1996 TOYOTA TERCEL oil type

SS0NF-07
- SERVICE SPECIFICATIONSSTARTING
SS-19
149 Author
: Date
:
1996 TERCEL (RM440U)
STARTING
SERVICE DATA
Starter
(Planetary type)Rated voltage and output power
No-load characteristics Current
rpm
Center bearing oil clearance STD
Maximum
Brush length STD
Minimum
Spring installed load STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runout Maximum12 V 0.8 kW
At 11.5 V 90 A or less
3,000 rpm or more
0.03 mm (0.0012 in.)
0.1 mm (0.004 in.)
14.0 mm (0.551 in.)
9.0 mm (0.354 in.)
13.7 - 17.6 N (1.4 - 1.8 kgf, 3.1 - 4.0 lbf)
8.8 N (0.9 kgf, 2.0 lbf)
28.0 mm (1.102 in.)
27.0 mm (1.063 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
Starter
(Reduction type)Rated voltage and output power
No-load characteristics Current
rpm
Brush length STD
Minimum
Spring installed load STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runout Maximum
Magnetic switch
Contact plate for wear Maximum12 V 1.0 kW
At 11.5 V 90 A or less
3,000 rpm or more
13.5 mm (0.531 in.)
8.5 mm (0.334 in.)
17.6 - 23.5 N (1.79 - 2.39 kgf, 4.0 - 5.3 lbf)
11.8 N (1.2 kgf, 2.6 lbf)
30.0 mm (1.181 in.)
29.0 mm (1.412 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
0.9 mm (0.035 in.)

SS0NH-03
- SERVICE SPECIFICATIONSCHARGING
SS-21
151 Author
: Date
:
1996 TERCEL (RM440U)
CHARGING
SERVICE DATA
BatterySpecific gravity at 20°C (68°F)1.25 - 1.29
Drive beltTension New belt
Used belt160 ± 20 lbf
100 ± 20 lbf
GeneratorRated output
Rotor coil resistance
Type A at 20°C (68°F)
Type B at 20°C (68°F)
Slip ring diameter STD
Minimum
Brush exposed length STD
Minimum12 V 70 A, 60 A
2.2 - 2.4 W
2.8 - 3.0 W
14.2 - 14.4 mm (0.559 - 0.567 in.)
12.8 mm (0.504 in.)
10.5 mm (0.413 in.)
1.5 mm (0.059 in.)
Voltage regulatorRegulating voltage at 25°C (77°F)
at 115°C (239°F)13.9 - 15.1 V
13.5 - 14.3 V

SS0NI-03
SS-22
- SERVICE SPECIFICATIONSCHARGING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Generator x Generator bracket4142030
Generator x Adjusting lever121209
Bearing retainer x Drive end frame2.62723 in.´lbf
Rectifier end frame x Drive end frame Type A, B4.54640 in.´lbf
Generator pulley x Rotor11 01,12581
Rectifier holder x Coil lead on rectifier end frame Type A, B1.962017 in.´lbf
Rear end cover x Rectifier holder Type A, B4.44540 in.´lbf
Terminal insulator x Rectifier holder4.14236 in.´lbf

P25779S00553A05593
DI-54
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
1 Check spark plug and spark of misfiring cylinder.
PREPARATION:
(a) Disconnect the high-tension cord or ignition coil.
(b) Remove the spark plug.
CHECK:
(a) Check plug type.
(b) Check for carbon deposits on electrode.
(c) Check electrode gap.
OK:
(1) Twin ground electrodes type.
Recommended spark plug:
ND: K16TR11
NGK: BKR5EKB-11
(2) No large carbon deposit present.
Not wet with gasoline or oil.
(3) Electrode gap: 1.0 - 1.1 mm (0.039 - 0.043 in.)
PREPARATION:
(a) Install the spark plug to the high-tension cord or ignition
coil.
(b) Disconnect the injector connector.
(c) Ground the spark plug.
CHECK:
Check if spark occurs while engine is being cracked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, do not crank the engine for more than 5 -
10 seconds at a time.
OK:
Spark jumps across electrode gap.
NG Replace or check ignition system (See page
IG-1).
OK

ST0N2-01
B11226
End CoverBrush Holder
Rear BearingArmature
Front Bearing
Field Frame (Field Coil)
Startor Housing
Bearing
Idler Gear
Magnetic Switch Assembly
Return Spring
Steel BallClutch Assembly

Terminal C Kit Part
Terminal 30 Kit Part
Terminal Nut
Wave Washer
O-Ring
Terminal Insulater Outer
Contact Plate
Insulation
Paper
Terminal Insulater Inner
Terminal Bolt
Lead Clamp
End Cover
GasketPlungerO-Ring
Wave Washer
Terminal Nut
Terminal Insulater Outer
Terminal Bolt
Lead Terminal
Contact Plate
Terminal Insulater Inner

Non-reusable part ST-2
- STARTINGSTARTER (Reduction Type)
647 Author
: Date
:
1996 TERCEL (RM440U)
STARTER (Reduction Type)
COMPONENTS

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.

P10821
Free
Lock
ST0204
Terminal 50
Continuity
Terminal C
ST0205
Continuity Terminal 50Switch Body ST-8
- STARTINGSTARTER (Reduction Type)
1996 TERCEL (RM440U)
13. INSPECT CLUTCH PINION GEAR
Rotate the pinion gear clockwise, and check that it turns freely.
Try to rotate the pinion gear counterclockwise and check that
it locks.
If necessary, replace the clutch assembly.
14. INSPECT REAR BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
15. INSPECT FRONT BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
16. DO PULL-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, check and replace the magnetic switch.
17. DO HOLD-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, check and replace the magnetic switch.

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)