1996 TOYOTA TERCEL Service Repair Manual

BR0RG-01
BR-12
- BRAKEBRAKE MASTER CYLINDER
1996 TERCEL (RM440U)
INSPECTION
HINT:
Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

BR0RH-02
- BRAKEBRAKE MASTER CYLINDER
BR-13
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-1 1).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by arrows (See page BR-9).

BR0RI-05
BR-14
- BRAKEBRAKE MASTER CYLINDER
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-10).
1. BEFORE INSTALLATION, ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD (See page
BR-18)
2. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE
SYSTEM (See page BR-4)
3. CHECK FOR LEAKS, CHECK AND ADJUST BRAKE PEDAL (See page BR-6)

BR2237
BR0RJ-01
BR2238
GOOD NO GOOD
1st2nd3rd
- BRAKEBRAKE BOOSTER ASSEMBLY
BR-15
889 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE BOOSTER ASSEMBLY
ON-VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal
for 30 seconds, the booster is air tight.

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

BR0RL-01
F05027
BR5055
R04651
- BRAKEBRAKE BOOSTER ASSEMBLY
BR-17
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE MASTER CYLINDER (See page BR-10)
2. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
3. REMOVE PEDAL RETURN SPRING
4. REMOVE CLIP AND CLEVIS PIN
5. REMOVE BRAKE BOOSTER
(a) Remove the No.1 brake line clamp.
(b) Remove the No.2 brake line clamp.
(c) Remove the 4 nuts and clevis.
(d) Pull out the brake booster and gasket.

BR0RM-04
F03521
SST
Gasket
N00744
SST
BR1728 BR0021
BR-18
- BRAKEBRAKE BOOSTER ASSEMBLY
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 14 N´m (145 kgf´cm, 10 ft´lbf)
(d) Insert the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
(f) Install the No.1 brake line clamp to the body.
(g) Install the No.2 brake line clamp to the body.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install the gasket on the master cylinder.
(b) Set SST on the gasket, and lower the pin until its tip slight-
ly touches the piston.
SST 09737-00010
(c) Turn SST upside down, and set it on the booster.
SST 09737-00010
(d) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod
slightly touches the pin head.
HINT:
When loosening the push rod nut, depress the brake pedal
enough so that the push rod sticks out.
3. INSTALL MASTER CYLINDER
4. CONNECT VACUUM HOSE TO BRAKE BOOSTER
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR-4)
6. CHECK FOR LEAKS

- BRAKEBRAKE BOOSTER ASSEMBLY
BR-19
1996 TERCEL (RM440U)
7. CHECK AND ADJUST BRAKE PEDAL
(See page BR-6)
Check and adjust the brake pedal, then tighten the clevis lock
nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
8. DO OPERATIONAL CHECK
(See page BR-15)