1985 TOYOTA TERCEL boot

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
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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

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.
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(d) lrfiiprr and torque the two instatlation bolts.
Torque: 255 kg-cm (18 ft-lb, 25 N'ml
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*12. CHECK THAT FLUID TEVEL IS AT "MAX" LINE
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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.
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(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
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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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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.
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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

.,ea-24BRAKE SYSTEM - Rear Brake (Sedan)
1 1. DISCONNECT BRAKE TUBE FROM WHEEL CYLINDER
Using SST, disconnect the line. Use a container to catch
the brake fluid.
ssr 09751-3601 1
12. REMOVE WHEET CYLINDER
Remove the two bolts and wheel cylinder.
REMOVE FOLLOWING
CYLINDER:
(d Two boots
(b) Two pistons
(c) Two piston cups
(d Spring
PARTS FROM WHEEL
INSPECTION OF REAR BRAKE COMPONENTS
1. INSPECT BRAKE DRUM INSIDE DIAMETER
Standard inside diameter: 180.0 mm (7.087 in.)
Maximum inside diameter: 181.0 mm (7.126 in.)
lf the drum is scored or worn, the brake drum may be
lathed to the maximum inside diameter.
NOTE: Perform operations with the following parts
removed:
(d Oil seal
(b) lnner and outer bearing
2. INSPECT BRAKE SHOE LINING THICKNESS
Standard thickness: 4.0 mm (0.157 in.l
Minimum thickness: 1.0 mm (0.039 in.)
lf the shoe lining is less than minimum or shows signs of
uneven wear, replace the brake shoes.
NOTE: lf the thickness of any brake shoe is not within
specification, replace all of the brake shoes.
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BRAKE SYSTEM - Rear Brake (Sedan)8R.25
Apply Grease
3. INSPECT BRAKE LINING AND DRUM FOR PROPER
CONTACT
Replace the brake shoe or lathe the brake drum as necess-
4ry.
4. INSPECT WHEEL CYLINDER FOR CORROSION OR
DAMAGE
5. INSPECT BACKING PLATE FOR WEAR OR DAMAGE
INSTALLATION OF REAR BRAKE
(See page BR-221
1. APPLY LITHIUM SOAP BASE GILYCOL GREASE
TO FOTLOWING PARTS:
(d Two piston cups
(b) Two pistons ,, ,
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2. ASSEMBLE WHEEL CYLINDER
(a) Install two new piston cups to the pistons.
(b) Install the two pistons and spring into the wheet
cylinder. Check that the flange of the pistons are
pointed inward.
(c) Install two new boots.
3. INSTALL WHEEL CYLINDER
Install the wheel cylinder on the backing plate with the two
bolts.
Torque: lOO kg-cm (7 ft-lb, 1O N.ml
4. CONNECT BRAKE TUBE TO WHEEL CYLINDER
Using SST, connect the brake tube.
ssT 09751 -3601 1
Torque: 155 kg-cm (11ft-lb, 15 N.ml
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I Spring
Boot

BRAKE SYSTEM - Rear Brake (Wagon FWD)8R.31
9. DISCONNECT BRAKE TUBE FROM WHEEL
CYLINDER
Using SST, disconnect the line. Use a container to catch
the brake fluid.
10. REMOVE WHEEL CYLINDER
Remove the two bolts and wheel cylinder.
11. REMOVE FOLLOWING PARTS FROM WHEEL
CYLINDER:
(a) Two boots
(b) Two pistons
(c) Two piston cups
(d) Spring
INSPECTION OF REAR BRAKE COMPONENTS
1. INSPECT BRAKE DRUM INSIDE DIAMETER
Standard inside diameter: 200.0 mm (7.874 in.l
Maximum inside diameter: 201.0 mm (7.913 in.)
lf the drum is scored or worn, the brake drum may be
lathed to the maximum inside diameter.
2. INSPECT BRAKE SHOE LINING THICKNESS
Standard thickness: 4.0 mm (0.157 in.)
Minimum thickness: 1.O mm {0.039 in.l
lf the shoe lining is less than minimum or shows signs of
uneven wear, replace the brake shoes.
NOTE: lf the thickness of any brake shoe is not within
specification, replace the all of the brake shoes.
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IPiston
Boot
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