TOYOTA TERCEL 1985 Repair Manual

BR-l2BRAKE SYSTEM - Master Cylinder
INSTALL Tv\/O GROMMETS TO CYLINDER HOUSING
INSTALL CAP AND STRAINER TO RESERVOIR
6. INSTALL RESERVOIR TO CYLINDER HOUSING
Push the reservoir onto the cylinder and install the screw.
Torque: 10 - 25 kg-cm
19 - 21 in.-lb, 1.0 - 2.4 N.ml
CAUTION: Because the master cylinder and reser-
voir tank union is a grommet type, the set screw is
designed not to separate from the reservoir or cylinder
and will not tighten down the reservoir. Therefore,
there is a clearance at point A. Do not insert washers
or such when tightening.
4.
5.
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BRAKE SYSTEM - Master CylinderBR-l3
INSTALLATION OF MASTER CYLINDER
(See page BR-91
1. CLEAN OUT GROOVE ON LOWER INSTALLATION
SURFACE OF MASTER CYLINDER
2. CHECK THAT ''VP" MARK ON MASTER CYLINDER
BOOT IS IN CORRECT POSITION
3. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD
BEFORE INSTALLING MASTER CYLINDER
(See page BR-151
4. INSTALL MASTER CYLINDER
Install a new gasket, the master cylinder and 3-way union
with the two nuts. Torque the nuts.
Torque: 130 kg-cm (9 ft-lb, 13 N.ml
*
5. CONNECT BRAKE TUBES
Using SST, connect the brake tubes to the master cyliner
and 3-way union. Torque the nuts.
ssr 09751-3601 1 ;
Torque: 155 kg-cm (11ft-lb, 15 N'ml
1?
6. FILL BRAKE RESERVOIR WITH BRAKE FLUID
AND BLEED BRAKE SYSTEM {See page BR-71
7. CHECK AND ADJUST BRAKE PEDAL (See page BR-61

8R.14BRAKE SYSTEM - Brake Booster
REMOVAL OF BRAKE BOOSTER
levis
II
dCI
130 (9, 131f=s(lr=' I
5
llJ
3-Way Unionl
(ft-lb, N.m):Tightening torque
0 : Non-reusable part
Brake Fluid Level Warning
Switch Connector
Brake Booster
BRAKE BOOSTER
1. REMOVE MASTER CYLINDER (See page Bn-gl
2. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
3. REMOVE DISTRIBUTOR CAP
4. REPEAT PROCEDURE FOR EACH WHEEL
5. REMOVE HEATER AIR DUCT
6. DISCONNECT PEDAL RETURN SPRING FROM
BRAKE PEDAL
7. DISCONNECT PUSH ROD CLEVIS FROM BRAKE
PEDAL
Remove the clip and clevis pin.
8. REMOVE BRAKE BOOSTER
Remove the four nuts, and pull out the brake booster.

BRAKE SYSTEM - Brake Booster8R.15
INSTALLATION OF BRAKE BOOSTER
(See page BR-l41
1. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Set SST on the master cylinder with the gasket and
lower the pin until its tip slightly touches the piston.
ssr 09737-00010
(d Tum SST upside down, and set it on the booster.
ssT 09737-OOO10
(c) Check that there is no clearance between the booster
push rod and pin head of SST.
Clearance: O mm (0 in.l
(d) Adjust the booster push rod length untilthe push rod
lightly touches the pin head.
2. INSTALL BRAKE BOOSTER
Torque: 130 kg-cm (9 ft-lb, 13 N'ml
3. INSTALL MASTER CYLINDER (See page BR-131
4. CONNECT VACUUM HOSE TO BRAKE BOOSTER
5. CONNECT PUSH ROD CLEVIS TO BRAKE PEDAL
Install the clevis pin and clip.
6. CONNECT PEDAL RETURN SPRING TO PEDAL
SPRING
INSTALL HEATER AIR DUCT
INSTALL LOWER FINISH PANEL
INSTALL IIA CAP
FILL BRAKE RESERVOIR WITH BRAKE FLUID
AND BLEED BRAKE SYSTEM (See page BR-71
CHECK BRAKE PEDAL (See page BR-61
PERFORM OPERATIONAL CHECK (See page BR-71
7.
8.
9.
10.
11.
12.

BR-l6BRAKE SYSTEM - Front Brake
FRONT BRAKE
COMPONENTS
I
IREPLACEMENT OF BRAKE PADS
. lf a squeaking noise occurs while braking, inspect the
. brake pads. Brake squeak will occur when the gap be-
tween the pad wear indicator plate and rotor disc reaches
about 2.5 mm (0.098 in.).
1. REMOVE FRONT WHEET
Rqmove the wheel and temporarily fasten the rotdfu discwith the wheel nuts. ;:E "'
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the cylinder inspection' hole and replace pads if not within specification.
Standard
Minimum
1O.0 mm (0.394-in.l
1.0 mm (0.039 in.)
\_ [-5s ntzst IFlexible Hose--\\>.;lco
Ja-- |I 'r fa-l
235 117,231
900 165,88)j Torque Plate
Leh
A\H)
Rotor Disc
Anti-squeal shim __Anti-squeal
I Spring
-cm (ft-lb, N.m)
8ao?36

l'-
BRAKE SYSTEM - Front Brake
,ritl t'i'.ihffi:ir ''$,8R.17
3. REMOVE CYLINDER FROM TOROUE PLATE
(a) Remove the two installation bolts from the torque
plate.
(b) Remove the brake cylinder and suspend it so the
hose is not stretched.
NOTE: Do not disconnect the brake hose.
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I
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REMOVE FOLLOWING PARTS:
(a) Two anti-squeal springs
(b) Two brake pads
(d ."Two anti-squeal shims
(d) 'Two pad wear indicator plates
(e) .'FoUr support plates
CHECK ROTOR DISC THICKNESS(See*step 2 on page BR-l91
CHECK ROTOR DISC RUNOUT(See step 3 on page BR-2OI
INSTALL NEW PAD SUPPORT PLATES
4.
5.
6.
7.
$
INSTALL NEW PADS
(a) Install new pad wear indicator plates to each pad.
NOTE: Be sure the arrow on the pad we*fiQicator plate
is pointing in the rotating direction of thd diiHt_
(b) Install new anti-squeal shims to each pad.
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8.
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# BRo281
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BR-l8BRAKE SYSTEM - Front Brake
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(c! Install the pads onto each support plate'
9. INSTALL NEW ANTI-SOUEAL SPRINGS
10. INSTALL CYLINDER
(d Draw out a small amount of brake fluid from the
reservoir.
(b) Press in piston with a hammer handle or such.
NOTE: Always change the pad on one wheel at a time as
there is possibility of the opposite piston flying out
(c) Insert the brake cylinder carefully so the dust boot is
not wedged.
t1.,
(d) lrfiiprr and torque the two instatlation bolts.
Torque: 255 kg-cm (18 ft-lb, 25 N'ml
t t. tNsrArL FRoNr Itr#
*12. CHECK THAT FLUID TEVEL IS AT "MAX" LINE
I,iw,i
REMOVAL OF CYUTNDER '
(See page BR-l61
1. REMOVE CYLINDER
(a) Using SST, disconnect the brake line.
Use a container to catch the brake fluid.
ssT 09751 -3601 1
(b) Rembve the two installation bolts and cylinder.
2. REMOVE PADS (See step 4 on.page BR-l71
DISASSEMBLY OF CYLINDER
(See page BR-l61
1. REMOVE FOLLOWING PARTS:
(a) Two slide bushings
(b) Four dust boots
(d Two collars
I'idr
SST
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BRAKE SVSTEM - Front Brake8R.19
2. REMOVE CYLINDER BOOT SET RING AND CYLINDER
BOOT
Using a screwdriver, remove the set ring and boot.
3. REMOVE PISTON FROM CYLINDER
(a) Put a piece of cloth or such between the piston and
cylinder.
(d Use compressed air to remove the piston from the
cylinder.
WARNING: Do not place your fingers in front of the
piston when using compressed air.
- REMOVE PISTON SEAL FROM BRAKE CYLINDER
Using a screwdriver, remove the piston seal.
INSPECTION AND REPAIR OF FRONT BRAKE
COMPONENTS
1. TNSPECT PAD LINING THICKNESS
Standard thickness: 10.O mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.l
Replace the pad if the thickness is less than minimum (the
1.0 mm slit is no longer visible) or if it shows signs of
uneven wear.
INSPECT ROTOR DISC THICKNESS
Standard thickness: 1 1.0 mm (0.433 in.l
Minimum thickness: 10.0 mm {0r39a in.}
lf the disc is scored or worn, or if thickness is less than
minimum, repair or replace the disc.
4.
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*i,

BR-2OBRAKE SYSTEM - Front Brake
3. INSPECT ROTOR DISC RUNOUT
Measure the rotor disc runout at 1O mm (0.39 in.) from the
outer edge of the rotor disc.
Maximum disc runout: 0.15 mm (0.0059 in.l
lf the runout is greater than maximum, replace the disc.
NorE: Before measuring the runout check that the front
bearing play is within specification.
4. IF NECESSARY, REPLACE ROTOR DISC
(d Remove the torque plate from the knuckle.
(b) Remove the wheel nuts of the temporarily installed
disc and pull off the rotor disc from the axle hub.
(c) Temporarily install a new rotor disc with the wheel
nuts.
(d) Install the torque plate onto the knuckle.
Torque: 900 kg-cm (65 ft-lb, 88 N'm)
ASSEMBLY OF CYLINDER
(See page BR-161
1. APPLY LITHUM SOAP BASE GLYCOL GREASE
TO PARTS INDICATED BY ARROWS
2. INSTALL PISTON SEAL AND PISTON IN CYLINDER
INSTALL CYLINDER BOOT AND SET RING IN
CYLINDER
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3.
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BRAKE SYSTEM - Front BrakeBR-2;1,,,":l-.,
4. INSTALL COLLAR, DUST BOOT AND CYLINDER
SLIDE BUSHING
(a) Installthe collar and dust boot into the brake "VlinOer.'"'f,.@,*;
(b) Check that the boot is secured firmly to the brlkp
cylinder groove. ';1"t,
(c) Install the bushing into the boot.
(d) Check that the boot is secured firmly to the bushing
groove.
t:' t;
INSTALLATION OF CYLINDER JS .t
(See page BR-l61
1. INSTALL PADS ,,,\$,(See steps 7 to 9 on pag6s BR-17 and 18)-i
2. INSTALL CYLINDER(See step 11 on page BR-271
3. INSTALL FLEXIBLE HOSE TO BRAKE CYLINDER
Torque: 235 kg-cm (17 ft-lb, 23 N.m)
4. CONNECT FLEXIBLE HOSE TO BRAKE TUBE
Using SST, connect the flexible hose.
ssT 09751 -3601 1
Torque: 155 kg-cm (11 ft-lb, 15 N.ml
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID
AND BLEED BRAKE SYSTEM (See page BR-71
SST