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Toyota Tercel 1980-1999 Workshop Repair & Service Manual
Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Toyota Tercel 1980-1999. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your Tercel like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.
This manual for Toyota Tercel 1980-1999 is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.
EXCERPT:
BRAKE – FRONT BRAKE PAD
REPLACEMENT
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with hub nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole and replace the pads if they are not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. REMOVE CALIPER
(a) Remove the 2 installation bolts from the torque plate.
(b) Remove the caliper and suspend it securely.
HINT: Do not disconnect the flexible hose.
4. REMOVE THESE PARTS:
(a) 2 brake pads
(b) 3 anti-squeal shims
(c) Pad wear indicator plate
(d) 4 pad support plates
NOTICE:
The support plates can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off.
5. CHECK DISC THICKNESS AND RUNOUT (See page BR-26 )
6. INSTALL 4 PAD SUPPORT PLATES
7. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti-squeal shims and wear indicator plates must be replaced together with the pads.
(a) Install a pad wear indicator plate on the inner pad.
(b) Apply disc brake grease to the anti-squeal shims (See page BR-23 ).
(c) Install the 2 anti-squeal shims on the outer pad.
(d) Install the anti-squeal shim on the inner pad.
(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 equivalent.
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
FRONT BRAKE CALIPER
COMPONENTS
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 caliper.
(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.
DISASSEMBLY
1. REMOVE THESE PARTS:
(a) 2 sliding bushings.
(b) 4 dust boots.
2. REMOVE CYLINDER BOOT SET RING AND CYLINDER
BOOT
Using a screwdriver, remove the cylinder boot set ring and cylinder boot from the caliper.
3. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and the caliper.
(b) Use compressed air to remove the piston from the cylinder.
CAUTION:
Do not place your fingers in front of the piston when using compressed air.
4. REMOVE PISTON SEAL
Using a screwdriver, remove the piston seal from the cylinder.
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