1996 TOYOTA TERCEL e brake

PP17V-01
- PREPARATIONBRAKE
PP-61
1996 TERCEL (RM440U)
LUBRICANT
ItemCapacityClassification
Brake fluid-SAEJ1703 or FMVSS No.116 DOT 3

SS0LP-06
- SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS-33
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
FRONT:
Disc brake dust cover x Steering knuckle8.38574 in.´lbf
Lower ball joint x Steering knuckle981,00072
Steering knuckle x Shock absorber2452,500181
Lower ball joint x Lower suspension arm8082059
Tie rod end lock nut4748035
Tie rod end x Steering knuckle4950036
Disc brake caliper x Steering knuckle8890065
Drive shaft lock nut2162,200159
Piston rod x Suspension support4747534
Suspension support x Body3940029
Flexible hose x Shock absorber2930022
Lower suspension arm x BodyFront side1421,450105Lower sus ension arm x Body Front side
Rear side
142
74
1,450
750
105
55
Hub nut1031,05076
ABS speed sensor x Steering knuckle7.88069 in.´lbf
REAR:
Piston rod x Suspension support3435025
Suspension support x Body3940029
Shock absorber x Axle beam6869050
Backing plate x Axle beam7071051
Parking brake cable x Backing plate7.88069 in.´lbf
Brake line x Wheel cylinder1515511
Body x Axle beam1421,450105
Lateral control rod x Axle beam8385061
Lateral control rod x Body11 31,15083
ABS speed sensor x Axle beam7.88069 in.´lbf
ABS speed sensor wire x Axle beam5.45548 in.´lbf

SS0M2-1 1
SS-34
- SERVICE SPECIFICATIONSBRAKE
164 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE
SERVICE DATA
Brake pedal height (from asphalt sheet) EZ grade143.0 - 153.0 mm (5.63 - 6.02 in.)Brake edal height (from as halt sheet) EZ grade
Except EZ grade
143.0 153.0 mm (5.63 6.02 in.)
140.0 - 150.0 mm (5.51 - 5.91 in.)
Brake pedal freeplay1 - 6 mm (0.04 - 0.24 in.)
Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf) w/o ABSMore than 60 mm (2.36 in.)Brake edal reserve distance at 490 N (50 kgf, 11 0.2 lbf) w/o ABS
w/ ABS
More than 60 mm (2.36 in.)
More than 55 mm (2.17 in.)
Brake booster push rod to piston clearance (w/ SST)0 mm (0 in.)
Front brake pad thickness STD10.0 mm (0.394 in.)Front brake ad thickness STD
Minimum
10.0 mm (0.394 in.)
1.0 mm (0.039 in.)
Front brake disc thickness STD18.0 mm (0.709 in.)Front brake disc thickness STD
Minimum
18.0 mm (0.709 in.)
17.0 mm (0.669 in.)
Front brake disc runout Maximum0.07 mm (0.0028 in.)
Rear brake drum inside diameter STD180 mm (7.087 in.)Rear brake drum inside diameter STD
Maximum
180 mm (7.087 in.)
181 mm (7.126 in.)
Rear brake lining thickness STD4.0 mm (0.157 in.)Rear brake lining thickness STD
Minimum
4.0 mm (0.157 in.)
1.0 mm (0.039 in.)
Rear brake drum to shoe clearance0.6 mm (0.024 in.)
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf)5 - 8 clicks

SS0M3-10
- SERVICE SPECIFICATIONSBRAKE
SS-35
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Master cylinder x Piston stopper bolt101007
Master cylinder x Reservoir1.717.515.2 in.´lbf
Master cylinder x Brake booster131309
Brake line union nut1515511
Brake booster clevis lock nut2526019
Brake booster x Pedal bracket1414510
Front disc brake caliper installation bolt2525518
Bleeding plug8.38574 in.´lbf
Front disc brake torque plate x Steering knuckle8890065
Front disc brake caliper x Flexible hose3031022
Rear drum brake wheel cylinder x Backing plate101007
ABS actuator assembly x Body1919514
ABS actuator x ABS actuator bracket assembly5.45548 in.´lbf
ABS actuator x ABS actuator No. 3 bracket1919514
Front speed sensor x Steering knuckle8.08271 in.´lbf
Front speed sensor wire harness clamp installation bolt5.05144 in.´lbf
Rear speed sensor x Axle beam8.08271 in.´lbf
Rear speed sensor wire harness clamp installation bolt5.05144 in.´lbf

DI4LN-02
Vehicle Brought to Workshop
Customer Problem Analysis
P. DI-1 10
Check and Clear DTC (Pre-check)
P.
DI-1 11
Items inside
are titles of pages in this manual,
with the page number in the bottom portion. See
the indicated pages for detailed explanations.
Problem Symptom ConfirmationSymptom Simulation
P. IN-26
Symptom
does not occur
Symptom
occurs
DTC Check
P. DI-1 11
Sensor CheckCircuit Inspection
P. DI-1 19 - DI-145
DTC Chart
P. DI-1 15Problem Symptoms Table
P. DI-1 18
Check for Fluid Leakage
P. DI-145
Identification of Problem
Normal code
Repair
Confirmation Test
End
1
2
3
4
5
67
89
10
11
Step 8:Diagnostic steps permitting the use of the
TOYOTA hand-held tester, or TOYOTA
brake-out-box.
- DIAGNOSTICSANTI-LOCK BRAKE SYSTEM
DI-109
283 Author
: Date
:
1996 TERCEL (RM440U)
ANTI-LOCK BRAKE SYSTEM
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshooting in accordance with the procedure on the following pages.

DI4LO-01
ABS Check SheetInspector 's
Name:
Customer 's Name
Date Vehicle
Brought InRegistration Year Registration No.
Frame No.
Odometer Reading/ /
/ /
Date Problem First Occurred
Frequency Problem Occurs/ /
ContinuousIntermittent ( times a day)
Remains ONDoes not Light Up
DTC Check1st Time
2nd TimeNormal Code
Malfunction Code (Code )
Normal CodeMalfunction Code (Code )
Symptomskm
miles
ABS does not operate.
ABS Warning Light
AbnormalABS does not operate intermittently. DI-1 10
- DIAGNOSTICSANTI-LOCK BRAKE SYSTEM
1996 TERCEL (RM440U)
CUSTOMER PROBLEM ANALYSIS CHECK

R12149
DI4LP-02
FI6443
Short Pin
DLC1
R13006
DLC1
E
1
Tc
R01346
Normal Code
0.25 sec.
0.25 sec.
ON
OFF
ON
OFF0.5 sec.
Code 11 and 21
4 sec.1.5
sec.2.5 sec.
Code 11Code 21
2 sec.
0.5 sec.
- DIAGNOSTICSANTI-LOCK BRAKE SYSTEM
DI-1 11
1996 TERCEL (RM440U)
PRE-CHECK
1. DIAGNOSIS SYSTEM
(a) Check the indicator.
When the ignition switch is turned ON, check that the ABS
warning light goes on for 3 seconds.
HINT:
If the indicator check result is not normal, proceed to trouble-
shooting for the ABS warning light circuit (See page DI-138).
(b) Check the DTC.
(1) Turn the ignition switch ON.
(2) Disconnect the short pin from the DLC1.
(3) Using SST, connect terminals Tc and E
1 of the
DLC1.
SST 09843-18020
(4) Read the DTC from the ABS warning light on the
combination meter.
HINT:

If no code appears, inspect the diagnostic circuit or ABS
warning light circuit (See page DI-141 or DI-138).

As an example, the blinking patterns for normal code and
codes 11 and 21 are shown in the illustration.
(5) Code are explained in the code table on page
DI-1 15.
(6) After completing the check, disconnect terminals Tc
and E
1, and turn off the display.
If 2 or more malfunctions are indicated at the same time, the
lowest numbered DTC will be displayed 1st.

BR3890
FI6443
Short Pin
DLC1
N09348
Interface Box
Harness VehicleTOYOTA
Tester Hand-held
TOYOTA Break-out-box DI-1 12
- DIAGNOSTICSANTI-LOCK BRAKE SYSTEM
1996 TERCEL (RM440U)
(c) Clear the DTC.
(1) Using SST, connect terminals Tc and E
1 of the
DLC1 and remove the short pin from the DLC1.
SST 09843-18020
(2) IG switch ON.
(3) Clear the DTC stored in ECU by depressing the
brake pedal 8 or more times within 3 seconds.
(4) Check that the warning light shows the normal
code.
(5) Remove the SST from the terminals of the DLC1.
SST 09843-18020
(6) Connect the short pin to the DLC1.
HINT:
Cancellation can also be done by removing the DOME fuse , but
in this case, other memory systems will also be cancelled out.
(d) Using TOYOTA break-out-box and TOYOTA hand-held
tester, measure the ECU terminal values.
(1) Hook up the TOYOTA hand-held tester and TOYO-
TA break-out-box to the vehicle.
(2) Read the ECU input/output values by following the
prompts on the tester screen.
HINT:
TOYOTA hand-held tester has a ºSnapshot º function. This re-
cords the measured values and is effective in the diagnosis of
intermittent problems.
Please refer to the TOYOTA hand-held tester/TOYOTA break
out-box operators manual for further details.