charging TOYOTA TERCEL 1996 Service Owner's Manual

CH06B-03
Z19164
Z19165
P04193
P04216
Socket
Wrench
P04217
SST
Lowerward
- CHARGINGGENERATOR
CH-13
1996 TERCEL (RM440U)
REPLACEMENT
1. REPLACE BRUSHES
(a) Unsolder and remove the brush and spring.
(b) Run the wire of a new brush through the spring and the
hole in the brush holder, and insert the spring and brush
into the brush holder.
(c) Solder the brush wire to the brush holder at the specified
exposed length.
Exposed length: 10.5 mm (0.413374 - 0.453 in.)
(d) Check that the brush moves smoothly in the brush holder.
(e) Cut off the excess wire.
(f) Apply insulation paint to the soldered area.
2. REPLACE FRONT BEARING
(a) Remove the 4 screws, bearing retainer and bearing.
(b) Using a socket wrench and press, press out the
bearing.
(c) Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00460)
(d) Install the bearing retainer with the 4 screws.
Torque: 2.6 N´m (27 kgf´cm, 23 in.´lbf)

N00581
SST
P05052
Bearing Cover
N00578
SST
P00074
SST
CH-14
- CHARGINGGENERATOR
1996 TERCEL (RM440U)
3. REPLACE REAR BEARING
(a) Using SST, remove the bearing cover (outside) and bear-
ing.
SST 09820-00021
NOTICE:
Be careful not to damage the fan.
(b) Remove the bearing cover (inside).
(c) Place the bearing cover (inside) on the rotor.
(d) Using SST and a press, press in a new bearing.
SST 09820-00030
(e) Using SST, push in the bearing cover (outside).
SST 09285-76010

CH0HC-01
P04218
P13695
29 mm
Socket
Wrench
P04209
SST (A)
Turn SST (B)
P04210
SST (C)
- CHARGINGGENERATOR
CH-15
1996 TERCEL (RM440U)
REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Install the generator washer to the rectifier end frame.
NOTICE:
Be careful of the generator washer installation direction.
(b) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(c) Type A
Install the 4 nuts.
Torque: 4.5 N´m (46 kgf´cm, 40 in.´lbf)
(d) Type B:
Install the 2 nuts and 2 bolts.
Torque: 4.5 N´m (46 kgf´cm, 40 in.´lbf)
4. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820-63010
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(c) Check that SST (A) is secured to the pulley shaft.
(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

P04395
SST (A) Turn SST (C)
P04393
SST (A)
Turn SST (B)
Z19166
Type A
Inside
Z19167
Type A
Push
Z14817
Type B CH-16
- CHARGINGGENERATOR
1996 TERCEL (RM440U)
(f) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
Torque: 110 N´m (1,125 kgf´cm, 81 ft´lbf)
(g) Remove the generator from SST (C).
(h) Turn SST (B), and remove SST (A and B).
5. Type A
INSTALL RECTIFIER HOLDER
(a) Install the 4 rubber insulators on the lead wires.
NOTICE:
Be careful of the rubber insulators installation direction.
(b) Install the rectifier holder while pushing it with the 4
screws.
Torque: 1.96 N´m (20 kgf´cm, 17 in.´lbf)
6. Type B:
INSTALL RECTIFIER HOLDER
(a) Install the rectifier holder.
(b) Bend the 4 stator lead wires as shown in the illustration.

Z14818
Type B
Z19168
Upward
Protrusion
Z19169
Z19170
Approx.
1.0 mm
Z19171
Push
- CHARGINGGENERATOR
CH-17
1996 TERCEL (RM440U)
(c) Install the 4 screws.
Torque: 1.96 N´m (20 kgf´cm, 17 in.´lbf)
7. INSTALL VOLTAGE REGULATOR AND BRUSH
HOLDER
(a) Install the brush holder cover to the brush holder.
NOTICE:
Be careful of the holder installation direction.
(b) Place the voltage regulator together with the brush holder
horizontally on the rectifier end frame.
(c) Install the 5 screws until there is a clearance of approx.
1.0 mm (0.04 in.) between the brush holder and voltage
regulator.
(d) Fit the brush holder cover.

Z10245
Type A
Z14809
Type B CH-18
- CHARGINGGENERATOR
1996 TERCEL (RM440U)
8. INSTALL REAR END COVER
(a) Type A:
Install the end cover with the 3 nuts.
Torque: 4.4 N´m (45 kgf´cm, 40 in.´lbf)
(b) Type B:
Install the end cover with the 3 bolts.
Torque: 4.4 N´m (45 kgf´cm, 40 in.´lbf)
(c) Install the terminal insulator with the nut.
Torque: 4.1 N´m (42 kgf´cm, 36 in.´lbf)
9. CHECK THAT ROTOR ROTATES SMOOTHLY

CH06D-03
- CHARGINGGENERATOR
CH-19
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page CH-6).

Z14034
Fig.1
Power Source
Safing
Sensor
Squibs
Deceleration
Sensor Fig.2 RS-6
- SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
1996 TERCEL (RM440U)
(b) When the vehicle is involved in a frontal collision in the
hatched area (Fig. 1) and the shock is larger than the pre-
determined level, the SRS is activated automatically. A
safing sensor is designed to go on at a smaller decelera-
tion rate than the airbag sensors. As illustrated in Fig. 2,
ignition is caused when a safing sensor and the decelera-
tion sensor go on simultaneously. When a deceleration
force acts on the sensors, two squibs in the driver airbag
and front passenger airbag ignite and generate gas. The
gas discharging into the driver and front passenger air-
bags rapidly increases the pressure inside the bags
breaking open the steering wheel pad and instrument
panel door. Bag inflation then ends, and the bags deflate
as the gas is discharged through discharge holes at the
bag's rear or side.

AC2810
AC1DR-02
AC2811
N11084
Wrong Okay
HI LO HILO
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-1
1153 Author
: Date
:
1996 TERCEL (RM440U)
AIR CONDITIONING SYSTEM
PRECAUTION
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN
YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cool water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a physician or hospital for professional
treatment.
4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5. BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPLY PHYSICAL SHOCKS TO IT
6. DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERATION SYS-
TEM
If there is not enough refrigerant in the refrigerant system oil lu-
brication will be insufficient and compressor burnout may occur,
so that care to avoid this.
7. DO NOT OPEN PRESSURE MANIFOLD VALVE WHILE
COMPRESSOR IS OPERATE
If the high pressure valve is opened, refrigerant flows in the re-
verse direction and could cause the charging cylinder to rup-
ture, so open and close the only low pressure valve.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as insuffi-
cient cooling, poor fuel economy, engine overheating etc.

AC1DT-01
N13795
Quick Disconnect
Adapter
Charging
Service ValveHose
N13794
Vacuum Pump
Vacuum Pump Adapter
N13791
Low Pressure
Service Valve
Vacuum Pump Adapter High Pressure
Service ValveManifold
Gauge
Set
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-1 1
1996 TERCEL (RM440U)
EVACUATING
1. CONNECT QUICK DISCONNECT ADAPTER TO
CHARGING HOSES
2. REMOVE CAPS FROM SERVICE VALVES ON RE-
FRIGERANT LINES
3. SET ON MANIFOLD GAUGE SET
(a) Close both hand valves of manifold gauge set.
(b) Connect the quick disconnect adapters to the service
valves.
4. EVACUATE AIR FROM REFRIGERATION SYSTEM
(a) Connect the vacuum pump adapter to the vacuum pump.
(b) Connect the center hose of the manifold gauge set to the
vacuum pump adapter.
(c) Open both the high and low hand valves and run the vacu-
um pump.
(d) After 10 minutes or more, check that the low pressure
gauge indicates 750 mmHg (30 in. Hg) or more.
HINT:
If the reading is 750 mmHg (30 in. Hg) or more, close both hand
valves of manifold gauge set and stop the vacuum pump.
Check the system for leaks and repair if necessary.
(e) Close both the high and low hand valves and stop the vac-
uum pump.
(f) Leave the system in this condition for 5 minutes or more
and check that there is no gauge indicator.