TOYOTA TERCEL 1996 Service Repair Manual

BR0RU-04
BR-28
- BRAKEFRONT BRAKE CALIPER
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-24).
1. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE
SYSTEM (See page BR-4)
2. CHECK FOR LEAKS

BR0RV-04
- BRAKEREAR DRUM BRAKE
BR-29
903 Author
: Date
:
1996 TERCEL (RM440U)
REAR DRUM BRAKE
COMPONENTS

BR4239
BR0RW-03
BR4240
N00750 BR0405 BR0406
BR4241
SST BR-30
- BRAKEREAR DRUM BRAKE
1996 TERCEL (RM440U)
REMOVAL
1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lining
thickness through the hole.
If less than minimum, replace the shoes.
Minimum thickness: 1.0 mm (0.039 in.)
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM (See page SA-39)
HINT:
If the brake drum cannot be removed easily, do the following
steps.
(a) Insert a screwdriver through the hole in the backing plate,
and hold the automatic adjusting lever away from the ad-
juster.
(b) Using another screwdriver, reduce the brake shoe adjust-
er by turning the adjusting wheel.
4. REMOVE FRONT SHOE
(a) Using, remove the return spring and calmp.
(b) Using SST, remove the shoe hold-down spring, cups and
pin.
SST 09718-00010
(c) Disconnect the anchor spring from the front shoe and re-
move the front shoe.
(d) Remove the anchor spring from the rear shoe.
5. REMOVE REAR SHOE
(a) Using SST, remove the shoe hold-down spring, cups and
pin.
SST 09718-00010
(b) Using pliers, remove the adjusting lever spring.
(c) Remove the adjuster.

BR4387
BR3027
SST
BR0370
- BRAKEREAR DRUM BRAKE
BR-31
1996 TERCEL (RM440U)
(d) Using pliers, disconnect the parking brake cable from the
parking brake lever and remove the rear shoe.
6. REMOVE AUTOMATIC ADJUSTING LEVER AND
PARKING BRAKE LEVER
(a) Remove the E-ring.
(b) Remove the automatic adjusting lever.
(c) Remove the C-washer.
(d) Remove the parking brake lever.
7. REMOVE WHEEL CYLINDER
(a) Using SST, disconnect the brake line. Use a container to
catch the brake fluid.
SST 09751-3601 1
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
(b) Remove the 2 bolts and the wheel cylinder.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
8. DISASSEMBLE WHEEL CYLINDER
Remove the these parts from the wheel cylinder.

2 boots

2 pistons

2 piston cups

Spring

BR0RX-01
BR4081
BR0394
BR0395
BR-32
- BRAKEREAR DRUM BRAKE
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. MEASURE BRAKE SHOE LINING THICKNESS
Using a ruler, measure the shoe lining thickness.
Standard thickness: 4.0 mm (0.157 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the thickness is less than the minimum or shoe lining shows
signs of uneven wear, replace the brake shoes.
HINT:
If a brake shoes needs replacing, the brake shoes must be re-
placed as a set
3. MEASURE BRAKE DRUM INSIDE DIAMETER
Using a vernier calipers, measure the inside diameter of the
drum.
Standard inside diameter: 180.0 mm (7.087 in.)
Maximum inside diameter: 181.0 mm (7.126 in.)
If the drum is scored or worn, the brake drum may be lathed to
the maximum inside diameter.
4. INSPECT REAR BRAKE LINING AND DRUM FOR
PROPER CONTACT
If the contact between the brake lining and drum is improper, re-
pair the lining with a brake shoe grinder, or replace the brake
shoe assembly.

BR0RY-04
BR4247
N00755
BR0376 BR0412
N00756 BR0394 BR0413
- BRAKEREAR DRUM BRAKE
BR-33
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page
BR-30).
1. AFTER INSTALLATION, FILL BRAKE RESERVOIR
WITH BRAKE FLUID, BRAKE SYSTEM
NOTICE:
Apply lithium soap base glycol grease and high tempera-
ture grease to the parts indicated by the arrows (See page
BR-29).
2. CHECK OPERATION OF AUTOMATIC ADJUSTING
MECHANISM
(a) Move the parking brake lever of the rear shoe back and
forth. Check that the adjuster turns.
If the adjuster does not turn, check for incorrect installation of
the rear brake.
(b) Adjust the adjuster length to the as short as possible.
(c) Install the brake drum.
(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.
3. CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM
(a) Remove the brake drum (See page SA-39).
(b) Measure the brake drum inside diameter and diameter of
the brake shoes. Check that the difference between the
diameters is the correct shoe clearance.
Shoe clearance: 0.6 mm (0.024 in.)
If incorrect, check the parking brake system.
(c) Install the brake drum (See page SA-42).

BR0RZ-06
R04666
SSTSST BR-34
- BRAKEPROPORTIONING VALVE (P VALVE)
908 Author
: Date
:
1996 TERCEL (RM440U)
PROPORTIONING VALVE (P VALVE)
ON-VEHICLE INSPECTION
1. INSTALL LSPV GAUGE (SST)
SST 09709-29018
2. BLEED AIR FROM FLUID PRESSURE GAUGE
3. RAISE FRONT BRAKE CALIPER PRESSURE AND CHECK REAR WHEEL CYLINDER PRES-
SURE
w/o ABS
Front brake caliper pressureRear wheel cylinder pressure
2,452 kPa (25 kgf/cm2, 356 psi)2,452 kPa (25 kgf/cm2, 356 psi)
7,845 kPa (80 kgf/cm2, 1,138 psi)3,805 kPa (38.8 kgf/cm2, 552 psi)
w/ ABS
Front brake caliper pressureRear wheel cylinder pressure
2,942 kPa (30 kgf/cm2, 427 psi)2,942 kPa (30 kgf/cm2, 427 psi)
7,845 kPa (80 kgf/cm2, 1,138 psi)4,168 kPa (42.5 kgf/cm2, 604 psi)
When inspecting the fluid pressure, inspect the left front and right rear together, and the right front and left
rear together.
If the rear wheel cylinder pressure is incorrect, replace the P valve assembly.
4. BLEED BRAKE SYSTEM (See page BR-4)
5. CHECK FOR LEAKS

BR1DU-01
F04750
R04103
Sub-Wire Harness C (SST)
Control Relay
Sub-Wire Harness I (SST) To Body
To Body
ABS
Actuator(SST)
- BRAKEABS ACTUATOR
BR-35
909 Author
: Date
:
1996 TERCEL (RM440U)
ABS ACTUATOR
ON-VEHICLE INSPECTION
1. INSPECT BATTERY POSITIVE VOLTAGE
Battery positive voltage: 10 - 14 V
2. DISCONNECT CONNECTORS
(a) Disconnect the 2 connectors from the control relay.
(b) Disconnect the connector from the actuator.
3. CONNECT ACTUATOR CHECKER (SST) TO ACTUA-
TOR
(a) Connect the actuator checker (SST) to the actuator, con-
trol relay and body side wire harnesses through the sub-
wire harnesses C and I (SST), as shown.
SST 09990-00150, 09990-00200, 09990-00300
(b) Connect the red cable of the checker to the battery posi-
tive (+) terminal and black cable to the negative (-) termi-
nal. Connect the black cable of the sub-wire harnesses
to the battery negative (-) terminal or body ground.
(c) Place the ºSHEET Aº (SST) on the actuator checker.
SST 09990-00163

F04746
R00326
R00324
R00325
BR1813
BR-36
- BRAKEABS ACTUATOR
910 Author
: Date
:
1996 TERCEL (RM440U)
4. INSPECT BRAKE ACTUATOR OPERATION
(a) Start the engine, and run it at idle.
(b) Turn the selector switch of the actuator checker to
ºFRONT RHº position.
(c) Push and hold in the MOTOR switch for a few seconds.
Make sure that you can hear the motor running.
(d) Depress the brake pedal and hold it for about 15 seconds,
and check that the brake pedal dose not go down.
(e) With your foot still applied onto the brake pedal, push the
MOTOR switch and check the brake pedal does not pul-
sate.
(f) Depress the brake pedal and hold it. As you hold the ped-
al down, push and hold in the POWER SWITCH for a few
seconds. Check the pedal does not go down.
(g) With your foot still applied onto the brake pedal, release
the POWER SWITCH and check that the pedal goes
down.
(h) With your foot still applied on the brake pedal, push the
MOTOR switch and check the brake pedal returns.
(i) Release the brake pedal.
5. INSPECT FOR OHTER WHEELS
(a) Turn the selector switch to ºFRONT LHº position.
(b) Repeat (c) to (i) of step 4, check the actuator operation as
before.
(c) Similarly, inspect ºREAR RHº and ºREAR LHº position.
HINT:
When inspecting ºREAR LHº position, push the REAR LH
switch instead of the POWER SWITCH, and you can inspect in
any selector switch position.

- BRAKEABS ACTUATOR
BR-37
911 Author
: Date
:
1996 TERCEL (RM440U)
6. PUSH MOTOR SWITCH
(a) Push and hold in the MOTOR switch for a few seconds.
(b) Stop the engine.
7. DISCONNECT ACTUATOR CHECKER (SST)
Remove the ºSHEET Aº (SST) and disconnect the actuator
checker (SST) and sub-wire harness (SST) from the actuator,
control relay and body side wire harness.
8. CONNECT CONNECTORS
(a) Connect the connector to the actuator.
(b) Connect the 2 connectors to the control relay.
9. CLEAR DTC (See page DI-1 11)