TOYOTA TERCEL 1996 Service Repair Manual

ST0009
Magnet
P25752
ST0198
- STARTINGSTARTER (Reduction Type)
ST-5
1996 TERCEL (RM440U)
3. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch
shaft hole.
4. REMOVE BRUSHES AND BRUSH HOLDER
(a) Remove the 2 screws and end cover from the field frame.
Torque: 1.5 N´m (15 kgf´cm, 13 in.´lbf)
(b) Using a screwdriver, hold the spring back and disconnect
the brush from the brush holder. Disconnect the 4
brushes, and remove the brush holder.
NOTICE:
Check that the positive (+) lead wire are not grounded.
5. REMOVE ARMATURE FROM FIELD FRAME

ST0IY-01
P10584
Ohmmeter
Continuity
P10585
Ohmmeter
No Continuity
P10586
P10587
ST0040
ST-6
- STARTINGSTARTER (Reduction Type)
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
2. INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACE
If the surface is dirty or burnt, correct it with sandpaper (No.400)
or on a lathe.
4. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V-blocks.
(b) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
5. INSPECT COMMUTATOR DIAMETER
Using a vernier caliper, measure the commutator diameter.
Standard diameter: 30.0 mm (1.181 in.)
Minimum undercut depth: 29.0 mm (1.412 in.)
If the diameter is less than minimum, replace the armature.
6. INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign mate-
rials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.24 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

ST0199
Continuity
ST0200
No Continuity
N00337
ST0019
ST0203
Continuity
- STARTINGSTARTER (Reduction Type)
ST-7
1996 TERCEL (RM440U)
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. INSPECT FIELD COIL FOR GROUND
Using an ohmmeter, check that there is no continuity between
the field coil end and field frame.
If there is continuity, replace the field frame.
9. INSPECT BRUSH LENGTH
Using a vernier caliper, measure the brush length.
Standard length: 13.5 mm (0.531 in.)
Minimum length: 8.5 mm (0.334 in.)
If the length is less than minimum, replace the brush holder and
field frame.
10. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard spring installed load:
17.6 - 23.5 N (1.79 - 2.39 kgf, 4.0 - 5.3 lbf)
Minimum spring installed load:
11.8 N (1.2 kgf, 2.6 lbf)
If the installed load is not as specified, replace the brush
springs.
11. INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idle gear and the clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for wear or
damage.

P10821
Free
Lock
ST0204
Terminal 50
Continuity
Terminal C
ST0205
Continuity Terminal 50Switch Body ST-8
- STARTINGSTARTER (Reduction Type)
1996 TERCEL (RM440U)
13. INSPECT CLUTCH PINION GEAR
Rotate the pinion gear clockwise, and check that it turns freely.
Try to rotate the pinion gear counterclockwise and check that
it locks.
If necessary, replace the clutch assembly.
14. INSPECT REAR BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
15. INSPECT FRONT BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
16. DO PULL-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, check and replace the magnetic switch.
17. DO HOLD-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, check and replace the magnetic switch.

ST0IZ-02
P10593
SST
P10595
SST
P10596
SST
Upward
Downward
P25438
Wear
P25439
SST
- STARTINGSTARTER (Reduction Type)
ST-9
1996 TERCEL (RM440U)
REPLACEMENT
1. REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286-4601 1
(b) Using a press, press in a new rear bearing.
2. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286-4601 1
(b) Using SST and a press, press in a new bearing.
NOTICE:
Be careful of the bearing installation direction.
SST 09820-00030
3. REPLACE MAGNETIC SWITCH TERMINAL KIT
PARTS
(a) Remove the magnetic switch end the cover.
Remove the 3 bolts, lead clamp, end cover, gasket and
plunger.
(b) Inspect the contact plate for wear.
Using vernier calipers, measure the contact plate for
depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
(c) Remove the terminal kit parts.
(1) Using SST, loosen the terminal nuts.
SST 09810-38140
(2) Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O- ring, terminal bolt, contact
plate and terminal insulator (inside).

S05634
(8)
(7)
(6)
(5)
Inside
(4) (3) Short
Long (1)
S05635
(7)
(6)
(5)Inside (4) (3)
ShortLong
(1) (2) ST-10
- STARTINGSTARTER (Reduction Type)
1996 TERCEL (RM440U)
(3) Terminal 30:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O- ring, terminal bolt, contact
plate, terminal insulator (inside) and insulation pa-
per.
(d) Temporarily install these new terminal 30 kit parts.
(1) Insulation paper
(2) Terminal insulator (inside)
(3) Contact plate
(4) Terminal bolt
(5) O-ring
(6) Terminal insulator (outside)
(7) Wave washer
(8) Terminal nut
NOTICE:
Be careful to install the terminal insulators (inside) and
wave washer in the correct direction.
(e) Temporarily install these new terminal C kit parts.
(1) Terminal insulator (inside)
(2) Contact plate
(3) Terminal bolt
(4) O-ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
NOTICE:
Be careful to install the terminal insulators (inside) and
wave washer in the correct direction.

P25608
Wooden
Block
40 mm
37 mm
20 mmContact
Plate
V06796
P25609
SST
P25479
- STARTINGSTARTER (Reduction Type)
ST-1 1
1996 TERCEL (RM440U)
(f) Temporarily tighten the terminal nuts.
(g) Tighten the terminal nut.
(1) Put a wood block on the contact plate and press it
down with a hand press.
Dimensions of wood block:
20 x 37 x 40 mm (0.97 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:

Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when 981 N
(100 kgf, 221 lbf) of force is applied.

If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(2) Using SST, tighten the nut to the specified torque.
SST 09810-38140
Torque: 17 N´m (173 kgf´cm, 12 ft´lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
(h) Clean the contact surfaces of the contact plate and plung-
er.
Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.
(i) Reinstall the magnetic switch end cover.
Install the plunger, new gasket, end cover and lead clamp
with 3 bolts.
Torque: 3.6 N´m (36 kgf´cm, 32 in.´lbf)

ST0J0-02
ST-12
- STARTINGSTARTER (Reduction Type)
1996 TERCEL (RM440U)
REASSEMBLY
Ressembly is in the reverse order of disassembly (See page ST-4).
HINT:
Use high-temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling
the starter.

ST0J1-01
P13459
Terminal 50
Terminal C
Battery
P13460
Terminal C
Battery
Disconnect
P13461
Battery
Disconnect
P13462
Battery
Ammeter Terminal 50
Terminal 30
- STARTINGSTARTER (Reduction Type)
ST-13
1996 TERCEL (RM440U)
TEST
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid burning out the coil.
1. DO HOLD-IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD-IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (-) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) lead from the switch body.
Check that the clutch pinion gear returns inward.
4. DO NO-LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter the
current specified in the respective repair manual.

ST0J2-02
ST-14
- STARTINGSTARTER (Reduction Type)
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page ST-3).