1996 TOYOTA TERCEL lock

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.).

- 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)

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.

BR0S7-06
R15522
Sensor Rotor
Brake Drum
Outer Bearing
Nut Lock
Grease Cap Claw Washer

Cotter Pin Rear Speed Sensor

Non-reusable part BR-44
- BRAKEREAR SPEED SENSOR
918 Author
: Date
:
1996 TERCEL (RM440U)
REAR SPEED SENSOR
COMPONENTS

Z00038
DENSO BorroughsSR1F5-01
CH0087
CORRECT
WRONG
WRONG
R11541
PS Vane
Pump
CORRECTWRONG C
D
E
F
- STEERINGDRIVE BELT
SR-3
923 Author
: Date
:
1996 TERCEL (RM440U)
DRIVE BELT
INSPECTION
1. CHECK DRIVE BELT TENSION
Using a belt tension gauge, measure the belt tension.
Belt tension gauge:
DENSO BTG-20 (95506-00020) or
Borroughs No. BT-33-73F
Drive belt tension:
New belt: 140 - 180 lbf
Used belt: 80 - 120 lbf
NOTICE:
After installing the belt, check that it fits properly in the
ribbed grooves.
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
2. VEHICLES WITH BELT TENSION ADJUSTING BOLT:
ADJUST DRIVE BELT TENSION
(a) Loosen the bolts A and B.
(b) Loosen the lock nuts D and E.
(c) Adjust adjusting bolt F so that its protrusion above nut C
is ± 0 mm (0 in.).
(d) Fix nut C using lock nut D.
(e) Push up the PS pump body so that there is no free play
in the belt. Turn adjusting bolt F to obtain the play in the
correct belt tension as specified above.
NOTICE:
Ensure that the pump body and nut C are positioned cor-
rectly, as shown before turning bolt F to adjust the bet ten-
sion.
(f) Torque the bolt A.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)

SR-4
- STEERINGDRIVE BELT
924 Author
: Date
:
1996 TERCEL (RM440U)
(g) Torque the bolt B.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(h) Loosen adjusting bolt F by 4 or 5 turns.
NOTICE:
Check that there is a gap of 5 mm (0.20 in.) or more between
the tip of nut C and the pump body.
(i) Fix adjusting bolt F with lock nut E.
(j) Recheck the belt tension.

SR05P-15
R07281
Normal
Abnormal
- STEERINGPOWER STEERING FLUID
SR-5
925 Author
: Date
:
1996 TERCEL (RM440U)
POWER STEERING FLUID
BLEEDING
1. CHECK FLUID LEVEL (See page SR-6)
2. JACK UP FRONT OF VEHICLE AND SUPPORT IT
WITH STANDS
3. TURN STEERING WHEEL
With the engine stopped, turn the wheel slowly from lock to lock
several times.
4. LOWER VEHICLE
5. START ENGINE
Run the engine at idle for a few minutes.
6. TURN STEERING WHEEL
(a) With the engine idling, turn the wheel to left or right full
lock position and keep it there for 2-3 seconds, then turn
the wheel to the opposite full lock position and keep it
there for 2-3 seconds.
(b) Repeat (a) several times.
7. STOP ENGINE
8. CHECK FOR FOAMING OR EMULSIFICATION
If the system has to be bled twice specifically because of foam-
ing or emulsification, check for fluid leaks in the system.
9. CHECK FLUID LEVEL (See page SR-6)

SR05Q-17
R11229
NormalAbnormal
R11025Engine Idling Engine Stopped5 mm (0.20 in.)
or less SR-6
- STEERINGPOWER STEERING FLUID
1996 TERCEL (RM440U)
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON® II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir cap dipstick. If the fluid is cold, check that it is within
the COLD LEVEL range.
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
(e) Check for foaming or emulsification.
If there is foaming or emulsification, bleed power steering sys-
tem. (See page SR-5)
(f) With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system.
(See page SR-5)
(i) Check the fluid level.