TOYOTA TERCEL 1996 Service Repair Manual

ST085-03
ST0646
Grease
ST0647
Hollow
Protrusion
ST0671
Planet Carrier Shaft
Plate Washer Shock Absorber
ST0672
ST0673
- STARTINGSTARTER (Planetary Type)
ST-25
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Use high temperature-resistant grease to lubricate the bear-
ings and sliding parts when assembling the starter.
1. INSTALL INTERNAL GEAR AND PLANET CARRIER
SHAFT
(a) Apply grease to the internal gear touching the shock ab-
sorber and planetary gears.
(b) Align the hollow of the internal gear with the protrusion in-
side the shock absorber.
(c) Insert and turn the internal gear so that it interlocks with
the shock absorber.
(d) Apply turbine oil to the center bearing.
(e) Apply grease to the plate washer, and install it to the plan-
et carrier shaft.
(f) Install the planet carrier shaft to the shock absorber.
(g) Using snap ring pliers, install the plate washer and snap
ring.
2. INSTALL STARTER CLUTCH
(a) Apply grease to the bushing and spline of the starter
clutch stop collar.
(b) Place the starter clutch and stop collar on the planet carri-
er shaft.
(c) Apply grease to the snap ring, and install it to the planet
carrier shaft groove.
(d) Using a vise, compress the snap ring.

ST0674
Z07229
Protrusion
Cutout
ST1086
ST1089
Cutout
Protrusion
ST0656
ST-26
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
(e) Hold the starter clutch, tap the planet carrier shaft and
install the stop collar onto the snap ring with a plastic-
faced hammer.
3. INSTALL PLANETARY GEARS
(a) Apply grease to the planetary gears and flange pin parts
of the planet carrier shaft.
(b) Install the plate washer and 3 planetary gears.
(c) Align the cutout of the plate with the protrusion inside the
shock absorber, and install the plate.
4. INSTALL DRIVE LEVER AND STARTER CLUTCH
WITH SHOCK ABSORBER
(a) Apply turbine oil to the bearing of the starter drive hous-
ing.
(b) Apply grease to the drive lever touching the starter pivot
part of the drive lever.
(c) Install the drive lever to the starter clutch.
(d) Align the protrusion of the shock absorber with the cutout
of the drive housing and install them.
5. PLACE ARMATURE INTO FIELD FRAME
6. INSTALL BRUSH HOLDER
(a) Place the brush holder in position on the armature.
(b) Using a screwdriver, hold the brush spring back, and con-
nect the brush into the brush holder. Connect the 4
brushes.
NOTICE:
Check that positive (+) lead wires are not grounded.
(c) Install a new O-ring to the groove of the field frame.
(d) Apply turbine oil to the bearing of the end cover.

ST1091
Cutout Protrusion
- STARTINGSTARTER (Planetary Type)
ST-27
1996 TERCEL (RM440U)
(e) Install the end cover to the field frame with 2 screws.
Torque: 1.5 N´m (15 kgf´cm, 13 in.´lbf)
7. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY
(a) Install a new O-ring to the groove of the field frame.
(b) Align the cutout of the field frame with the protrusion of the
shock absorber.
(c) Install the field frame and armature assembly with the 2
through bolts.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
8. INSTALL MAGNETIC SWITCH
(a) Install the plunger cover to the magnetic switch.
(b) Hang the plunger of the magnetic switch to the drive lever
from the upper side.
(c) Install the magnetic switch with the 2 nuts.
Torque: 8.3 N´m (85 kgf´cm, 73 in.´lbf)
(d) Connect the lead wire to the terminal, and install the nut.
Torque: 9.8 N´m (100 kgf´cm, 87 in.´lbf)

ST086-01
P25503
Terminal C
Terminal 50
P25510
Disconnect
P25511
Disconnect
P25512
ST-28
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
TEST
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid burning out the coil.
1. DO PULL-IN TEST
(a) Disconnect the field coil lead from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
If the clutch pinion gear does not move, replace the magnetic
switch.
2. DO HOLD-IN TEST
While connected as above with the clutch pinion gear out, dis-
connect the negative (-) lead from terminal C. Check that the
clutch pinion gear remains out.
If the clutch pinion gear returns inward, replace the magnetic
switch.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) lead from the switch body. Check
that the clutch pinion gear returns inward.
If the clutch pinion gear does not return, replace the magnetic
switch.
4. INSPECT CLUTCH PINION GEAR CLEARANCE
(a) Connect the battery to the magnetic switch as shown.

ST1090
P25513
Terminal 30
Terminal 50
Ammeter
- STARTINGSTARTER (Planetary Type)
ST-29
1996 TERCEL (RM440U)
(b) Move the pinion gear toward the armature to remove
slack and measure the clearance between the pinion
gear end and stop collar.
Standard clearance: 1 - 5 mm (0.04 - 0.20 in.)
5. DO NO-LOAD PERFORMANCE TEST
(a) Connect the field coil lead to terminal C. Make sure the
lead is not grounded.
(b) Connect the battery and ammeter to the starter as shown.
(c) Check that the starter rotates smoothly and steadily with
the clutch pinion gear moving out. Check that the amme-
ter reads the specified current.
Specified current: At 11.5 V: 90 A or less

ST087-04
ST-30
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page ST-16).

B04265
Starter Relay
ST088-10
Z14237
Ohmmeter
OhmmeterContinuity
No Continuity86
87
30
85
Z14236
Ohmmeter
Battery Continuity
30
8586
87
- STARTINGSTARTER RELAY
ST-31
676 Author
: Date
:
1996 TERCEL (RM440U)
STARTER RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE STARTER RELAY (Marking: ºSTº)
3. INSPECT RELAY CONTINUITY
(a) Using an ohmmeter, check that there is continuity be-
tween terminals 85 and 86.
If there is no continuity, replace the relay.
(b) Check that there is no continuity between terminals 30
and 87.
If there is continuity, replace the relay.
4. INSPECT RELAY OPERATION
(a) Apply battery voltage across terminals 85 and 86.
(b) Using an ohmmeter, check that there is continuity be-
tween terminals 30 and 86.
If there is no continuity, replace the relay.
5. REINSTALL STARTER RELAY
6. REINSTALL RELAY BOX COVER

CH065-01
- CHARGINGCHARGING SYSTEM
CH-1
677 Author
: Date
:
1996 TERCEL (RM440U)
CHARGING SYSTEM
PRECAUTION

Check that the battery cables are connected to the correct terminals.

Disconnect the battery cables when the battery is given a quick charge.

Do not perform tests with a high voltage insulation resistance tester.

Never disconnect the battery while the engine is running.

CH0H6-01
Z11580
Blue White Red
OK Charging
NecessaryInsufficient
Water
N00313
CH-2
- CHARGINGCHARGING SYSTEM
1996 TERCEL (RM440U)
ON-VEHICLE INSPECTION
1. CHECK BATTERY SPECIFIC GRAVITY AND ELEC-
TROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
If insufficient, refill with distilled (or purified) water.
(b) Check the specific gravity of each cell.
Standard specific gravity:
1.27 - 1.29 at 20°C (68°F)
If the specific gravity is less than specification, charge the bat-
tery.
HINT:
Check the indicator as shown in illustration.
2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
If the terminals are corroded, clean the terminals.
(b) Check the fusible link and fuses for continuity.
Fusible linkMAIN 2.0A
HfALT 100AH-fuseAM1 50A
AM2 15A
FGAUGE 15AFuseIGN 7.5A
ALT-S 7.5A
3. INSPECT DRIVE BELT
(a) Visually check the drive belt for excessive wear, frayed
cords etc.
If any defect is found, replace the drive belt.
HINT:
Cracks on the rib side of a drive belt are considered acceptable.
If the drive belt has chunks missing from the ribs, it should be
replaced.

N00280
DENSO
Borroughs
CH0087
CORRECTWRONG WRONG
P13685
CH0732
Disconnect Wire
from Terminal B
Generator
Voltmeter BatteryAmmeter
B
- CHARGINGCHARGING SYSTEM
CH-3
1996 TERCEL (RM440U)
(b) Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
DENSO BTG-20 (95506-00020)
Borroughs No. BT-33-73F
Drive belt tension:
New belt
Used belt160 ± 20 lbf
100 ± 20 lbf
If the belt tension is not as specified, adjust it.
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.

After installing a belt, check that it fits properly in the
ribbed grooved.

Check by hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.

After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.
4. VISUALLY CHECK GENERATOR WIRING AND
LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.
5. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
(c) Turn the ignition switch ºONº. Check that the charge warn-
ing light is lit.
(d) Start the engine. Check that the light goes off.
If the light does not go off as specified, troubleshoot the charge
light circuit.
6. INSPECT CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit as per manufacturer's instructions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:

Disconnect the wire from terminal B of the generator
and connect it to the negative (-) tester probe of the
ammeter.