ABS TOYOTA TERCEL 1996 Service Manual Online

SA11D-02
R11755
SA-28
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 TERCEL (RM440U)
DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO REMOVE GAS FROM CYLINDER
Using a drill, make a hole in the cylinder, as shown to remove
the gas inside.
CAUTION:
The gas coming out is harmless, but be careful of chips
which may fly up when drilling.

SA1WA-01
W03399
SST
W03400
MP Grease
SST
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA-29
1996 TERCEL (RM440U)
REASSEMBLY
1. INSTALL LOWER INSULATOR ONTO SHOCK AB-
SORBER
2. INSTALL COIL SPRING AND SUSPENSION SUPPORT
(a) Using SST, compress the coil spring.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Install the spring bumper to the piston rod.
(c) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring into the gap of the spring seat
of shock absorber.
(d) Install the spring seat with the upper insulator.
(e) Install the dust seal and suspension support.
(f) Using SST, to hold the spring seat, install a new nut.
SST 09729-22031
Torque: 47 N´m (475 kgf´cm, 39 ft´lbf)
(g) Remove the SST.
(h) Pack the suspension support with MP grease.
(i) Install the cap.

SA11F-02
SA-30
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-25).
HINT:
After installation, check front wheel alignment (See page SA-2).

R12355
Pedal Freeplay
BR4228
Pedal Reserve Distance
- BRAKEBRAKE PEDAL
BR-7
881 Author
: Date
:
1996 TERCEL (RM440U)
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the resistance begins to
be felt, then measure the distance, as shown.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
4. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake.
(b) With the engine running, depress the pedal and measure
the pedal reserve distance.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf):
w/o ABS: More than 60 mm (2.36 in.)
w/ ABS: More than 55 mm (2.17 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.

BR0RD-06
F04745
Air Cleaner Assembly
2-wayBrake Booster
Master Cylinder Clamp

Gasket w/o ABS:
w/o ABS:
w/ ABS:
Cap
Stariner
Reservoir
Set ScrewNo.1 Piston and Spring
GrommetSnap Ring
Master Cylinder Body
Piston Stopper Bolt Reservoir

GasketNo.2 Piston and SpringCap
Stariner
Reservoir
Grommet
Reservoir Set Screw
No.1 Piston and Spring
Snap Ring
No.2 Piston and Spring
Master Cylinder Body

Gasket

Non-reusable partw/ ABS:
Lithium soap base glycol grease
- BRAKEBRAKE MASTER CYLINDER
BR-9
883 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE MASTER CYLINDER
COMPONENTS

BR0RE-01
BR5042
SST
BR5041
BR-10
- BRAKEBRAKE MASTER CYLINDER
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE AIR CLEANER ASSEMBLY
2. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
3. DRAW OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
4. DISCONNECT BRAKE LINES
Using SST, disconnect the brake lines from the master cylinder.
SST 09751-3601 1
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
5. REMOVE MASTER CYLINDER
(a) w/o ABS:
Remove the 2 mounting nuts, clamp and pull out the mas-
ter cylinder and gasket.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(b) w/ ABS:
Remove the 2 mounting nuts, 2-way and pull out the
master cylinder and gasket.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)

BR0RK-06
R12151
Air Cleaner Assembly
Brake Booster Master Cylinder

Non-reusable part2-way Clamp
Gasket
Gasket
Clip
Pin
Clevis w/o ABS:
w/ ABS:Clip Vacuum Hose
BR-16
- BRAKEBRAKE BOOSTER ASSEMBLY
1996 TERCEL (RM440U)
COMPONENTS

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.