Toyota Corolla (E120) 2002–2008 Repair Manual / Starting & charging / Starting system
Toyota Corolla (E120): Starting system
Inspection
1. Inspect starter assy
Notice
: these tests must be performed within 3 to 5 seconds to prevent burnout of the coil.
- perform the pull–in test.
- Remove the nut, then disconnect the lead wire from terminal c.
- 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 repair service kit.
- Perform the hold–in test.
- Disconnect the negative (–) lead from terminal c
with the lead wire disconnected from terminal c.
Check that the clutch pinion gear remains extended.
If the clutch pinion gear returns, replace the starter repair service kit.
- Check the clutch pinion gear returns.
- 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 repair service kit.
- Perform the no–load performance test.
- Connect the lead wire to terminal c with the nut.
Make sure that the lead is not grounded.
Torque: 10 nvm (102 Kgf·cm, 7 ft·lbf)
- Clamp the starter in a vise.
- Connect the battery and an ammeter to the starter as shown in the illustration.
- 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 service kit.
2. Inspect starter relay assy
- Check the continuity.
- Using an ohmmeter, check for continuity between each terminal.
Specified condition:
If the result is not as specified, replace the starter relay.
Other materials:
Inspection procedure
Hint:
start the inspection from step 1 in case of using the hand–held tester and start
from step 2 in case of not
using the hand–held tester.
1 Read value of hand–held tester(skid control sensor)
Check that there is no difference between the speed value output from
the speed sensor ...
Replacement
1. Remove hood sub–assy
2. Remove cylinder head cover no.2
3. Remove battery
4. Remove battery carrier
Remove the 4 bolts and battery carrier.
5. Remove air cleaner assembly with hose
6. Remove floor shift cable transmission control shift
Remove the nut from the control shaf ...
Replacement
1. Work for preventing gasoline from spilling out
2. Remove cylinder head cover no.2
Remove the 2 nuts, 2 clips and cylinder head cover.
3. Disconnect ventilation hose
Disconnect the ventilation hose from the cylinder head
cover.
4. Disconnect engine wire
Disconnect ...