1996 TOYOTA TERCEL stop start

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.

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

CL0649
Push Rod Play and Freeplay Adjust Point
Pedal Height
Adjust Point
Push Rod Play
Pedal HeightCL05P-04
CL0102
Pedal Freeplay
CL0512
25 mm (0.98 in.) or More
Full Stroke
End PositionRelease Point
CL-2
- CLUTCHCLUTCH PEDAL
697 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH PEDAL
INSPECTION
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from dash panel:
143.0 - 151.0 mm (5.629 - 5.944 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
Push in on the pedal until the beginning of clutch resistance is
felt.
Pedal freeplay: 5.0 - 15.0 mm (0.196 - 0.591 in.)
Gently push on the pedal until the resistance begins to in-
crease.
Push rod play at pedal top:
1.0-5.0 mm (0.039-0.196 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
(d) Connect the air duct and install the lower finish panel.
5. CHECK CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into reverse position until the gears contact.
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point that the gear noise stops
(release point) up to the full stroke end position.
Standard distance:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, perform the following opera-
tions.

Inspect pedal height.

Inspect push rod play and pedal freeplay.

Bleed the clutch line.

Inspect the clutch cover and disc.

Z13623
RPMidle
AT5867Drain plug Filler plug
MT0613
Filler Hole
Fluid Level
0 - 5 mm
e
Z15674
Adjusting Nut
Outer Cable Rubber Boot
Cable Stopper0 - 1 mm
BE1485
8 423
5 761
9 AX-4
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
(4) Start the engine and shift the selector into all posi-
tions from the P position through the L position and
then shift it into the P position.
(5) With the engine idling, check the fluid level. Add the
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature 70 - 80 °C (158 - 176 °F) and add as nec-
essary.
NOTICE:
Do not overfill.
(d) If necessary, replace the differential fluid.
(1) Using a hexagon wrench, remove the drain plug
and drain the fluid.
(2) Using a hexagon wrench, install the drain plug se-
curely.
(3) Remove the filler plug.
(4) Add new fluid until it begins to run out of the filler
hole.
Fluid type: ATF D-ll or DEXRON®lll (DEXRON®ll)
Capacity: 1.4 liters (1.5 US qts, 1.2 lmp.qts)
(e) Check the differential fluid level.
Remove the filler plug and check the differential fluid lev-
el.
(f) Inspect and adjust the throttle cable.
(1) Depress the accelerator pedal all the way and
check that the throttle valve opens fully.
HINT:
If the throttle valve does not open fully, adjust the accelerator
link.
(2) Fully depress the accelerator.
(3) Loosen the adjustment nuts.
(4) Adjust the outer cable so that the distance between
the end of the boot and the stopper on the cable is
the standard.
Standard boot and cable stopper distance:
0 - 1 mm (0 - 0.04 in.)
(5) Tighten the adjusting nuts.
(6) Recheck the adjustment.
(g) Inspect the park/neutral position switch.
(1) Remove the park/neutral position switch
(See page AX-15).

AX-6
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
(4) Keep your left foot pressing firmly on the brake pedal.
(5) Start the engine.
(6) Shift it into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed: 2,300 ± 200 rpm
(7) Do the same test in the R position.
Stall speed: 2,300 ± 200 rpm
EVALUATION
ProblemPossible cause
(a) Stall speed low in D and R positions. Engine output may be insufficient
 Stator one-way clutch is not operating properly
(b) Stall speed high in D position.
 Line pressure too low
 Forward clutch slipping
 No.2 one-way clutch not operating properly
(c) Stall speed high in R position.
 Line pressure too low
 Direct clutch slipping
 1st and reverse brake slipping
(d) Stall speed high in D and R positions. Line pressure too low
 Improper fluid level
4. MEASURE TIME LAG TEST
When the shift lever is shifted while the engine is idling, there will be a certain time elapse or lag before the
shock can be felt. This is used for checking the condition of the forward clutch, direct clutch and 1st and re-
verse brake.
NOTICE:
Do the test at normal operating fluid temperature 50 - 80 °C (122 - 176°F).
Make sure to allow 1 minute interval tests.
Make 3 measurements and take the average value.
(1) Fully apply the parking brake.
(2) Start the engine and check the idle speed.
Idling speed: 750 ± 50 rpm (In N position and A/C OFF)
(3) Shift the shift lever from the N to D position. Using a stop watch, measure the time it takes from
shifting the lever to the shock is felt.
Time lag: Less than 1.2 seconds
(4) In the same way, measure the time lag for N " R.
Time lag: Less than 1.5 seconds
EVALUATION (If N " D time lag are longer than than specified):
ProblemPossible cause
NDti l i l
 Line pressure too low
 Forward clutch worn
N " D time lag is longer Forward clutch worn
 Direct clutch worn
 1st and reverse brake worn

Z15674
Adjusting Nut
Outer Cable Rubber Boot
Cable Stopper0 - 1 mm
Q06559
Q01095
AX-4
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
1996 TERCEL (RM440U)
NOTICE:
Do not overfill.
(d) Inspect and adjust the throttle cable.
(1) Depress the accelerator pedal all the way and
check that the throttle valve opens fully.
HINT:
If the throttle valve does not open fully, adjust the accelerator
link.
(2) Fully depress the accelerator.
(3) Loosen the adjustment nuts.
(4) Adjust the outer cable so that the distance between
the end of the boot and the stopper on the cable is
the standard.
Standard boot and cable stopper distance:
0 - 1 mm (0 - 0.04 in.)
(5) Tighten the adjusting nuts.
(6) Recheck the adjustment.
(e) Adjust the shift control cable.
When shifting the shift lever from the N position to other
positions, check that the lever can be shifted smoothly
and accurately to each position and that the position indi-
cator correctly indicates the position.
(1) Remove the engine under cover.
(2) Loosen the nut on the control shaft lever.
(3) Push the control shaft lever fully toward the right
side of the vehicle.
(4) Return the lever 2 notches to the NEUTRAL posi-
tion.
(5) Set the shift lever to the N position.
(6) While holding the lever lightly toward the ºRº posi-
tion side, tighten the swivel nut.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
(f) Adjust the park/neutral position switch.
If the engine will start with the shift selector in any position other
than the N or P position, adjustment is required.
(1) Loosen the park/neutral position switch bolts and
set the shift selector to the N position.
(2) Align the groove with neutral basic line.
(3) Hold the switch in the position and tighten the bolts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(g) Inspect the idle speed.
Idle speed:
750 ± 50 rpm (In the N position and A/C OFF)