1996 TOYOTA TERCEL torque

ST081-01
P21028
Z193254A/T M/T
3A/T ST-16
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE AIR CLEANER HOSE
2. REMOVE INTAKE MANIFOLD STAY
(a) Disconnect the engine wire clamps from intake
manifold stay.
(b) Remove the bolt, nut and intake manifold stay.
Torque: 17.5 N´m (175 kgf´cm, 13 ft´lbf)
3. REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter wire.
Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
(c) Remove the 2 bolts, wire clamp and starter.
Torque: 37 N´m (370 kgf´cm, 27 ft´lbf)

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)

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.

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).

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)

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.