1985 TOYOTA TERCEL Repair Manual

aBR.lOBRAKE SYSTEM - Master Cylinder
COMPONENTS
Reservor Set Screw
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%-Reservoir
I
9-.o
RN ry'jbTry^?
Snap Ring
}N ryofltort""* | |-+)rlllsciot
| |
*" 1 Piston (with SPring)
\p-l ^l No.2pistonRins
I I uprrng
-^ I I roo tz, rot Ierl
(ft-rb, N
O : Non-reusable part
Piston Stopper Bolt
: Tightening torque
O Gasket
DISASSEMBLY OF MASTER CYLINDER
1. REMOVE RESERVOIR FROM CYLINDER HOUSING
(a) Remove the cap and strainer.
(d Remove the set screw.
(c) Pull out the reservoir.
2. MOUNT CYLINDER HOUSING IN VISE
3. REMOVE TWO GROMMETS FROM CYLINDER
HOUSING
4. REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and
remove the piston stopper'bolt.

BRAKE SYSTEM - Master CylinderBR-11
5. REMOVE TWO PISTONS AND SPRINGS
(d Using a screwdriver and snap ring pliers, remove the
snap ring.
(b) Place a rag on two wooden blocks and lightly tap the
cylinder flange between the blocks until the piston tip
protrudes.
(c) Remove the piston by hand, pulling straight out, not
at an angle.
NOTE: lf pulled out at an angle, there is a possibility of
damaging the cylinder bore.
ASSEMBLY OF MASTER CYLINDER
(See page BR-10)
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE
TO RUBBER PARTS INDICATED BY ARROWS
2. INSTALL TWO SPRINGS AND PISTONS
CAUTION: Be careful not to damage the rubber lips
on the pistons.
(d lnsert the spring and pistons straight in, not at an
angle.
(b) Push in the piston and, using snap ring pliers, install
the snap ring.
INSTALL PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and
install the piston stopper bolt with the gasket. Torque the
bolt.
Torque: 100 kg-cm (7 ft-lb, 1O N.m)
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3.

BR-l2BRAKE SYSTEM - Master Cylinder
INSTALL Tv\/O GROMMETS TO CYLINDER HOUSING
INSTALL CAP AND STRAINER TO RESERVOIR
6. INSTALL RESERVOIR TO CYLINDER HOUSING
Push the reservoir onto the cylinder and install the screw.
Torque: 10 - 25 kg-cm
19 - 21 in.-lb, 1.0 - 2.4 N.ml
CAUTION: Because the master cylinder and reser-
voir tank union is a grommet type, the set screw is
designed not to separate from the reservoir or cylinder
and will not tighten down the reservoir. Therefore,
there is a clearance at point A. Do not insert washers
or such when tightening.
4.
5.
'*i,.

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
1?
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

8R.14BRAKE SYSTEM - Brake Booster
REMOVAL OF BRAKE BOOSTER
levis
II
dCI
130 (9, 131f=s(lr=' I
5
llJ
3-Way Unionl
(ft-lb, N.m):Tightening torque
0 : Non-reusable part
Brake Fluid Level Warning
Switch Connector
Brake Booster
BRAKE BOOSTER
1. REMOVE MASTER CYLINDER (See page Bn-gl
2. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
3. REMOVE DISTRIBUTOR CAP
4. REPEAT PROCEDURE FOR EACH WHEEL
5. REMOVE HEATER AIR DUCT
6. DISCONNECT PEDAL RETURN SPRING FROM
BRAKE PEDAL
7. DISCONNECT PUSH ROD CLEVIS FROM BRAKE
PEDAL
Remove the clip and clevis pin.
8. REMOVE BRAKE BOOSTER
Remove the four nuts, and pull out the brake booster.

BRAKE SYSTEM - Brake Booster8R.15
INSTALLATION OF BRAKE BOOSTER
(See page BR-l41
1. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Set SST on the master cylinder with the gasket and
lower the pin until its tip slightly touches the piston.
ssr 09737-00010
(d Tum SST upside down, and set it on the booster.
ssT 09737-OOO10
(c) Check that there is no clearance between the booster
push rod and pin head of SST.
Clearance: O mm (0 in.l
(d) Adjust the booster push rod length untilthe push rod
lightly touches the pin head.
2. INSTALL BRAKE BOOSTER
Torque: 130 kg-cm (9 ft-lb, 13 N'ml
3. INSTALL MASTER CYLINDER (See page BR-131
4. CONNECT VACUUM HOSE TO BRAKE BOOSTER
5. CONNECT PUSH ROD CLEVIS TO BRAKE PEDAL
Install the clevis pin and clip.
6. CONNECT PEDAL RETURN SPRING TO PEDAL
SPRING
INSTALL HEATER AIR DUCT
INSTALL LOWER FINISH PANEL
INSTALL IIA CAP
FILL BRAKE RESERVOIR WITH BRAKE FLUID
AND BLEED BRAKE SYSTEM (See page BR-71
CHECK BRAKE PEDAL (See page BR-61
PERFORM OPERATIONAL CHECK (See page BR-71
7.
8.
9.
10.
11.
12.

BR-l6BRAKE SYSTEM - Front Brake
FRONT BRAKE
COMPONENTS
I
IREPLACEMENT OF BRAKE PADS
. lf a squeaking noise occurs while braking, inspect the
. brake pads. Brake squeak will occur when the gap be-
tween the pad wear indicator plate and rotor disc reaches
about 2.5 mm (0.098 in.).
1. REMOVE FRONT WHEET
Rqmove the wheel and temporarily fasten the rotdfu discwith the wheel nuts. ;:E "'
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the cylinder inspection' hole and replace pads if not within specification.
Standard
Minimum
1O.0 mm (0.394-in.l
1.0 mm (0.039 in.)
\_ [-5s ntzst IFlexible Hose--\\>.;lco
Ja-- |I 'r fa-l
235 117,231
900 165,88)j Torque Plate
Leh
A\H)
Rotor Disc
Anti-squeal shim __Anti-squeal
I Spring
-cm (ft-lb, N.m)
8ao?36

l'-
BRAKE SYSTEM - Front Brake
,ritl t'i'.ihffi:ir ''$,8R.17
3. REMOVE CYLINDER FROM TOROUE PLATE
(a) Remove the two installation bolts from the torque
plate.
(b) Remove the brake cylinder and suspend it so the
hose is not stretched.
NOTE: Do not disconnect the brake hose.
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REMOVE FOLLOWING PARTS:
(a) Two anti-squeal springs
(b) Two brake pads
(d ."Two anti-squeal shims
(d) 'Two pad wear indicator plates
(e) .'FoUr support plates
CHECK ROTOR DISC THICKNESS(See*step 2 on page BR-l91
CHECK ROTOR DISC RUNOUT(See step 3 on page BR-2OI
INSTALL NEW PAD SUPPORT PLATES
4.
5.
6.
7.
$
INSTALL NEW PADS
(a) Install new pad wear indicator plates to each pad.
NOTE: Be sure the arrow on the pad we*fiQicator plate
is pointing in the rotating direction of thd diiHt_
(b) Install new anti-squeal shims to each pad.
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8.
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# BRo281
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