TOYOTA TERCEL 1996 Service Repair Manual

BR0RM-04
F03521
SST
Gasket
N00744
SST
BR1728 BR0021
BR-18
- BRAKEBRAKE BOOSTER ASSEMBLY
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 14 N´m (145 kgf´cm, 10 ft´lbf)
(d) Insert the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
(f) Install the No.1 brake line clamp to the body.
(g) Install the No.2 brake line clamp to the body.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install the gasket on the master cylinder.
(b) Set SST on the gasket, and lower the pin until its tip slight-
ly touches the piston.
SST 09737-00010
(c) Turn SST upside down, and set it on the booster.
SST 09737-00010
(d) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod
slightly touches the pin head.
HINT:
When loosening the push rod nut, depress the brake pedal
enough so that the push rod sticks out.
3. INSTALL MASTER CYLINDER
4. CONNECT VACUUM HOSE TO BRAKE BOOSTER
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR-4)
6. CHECK FOR LEAKS

- BRAKEBRAKE BOOSTER ASSEMBLY
BR-19
1996 TERCEL (RM440U)
7. CHECK AND ADJUST BRAKE PEDAL
(See page BR-6)
Check and adjust the brake pedal, then tighten the clevis lock
nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
8. DO OPERATIONAL CHECK
(See page BR-15)

BR0RN-05
BR-20
- BRAKEFRONT BRAKE PAD
894 Author
: Date
:
1996 TERCEL (RM440U)
FRONT BRAKE PAD
COMPONENTS

BR0RO-03
BR4213
BR4214
BR0272
- BRAKEFRONT BRAKE PAD
BR-21
1996 TERCEL (RM440U)
REPLACEMENT
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with hub
nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace the pads if they are not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. REMOVE CALIPER
(a) Remove the 2 installation bolts from the torque plate.
(b) Remove the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose.
4. REMOVE THESE PARTS:
(a) 2 brake pads
(b) 3 anti-squeal shims
(c) Pad wear indicator plate
(d) 4 pad support plates
NOTICE:
The support plates can be used again provided that they
have sufficient rebound, no deformation, cracks or wear,
and have had all rust, dirt and foreign particles cleaned off.
5. CHECK DISC THICKNESS AND RUNOUT
(See page BR-26)
6. INSTALL 4 PAD SUPPORT PLATES
7. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti-squeal shims and
wear indicator plates must be replaced together with the
pads.
(a) Install a pad wear indicator plate on the inner pad.
(b) Apply disc brake grease to the anti-squeal shims (See
page BR-23).
(c) Install the 2 anti-squeal shims on the outer pad.
(d) Install the anti-squeal shim on the inner pad

N00746
BR-22
- BRAKEFRONT BRAKE PAD
1996 TERCEL (RM440U)
(e) Install inner pad with the pad wear indicator plate facing
upward.
(f) Install outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.
8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or an equiva-
lent.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.
(c) Install the caliper.
(d) Install and torque the 2 installation bolts.
Torque: 25 N´m (255 kgf´cm, 18 ft´lbf)
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

BR0RP-06
- BRAKEFRONT BRAKE CALIPER
BR-23
897 Author
: Date
:
1996 TERCEL (RM440U)
FRONT BRAKE CALIPER
COMPONENTS

BR0RQ-05
BR4220
BR-24
- BRAKEFRONT BRAKE CALIPER
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)
HINT:
Install the flexible hose lock securely in the lock hole in the cali-
per.
(b) Use a container to catch the brake fluid as it drains out.
2. REMOVE CALIPER
Remove the 2 installation bolts, and caliper.
Torque: 25 N´m (255 kgf´cm, 18 ft´lbf)
3. REMOVE THESE PARTS:
(a) 2 brake pads with anti-squeal shims.
(b) 4 pad support plates.

BR0RR-03
N00747 BR3964 BR3965
BR3966
BR3968
BR3969
- BRAKEFRONT BRAKE CALIPER
BR-25
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE THESE PARTS:
(a) 2 sliding bushings.
(b) 4 dust boots.
2. REMOVE CYLINDER BOOT SET RING AND CYL-
INDER BOOT
Using a screwdriver, remove the cylinder boot set ring and cylin-
der boot from the caliper.
3. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and
the caliper.
(b) Use compressed air to remove the piston from the cylin-
der.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
4. REMOVE PISTON SEAL
Using a screwdriver, remove the piston seal from the cylinder.

BR0RS-07
BR4362
BR4237
BR4238
BR4221
BR-26
- BRAKEFRONT BRAKE CALIPER
1996 TERCEL (RM440U)
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad's thickness is at the minimum thick-
ness or less, or if the pad has severe and uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 18.0 mm (0.709 in.)
Minimum thickness: 17.0 mm (0.689 in.)
Replace the disc if the disc's thickness is at the minimum thick-
ness or less. Replace the disc or grind it on a lathe if it is badly
scored or worn unevenly.
3. MEASURE DISC RUNOUT
Using a dial indicator, measure disc runout 10 mm (0.39 in.)
away from the outer.
Maximum disc runout: 0.07 mm (0.0028 in.)
If the disc's runout is the maximum value or greater, check the
bearing play is in the axial direction and check the axle hub run-
out (See page SA-10). If the bearing play and axle hub runout
are not abnormal, adjust the disc runout or grind it on a ºOn-carº
brake late.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the torque plate from the knuckle.
(b) Remove the hub nuts and the disc. Reinstall the disc in
the position turned 1/4 from its original position on the
hub. Install and torque the hub nuts.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
Remeasure the disc runout. Make a note of the runout and the
disc's position on the hub.
(c) Repeat (b) until the disc has been installed on the 2 re-
maining hub positions.
(d) If the minimum runout recorded in (b) and (c) is less than
0.07 mm (0.0028 in.), install the disc in that position.
(e) If the minimum runout recorded in (b) and (c) is greater
than 0.07 mm (0.0028 in.), replace the disc and repeat
step 3.
(f) Install the torque plate and fighten the 2 bolts.
Torque: 88 N´m (900 kgf´cm, 65 ft´lbf)

BR0RT-04
- BRAKEFRONT BRAKE CALIPER
BR-27
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-25).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by arrows (See page BR-23).