1985 TOYOTA TERCEL torque

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.
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(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
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235 117,231
900 165,88)j Torque Plate
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Rotor Disc
Anti-squeal shim __Anti-squeal
I Spring
-cm (ft-lb, N.m)
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BRAKE SYSTEM - Front Brake
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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.
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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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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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SST
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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

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

Wagon FWD
COMPONENTS
/a 7-Automatic Adjustiuu A Lever
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Parkirfs e,"x" / ///cc-Lever 4//Return Spring
Wheel Cylinder
Rear Shoe
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Anchor sprins I LZ/
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Front Shoe
Adjusting Lever Spring-.-Retainer- @ ^ Shoe Hold-Down Spring
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kg-cm (ft-lb, N'm):Tightening torque
| : Non-reusable part
Drum
100 (7, r0l
Backing Plate
REMOVAL OF REAR BRAKE
1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lin-
ing thickness through the hole.
lf less than minimum, replace the shoes.
Standard thickness: 4.0 mm (0.157 in.l
Minimum thickness: 1.0 mm (0.039 in.l
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM
lf the brake drum cannot be easily removed, do the follow-
ing procedure:
(d Insert a screwdriver through the hole in the backing
plate, and hold the automatic adiusting lever away
from the adjusting bolt.
(b) Using another screwdriver, reduce the brake shoe
adjustment by turning the adjusting bolt.