1996 TOYOTA TERCEL Service Repair Manual

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)

N00581
SST
P05052
Bearing Cover
N00578
SST
P00074
SST
CH-14
- CHARGINGGENERATOR
1996 TERCEL (RM440U)
3. REPLACE REAR BEARING
(a) Using SST, remove the bearing cover (outside) and bear-
ing.
SST 09820-00021
NOTICE:
Be careful not to damage the fan.
(b) Remove the bearing cover (inside).
(c) Place the bearing cover (inside) on the rotor.
(d) Using SST and a press, press in a new bearing.
SST 09820-00030
(e) Using SST, push in the bearing cover (outside).
SST 09285-76010

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.

Z10245
Type A
Z14809
Type B CH-18
- CHARGINGGENERATOR
1996 TERCEL (RM440U)
8. INSTALL REAR END COVER
(a) Type A:
Install the end cover with the 3 nuts.
Torque: 4.4 N´m (45 kgf´cm, 40 in.´lbf)
(b) Type B:
Install the end cover with the 3 bolts.
Torque: 4.4 N´m (45 kgf´cm, 40 in.´lbf)
(c) Install the terminal insulator with the nut.
Torque: 4.1 N´m (42 kgf´cm, 36 in.´lbf)
9. CHECK THAT ROTOR ROTATES SMOOTHLY

CH06D-03
- CHARGINGGENERATOR
CH-19
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page CH-6).