1996 TOYOTA TERCEL Service Repair Manual

BR0RA-07
BR5038
BR5040
BR5039
BR3885
BR-4
- BRAKEBRAKE FLUID
878 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE FLUID
BLEEDING
HINT:
If any work is done on the brake system or air in the brake lines
is suspected, bleed the system of air.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Fluid: SAEJ1703 or FMVSS No.116 DOT3
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or the reservoir
becomes empty, bleed the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outer holes with your finger and release the
brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Repeat the above procedure to bleed the air out of the
brake line for each wheel.

- BRAKEBRAKE FLUID
BR-5
879 Author
: Date
:
1996 TERCEL (RM440U)
4. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary.
Fluid: SAEJ1703 or FMVSS No.116 DOT3

R12354
Stop Light Switch
Push Rod
Pedal Height
BR4980
A
BR1DT-01
BR-6
- BRAKEBRAKE PEDAL
880 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE PEDAL
ON-VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
EZ Grade:
143.0 - 153.0 mm (5.630 - 6.024 in.)
Except EZ Grade:
140.0 - 150.0 mm (5.512 - 5.906 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and
pedal.
Clearance: 0.5 - 2.4 mm (0.020 - 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check the stop lights come on when the brake pedal is de-
pressed, and go off when the brake pedal is released.
(l) After adjusting the pedal height, check the pedal freeplay.
HINT:
If clearance (A) between the stop light switch and the brack ped-
al stopper has been adjusted correctly, the pedal freeplay will
meet the specifications.

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.

BR0786
BR0RC-06
BR5045
BR-8
- BRAKEPARKING BRAKE LEVER
882 Author
: Date
:
1996 TERCEL (RM440U)
PARKING BRAKE LEVER
ON-VEHICLE INSPECTION
1. CHECK PARKING BRAKE LEVER TRAVEL
Pull the parking brake lever all the way up, and count the num-
ber of clicks.
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf):
5 - 8 clicks
2. IF NECESSARY, ADJUST PARKING BRAKE
HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted.
For shoe clearance adjustment, see step 2 on page BR-33.
(a) Remove the console box.
(b) Loosen the lock nut and turn the adjusting nut until the le-
ver travel is correct.
(c) Tighten the lock nut.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(d) Install the console box.

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)

BR0RF-06
BR5036
Soft Jaws
BR5037
Soft Jaws
R12236
A
- BRAKEBRAKE MASTER CYLINDER
BR-1 1
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N´m (17.5 kgf´cm, 15.2 in.´lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. PLACE CYLINDER IN VISE
4. REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
5. REMOVE PISTONS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
(b) Remove the No.1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:

If pulled out and installed at an angle, there is a possi-
bility that the cylinder bore could be damaged.

Be careful not to damage the rubber lips on the pis-
tons.
(c) Place a rag and 2 wooden blocks on the work table and
lightly tap the cylinder flange against the block edges until
the No.2 piston drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag to the top of the blocks
is at least 100 mm (3.94 in.).