TOYOTA LAND CRUISER 1996 J80 Workshop Manual

BR1DD−01
BR−48−
BRAKE LOAD SENSING PROPORTIONING AND BY− PASS
VALVE (LSP & BV)
1996 LAND CRUISER (RM451U)
REMOVAL
1. DISCONNECT SHACKLE NO.2 FROM BRACKET
(a) Remove the cotter pin.
(b) Remove the nut and disconnect the shackle No.2 from the bracket.
(c) Remove the retainer, 2 cushions and collar.
2. REMOVE LSP & BV ASSEMBLY
(a) Using SST, disconnect the 3 brake lines from the valve body.
SST 09751−36011
(b) Remove the valve bracket and 4 mounting bolts, then re-
move the LSP & BV assembly.
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BR1DE−01
−
BRAKE LOAD SENSING PROPORTIONING AND BY− PASS
VALVE (LSP & BV)BR−49
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE VALVE BRACKET
(a) Remove the nut, bolt and 2 plate washers.
(b) Remove the 2 nuts, bracket and set plate from the valve
body.
2. DISCONNECT SPRING FROM VALVE
Using pliers, remove the clip, and remove the spring from the
valve.
3. REMOVE SHACKLE NO.1 AND NO.2
(a) Remove the bolt and nut, then remove the these parts:
Load sensing spring
2 plate washers
(b) Loosen the 2 nuts, and remove the shackle No.1 from the
shackle No.2.
4. DISASSEMBLE LOAD SENSING SPRING
Disassembly the these parts:
4 bushings
2 collars
2 rubber plates
Load sensing valve boot
Load sensing spring boot
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BR1DF−01
BR−50−
BRAKE LOAD SENSING PROPORTIONING AND BY− PASS
VALVE (LSP & BV)
1996 LAND CRUISER (RM451U)
INSPECTION
INSPECT VALVE PISTON PIN AND LOAD SENSING
SPRING CONTACT SURFACE FOR WEAR Wear limit: 0.7 mm (0.028 in.)
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BR1DG−01
BR0070
−
BRAKE LOAD SENSING PROPORTIONING AND BY− PASS
VALVE (LSP & BV)BR−51
1996 LAND CRUISER (RM451U)
REASSEMBLY
1. ASSEMBLE THESE PARTS TO LOAD SENSING
SPRING:
Load sensing valve boot
Load sensing spring boot
4 bushings
2 rubber plates
2 collars
HINT:
Apply lithium soap base glycol grease to the parts indicated by
the arrrows. Do not mistake the valve side for the shackle side
of the load sensing spring.
2. INSTALL SHACKLE NO.1 AND NO.2 TO LOAD SENS-
ING SPRING
(a) Install the lock nut and shackle No. 1 to the shackle No. 2.
(b) Torque the bolt and nut through the 2 plate washers. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
3. INSTALL LOAD SENSING SPRING TO VALVE BODY
Install the load sensing spring assembly to the load sensing
valve with the clip.
4. INSTALL VALVE BRACKET
(a) Install the set plate to the valve assembly through the valve bracket and temporarily tighten the 2 valve body
mounting nuts.
(b) Torque the bolt and nut through the 2 plate washers. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
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BR1DH−01
R05477
A
BR−52−
BRAKE LOAD SENSING PROPORTIONING AND BY− PASS
VALVE (LSP & BV)
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL LSP & BV ASSEMBLY
Install the LSP & BV assembly to the frame with the 4 bolts. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
2. CONNECT SHACKLE NO.2 TO BRACKET
(a) Set the dimension A by turning shackle No.2. Initial set: 90 mm (3.54 in.)
(b) Tighten the lock nut. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Install the 2 bushings and collar to the load sensing spring
shackle.
(d) Install the load sensing spring shackle to the shackle bracket with a retainer and nut.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(e) Install a new cotter pin.
3. CONNECT BRAKE LINES
Using SST, connect the 3 brake lines. SST 09751−36011
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
4. SET REAR AXLE LOAD (See page BR−45 )
5. SET VALVE BODY
(a) When pulling down the load sensing spring, confirm that the valve piston moves down smoothly.
(b) Position the valve body so that the valve piston lightly contacts the load sensing spring.
(c) Tighten the 2 valve body mounting nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
6. BLEED BRAKE SYSTEM (See page BR−4 )
7. CHECK FLUID LEAKAGE
8. CHECK AND ADJUST LSP & BV FLUID PRESSURE (See page BR−45 )
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BR1DI−01
−
BRAKE ABS ACTUATOR
BR−53
1035
Author: Date:
1996 LAND CRUISER (RM451U)
ABS ACTUATOR
ON−VEHICLE INSPECTION
1. INSPECT BATTERY POSITIVE VOLTAGE
Battery positive voltage: 10 − 14 V
2. DISCONNECT CONNECTORS
(a) Disconnect the connector from the actuator.
(b) Remove the control relay from the actuator bracket.
(c) Disconnect the 2 connectors from the control relay.
3. CONNECT ACTUATOR CHECKER (SST) TO ACTUA-
TOR
(a) Connect the actuator checker (SST) to the actuator, con-
trol relay and body side wire harness through the sub −
wire harness C (SST) and E (SST), as shown.
SST 09990−00150, 09990 −00200, 09990−00210
(b) Connect the red cable of the checker to the battery posi- tive (+) terminal and black cable to the negative ( −) termi-
nal. Connect the black cable of the sub −wire harness to
the battery negative (−) terminal or body ground.
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BR1334
R00326
BR−54
−
BRAKE ABS ACTUATOR
1036
Author: Date:
1996 LAND CRUISER (RM451U)
4. INSPECT BRAKE ACTUATOR OPERATION
(a) Start the engine, and run it at idle.
(b) Turn the selector switch of the actuator checker to
”FRONT RH” position.
(c) Push and hold in the SUB MOTOR switch for a few se- conds.
(d) Depress the brake pedal and hold it until the step (g) is
completed.
(e) Push the POWER switch, and check that the brake pedal
does not go down.
NOTICE:
Do not keep the POWER switch pushed down for more than
10 seconds.
(f) Release the switch, and check that the pedal goes down.
(g) Push and hold in the SUB MOTOR switch for a few se- conds, and check that the pedal returns.
(h) Release the brake pedal.
(i) Push and hold in the SUB MOTOR switch for a few se- conds.
(j) Depress the brake pedal and hold it for about 15 seconds.
As you hold the pedal down, push the SUB MOTOR
switch for a few seconds. Check that the brake pedal
does not pulsate.
(k) Release the brake pedal.
5. INSPECT FOR OTHER WHEELS
(a) Turn the selector switch to ”FRONT LH” position.
(b) Repeating (c) to (j) of the step 4, check the actuator opera-
tion similarly.
(c) Similarly, inspect ”REAR” position.
6. PUSH SUB MOTOR SWITCH
(a) Push and hold in the SUB MOTOR switch for a few se- conds.
(b) Stop the engine.
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BR1334
−
BRAKE ABS ACTUATOR
BR−55
1037
Author: Date:
1996 LAND CRUISER (RM451U)
7. DISCONNECT ACTUATOR CHECKER (SST) FROM
ACTUATOR
Disconnect the actuator checker (SST) and sub−wire harness
(SST) from the actuator, control relay and body side wire har-
ness.
SST 09990−00150, 09990 −00200, 09990−00210
8. CONNECT CONNECTORS
(a) Connect the 2 connectors to the control relay.
(b) Connect the connector to the actuator.
(c) Install the control relay to the actuator bracket.
9. CLEAR DTC (See page DI−190 )
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BR1DJ−01
BR−56
−
BRAKE ABS ACTUATOR
1996 LAND CRUISER (RM451U)
COMPONENTS
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BR1DK−01
−
BRAKE ABS ACTUATOR
BR−57
1996 LAND CRUISER (RM451U)
REMOVAL
1. REMOVE CONTROL RELAY FROM ACTUATOR
BRACKET
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
2. DISCONNECT BRAKE LINES
Using SST, disconnect the brake lines from the ABS actuator. SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
3. REMOVE ABS ACTUATOR ASSEMBLY
(a) Disconnect the 2 connectors from the actuator.
(b) Remove the 4 bolts and actuator assembly. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
4. REMOVE ABS ACTUATOR
(a) Remove the 3 nuts and actuator from the actuator brack-
et.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(b) Remove the 3 holders and cushions from the ABS actua-
tor.
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