpaper or lather.
Fig. 38: Checking Commutator Surface For Dirt And Burn

c. Check the commutator depth.

1. Using vernier calipers, measure the commutator depth.
Standard depth: 3.1 mm (0.122 in.)
Maximum depth: 3.8 mm (0.150 in.)
If the depth is greater than maximum, replace the starter armature.
Fig. 39: Measuring Commutator Depth Using Vernier Calipers

11. INSPECT STARTER COMMUTATOR END FRAME ASSY

a. Check the brush length.
1. Using vernier calipers, measure the brush length.
Standard length: 9.0 mm (0.354 in.)
Minimum length: 4.0 mm (0.158 in.)
If the length is less than minimum, replace the starter commutator end frame.
Fig. 40: Measuring Brush Length Using Vernier Calipers


1. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes.
Standard: 10 kohms or higher
If the resistance is not as specified, repair or replace the brush holder.
Fig. 41: Measuring Resistance Between Positive (+) And Negative (-) Brushes Using Ohmmeter
12. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSY

a. Check the operation.
1. Turn the clutch pinion gear clockwise, then check that it turns freely. Try to turn the clutch
pinion gear counterclockwise, then check that it locks.
If necessary, replace the starter center bearing clutch.
Fig. 42: Checking Clutch Pinion Turns Freely

b. Check for wear and damage.

1. Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or
damage.
If worn or damaged, replace the starter center bearing clutch.
13. INSTALL STARTER DRIVE LEVER SET PIN

a. Install the starter drive lever set pin to the starter center bearing clutch as shown in the illustration.
Fig. 43: Installing Starter Drive Lever Set Pin To Starter Center Bearing Clutch
14. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSY

a. Install the starter center bearing clutch together with the starter drive lever set pin to the starter
drive housing.
Fig. 44: Installing Starter Center Bearing Clutch Together With Starter Drive Lever
15. INSTALL PLANETARY GEAR

a. Apply grease to the planetary gears and planetary shaft pins.
b. Install the 3 planetary gears to the starter center bearing clutch.
Fig. 45: Installing Planetary Gears To Starter Center Bearing Clutch

16. INSTALL STARTER ARMATURE ASSY

a. Apply grease to the washer and armature shaft.
b. Install the starter armature and washer onto the starter commutator end frame.
c. Using snap ring pliers, install a new snap ring.
Fig. 46: Installing Snap Ring Using Snap Ring Pliers

d. Check the snap ring length.

1. Using vernier calipers, measure the snap ring length.
Maximum length: 5.0 mm (0.197 in.)
If the length is greater than maximum, replace it with a new snap ring.
Fig. 47: Measuring Snap Ring Length Using Vernier Calipers

17. INSTALL STARTER COMMUTATOR END FRAME COVER

a. Install the starter commutator end frame cover onto the starter commutator end frame.
Fig. 48: Installing Starter Commutator End Frame Cover Onto Starter Commutator End Frame
18. INSTALL STARTER ARMATURE PLATE

a. Align the keyway of the starter armature plate with the key inside the starter yoke, then install the
armature plate onto the starter yoke.
Fig. 49: Installing Armature Plate Onto Starter Yoke

19. INSTALL STARTER COMMUTATOR END FRAME ASSY

a. Align the rubber with the cutout of the starter yoke, then install the starter commutator end frame
onto the starter yoke.
Fig. 50: Installing Starter Commutator End Frame Onto Starter Yoke
20. INSTALL STARTER YOKE ASSY

a. Align the key of the starter yoke with the keyway of the starter drive housing, then install the starter
yoke onto the starter drive housing.
Fig. 51: Installing Starter Yoke Onto Starter Drive Housing

b. Tighten the 2 through bolts.
Fig. 52: Tightening Through Bolts

21. INSTALL MAGNET SWITCH BODY

a. Apply grease to the plunger and hook.
b. Hang the plunger hook of the magnet switch on the starter drive lever set pin.
c. Install the plunger and return spring.
Fig. 53: Installing Plunger And Return Spring

d. Install the magnet switch with the 2 screws.
Fig. 54: Installing Magnet Switch With 2 Screws

e. Connect the lead wire with to terminal C the nut.
Fig. 55: Connecting Lead Wire With To Terminal C Nut

CHARGING SYSTEM (1ZZ-FE/2ZZ-GE)

PRECAUTION
1. Check that the battery cables are connected to the correct terminals.
2. Disconnect the battery cables if 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 tightly connected to terminal B of the generator and the fuse box.
6. Do not check whether the generator generates or not while terminal F is connected to other
terminal.
ON-VEHICLE INSPECTION
1. CHECK BATTERY VOLTAGE (MAINTENANCE-FREE BATTERY)

a. If it has been less than 20 minutes since you stopped driving the vehicle, turn the ignition switch
ON and turn on the electrical systems (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 systems.
c. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Fig. 56: Measuring Battery Voltage

Standard voltage: 12.5 to 12.9 V at 20°C (68°F)
HINT:
If the voltage is less than the specified range, charge the battery.
d. Check the indicator as shown in the illustration.
INDICATOR CONDITION SPECIFICATION
IndicatorColor Condition
Green OK
Dark Charging Necessary
Clearor light yellow Insufficient Water
Fig. 57: Checking Battery Charge Indicator

2. 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.

3. INSPECT DRIVE BELT
a. Visually check the belt for excessive wear, frayed cords etc.
HINT:
l If any defect are found, replace the drive belt.

l Cracks on the rib side of a belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be replaced.
Fig. 58: Checking Belt For Excessive Wear, Frayed Cords

b. Check that the belt fits properly in the ribbed grooves.
HINT:
Confirm by hand that the belt has not slipped out of the grooves on the bottom of the pulley.
Fig. 59: Checking Belt Fits Properly In Ribbed Grooves

4. VISUALLY CHECK ALTERNATOR WIRING

a. Check that the wiring is in good condition.
5. LISTEN FOR ABNORMAL NOISES FROM ALTERNATOR
a. Check that no abnormal noises are heard from the generator while the engine is running.
6. 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:
HINT:
If the light does not operate as specified, troubleshoot the charge warning light circuit.
7. INSPECT CHARGING CIRCUIT WITHOUT LOAD

a. If a battery/alternator tester is available, connect the tester to the charging circuit as
permanufacturer's instructions.
b. If a tester is not available, connect a voltmeter to the charging circuit as follows.
1. Disconnect to the wire from terminal B of the generator and connect it to the negative (-) lead
of the ammeter.
2. Connect the positive (+) lead of the ammeter to terminal B of the generator.
3. Connect the positive (+) lead of the voltmeter to terminal B of the generator.
4. Ground the negative (-) lead of the voltmeter.
Fig. 60: Connecting Positive (+) Lead Of Voltmeter To Terminal B Of Generator

c. Check the charging circuit.

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 to 14.9 V
8. INSPECT CHARGING CIRCUIT WITH LOAD

a. With the engine running at 2,000 rpm, turn the high beam headlights ON and turn the heater blower
switch to the "HI" position.
b. Check the reading on the ammeter. Standard amperage: 30 A or more
HINT:
l If the ammeter reading is less than standard amperage, repair the generator.
l If the battery is fully charged, the indication will sometimes be less than standard amperage.
GENERATOR ASSY (1ZZ-FE/2ZZ-GE)
COMPONENTS
Fig. 61: Identifying Generator Assy (1ZZ-FE/2ZZ-GE) Components (1 Of 2)

Fig. 62: Identifying Generator Assy (1ZZ-FE/2ZZ-GE) Components (2 Of 2)

REPLACEMENT

2. REMOVE CYLINDER HEAD COVER NO.2 (2ZZ-GE ENGINE TYPE) (See REMOVAL &
INSTALLATION AND DISASSEMBLY & REAS )
3. REMOVE AIR SWITCHING VALVE ASSY (2ZZ-GE ENGINE TYPE) (See REPLACEMENT )
4. REMOVE ENGINE UNDER COVER RH

5. REMOVE FAN AND GENERATOR V BELT
HINT:
1ZZ-FE: (See FAN AND GENERATOR V BELT (1ZZ-FE) )

l
l 2ZZ-GE: (See FAN AND GENERATOR V BELT (2ZZ-GE) )
6. REMOVE AIR PUMP OUTLET PIPE (2ZZ-GE ENGINE TYPE)

a. Disconnect the air hose No. 5.
b. Remove the 2 bolts, then remove the air pump outlet pipe.
Fig. 63: Removing Air Pump Outlet Pipe

7. REMOVE GENERATOR ASSY

a. Remove the wire harness clamp. (2ZZ-GE ENGINE TYPE)
b. Remove the terminal cap No. 2.
c. Remove the nut, then remove the generator wire.
d. Disconnect the generator connector.

e. Remove the wire harness clamp.
f. Disconnect the A/C connector.
Fig. 64: Disconnecting A/C Connector

g. Remove the bolt, then remove the wire harness clamp bracket. (2ZZ-GE ENGINE TYPE)
Fig. 65: Removing Wire Harness Clamp Bracket

h. Remove the 2 bolts, then remove the generator bracket No. 1. (2ZZ-GE ENGINE TYPE)
Fig. 66: Removing Generator Bracket

i. Remove the 2 bolts, then remove the generator.
Fig. 67: Removing Generator

8. INSTALL GENERATOR ASSY

a. Install the generator with the 2 bolts.
Torque:
25 N.m (250 kgf.cm, 18 ft.lbf) for bolt A
54 N.m (550 kgf.cm, 40 ft.lbf) for bolt B (1ZZ-FE ENGINE TYPE)
58 N.m (590 kgf.cm, 43 ft.lbf) for bolt B (2ZZ-GE ENGINE TYPE)
Fig. 68: Installing Generator

b. Install the wire harness clamp bracket with the bolt. (2ZZ-GE ENGINE TYPE)
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
Fig. 69: Installing Wire Harness Clamp Bracket

c. Connect the A/C connector.

d. Install the wire harness clamp.
e. Connect the generator connector.
f. Install the generator wire with the nut.
Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf)
g. Install the terminal cap No. 2.
Fig. 70: Installing Terminal Cap No. 2

h. Install the generator bracket No. 1 with the 2 bolts. (2ZZ-GE ENGINE TYPE)
Torque: 29 N.m (296 kgf.cm, 21.ft.lbf)
i. Install the wire harness clamp.
Fig. 71: Installing Generator Bracket & Wire Harness Clamp

9. INSTALL AIR PUMP OUTLET PIPE (2ZZ-GE ENGINE TYPE)

a. Install the air pump outlet pipe with the 2 bolts.
b. Connect the air hose No. 5.
Fig. 72: Connecting Air Hose

10. INSTALL FAN AND GENERATOR V BELT
HINT:
l 1ZZ-FE: (See FAN AND GENERATOR V BELT (1ZZ-FE) )

l 2ZZ-GE: (See FAN AND GENERATOR V BELT (2ZZ-GE) )
11. INSTALL ENGINE UNDER COVER RH

12. INSTALL AIR SWITCHING VALVE ASSY (2ZZ-GE ENGINE TYPE) (See AIR SWITCHING
VALVE ASSY (2ZZ-GE) )
13. INSTALL CYLINDER HEAD COVER NO.2 (2ZZ-GE ENGINE TYPE) (See REMOVAL &
INSTALLATION AND DISASSEMBLY & REAS )
Torque: 54 N.m (55 kgf.cm, 48 in. bf)
OVERHAUL
1. REMOVE GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
HINT:
SST SPECIFICATION
SST 1 - A and B 09820-06010
SST 2 09820-06020
a. Hold SST 1-A with a torque wrench, then tighten SST 1-B clockwise to the specified torque.
NOTE: Check that SST is secured to the rotor shaft.
Fig. 73: Checking SST Is Secured To Rotor Shaft

b. Clamp SST 2 in a vise.
c. Insert SST 1-A and B into SST 2, then attach the pulley nut to SST 2.
Fig. 74: Clamping SST 2 In A Vise

d. To loosen the pulley nut, turn SST 1-A in the direction shown in the illustration.
NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut
more than a half turn.
e. Remove the generator from SST 2.
Fig. 75: Loosen The Pulley Nut, Turn SST 1-A In The Direction Shown
f. Turn SST 1-B, then remove SST 1-A and B.

g. Remove the pulley nut, then remove the generator pulley.
Fig. 76: Removing Generator Pulley

2. REMOVE GENERATOR BRUSH HOLDER ASSY

a. Remove the nut, then remove the terminal insulator.
b. Remove the screw and nut, then remove the terminal plate.
c. Remove the 2 nuts, then remove the rear end cover.
d. Remove the generator brush cover from the generator brush holder.
e. Remove the 2 screws, then remove the generator brush holder.
f. Remove the generator plate seal from the generator rectifier end frame.
3. REMOVE GENERATOR REGULATOR ASSY
a. Remove the 3 screws, then remove the generator regulator.
4. REMOVE GENERATOR HOLDER W/RECTIFIER
a. Remove the 4 screws, then remove the generator holder with rectifier.
5. REMOVE GENERATOR RECTIFIER END FRAME
a. Remove the 4 terminal insulators from the generator rectifier end frame.
b. Remove the 4 nuts and generator cord clip.
c. Using SST, remove the generator rectifier end frame.
SST 09286-16011
Fig. 77: Removing Generator Rectifier End Frame

6. REMOVE GENERATOR ROTOR ASSY

a. Remove the generator washer from the generator rotor.
b. Remove the generator rotor from the generator drive end frame.
7. INSPECT GENERATOR BRUSH HOLDER ASSY
a. Check the brush length.
1. Using vernier calipers, measure the exposed brush length.
Standard exposed brush length :
9.5 to 11.5 mm (0.374 to 0.453 in.)
Minimum exposed brush length : 4.5 mm (0.177 in.)
If the exposed brush length is less than minimum, replace the generator brush holder.
Fig. 78: Measuring Exposed Brush Length Using Vernier Calipers

8. INSPECT GENERATOR REGULATOR ASSY

1. Using an ohmmeter, measure the resistance between terminals F and B.
Standard:
When the positive and negative poles of terminals F and B are switched over, there is a
resistance of below 1 ohms in one direction but 10 kohms or higher in the other
direction.
If the resistance is not as specified, replace the generator regulator.
Fig. 79: Measuring Resistance Between Terminals F And B Using Ohmmeter

2. Using an ohmmeter, measure the resistance between terminals E and F.
Standard:
When the positive and negative poles of terminals F and E are switched over, there is a
resistance of below 1 ohms in one direction but 10 kohms or higher in the other direction.
If the resistance is not as specified, replace the generator regulator.
Fig. 80: Measuring Resistance Between Terminals E And F Using An Ohmmeter

9. INSPECT GENERATOR HOLDER W/RECTIFIER

1. Using an ohmmeter, measure the resistance between the positive (+) terminal and each
rectifier terminal.
Standard:
When the positive and negative poles of the positive (+) terminal and each rectifier
terminal are switched over, there is a resistance of below 1 ohms in one direction but 10
kohms or higher in the other direction.
If the resistance is not as specified, replace the generator holder with rectifier.
Fig. 81: Measuring Resistance Between Positive (+) Terminal And Each Rectifier
Terminal Using An Ohmmeter
2. Using an ohmmeter, measure the resistance between the negative (-) terminal and each
rectifier terminal.
Standard :
When the positive and negative poles of the negative (-) terminal and each rectifier terminal
are switched over, there is a resistance of below 1 ohms in one direction but 10 kohms or
higher in the other direction.
If the resistance is not as specified, replace the generator holder with rectifier.
Fig. 82: Measuring Resistance Between Negative (-) Terminal And Each Rectifier Terminal
Using Ohmmeter
10. INSPECT GENERATOR ROTOR ASSY

a. Check for roughness or wear.
1. Check that the bearing is not rough or worn.
l If necessary, replace the bearing. (1ZZ-FE ENGINE TYPE)
l If necessary, replace the generator rotor. (2ZZ-GE ENGINE TYPE)
Fig. 83: Checking Bearing Is Not Rough Or Worn


1. Using an ohmmeter,measure the resistance between the slip rings.
Standard resistance: 2.1 to 2.5 ohms at 20°C (68°F)
If the resistance is not as specified, replace the generator rotor.
Fig. 84: Measuring Resistance Between Slip Rings Using An Ohmmeter

2. Using an ohmmeter, measure the resistance between the slip ring and rotor.
Standard: 1M ohms. or higher
If the result is not as specified, replace the generator rotor shaft.
Fig. 85: Measuring Resistance Between The Slip Ring And Rotor
c. Check the appearance.

1. Check that the slip rings are not rough or scored. If rough or scored, replace the generator
rotor.
d. Check the slip ring diameter.
1. Using vernier calipers, measure the slip ring diameter.
Standard diameter:
14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter: 14.0 mm (0.551 in.)
If the diameter is less than minimum, replace the generator rotor.
Fig. 86: Measuring Slip Ring Diameter Using Vernier Calipers

11. INSPECT GENERATOR RECTIFIER END FRAME

a. Check for roughness or wear.
1. Check that the bearing is not rough or worn.
l If necessary, replace the bearing. (1ZZ-FE ENGINE TYPE)
l If necessary, replace the generator drive end frame. (2ZZ-GE ENGINE TYPE)
Fig. 87: Checking Bearing Is Not Rough Or Worn


1. Using an ohmmeter, measure the resistance between the coil wires.
Standard: Below 1ohms
If the resistance is not as specified, replace the generator drive end frame.
Fig. 88: Measuring Resistance Between Coil Wires Using An Ohmmeter

2. Using an ohmmeter, measure the resistance between the coil wire and body.
Standard: 1Mohms or higher
If the resistance is not as specified, replace the generator drive end frame.
Fig. 89: Measuring Resistance Between Coil Wire And Body Using Ohmmeter
12. REMOVE GENERATOR ROTOR BEARING (1ZZ-FE ENGINE TYPE)

a. Clamp the generator rotor in a vise.
b. Using SST, remove the generator bearing cover (outside) and bearing.
SST 09820-00021
NOTE: Be careful not to damage the fan.
c. Remove the generator bearing cover (inside) from the generator rotor.
Fig. 90: Removing Generator Bearing Cover (Outside) And Bearing Using SST
13. INSTALL GENERATOR ROTOR BEARING (1ZZ-FE ENGINE TYPE)

a. Place the generator rotor on the generator pulley.
b. Install the generator bearing cover (inside) onto the generator rotor.
c. Using SST and a press, push a new bearing in.
SST 09820-00031
Fig. 91: Pressing Bearing Using SST

d. Using SST, push the generator bearing cover (outside) in.
SST 09285-76010
Fig. 92: Pressing Generator Bearing Cover Using SST

14. REMOVE GENERATOR DRIVE END FRAME BEARING (1ZZ-FE ENGINE TYPE)
a. Remove the 4 screws, then remove the retainer plate.
Fig. 93: Removing Retainer Plate

b. Using SST and a press, push the bearing out.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07100)
Fig. 94: Pressing Bearing Out Using SST

15. INSTALL GENERATOR DRIVE END FRAME BEARING (1ZZ-FE ENGINE TYPE)
a. Using SST and a press, push a new bearing in.
SST 09950-60010 (09951-00530), 09950-70010 (09951-07100)
Fig. 95: Pressing In Bearing Using SST

b. Install the retainer plate with the 4 screws.
Fig. 96: Installing Retainer Plate

16. INSTALL GENERATOR ROTOR ASSY

a. Place the generator drive end frame on the generator pulley.
b. Install the generator rotor onto the generator drive end frame.
c. Install the generator washer onto the generator rotor.
Fig. 97: Installing Generator Rotor Assembly

17. INSTALL GENERATOR RECTIFIER END FRAME

a. Using a socket wrench 29 and a press, slowly push in the generator rectifier end frame.
Fig. 98: Pressing In Generator Rectifier End Frame

b. Install the generator cord clip and 4 nuts.
Torque:
4.5 N.m (46 kgf.cm, 40 in. bf) for nut A
5.4 N.m (55 kgf.cm, 48 in. bf) for nut B
c. Install the 4 terminal insulators onto the generator rectifier end frame.
Fig. 99: Installing Terminal Insulators Onto Generator Rectifier End Frame
18. INSTALL GENERATOR HOLDER W/RECTIFIER

a. Install the generator holder with rectifier with the 4 screws.
19. INSTALL GENERATOR REGULATOR ASSY

a. Install the generator regulator with the 3 screws.
20. INSTALL GENERATOR BRUSH HOLDER ASSY

a. Install the generator plate seal onto the generator rectifier end frame.
b. Install the generator brush holder with the 2 screws.
NOTE: Pay attention that the generator brush holder is in the correct
direction.
c. Install the generator brush cover onto the generator brush holder.
Fig. 100: Installing Generator Brush Cover Onto Generator Brush Holder
d. Install the generator rear and cover it with the 2 nuts.
e. Install the terminal plate.
Torque:
3.9 N.m (40 kgfcm, 35 in. bf) for bolt
4.4 N.m (45 kgf.cm, 39 in. bf) for nut
f. Install the terminal insulator with the nut.
21. INSTALL GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
HINT:
SST SPECIFICATION
SST1-A and B 09820-06010
SST2 09820-06020
a. Install the generator pulley onto the rotor shaft by tightening the pulley nut by hand.
b. Hold SST 1-A with a torque wrench, then tighten SST 1-B clockwise to the specified torque.
Fig. 101: Tightening SST 1-B Specified Torque

NOTE: Check that SST is secured to the rotor shaft.
c. Clamp SST 2 in a vise.

d. Insert SST 1-A and B into SST 2, then attach the pulley nut to SST 2.
Fig. 102: Attaching Pulley Nut To SST 2

e. Tighten the pulley nut, then turn SST 1-A in the direction shown in the illustration.
Torque: 111 N.m (1,132 kgf.cm, 82 ft.lbf)
f. Remove the generator from SST 2.
Fig. 103: Removing Generator From SST 2

g. Turn SST 1-B, then remove SST 1-A and B.

h. Turn the generator pulley, then check that the generator pulley moves smoothly.
Fig. 104: Turning SST 1-B, Then Remove SST 1-A And B

Toyota Corrolla 2005 - 2006 Sistema de Arranque y Carga

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2005 Toyota Corolla LE

2005-06 ENGINE Starting & Charging - Corolla

Starting & Charging - Corolla

STARTING SYSTEM (1ZZ-FE/2ZZ-GE)

1. INSPECT STARTER ASSY

NOTE: These tests must be performed within 3 to 5 seconds to prevent burnout of

a. Perform the pull-in test.

Fig. 1: Disconnecting Lead Wire From Terminal C

martes, 9 de junio de 2020 15:49:59

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 2: Connecting Battery To Starter

b. Perform the hold-in test.

Fig. 3: Disconnecting Negative (-) Lead From Terminal

c. Check the operation.

Fig. 4: Disconnecting Negative (-) Lead From Starter Body

d. Perform the no-load performance test.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

Fig. 5: Connecting Lead Wire To Terminal C With Nut

2. Clamp the starter in a vise.

Specified current: 90 A or less at 11.5 V

If the current is not as specified, replace the magnet switch.

2. INSPECT STARTER RELAY ASSY

TESTER CONNECTION - SPECIFIED CONDITION

If the resistance is not as specified, replace the starter relay.

Fig. 7: Measuring Resistance Between Terminals Using Ohmmeter

3. INSPECT IGNITION OR STARTER SWITCH ASSY

TESTER CONNECTION - SPECIFIED CONDITION

If the resistance is not as specified, replace the ignition starter switch.

Fig. 8: Measuring Ignition Starter Switch Resistance

IGNITION OR STARTER SWITCH ASSY (1ZZ-FE/2ZZ-GE)

1. DISCONNECT BATTERY NEGATIVE TERMINAL

Fig. 9: Removing Steering Column Cover LWR

3. REMOVE IGNITION OR STARTER SWITCH ASSY

c. Disconnect the wire harness from the steering assy.

Fig. 12: Disconnecting Wire Harness From Steering Assy

d. Remove the 2 screws, then remove the ignition switch assy.

Fig. 13: Removing Ignition Switch Assy

4. INSTALL IGNITION OR STARTER SWITCH ASSY

Fig. 14: Installing Ignition Switch Assy With Screws

b. Connect the wire harness to the steering assy.

Fig. 15: Connecting Wire Harness To Steering Assy

5. INSTALL STEERING COLUMN COVER LWR

Fig. 18: Installing Steering Column Cover LWR With Screws

6. CONNECT BATTERY NEGATIVE TERMINAL

Torque: 5.4 N.m (55 kgf.cm, 48 in. bf)

STARTER ASSY (1ZZ-FE/2ZZ-GE)

Fig. 19: Identifying Starter Assy (1ZZ-FE/2ZZ-GE) Components

1. DISCONNECT BATTERY NEGATIVE TERMINAL

3. REMOVE ENGINE UNDER COVER LH

Fig. 20: Removing Starter Wires

d. Remove the 2 bolts, then remove the starter.

Fig. 21: Removing Starter

5. INSTALL STARTER ASSY

Torque: 37 N.m (378 kgf.cm, 27 ft.lbf)

Fig. 22: Installing Starter Assembly

b. Install the starter wire with the nut.

Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf)

c. Put the terminal cover.

Fig. 23: Connecting Starter Connector

6. INSTALL ENGINE UNDER COVER LH

Torque: 5.4 N.m (55 kgf.cm, 48in..lbf)

1. REMOVE MAGNET SWITCH BODY

Fig. 24: Disconnecting Lead Wire From Magnet Switch