TOYOTA TERCEL 1985 Repair Manual

FA.1
FRONT AXLE AND
SUSPENSION
TROUBLESHOOTING
FRONT WHEEL ALIGNMENT
AXLE HUB
FRONT DRIVE SHAFT
FRONT SHOCK ABSORBER
FRONT SUSPENSION
Ball Joints
Lower Arm
Stabilizer Bar
Page
FA-2
FA.3
FA.23
FA-24
FA-7
FA.13
F4.19
FA-23
F4.27

FA.2FRONT AXLE AND SUSPENSION - Troubleshooting
TROUBLESHOOTING
ProblemPossible caussRemedyPage
Wanders/pullsTires worn or improperly inflated
Alignment incorrect
Wheel bearing worn
Front or rear suspension parts loose or
broken
Steering linkage loosen or worn
Steering gear out of adjustment or broken
Replace tire or inflate tires to
proper pressure
Check front end alignment
Replace wheel bearing
Tighten or replace suspension
part
Tighten or replace steering
linkage
Adjust or repair steering gear
FA-3
FA-3
FA.8
sR-9
BottomingVehicle overloaded
Shock absorber worn out
Springs weak
Check loading
Replace shock absorber
Replace spring
FA.19
FA.l9
Sways/pitchesTires improperly inflated
Stabilizer bar bent or broken
Shock absorber worn out
lnflate tires to proper pressure
Replace stabilizer bar
Replace shock absorber
FA-3
FA-27
FA-19
Front wheel shimmyTires worn or improperly inflated
Wheel out of balance
Shock absorber worn out
Alignment incorrect
Wheel bearing worn
Balljoints or bushing worn
Steering linkage loosen or worn
Steering gear out of adjustment or broken
Replace tire or inflate tires
to proper pressure
Balance wheel
Replace shock absorber
Check front end alignment
Replace wheel bearing
Inspect ball joint and bushing
Tighten or replace steering
linkage
Adjust or repair steering gear
FA-3
FA-19
FA.3
FA-8
FA.23
sR-9
Abnormal tire wearTires improperly inflated
Shock absorber worn out
Alignment incorrect
Suspension parts worn
Inflate tires to proper pressure
Replace shock absorber
Check toe-in
Replace suspension part
FA.3
FA-19
FA.3

FRONT AXLE AND SUSPENSION - Front Wheel AlignmentFA-3
FRONT WHEEL ALIGNMENT
1. MAKE FOLLOWING CHECKS AND CORRECT ANY
PROBLEMS
(d Check the tires for wear and proper inflation.
Cold tire inflation pressure kg/cm2(psi, kPa)
Tire sizeFront and Rear
FWD
145 SR 13
3A-C 4-speed M/T
Others
2.2 (32.220l.
2.O Q8,2001
155 SR 131.8(26. 180)
165 SR131 .8 (26, 180)
4WD155 SR 132.O Q8,2001
175 SR 131 .8 (26. 180)
(b) Check the front wheel bearings for looseness.
(d Check the wheel runout.
Lateral runout: 1.2 mm (0.047 in.) or less
(d) Check the front suspension for looseness.
(e) Check the steering linkage for looseness.
(f) Check that the front absorbers work properly by
using the standard bounce test.
ADJUST TOE.IN
Adjust toe-in with a toe-in gauge by the following pro-
cedure.
(d Check to see that both right and left tie rods measure
the same in length.
Left-right error: 1.5 mm (0.059 in.l or less
Move the vehicle forward a few meters with the front
wheels in the straight-ahead position on a level place.
Mark the center of each rear tread and measure the
distance between marks of the right and left tires.
(d) Advance the vehicle till the marks on the rear of the
tires come to the measuring heights of the gauge on
the front.
(e) Measure the distance between the marks on the front
of the tires.
Toe-in: lnspection STD -1 {- 1 mm(-0.O4 + O.O4 in.)
AA
+=ruf,ffi Wry@=S
--A-- F--B--i
A=B
2.
(b)
(c)
!,.-!'ru,

FA.4FRONT AXLE AND SUSPENSION - Front Wheel Alignment
(f) lf the toe-in is not within inspection STD, adjust the
toe-in.
(1) Loosen the clamp.
el Remove the boot clip.
(3) Turn the left and right rack ends an equal
amount to adjust.
Wl Check that the length of the left and right tie
rods are the same.
(5) Torque the tie rod end clamp.
Torque: 195 kg-cm (14 ft-lb, 19 N'ml
(6) Place the boot on the seal and clamp it.
NOTE: Check that the boot is not twisted.
3. INSTALT WHEEL ALIGNMENT EOUIPMENT
Follow the specific instructions of the equipment manu-
facturer.
fuwry'$A=B

FRONT AXLE AND SUSPENSION - Front Wheel AlignmentFA-5
Front Rear (FWDI
Rear (4WD)
More Camber
4, INSPECT VEHICLE HEIGHT
Vehicle heightmm (in.)
lf height of the vehicle is not within specification, try to
level it by shaking it down. lf the height is still not correct,
check for bad springs and worn or loose suspension parts.
5. ADJUST CAMBER camber:
VehicleInspection standardLeft-right error
FWDSedan10'+ 30'
30' or lessWagons' + 30'
4WD40' -t- 30'
lf camber is out of tolerance, adjust by turning the camber
adjusting cam.
(a) Loosen the shock absorber mount nut.
(b) Turn the cam to adjust.
NOTE: Camber changes about 20'with each graduation
of the cam.
(c) Tighten to the specified torque.
Torque: 1,45O kg-cm {105 ft-lb, 142 N'm)
6. ADJUST STEERING AXIS INCLINATION
VehicleInspection standardLeft-right error
FWDSedan12'30'* 30'
30' or lessWagon12035'+ 30'
4WD1 1'50' -t- 30'
lf the steering axis inclination is out of tolerance, inspect
and replace any damaged or worn front s$rplnsion parts.
s[
Tire sizeFrontRear
o
3
Sedan
145 SR 13
155 SR 13
165/70 SR 13
203.0 17.9921208.0 (8.189)
204.0 (8.O31)
287.O
292.O
288.0
1 1.299)
11.496)
1 1.339)
Wagor155SR13207 (8.150)308.512.146l.
4WD155 SR 13
t75/70 SR 13
234.419.2281
235.4 (9.268)273.O274.O
10.748)10.787)

FA.6FRONT AXLE AND SUSPENSION - Front Wheel Alignment
Front a-
Spacer
(o
7. ADJUSTCASTER
Caster
w/oPSw/ PS
o
3lt-
Inspection
Standard
Sedan1'10'+ 30'2"40' + 30'
Wagon0045' + 30'2"15' + 30'
Left-right error30' or less
o
3 Inspection standard2"25' -+- 30'
Left-right error30' or less
1'
lf the caster is not within specification, adjust by increas-
ing or decreasing the number of spacers. Do not install
more than two spacers.
Torque: 1,O75 kg-cm (78 ft-lb, 105 N.ml
NOTE: The caster will change 13' with each spacer.
ADJUST WHEEL ANGLE
Wheelangle
Inside wheelOutside wheel
o
=|'l-
Sedan
w/oPS
Max.36020' + 1032040' + 1"
at 2Oo21"30'200
w/ PSMax.35050' ! 1032'55'f 10
at 20o21"05'20"
Wagon
w/o PS
Max.36013' + 1032058'+ 10
at 2Oo21'25'20"
wi PSMax.35047'1 1'32050'= 1"
at 20"21"O9'20"
4WD
w/o PS
Max.36030' + 103301s'+ 10
at 2002'1"15'20"
w/ PSMax.36020'+ 1033020'+ 1'
at 2Oo21005'200
lf the steering angles differ from the standard specifica-
,'4o* tion, check to see that the length of the left and right tiet:ry rods are the same.
NOTE: lf the tie rod lengths are not equal, the steering
angle cannot be adjusted propedy.
lf the rie rod lengths were changed to adjust the steering
anble, reinspect the toe-in.
9. INSPECT SIDE SLIP WITH SIDE SLIP TESTER
Side slip: 3.O mm/m (O.118 in./3.3 ft) or less
lf the side slip is not within specification, the toe-in or
front wheel alignment may not be correct.
8.
\
--,-,-j:*-at-

FRONT AXLE AND SUSPENSION - Axle HubFA.7
AXLE HUB
COMPONENTS
1,450 (105, 142)
Disc Brake Caliper
shocknusoruer-----'1 I I i I wheet Bearins
ntdliff*>> q$J d^%J- |
*@r
rie Rod r"o \E
h^
t.''"'lo:'t cam
:-\^'
*9@n^6g1'
i:T:":it:i Y9J'A-
ffi31?yrnnerRacel l*ryDise Brake Dust cover t"'" *1":iHJ"r,""l
Lt^:::l1l"ner Race (NSK rype) -l
a?6,
I
iOuter Oit Seal
Lock Nut Cap
ir
/1"i"
Y&r-A
lSU
Ikg-cm (ft-lb, N.m)l : Tightening torque
O : Non-reusable part

nIFA.8FRONT AXLE AND SUSPENSION- Axle Hub
REMOVAL OF FRONT AXLE HUB
1. REMOVE COTTER PIN. BEARING LOCK NUT CAP AND
LOCK NUT
(a) Remove the cotter pin and lock nut cap.
(b) Before removing the brake caliper, loosen the lock
nut while depressing the brake pedal.
2. REMOVE BRAKE CALIPER
Remove the brake caliper from the steering knuckle and
suspend it with wire.
REMOVE DISC
*fi*frcr BEARTNG pLAy rN AxtAL DtREcnoN
'' Maximum: 0.05 mm (O.OO2O in.l
5. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE
(d Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod end.
ssT 09610-20012
(Le rnorrn*fucr6. DISCONNECT STEERING KNUCI
nC
t
rY
I
ItI
Ili
,
)t-5f'
ABSORBER
(d Place matchmarks on the shock absorber lower
bracket and camber adjust cam.
(b) Remove the two boltsend nuts, and disconnect the
steering knuckle.
DISCONNECT LOWER ARM FiOM STEERING
KNUCKLE
Remove the two bolts holding the balljoint to the steering
knuckle.
7.
.. ...t
3.
4.
".-*ffi,i.,.*f.isEl;-*r: .

FRONT AXLE AND SUSPENSION - Axle Hub
8. REMOVE AXLE HUB FROM
Using SST, remove the axle hub.
ssT 09950-2001 5
,. CAUTION: Cover the drive shaftrhl
( protect it from damage. (r':q
;; , +in f,rlve tl""ff\ii
!,ocr* d i t{" cIo*h to " .rr:'r,
g ra *e c* i t € ro*r ata ^4 1e.
REPLACEMENT OF FRONT AXLE HUB AND
WHEEL BEARING
(See page FA-7)
1. REMOVE DUST DEFLECTOR
Using a screwdriver, remove the dust deflector.
REMOVE INNER OIL SEAL FROM STEERING
KNUCKLE
Using SST, pull ou.t the oil seal.
ssr 09308-0001 0
REMOVE HOLE SNAP RING
Using snap ring pliers, remove the hole snap ring.
REMOVE THREE BOLTS
Remove the three bolts holding the disc brake dust
to the steering knuckle.
,..F. REMOVE AXLE HUQ FROM STEERING KNUCKLE€r:
Using SST, push off the axle hub.
ssT 09950-2001 5
6. REMOVE DISC BRAKE DUST COVER
7. REMOVE BEARING INNER RACE'(INSIDE)
2.
a
,{n.1n
t
3.
4.
fr
,f+
8. REMOVE. BEARTNG rlruen.qAbe (OUrSlOe)
Using 9ST, pull off the beaiing'inner race.
ssT 09950;20015 t r

FA.1O
' -'v7:'
FRONT AXLE AND SUSPENSION - Axle Hub
9. REMOVE OUTER OIL SEAL
Using SST, pull out oil seal.
ssT 09308-0001 0
1O. REPLACE WHEEL BEARING
h) First place the inner race (outside) of the bearing in
the bearing
(b) Using SST, press out the bearing.
SST 09228-22O2O and 09950-20015
(c) U$ilfi SST, prestffi a new bearing.
ssT 09309-3501 0
NOTE: There are two types of bearings; KOYO and NSK.
INSTALL OUTER OIL SEAL
h) Install the bearing inner race (outside) before install-
ing a pew oil seal.
(b) Using SST, drive the oil seal into the steering knuckle.
ssT 09515-35010
(c) Apply MP grease to the oit seal lip.
INSTALL DISC BRAKE DUST COVER ONTO STEERING
KNUCKLE WITH THREE BOLTS,
Apply liquid sealer to the dust cover and steering knuckle
connection before assembly.
INSTALL AXLE HUB
(a) Install new inner races into the inner bearing.
(b) Using SST, ggss in the inner race until it is tightty
against the sftlulder of the hub.
SST 09228-22O2O and O9310-35010
NOTE: Do not interchange the inner and outer races
when installing.
'.tfi
\
H
r
FE
11.
12.
13.
i
fr_, .,,iW;ffiqa-*L- L __