TOYOTA TERCEL 1996 Service Repair Manual

P13734
Terminal F CH-4
- CHARGINGCHARGING SYSTEM
1996 TERCEL (RM440U)

Connect the positive (+) tester probe of the amme-
ter to terminal B of the generator.

Connect the positive (+) tester probe of the voltme-
ter to terminal B of the generator.

Ground the negative (-) tester probe of the voltme-
ter.
(b) Check the charging circuit as follows:
With the engine running from idling to 2,000 rpm, check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage:
at 25°C (77°F)13.9 - 15.1 V
at 115°C (239°F)13.5 - 14.3 V
If the voltmeter reading is greater than standard voltage, re-
place the voltage regulator.
If the voltmeter reading is less than standard voltage, check the
voltage regulator and generator as follows:

With terminal F grounded, start the engine and
check the voltmeter reading of terminal B.

If the voltmeter reading is greater than standard
voltage, replace the voltage regulator.

If the voltmeter reading is less than standard volt-
age, check the generator.
7. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater blower switch at
ºHIº.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than the standard amperage, re-
pair the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.

CH0H8-01
- CHARGINGGENERATOR
CH-5
681 Author
: Date
:
1996 TERCEL (RM440U)
GENERATOR
COMPONENTS

CH0H9-01
P13685
P21508
Adjusting Bolt
Pivot Bolt
CH-6
- CHARGINGGENERATOR
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT CONNECTOR AND WIRE FROM
GENERATOR
(a) Disconnect the connector from the generator.
(b) Remove the connector cover and nut, and disconnect the
wire from the generator.
2. REMOVE DRIVE BELT
Loosen the pivot bolt and adjusting bolt, and remove the drive
belt.
Torque:
Pivot bolt: 41 N´m (420 kgf´cm, 30 ft´lbf)
Adjusting bolt: 12 N´m (120 kgf´cm, 9 ft´lbf)
3. REMOVE GENERATOR
(a) Remove the pivot bolt, nut and adjusting bolt.
(b) Remove the generator.

P13686
CH0HA-01
Z10245
Type A
Z14809
Type B
P13644
P13688
- CHARGINGGENERATOR
CH-7
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
(b) Type A:
Remove the 3 nuts and end cover.
(c) Type B:
Remove the 3 bolts and end cover.
2. REMOVE BRUSH HOLDER AND VOLTAGE
REGULATOR
(a) Remove the 5 screws, brush holder and voltage
regulator.
(b) Remove the brush holder cover from the brush holder.

Z19162
Type A
Z14812
Type B
P04209
SST(A)
Turn SST(B)
P04210
SST (C)
CH-8
- CHARGINGGENERATOR
1996 TERCEL (RM440U)
3. Type A
REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws and rectifier holder.
(b) Remove the 4 rubber insulators.
4. Type B:
REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws.
(b) Using needle-nose pliers, straighten the stator lead wire.
(c) Remove the rectifier holder.
5. REMOVE PULLEY
(a) 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)
(b) Check that SST (A) is secured to the rotor shaft.
(c) Mount SST (C) in a vise.
(d) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

P04394
SST (C)
SST (A)
Turn
P04393
SST (A)
SST (B)
Turn
Z19163
Type A
Z14814
Type B
P13692
SST
- CHARGINGGENERATOR
CH-9
1996 TERCEL (RM440U)
(e) To loosen the pulley nut, turn SST (A) in the direction
shown in the illustration.
NOTICE:
To prevent damage to the rotor shaft, do not loosen the
pulley nut more than one-half of a turn.
(f) Remove the generator from SST (C).
(g) Turn SST (B), and remove SST (A and B).
(h) Remove the pulley nut and pulley.
6. REMOVE RECTIFIER END FRAME
(a) Type A
Remove the 4 nuts.
(b) Type B:
Remove the 2 nuts, 2 bolts.
(c) Using SST, remove the rectifier end frame.
SST 09286-4601 1

CH-10
- CHARGINGGENERATOR
1996 TERCEL (RM440U)
(d) Using snap ring pliers, remove the generator washer from
the rectifier end frame.
7. REMOVE ROTOR FROM DRIVE END FRAME

CH0HB-01
CH0784
Ohmmeter
Continuity
CH0783
Ohmmeter
No Continuity
CH1023
P04189
Ohmmeter
Continuity
P04215
Ohmmeter No Continuity
- CHARGINGGENERATOR
CH-1 1
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT ROTOR
(a) Check the rotor for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the slip rings.
Type A:2.2 - 2.4 W at 20°C (68°F)
Type B:2.8 - 3.0 W at 20°C (68°F)
If there is no continuity, replace the rotor.
(b) Check the rotor for ground.
Using an ohmmeter, check that there is no continuity be-
tween the slip ring and rotor.
If there is continuity, replace the rotor.
(c) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(d) Using vernier calipers, measure the slip ring diameter.
Standard diameter: 14.2 - 14.4 mm (0.559 - 0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.
2. INSPECT STATOR (DRIVE END FRAME)
(a) Check the stator for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the coil leads.
If there is no continuity, replace the drive end frame assembly.
(b) Check the stator for ground.
Using an ohmmeter, check that there is no continuity be-
tween the coil lead and drive end frame.
If there is continuity, replace the drive end frame assembly.

P13534
P13568
Ohmmeter
Positive (+)
Terminal
Rectifier
Terminal
P13566
Ohmmeter
Negative (-)
Terminal
CH-12
- CHARGINGGENERATOR
1996 TERCEL (RM440U)
3. INSPECT BRUSHES
Using vernier calipers, measure the exposed brush length.
Standard exposed length:
10.5 mm (0.413 in.)
Minimum exposed length:
1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brushes
(Type A) or brush holder assembly (Type B).
4. INSPECT RECTIFIERS (RECTIFIRE HOLDER)
(a) Check the positive rectifier.
(1) Using an ohmmeter, connect one tester probe to the
positive (+) terminal and the other to each rectifier
terminal.
(2) Reverse the polarity of the tester probes and repeat
step (a).
(3) Check that one shows continuity and the other
shows no continuity.
If continuity is not as specified, replace the rectifier holder.
(b) Check the negative (-) rectifire.
(1) Using an ohmmeter, connect one tester probe to
each negative (-) terminal and the other to each
rectifier terminal.
(2) Reverse the polarity of the tester probes and repeat
step (a).
(3) Check that one shows continuity and the other
shows no continuity.
If continuity is not as specified, replace the rectifier holder.
5. INSPECT BEARING
Check the bearing is not rough or worn.

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)