1996 TOYOTA TERCEL length

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

BR0RY-04
BR4247
N00755
BR0376 BR0412
N00756 BR0394 BR0413
- BRAKEREAR DRUM BRAKE
BR-33
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page
BR-30).
1. AFTER INSTALLATION, FILL BRAKE RESERVOIR
WITH BRAKE FLUID, BRAKE SYSTEM
NOTICE:
Apply lithium soap base glycol grease and high tempera-
ture grease to the parts indicated by the arrows (See page
BR-29).
2. CHECK OPERATION OF AUTOMATIC ADJUSTING
MECHANISM
(a) Move the parking brake lever of the rear shoe back and
forth. Check that the adjuster turns.
If the adjuster does not turn, check for incorrect installation of
the rear brake.
(b) Adjust the adjuster length to the as short as possible.
(c) Install the brake drum.
(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.
3. CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM
(a) Remove the brake drum (See page SA-39).
(b) Measure the brake drum inside diameter and diameter of
the brake shoes. Check that the difference between the
diameters is the correct shoe clearance.
Shoe clearance: 0.6 mm (0.024 in.)
If incorrect, check the parking brake system.
(c) Install the brake drum (See page SA-42).

SR1EZ-01
Z13631
Thickness
Height
Length
R10282
Feeler Gauge
R13897Inscribed Mark
- STEERINGPOWER STEERING VANE PUMP
SR-27
1996 TERCEL (RM440U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE OIL CLEARANCE BETWEEN VANE PUMP
SHAFT AND BUSHING
Using a micrometer and a caliper gauge, measure the oil clear-
ance.
Standard clearance:
0.01 - 0.03 mm (0.0004 - 0.0012 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the maximum, replace the front housing and
vane pump shaft.
2. INSPECT VANE PUMP ROTOR AND VANE PLATES
(a) Using a micrometer, measure the height, thickness and
length of the 10 plates.
Minimum height: 8.0 mm (0.315 in.)
Minimum thickness: 1.77 mm (0.0697 in.)
Minimum length: 14.97 mm (0.5894 in.)
(b) Using a feeler gauge, measure the clearance between
the rotor groove and plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the plate and/or rotor
with the one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None

Z13632
R07591
Compressed Air
SR-28
- STEERINGPOWER STEERING VANE PUMP
1996 TERCEL (RM440U)
HINT:
There are 5 vane plate lengths with the following rotor and cam
ring marks:
Rotor and
cam ring markVane plate
part numberVane plate length
mm (in.)
None44345-1201014.996 - 14.998
(0.59039 - 0.59047)
144345-1202014.994 - 14.996
(0.59032 - 0.59032)
244345-1203014.992 - 14.994
(0.59024 - 0.59032)
344345-1204014.990 - 14.992
(0.59016 - 0.59024)
444345-1205014.988 - 14.990
(0.59008 - 0.59016)
3. INSPECT FLOW CONTROL VALVE
(a) Coat the valve with power steering fluid and check that it
falls smoothly into the valve hole by its own weight.
(b) Check the flow control valve for leakage. Close one of the
holes and apply 392 - 490 kPa (4 - 5 kgf/cm
2, 57 - 71 psi)
of compressed air into the opposite side hole, and confirm
that air does not come out from the end holes.
If necessary, replace the valve with the one having the same let-
ter as inscribed on the front housing.
Inscribed mark: A, B, C, D, E or F

R08702
Calipers
- STEERINGPOWER STEERING VANE PUMP
SR-29
1996 TERCEL (RM440U)
4. INSPECT COMPRESSION SPRING
Using calipers, measure the free length of the spring.
Minimum length: 36 - 38 mm (1.42 - 1.49 in.)
If it is not within the specification, replace the spring.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
NOTICE:
Place the shop rag, as shown, be careful not to damage the
bushing of the front housing.
(b) Coat a new oil seal lip with power steering fluid.
(c) Using a socket wrench (24 mm), press in the oil seal.
NOTICE:
Make sure you install the oil seal facing the correct direc-
tion.

R12038
SSTFulcrum Length SR-42
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
(b) Using SST and a torque wrench, loosen the screw until
the preload is within specification.
SST 09612-24014 (09616-10010, 09616-10020)
Preload (turning):
0.23 - 0.32 N´m (2.3 - 3.3 kgf´cm, 2.0 - 2.9 in.´lbf)
6. INSTALL PINION BEARING ADJUSTING SCREW
LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using SST, stop the pinion bearing adjusting screw rotat-
ing and using another SST, torque the nut.
SST 09612-24014 (09616-10020), 09922-10010
Torque: 85 N´m (871 kgf´cm, 63 ft´lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 380 mm (14.96
in.).
(c) Recheck the pinion preload.
Preload (turning):
0.23 - 0.32 N´m (2.3 - 3.3 kgf´cm, 2.0 - 2.9 in.´lbf)
7. INSTALL RACK GUIDE, RACK GUIDE SPRING AND
RACK GUIDE SPRING CAP
(a) Apply sealant to 2 or 3 threads of the cap.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Temporarily install the cap.

R12818Hexagon Wrench12°
R15481
SST
Z14313
Hexagon WrenchSST
R15482
Hexagon
Wrench SST
Fulcrum
Length
- STEERINGMANUAL STEERING GEAR
SR-43
1996 TERCEL (RM440U)
8. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.
(b) Using a hexagon wrench (19 mm), torque the rack guide
spring cap.
Torque: 14.7 N´m (150 kgf´cm, 10.8 ft´lbf)
(c) Using a hexagon wrench (19 mm), return the cap 12°.
(d) Using SST, turn the pinion shaft right and left 1 or 2 times.
SST 09612-24014 (09616-10010)
(e) Using a hexagon wrench (19 mm), loosen the cap until the
rack guide spring is not functioning.
(f) Using SST, a torque wrench and hexagon wrench (19
mm), tighten the cap until the preload is within specifica-
tion.
SST 09612-24014 (09616-10010)
Preload (turning):
0.6 - 1.2 N´m (6 - 12 kgf´cm, 5.2 - 10.4 in.´lbf)
9. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a hexagon wrench (19 mm), hold the rack guide
spring cap rotating and using SST, torque the nut.
SST 09922-10010
Torque: 41 N´m (419 kgf´cm, 30 ft´lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Recheck the total preload.
Preload (turning):
0.6 - 1.2 N´m (6 - 12 kgf´cm, 5.2 - 10.4 in.´lbf)
(d) Remove the RH and LH rack ends.