Brake TOYOTA LAND CRUISER 1996 J80 User Guide

Q07409
AT−24
−
AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION UNIT
1996 LAND CRUISER (RM451U)
(d) Remove the 4 nuts and 2 gaskets, shift the front exhaust
pipe assembly to the vehicle’s outside.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
HINT:
At the time of installation, replace the used gaskets and nuts
with new gaskets and nuts.
15. REMOVE STARTER
(a) Remove the nut and disconnect the terminal and connec-
tor.
(b) Remove the lower side mounting bolt and starter. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
16. REMOVE CROSSMEMBER
(a) Support the transmission with a transmission jack.
(b) Remove the 8 bolts and 2 nuts, and then remove the crossmember.
Torque:
Bolt: 61 N·m (620 kgf·cm, 45 ft·lbf)
Nut: 74 N·m (750 kgf·cm, 54 ft·lbf)
17. REMOVE TRANSMISSION
(a) Lower the rear end of the transmission.
NOTICE:
Be careful not to damage the cooling fan, brake booster
and brake line.
(b) Separate the wire harness from the transmission and transfer.
(c) Remove the oil cooler pipe mounting bolts from the torque
converter clutch housing, and then disconnect the 2 oil
cooler pipes from the elbows.
(d) Remove the 10 bolts and transmission. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)
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−
BODY ELECTRICAL BODY ELECTRICAL SYSTEM
BE−5
1996 LAND CRUISER (RM451U)
Fuel gauge does not operate or abnormal operation.
1. Fuel Receiver Gauge
2. Fuel Sender Gauge
3. Meter Circuit
4. Wire HarnessBE−34
BE−34
BE−32
−
Engine coolant temperature gauge does not operation or
abnormal operate.
1. Engine Coolant Temperature Receiver Gauge
2. Engine Coolant Temperature Sender Gauge
3. Meter Circuit
4. Wire HarnessBE−34
BE−34
BE−32−
Oil pressure gauge does not operate or abnormal operation.
1. Oil Pressure Receiver Gauge
2. Oil Pressure Sender Gauge
3. Meter Circuit
4. Wire HarnessBE−34
BE−34
BE−34−
All illumination lights do not light up.
1. TAIL Fuse (I/P F/B)
2. Light Control Rheostat
3. Wire Harness−
BE−34 −
Brightness does not change even when rheostat turned.1. Bulb
2. Wire Harness−
−
Only one illumination light does not light up.1. Bulb
2. Wire Harness−
−
WARNING LIGHTS:
COMBINATION METER
SymptomSuspect AreaSee page
Warning lights do not lights up.
(Except discharge, SRS and door open)1. GAUGE Fuse (I/P F/B)
2. Meter Circuit
3. Wire Harness−
BE−32 −
Brake warning light does not light up.
1. Bulb
2. Brake Fluid Level Switch
3. Parking Brake Switch
4. Meter Circuit
5. Wire Harness−
BE−34
BE−34
BE−32 −
Open door warning light does not light up.
1. Bulb
2. Door Courtesy Switch
3. DOME Fuse (No.2 R/B)
4. Meter Circuit
5. Wire Harness−
BE−21
BE−21 −
−
−
SRS warning light does not light up
1. Bulb
2. Airbag Sensor Assembly
3. ECU− B Fuse (I/P F/B)
4. Meter Circuit
5. Wire Harness−
−
−
BE−32 −
Discharge warning light does not light up.
1. Bulb
2. IGN Fuse (No.1 J/B)
3. Generator
4. Meter Circuit
5. Wire Harness−
−
−
BE−32 −
Seat belt warning light does not light up.
1. Bulb
2. Seat Belt Buckle Switch
3. Seat Belt Warning Relay (I/P F/B)
4. Meter Circuit
5. Wire Harness−
BE−34 −
BE−32 −
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BE4917
Test LED
Battery
BE1217
Warning Light
Ignition
Switch Battery
N01212
BE−38
−
BODY ELECTRICAL COMBINATION METER
1996 LAND CRUISER (RM451U)
(c) Ground terminal on the wire harness side through a 3.4
W test bulb.
(d) Turn the ignition switch ON, and check that the bulb lights
up and that the receiver gauge needle moves to the high
side.
If operation is not as specified, measure the receiver gauge re-
sistance.
14. INSPECT OIL PRESSURE RECEIVER GAUGE RESIS- TANCE
Measure the receiver gauge resistance between terminals. Resistance:
40 − 48 Ω
If resistance value is not as specified, replace the receiver
gauge.
15. INSPECT OIL PRESSURE SENDER GAUGE OPERA-
TION
(a) Disconnect the connector from the sender gauge.
(b) Apply battery positive voltage to the sender gauge termi- nal through a test LED.
(c) Check that the bulb does not light when the engine is stopped.
(d) Check that the LED flashes when the engine is running. The number of flashed should vary with engine speed.
If operation is not as specified, replace the sender gauge.
16. INSPECT BRAKE WARNING LIGHT
(a) Disconnect the connectors from the level warning switch and parking brake switch.
(b) Connect terminals on the wire harness side connector of
the level warning switch connector.
(c) Turn the ignition switch ON, and check that the warning light lights up.
17. INSPECT PARKING BRAKE SWITCH
(a) Check that there is continuity between terminal and the switch set nut with switch pin released (parking brake le-
ver pulled up).
(b) Check that there is no continuity between terminal and the switch set nut with switch pin pushed in. (parking
brake lever released)
If operation is not as specified, replace the switch.
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BE2570
ON
OFF
BE0044
BE1428
−
BODY ELECTRICAL COMBINATION METER
BE−39
1996 LAND CRUISER (RM451U)
18. INSPECT BRAKE FLUID LEVEL WARNING SWITCH
(a) Check that there is no continuity between terminals with
the switch OFF (float up).
(b) Check that there is continuity between terminals with the switch ON (float down).
If operation is not as specified, replace the switch.
19. INSPECT OPEN DOOR WARNING LIGHT
(a) Disconnect the connector from the door courtesy switch and ground terminal on the wire harness side connector.
(b) Turn the ignition switch ON, and check that the warning light lights up.
If the warning light does not light up, test the bulb.
20. INSPECT DOOR COURTESY SWITCH
(a) Check that there is continuity between terminal and the
switch body with the switch ON (switch pin re-
leased:opened door).
(b) Check that there is no continuity between terminal and
the switch body with the switch OFF (switch pin pushed
in:closed door).
If operation is not as specified, replace the switch.
21. INSPECT SEAT BELT WARNING LIGHT
(a) Disconnect the connector from the seat belt warning relay.
(b) Ground terminal 9 on the wire harness side connector.
(c) Turn the ignition switch ON, and check that the warning
light lights up.
If the warning light does not light up, test the bulb.
22. INSPECT SEAT BELT BUCKLE SWITCH CONTINUITY
(a) Check that there is continuity between terminals with the switch ON (belt unfastened).
(b) Check that there is no continuity between terminals with the switch OFF (belt fastened).
If operation is not as specified, replace the seat belt inner.
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BR1CC−01
−
BRAKE BRAKE SYSTEM
BR−1
983
Author: Date:
1996 LAND CRUISER (RM451U)
BRAKE SYSTEM
GENERAL DESCRIPTION
Care must be taken to replace each part properly as it could affect the perfo\
rmance of the brake
system and result in a driving hazard. Replace the parts with parts of the same part number or
equivalent.
It is very important to keep parts and the area clean when repairing the\
brake system.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.
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BR1CD−01
BR−2
−
BRAKE TROUBLESHOOTING
984
Author: Date:
1996 LAND CRUISER (RM451U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Low pedal or spongy pedal
4. Fluid leaks for brake system
5. Air in brake system
6. Piston seals: worn or damaged
7. Master cylinder: faulty
8. Booster push rod: out of adjustment−
−
BR−33
BR−33 BR−9
BR−20
Brake drag
1. Brake pedal freeplay: minimal
2. Parking brake lever travel: out of adjustment
3. Parking brake wire: sticking
4. Pad: cracked or distorted
5. Piston: stuck
6. Piston: frozen
7. Tension or return spring: faulty
8. Booster push rod: out of adjustment
9. . Vacuum leaks for booster system
10.. Master cylinder: faultyBR−6
BR−8 −
BR−21
BR−30
BR−33
BR−33
BR−33
BR−33
BR−39
BR−20
BR−18 BR−9
Brake pull
1. Piston: stuck
2. Pad: oily
3. Piston: frozen
4. Disc: Scored
5. Pad: cracked or distortedBR−33
BR−33
BR−21
BR−30
BR−33
BR−33
BR−33
BR−33
BR−21
BR−30
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−
BRAKE TROUBLESHOOTING
BR−3
985
Author: Date:
1996 LAND CRUISER (RM451U)
Hard pedal but brake inef
ficient
1. Fluid leaks for brake system
2. Air in brake system
3. Pad: worn
4. Pad: cracked or distorted
5. Pad: oily
6. Pad: glazed
7. Disc: scored
8. Booster push rod: out of adjustment
9. Vacuum leaks for booster system−
−
BR−21
BR−30
BR−21
BR−30
BR−21
BR−30
BR−21
BR−30
BR−21
BR−30
BR−20
BR−18
Noise from brake
1. Pad: cracked or distorted
2. Installation bolt: loosen
3. Disc: scored
4. Pad support plate: loosen
5. Sliding pin: worn
6. Pad: dirty
7. Pad: glazed
8. Tension or return spring: faulty
9. Anti− squeal shim: damaged
10.. Hold− down spring: damagedBR−21
BR−30
BR−33
BR−33
BR−33
BR−33
BR−30
BR−33
BR−21
BR−30
BR−21
BR−30
BR−39
BR−21
BR−30
BR−39
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BR1CE−01
R13494
R00252
BR−4
−
BRAKE BRAKE FLUID
986
Author: Date:
1996 LAND CRUISER (RM451U)
BRAKE FLUID
BLEEDING
HINT:
If any work is done on the brake system or if air is suspected in
the brake lines, 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
Check the fluid level in the reservoir after bleeding each wheel.
Add fluid, if necessary. Fluid: SAE J1703 or FMVSS No.116 DOT3
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or if the reservoir
becomes empty, bleed the air from 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 outlet plugs with your fingers, and release the brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
3. CONNECT VINYL TUBE TO BRA KE CALIPER BLEED-
ER PLUG
Insert other end of the tube in a half −full container of brake fluid.
NOTICE:
Begin bleeding air from the brake caliper with the longest
hydraulic line.
4. BLEED BRAKE LINE
(a) Slowly depress the brake pedal several times.
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−
BRAKE BRAKE FLUID
BR−5
987
Author: Date:
1996 LAND CRUISER (RM451U)
(b) While an assistant depresses the pedal, loosen the
bleeder plug until fluid starts to run out. Then tighten the
bleeder plug.
(c) Repeat this procedure until there are no more air bubbles
in the fluid.
Bleeder plug tightening torque:
11 N·m (110 kgf·cm, 8 ft·lbf)
5. REPEAT PROCEDURE FOR EACH WHEEL
6. BLEED LSP & BV
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BR3295
Push RodStop Light Switch
Pedal Height
BR1CF−04
BR4980
A
BR0016
Pedal Freeplay
BR−6
−
BRAKE BRAKE PEDAL
988
Author: Date:
1996 LAND CRUISER (RM451U)
BRAKE PEDAL
ON−VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from dash panel:
167.5 − 177.5 mm (6.594 − 6.988 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between the stop light switch and pedal.
Clearance: 0.5 − 2.4 mm (0.020 − 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check that the stop lights come on when the brake pedal
is depressed, and go off when the brake pedal is re-
leased.
(l) earance (A) between the stop light switch and the pedal
stopper has been adjusted correctly, the pedal freeplay
will meet the specifications.
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the beginning of the se- cond resistance is felt. Measure the distance.
Pedal freeplay: 3 − 6 mm (0.12 − 0.24 in.)
HINT:
The freeplay to the 1st resistance is due to the play between the
clevis and pin. This is magnified up to 3 − 6 mm (0.12 − 0.24 in.)
at the pedal.
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