1996 TOYOTA TERCEL Service Repair Manual

P25608
Wooden
Block
40 mm
37 mm
20 mmContact
Plate
V06796
P25609
SST
P25479
- STARTINGSTARTER (Reduction Type)
ST-1 1
1996 TERCEL (RM440U)
(f) Temporarily tighten the terminal nuts.
(g) Tighten the terminal nut.
(1) Put a wood block on the contact plate and press it
down with a hand press.
Dimensions of wood block:
20 x 37 x 40 mm (0.97 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:

Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when 981 N
(100 kgf, 221 lbf) of force is applied.

If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(2) Using SST, tighten the nut to the specified torque.
SST 09810-38140
Torque: 17 N´m (173 kgf´cm, 12 ft´lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
(h) Clean the contact surfaces of the contact plate and plung-
er.
Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.
(i) Reinstall the magnetic switch end cover.
Install the plunger, new gasket, end cover and lead clamp
with 3 bolts.
Torque: 3.6 N´m (36 kgf´cm, 32 in.´lbf)

ST0J0-02
ST-12
- STARTINGSTARTER (Reduction Type)
1996 TERCEL (RM440U)
REASSEMBLY
Ressembly is in the reverse order of disassembly (See page ST-4).
HINT:
Use high-temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling
the starter.

ST0J1-01
P13459
Terminal 50
Terminal C
Battery
P13460
Terminal C
Battery
Disconnect
P13461
Battery
Disconnect
P13462
Battery
Ammeter Terminal 50
Terminal 30
- STARTINGSTARTER (Reduction Type)
ST-13
1996 TERCEL (RM440U)
TEST
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid burning out the coil.
1. DO HOLD-IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD-IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (-) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) lead from the switch body.
Check that the clutch pinion gear returns inward.
4. DO NO-LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter the
current specified in the respective repair manual.

ST0J2-02
ST-14
- STARTINGSTARTER (Reduction Type)
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page ST-3).

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

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)

ST0MX-01
P25603
ST1088
P25781
P25780
ST0656
- STARTINGSTARTER (Planetary Type)
ST-17
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE MAGNETIC SWITCH
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
(b) Loosen the 2 nuts holding the magnetic switch to the
starter housing.
(c) Pull the magnetic switch and while lifting the front part of
the magnetic switch, release the plunger hook from the
drive lever, then release the magnetic switch.
2. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the 2 through bolts.
(b) Pull out the field frame together with the armature.
(c) Remove the O-ring from the field frame.
3. REMOVE BRUSH HOLDER
(a) Remove the 2 screws and end cover from the field frame.
(b) Remove the O-ring from the field frame.
(c) Using a screwdriver, hold the spring back and disconnect
the brush holder. Disconnect the 4 brushes, and remove
the brush holder.
4. REMOVE ARMATURE FROM FIELD FRAME

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.