ABS TOYOTA TERCEL 1996 Service Manual PDF

ST0MW-01
B05050
Magnetic Switch
Drive Level
Plate Washer
PlateStop Collar
Starter Housing
Snap Ring
Starter Clutch
Planetary GearPlate Carrier ShaftIntemal Gear

Non-reusable partSnap Ring
Plate Washer
Center Beaning
Armature Plate Washer

O-Ring Shock Absorber
Field Frame
(Field Coil)
End CoverBrush Holder
O-Ring
- STARTINGSTARTER (Planetary Type)
ST-15
660 Author
: Date
:
1996 TERCEL (RM440U)
STARTER (Planetary Type)
COMPONENTS

ST1086
Z03210
(3)
(2)
(1)
Z15980
ST0659
ST0647
Hollow
Protrusion
ST-18
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
5. REMOVE DRIVE LEVER AND STARTER CLUTCH
WITH SHOCK ABSORBER FROM STARTER HOUS-
ING
6. REMOVE PLANETARY GEARS
Remove these parts from the shock absorber:
(1) Plate
(2) 3 planetary gears
(3) Plate washer
7. REMOVE STARTER CLUTCH
(a) Using a screwdriver, tap in the stop collar towards the
starter clutch.
(b) Using a screwdriver, pry off the snap ring.
(c) Remove the rear collar from the starter clutch.
8. REMOVE PLANET CARRIER SHAFT AND INTERNAL
GEAR
(a) Using snap ring pliers, remove the snap ring and plate
washer.
(b) Remove the planet carrier shaft and plate washer.
(c) Align the hollow of the internal gear with the protrusion in-
side the shock absorber, and remove the internal gear.

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)

CL05O-03
- CLUTCHTROUBLESHOOTING
CL-1
696 Author
: Date
:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
1. Engine mounting (Loosen)-1.Engine mounting (Loosen)
2. Clutch disc (Runout is excessive)
-
CL-14
2.Clutch disc (Runout is excessive)
3. Clutch disc (Oily)
CL-14
CL-14
Clutch grabs/chatters
3.Clutch disc (Oily)
4. Clutch disc (Worn out)
CL-14
CL-14Clutch grabs/chatters4.Clutch disc (Worn out)
5. Clutch disc torsion rubber (Damaged)
CL-14
CL-145.Clutch disc torsion rubber (Damaged)
6. Clutch disc (Glazed)
CL 14
CL-146.Clutch disc (Glazed)
7. Diaphragm spring (Out of tip alignment)
CL 14
CL-14
1. Clutch line (Air in line)-
Clutch pedal spongy
1.Clutch line (Air in line)
2. Master cylinder cup (Damaged)
-
CL-4
Clutch edal s ongy2.Master cylinder cu (Damaged)
3. Release cylinder cup (Damaged)
CL 4
CL-9
1. Release bearing (Worn, dirty, or damaged)CL-14
Clutch noisy
1.Release bearing (Worn, dirty, or damaged)
2. Input shaft bearing (Worn or damaged)
CL-14
-Clutch noisy2.In ut shaft bearing (Worn or damaged)
3. Clutch disc torsion rubber (Damaged)CL-14
1. Clutch pedal (Free play out of adjustment)CL-21.Clutch edal (Free lay out of adjustment)
2. Clutch disc (Oily)
CL-2
CL-14
Cl t h li
2.Clutch disc (Oily)
3. Clutch disc (Worn out)
CL-14
CL-14Clutch slips3.Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
CL 14
CL-144.Dia hragm s ring (Damaged)
5. Pressure plate (Distortion)
CL 14
CL-145. Pressure late (Distortion)
6. Flywheel (Distortion)
CL 14
-
1 Clutchpedal (Freeplay out of adjustment)CL-21.Clutch pedal (Free play out of adjustment)
2 Clutch line (Air in line)CL-2
-2.Clutch line (Air in line)
3 Master cylinder cu
p(Damaged)
-
CL-43.Master cylinder cup (Damaged)
4. Release cylinder cu
p(Damaged)
CL-4
CL
-94.Release cylinder cup (Damaged)
5
. Input shaft bearing (Worn or damaged)
CL-9
-5.In ut shaft bearing (Worn or damaged)
6. Clutch disc (Out of true)
-
CL-14
Cl t h d t di
6.Clutch disc (Out of true)
7. Clutch disc (Runout is excessive)
CL-14
CL-14Clutch does not disengage7.Clutch disc (Runout is excessive)
8. Clutch disc (Lining broken)
CL-14
CL-148.Clutch disc (Lining broken)
9. Clutch disc (Dirty or burned)
CL-14
CL-149.Clutch disc (Dirty or burned)
10.Clutch disc (Oily)
CL 14
CL-1410.Clutch disc (Oily)
11. Clutch disc (Lack of spline grease)
CL 14
CL-1711. Clutch disc (Lack of s line grease)
12.Diaphragm spring (Damaged)
CL 17
CL-14gg(g)
13.Diaphragm spring (Out of tip alignment)CL-17gg( g)
14.Pressure plate (Distortion)CL-14

SA10Z-04
- SUSPENSION AND AXLETROUBLESHOOTING
SA-1
817 Author
: Date
:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table to help you find the cause of the problem. The numbers indicate the priority of the likely case
of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Wander/pulls
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Steering linkage (Loosen or worn)
4. Hub bearings (Worn)
5. Steering gear (Out of adjustment or broken)
6. Suspension parts (Worn)SA-2
SA-4
SA-8
-
SA-10
SA-39
SR-34
SR-46
-
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)-
SA-24
SA-44
SA-24
SA-44
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Rear axle beam)
3. Shock absorber (Worn)SA-2
SA-54
SA-24
SA-44
Front wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheels (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Ball joint (Worn)
6. Hub bearing (Worn)
7. Steering linkage (Loosen or worn)
8. Steering gear (Out of adjustment or broken)SA-2
SA-2
SA-24
SA-4
SA-34
SA-10
-
SR-34
SR-46
Abnormal tire wear
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Suspension parts (Worn)
4. Shock absorber (Worn)SA-2
SA-4
SA-8
-
SA-24
SA-44

R11682
- SUSPENSION AND AXLETIRE AND WHEEL
SA-3
819 Author
: Date
:
1996 TERCEL (RM440U)
4. CHECK WHEEL BEARING LOOSENESS
(a) Check the backlash in bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
(b) Check the axle hub deviation.
Maximum: 0.05 mm (0.0020 in.)
5. CHECK FRONT SUSPENSION FOR LOOSENESS
6. CHECK STEERING LINKAGE FOR LOOSENESS
7. CHECK BALL JOINT FOR LOOSENESS
8. CHECK SHOCK ABSORBER WORKS PROPERLY

Check for oil leaks

Check mounting bushings for wear

Bounce front and rear of the vehicle

F03984
R15511



- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA-5
821 Author
: Date
:
1996 TERCEL (RM440U)
5. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe-in.
(a) Remove the front wheels.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
(c) Coat the threads of the nuts with engine oil.
(d) Temporarily install the 2 nuts.
(e) Adjust the camber by pushing or pulling the lower side of
the shock absorber in the direction in which the camber
adjustment is required.
Adjusting value: 0°06' - 0°30'
(f) Tighten the nuts.
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
(g) Install the front wheels.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(h) Check the camber.
Camber
Left-right error-0°20' ± 45'
45' (0.75°) or less
HINT:

Try to adjust the camber to the center value.

Adjusting value for the set bolts is 6' - 30' (0.1° - 0.5°).

SA114-03
R11682
F03986
F03987
SA-10
- SUSPENSION AND AXLEFRONT AXLE HUB
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. w/ ABS
REMOVE BOLT AND ABS SPEED SENSOR
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
3. REMOVE FRONT BRAKE CALIPER AND DISC
(a) Remove the 2 bolts and brake caliper from the steering
knuckle.
Torque: 88 N´m (900 kgf´cm, 65 in.´lbf)
(b) Support the brake caliper securely.
(c) Remove the disc.
4. CHECK BACKLASH IN BEARING SHAFT DIRECTION
Using a dial indicator, check the backlash near the center of the
axle hub, and check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the bearing.
5. CHECK AXLE HUB DEVIATION
Using a dial indicator, check the deviation at the surface of the
axle hub outside the hub bolt.
Maximum: 0.05 mm (0.0020 in.)
If the deviation exceeds the maximum, replace the axle hub.
6. REMOVE DRIVE SHAFT LOCK NUT
(a) Install the brake disc and caliper.
(b) Remove the cotter pin and lock cap.
(c) With applying the brakes, remove the nut.
Torque: 216 N´m (2,200 kgf´cm, 159 ft´lbf)
(d) Remove the brake caliper and disc.
7. LOOSEN 2 NUTS ON LOWER SIDE OF SHOCK AB-
SORBER
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
HINT:

Do not remove the 2 bolts.

Coat the nut's thread with engine oil.