light TOYOTA LAND CRUISER 1996 J80 Repair Manual

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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BR3297
Pedal Reserve Distancea
−
BRAKE BRAKE PEDAL
BR−7
989
Author: Date:
1996 LAND CRUISER (RM451U)
If incorrect, check the stop light switch clearance.
If the clearance is OK, then troubleshoot the brake system.
4. CHECK PEDAL RESERVE DISTANCE
Release the parking brake.
With the engine running, depress the pedal and measure
the pedal reserve distance, as shown.
Pedal reserve distance, ’a’, at 490 N (50 kgf, 110.2lbf):
More than 68 mm (2.68 in.)
If the reserve distance incorrect, troubleshoot the brake sys-
tem.
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BR1CJ-01
R12236
A
-
BRAKE BRAKE MASTER CYLINDER
BR-1 1
1996 LAND CRUISER (RM451U)
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. REMOVE BOLT AND CLAMP FROM CYLINDER BODY
4. PLACE CYLINDER IN VISE
5. 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)
6. REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(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 possibly
that the cylinder bore could be damaged.
NOTICE:
Be careful not to damage the rubber lips on the pistons.
(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 that the distance (A) from the rag to the top of the
blocks is at least 100 mm (3.94 in.).
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BR1CN-01
BR2238
-
BRAKE BRAKE BOOSTER ASSEMBLY
BR-15
1996 LAND CRUISER (RM451U)
BRAKE BOOSTER ASSEMBLY
OPERATION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the pedal goes
down furthest the 1st time, but gradually rises after the
2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal
for 30 seconds, the booster is air tight.
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BR2237
BR1NM−01
BR2238
−
BRAKE BRAKE BOOSTER ASSEMBLY
BR−17
999
Author: Date:
1996 LAND CRUISER (RM451U)
BRAKE BOOSTER ASSEMBLY
OPERATION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly. If the pedal goes
down furthest the 1st time, but gradually rises after the
2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal
for 30 seconds, the booster is air tight.
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BR1CQ−01
BR3976
SST
Gasket
R11347
SST
BR−20
−
BRAKE BRAKE BOOSTER ASSEMBLY
1996 LAND CRUISER (RM451U)
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: 13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install a new gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip slightly touches the piston.
SST 09737−00010
(c) Turn the 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 light-
ly touches the pin head.
3. INSTALL MASTER CYLINDER (See page BR−9 )
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 FLUID LEAKAGE
7. CHECK AND ADJUST BRAKE PEDAL (See page BR−6 )
8. DO OPERATIONAL CHECK (See page BR−17 )
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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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CH0EO−02
CH0712
BlueRed
White
Charging
Necessary
OK
Add Distilled
Water
CH−2
−
CHARGING CHARGING SYSTEM
1996 LAND CRUISER (RM451U)
CHARGING SYSTEM
ON−VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL AND VOLT-
AGE
(a) Check the electrolyte quantity of each cell.
If under the lower level, replace the battery (or add distilled wa-
ter if possible). check the charging system.
(b) Measure the battery voltage between the negative ( −)
and positive (+) terminals of the battery.
Standard voltage: At 20° C (68°F): 12.7 − 12.9 V
HINT:
Before measuring the voltage, turn the ignition switch
OFF and turn off the electrical systems (headlight, blower
motor, rear defogger etc.).
If the vehicle has been running, wait 20 minutes or more
after the vehicle stops before measuring the battery volt-
age.
If the voltage is less than specification, charge the battery.
HINT:
Check the indicator as shown in the illustration.
2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
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P03788
CORRECT WRONG
Clearance
Z00038
Nippondenso Borroughs
−
CHARGING CHARGING SYSTEM
CH−3
1996 LAND CRUISER (RM451U)
(b) Check the fusible link and fuses for continuity.
Fusible link
MAIN 2.0 A
AM1 1.25 B
AM2 0.3 P
H−fuseAM1 50 A
FuseIGN 7.5 A
GAUGE 15 A
3. INSPECT DRIVE BELTS
(a) Visually check the drive belt for cracks, oiliness or wear.
Check that the belt does not touch the bottom of the pulley
groove.
If necessary, replace the drive belts as a set.
(b) Using a belt tension gauge, measure the belt tension. Belt tension gauge:
Nippondenso BTG−20 (95506 −00020)
Borroughts No. BT−33−73F
Drive belt tension:
New belt400 − 580 N (41.0 − 59.1 kgf, 90.4 − 130.2 lbf)
Used belt200 − 390 N (20.4 − 40.0 kgf, 45.0 − 88.2 lbf)
If the belt tension is not as specified, adjust it.
HINT:
”New belt” refers to a belt which has been used less than
5 minutes on a running engine.
”Used belt” refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.
4. VISUALLY CHECK GENERATOR WIRING AND LIS- TEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.
5. INSPECT DISCHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ”ON”. Check that the discharge warning light comes on.
(b) Start the engine. Check that the light goes off.
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CH−4
−
CHARGING CHARGING SYSTEM
1996 LAND CRUISER (RM451U)
If the light does not operate as specified, troubleshoot the dis-
charge warning light circuit.
6. INSPECT CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit as per the manufacturer’s instructions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:
Disconnect the wire from terminal B of the generator
and connect it to the negative ( −) lead of the amme-
ter.
Connect the positive (+) lead of the ammeter to ter-
minal B of the generator.
Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.
Ground the negative ( −) lead of the voltmeter.
(b) Check the charging circuit as follows:
With the engine running from idle to 2,000 rpm, check the
reading on the ammeter and voltmeter.
Standard amperage 10 A or less
Standard voltage:
at 25° C ’(77°F)14.0 − 15.0 V
at 115°C ’(239° F)13.5 − 14.3 V
If the voltmeter reading is more than standard voltage, replace
the voltage regulator.
If the voltmeter reading is less than the standard voltage, check
the voltage regulator and generator as follows:
With terminal F grounded, start the engine and
check the voltmeter reading of terminal B.
If the voltmeter reading is more than standard volt-
age, replace the voltage regulator.
If the voltmeter reading is less than standard volt-
age, check the generator.
7. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater blower switch at
”HI”.
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