1996 TOYOTA TERCEL brake fluid

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

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)

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)

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

N00746
BR-22
- BRAKEFRONT BRAKE PAD
1996 TERCEL (RM440U)
(e) Install inner pad with the pad wear indicator plate facing
upward.
(f) Install outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.
8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or an equiva-
lent.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.
(c) Install the caliper.
(d) Install and torque the 2 installation bolts.
Torque: 25 N´m (255 kgf´cm, 18 ft´lbf)
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

BR0RQ-05
BR4220
BR-24
- BRAKEFRONT BRAKE CALIPER
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)
HINT:
Install the flexible hose lock securely in the lock hole in the cali-
per.
(b) Use a container to catch the brake fluid as it drains out.
2. REMOVE CALIPER
Remove the 2 installation bolts, and caliper.
Torque: 25 N´m (255 kgf´cm, 18 ft´lbf)
3. REMOVE THESE PARTS:
(a) 2 brake pads with anti-squeal shims.
(b) 4 pad support plates.

BR0RU-04
BR-28
- BRAKEFRONT BRAKE CALIPER
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-24).
1. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE
SYSTEM (See page BR-4)
2. CHECK FOR LEAKS