1996 TOYOTA TERCEL length

ST0199
Continuity
ST0200
No Continuity
N00337
ST0019
ST0203
Continuity
- STARTINGSTARTER (Reduction Type)
ST-7
1996 TERCEL (RM440U)
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. INSPECT FIELD COIL FOR GROUND
Using an ohmmeter, check that there is no continuity between
the field coil end and field frame.
If there is continuity, replace the field frame.
9. INSPECT BRUSH LENGTH
Using a vernier caliper, measure the brush length.
Standard length: 13.5 mm (0.531 in.)
Minimum length: 8.5 mm (0.334 in.)
If the length is less than minimum, replace the brush holder and
field frame.
10. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard spring installed load:
17.6 - 23.5 N (1.79 - 2.39 kgf, 4.0 - 5.3 lbf)
Minimum spring installed load:
11.8 N (1.2 kgf, 2.6 lbf)
If the installed load is not as specified, replace the brush
springs.
11. INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idle gear and the clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for wear or
damage.

ST0666
Continuity
ST0665No Continuity
ST0648
ST0019
ST0660
No Continuity ST-20
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
2. INSPECT FIELD COIL
(a) Check the field coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
(b) Check the field coil for ground.
Using an ohmmeter, check that there is no continuity be-
tween the field coil end and field frame.
If there is continuity, repair or replace the field frame.
3. INSPECT BRUSHES
Check the brush length.
Using vernier calipers, measure the brush length.
Standard length: 14.0 mm (0.551 in.)
Minimum length: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the brush (field frame
side) or brush holder, and dress with an emery cloth.
4. INSPECT BRUSH SPRINGS
Check the brush spring load.
Take the pull scale reading the instant the brush spring
separates from the brush.
Spring installed load:
13.7 - 17.6 N (1.4 - 1.8 kgf, 3.1 - 4.0 lbf)
Minimum spring installed load:
8.8 N (0.9 kgf, 2.0 lbf)
If the installed load is not as specified, replace the brush
springs.
5. INSPECT BRUSH HOLDER
Check the brush holder insulation.
Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.

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)

Q05798
Z10919
B
A
C
BDBD B C
OR0038
AT2796
Gasket
Strainer
- AUTOMATIC TRANSAXLE (A132L)VALVE BODY ASSEMBLY
AX-13
765 Author
: Date
:
1996 TERCEL (RM440U)
6. REMOVE MANUAL DETENT SPRING
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
HINT:
Check that the manual valve lever is in contact with the center
of the roller at the tip of the detent spring.
7. REMOVE MANUAL VALVE AND MANUAL VALVE
BODY
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
8. REMOVE VALVE BODY
(a) Remove the14 bolts.
Bolt Length:
A: 20 mm (0.79 in.)
B: 25 mm (0.98 in.)
C: 36 mm (1.47 in.)
D: 50 mm (1.97 in.)
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
(b) Disconnect the throttle cable.
NOTICE:
Be careful not to entangle the kick-down switch and sole-
noid wire.
(c) Remove the valve body.
9. REMOVE SECOND BRAKE APPLY GASKET AND
GOVERNOR OIL STRAINER
HINT:
Replace the used gasket with anew one.

AT3328
Z15031
B
B
A
C
A AA
B
OR0038
AT5616
AT2713
- AUTOMATIC TRANSAXLE (A242L)VALVE BODY ASSEMBLY
AX-17
799 Author
: Date
:
1996 TERCEL (RM440U)
6. REMOVE MANUAL DETENT SPRING
Remove the bolt and detent spring.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
HINT:
Check that the manual valve lever is in contact with the center
of the roller at the tip of the detent spring.
7. DISCONNECT SOLENOID CONNECTOR
8. REMOVE VALVE BODY
(a) Remove the 12 bolts.
Bolt length:
A: 20 mm (0.79 in.)
B: 30 mm (1.18 in.)
C: 55 mm (2.17 in.)
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
(b) Disconnect the throttle cable.
NOTICE:
Be careful not to entangle the kick-down switch and sole-
noid wire.
(c) Disconnect the manual valve connecting rod.
(d) Remove the valve body.
9. REMOVE 2ND BRAKE APPLY GASKET
HINT:
Replace the used gasket with a new one.

F01195
Bolt
Adjusting
ValueSet Bolt
15'
30'Adjusting Bolt90105-15001 90105-15004 90105-15005 90105-15006
45'
1°00'
1°15'
1°30'121212121 Dot 2 Dots 3 Dots
W00533
W00533
SA-6
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
822 Author
: Date
:
1996 TERCEL (RM440U)
If the camber is not within the specification, using the table be-
low, estimate of how much additional camber adjustment will be
required, and select the camber adjusting bolt.
(i) Follow the above mentioned steps again. Between step
(b) and (c), exchange 1 or 2 selected bolts.
HINT:
When exchanging the 2 bolts, exchange 1 bolt for each time.
6. ADJUST TOE-IN
(a) Remove the boot clamps.
(b) Loosen the tie rod end lock nuts.
(c) Turn the left and right rack ends an equal amount to adjust
the toe-in.
Toe-in
(total)A + B: 0.1° ± 0.2°
C - D: 1 ± 2 mm (0.04 ± 0.08 in.)
HINT:

Try to adjust the toe-in to the center value.

Make sure that the lengths of the left and right rack ends
are the same.
Tie rod end length difference: 1.5 mm (0.059 in.) or
less
(d) Torque the tie rod end lock nuts.
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
(e) Place the boots on the seat and install the clamps to them.
HINT:
Make sure that the boots are not twisted.

Z12938
RH
LH
R09908
SA-22
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 TERCEL (RM440U)
7. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Make sure the boot are on the shaft groove.
(b) Set the drive shaft length to the standard.
Standard length
RH785.1 ± 5.0 mm (30.909 ± 0.197 in.)
LH544.9 ± 5.0 mm (21.421 ± 0.197 in.)
(c) Place the 4 new boot clamps to the boots.
(d) Bend the band, and lock it with a screwdriver.
8. RH DRIVE SHAFT:
ASSEMBLE DYNAMIC DAMPER CLAMP
(a) Be sure the damper is on the shaft groove.
(b) Set the distance, as shown.
Distance: 361.4 ± 5.0 mm (14.335 ± 0.197 in.)
(c) Place a new damper clamp to the damper.
(d) Bend the band and lock it in the same procedure for the
boot clamp assembly.
9. INSTALL SNAP RING
Using a snap ring expander, install a new snap ring to the in-
board joint shaft.
10. CHECK DRIVE SHAFT (See page SA-20)