1986 TOYOTA LAND CRUISER ignition

F02821
Hydraulic Brake
BoosterSub-wire Harness S (SST)
AIR BLEED
FRONT
REAR BR-6
- BRAKEBRAKE FLUID
2142 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(b) Connect the actuator checker (SST) to the hydraulic
brake booster side wire harness via the sub-wire harness
(SST), as shown in the chart below.
SST 09990-00150, 09990-00480
HINT:
Connect the connector with the label of ºAIR BLEEDº attached
to the connector of actuator checker.
(c) Connect the red cable of the checker to the battery posi-
tive (+) terminal and the black cable to the negative (-) ter-
minal.
(d) Turn the ignition switch OFF, depress the brake pedal
more than 40 times.
HINT:
When a pressure in power supply system is released, reaction
force becomes light and stroke becomes longer.
(e) Turn the ignition switch ON, check that the pump stops af-
ter 30 to 40 sec.
NOTICE:
When the pump does not stop, repeat step (d) and (e) again.
(f) With the ignition switch remained ON, depress the brake
pedal more than 20 times.
(g) Observe the procedure in step 4 and bleed the right and
left front wheel caliper.
(h) Holding the brake pedal depressed, bleed the right and
left rear brake caliper.
HINT:
It is not necessary to depress the pedal continuously, as brake
fluid flows out by first depressing.

F04458
BR-8
- BRAKEBRAKE FLUID
2144 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(l) Observe the procedure in step (k) and bleed left rear
brake line.
(m) Disconnect the actuator checker (SST) and sub-wire har-
ness (SST) from the actuator.
SST 09990-00150, 09990-00480
(n) Connect the 2 connectors to the hydraulic brake booster.
(o) Clear the DTC (See page DI-505).
4. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Repeat the above procedure to bleed the brake line for
each wheel.
Torque: 11 N´m (110 kgf´cm, 8 ft´lbf)
5. CHECK FLUID LEVEL IN RESERVOIR
(a) With the ignition switch OFF, depress the brake pedal
more than 40 times.
HINT:
When a pressure in power supply system is released, reaction
force becomes light and stroke becomes longer.
(b) Remove the reservoir cap. Add brake fluid up to the
ºMAXº line.
Fluid: SAE J1703 or FMVSS NO. 116 DOT3

F04470
Brake Pedal Effort Gauge
SST
SST
BR12B-07
BR-40
- BRAKEHYDRAULIC BRAKE BOOSTER
2176 Author
: Date
:
2004 LAND CRUISER (RM1071U)
HYDRAULIC BRAKE BOOSTER
ON-VEHICLE INSPECTION
1. CHECK HYDRAULIC BRAKE BOOSTER FLUID PRES-
SURE CHANGE
(a) Inspect the battery positive voltage.
Battery positive voltage: 10 - 14 V
(b) Turn the ignition switch OFF, depress the brake pedal
more than 40 times.
HINT:
When a pressure in power supply system is released, reaction
force becomes light and stroke becomes longer.
(c) Install LSPV gauge (SST) and brake pedal effort gauge,
bleed air.
SST 09709-29018
(d) When booster does not operate:
Depress the brake pedal and check fluid pressure.
At 245 N (25 kgf, 55 lbf):
Front brake pressureRear brake pressure
2,700 kPa (27.5 kgf/cm2, 391 psi)
or more0 kPa (0 kgf/cm2, 0 psi)
At 343 N (35 kgf, 77 lbf):
Front brake pressureRear brake pressure
3,950 kPa (40 kgf/cm2, 568 psi)
or more0 kPa (0 kgf/cm2, 0 psi)
(e) w/ ABS only, when booster operate:
(1) Turn the ignition switch ON and wait until the pump
motor has stopped.
(2) Depress the brake pedal and check fluid pressure.
At 49 N (5 kgf, 11 lbf):
Front brake pressureRear brake pressure
1,618 - 2,795kPa
(16.5 - 28.5 kgf/cm2, 234 - 405 psi)
1,716 - 2,893 kPa
(17.5 - 29.5 kgf/cm2, 249 - 419 psi)
At 98 N (10 kgf, 22 lbf):
Front brake pressureRear brake pressure
4,413 - 5,624 kPa
(45 - 57 kgf/cm2, 639 - 809 psi)
3,187 - 4,364 kPa
(32.5 - 44.5 kgf/cm2, 462 - 632 psi)
At 147 N (15 kgf, 33 lbf):
Front brake pressureRear brake pressure
7,208 - 8,436 kPa
(73.5 - 85.5 kgf/cm2, 1,043 - 1,214 psi)
4,609 - 5,786 kPa
(47 - 59 kgf/cm2, 667 - 838 psi)
At 196 N (20 kgf, 44 lbf):
Front brake pressureRear brake pressure
9,905 - 11,082 kPa
(101 - 113 kgf/cm2, 1,434 - 1,604 psi)
6,031 - 7,208 kPa
(61.5 - 73.5 kgf/cm2, 873 - 1,044 psi)

I24672
TOYOTA Hand-held Tester
- BRAKEHYDRAULIC BRAKE BOOSTER
BR-41
2177 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(f) w/ ABS & TRAC & VSC ECU only, when booster operate:
(1) Turn the ignition switch ON and wait until the pump
motor has stopped.
(2) Depress the brake pedal and check fluid pressure.
At 49 N (5 kgf, 11 lbf):
Front brake pressureRear brake pressure
1,618 - 2,795kPa
(16.5 - 28.5 kgf/cm2, 234 - 405 psi)
1,716 - 2,893 kPa
(17.5 - 29.5 kgf/cm2, 249 - 419 psi)
At 98 N (10 kgf, 22 lbf):
Front brake pressureRear brake pressure
4,413 - 5,624 kPa
(45 - 57 kgf/cm2, 639 - 809 psi)
4,609 - 5,786 kPa
(47 - 59 kgf/cm2, 668 - 839 psi)
At 147 N (15 kgf, 33 lbf):
Front brake pressureRear brake pressure
7,208 - 8,436 kPa
(73.5 - 85.5 kgf/cm2, 1,043 - 1,214 psi)
7,502 - 8,679 kPa
(76.5 - 88.5 kgf/cm2, 1,088 - 1,259 psi)
At 196 N (20 kgf, 44 lbf):
Front brake pressureRear brake pressure
9,905 - 11,082 kPa
(101 - 113 kgf/cm2, 1,434 - 1,604 psi)
10,346 - 11,523 kPa
(105.5 - 117.5 kgf/cm2,
1,501 - 1,671 psi)
2. w/ ABS only,
In case of using TOYOTA hand-held tester:
INSPECT HYDRAULIC BRAKE BOOSTER OPERA-
TION
(a) Inspect the battery positive voltage.
Battery positive voltage: 10 - 14 V
(b) Turn the ignition switch OFF, depress the brake pedal
more than 40 times.
HINT:
When a pressure in power supply system is released, reaction
force becomes light and stroke becomes longer.
(c) Turn the ignition switch ON, check the pump motor opera-
tion noise.
If the pump motor does not operate, check and replace the wire
harness and pump motor (See page BR-64).
(d) Connect the TOYOTA hand-held tester.
(1) Connect the TOYOTA hand- held tester to the
DLC3.
(2) Turn the ignition switch ON.
(3) Select the ºACTIVE TESTº mode on the TOYOTA
hand-held tester.
HINT:

Please refer to the TOYOTA hand-held tester operator's
manual for further details.

I24672
TOYOTA Hand-held Tester
BR-44
- BRAKEHYDRAULIC BRAKE BOOSTER
2180 Author
: Date
:
2004 LAND CRUISER (RM1071U)

When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly. So rotate
the wheel as slowly as possible.
(j) Lower the vehicle.
(k) Disconnect the TOYOTA hand-held tester.
3. w/ ABS & TRAC & VSC only,
In case of using TOYOTA hand-held tester:
INSPECT HYDRAULIC BRAKE BOOSTER OPERA-
TION
(a) Inspect the battery positive voltage.
Battery positive voltage: 10 - 14 V
(b) Turn the ignition switch OFF, depress the brake pedal
more than 40 times.
HINT:
When a pressure in power supply system is released, reaction
force becomes light and stroke becomes longer.
(c) Check that the brake pedal becomes light to depress.
If the pedal does not become to be light to depress, check and
replace the brake line and hydraulic brake booster.
(d) Turn the ignition switch ON, check the pump motor opera-
tion noise.
If the pump motor does not operate, check and replace the wire
harness and pump motor (See page BR-64).
(e) Connect the TOYOTA hand-held tester.
(1) Connect the TOYOTA hand- held tester to the
DLC3.
(2) Turn the ignition switch ON.
(3) Select the ºACTIVE TESTº mode on the TOYOTA
hand-held tester.
HINT:

Please refer to the TOYOTA hand-held tester operator's
manual for further details.

To protect the solenoids, TOYOTA hand-held tester turns
OFF automatically 2 sec. after every solenoid has been
turned ON.
(f) Inspect the front TRAC & VSC solenoid operation.
(1) Select ºSA1º and ºSA2º on the TOYOTA hand-held
tester.
(2) With ºSA1º and ºSA2º turned ON simultaneously
with the TOYOTA hand-held tester, depress the
brake pedal with stable force and check that the
pedal cannot be depressed.

F04706
F02828
- BRAKEHYDRAULIC BRAKE BOOSTER
BR-49
2185 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(e) Place ºSHEET Gº (SST) of ºFRONTº on actuator checker.
SST 09990-00240
(f) Turn the ignition switch OFF, depress the brake pedal
more than 40 times.
HINT:
When a pressure in power supply system is released, reaction
force becomes light and stroke becomes longer.
(g) Turn the ignition switch ON, check the pump motor opera-
tion noise.
If the pump motor does not operate, check and replace the wire
harness and pump motor (See page BR-64).
(h) Inspect the front switching solenoid operation.
(1) Push in and hold the ºSA1º and ºSA2º switches si-
multaneously, depress strongly and hold the brake
pedal with stable force.
NOTICE:
Do not keep the ºSA1º and ºSA2º pushed down for more
than 10 sec. When operating it continuously, set the inter-
val of more than 20 sec.
(2) Check that the brake pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake
booster.
(3) Release the ºSA1º switch and check that the brake
pedal can be depressed.
If the pedal can not be depressed, replace the hydraulic brake
booster.
(4) Release the ºSA2º switch and check that the brake
pedal can be depressed.
If the pedal can not be depressed, replace the hydraulic brake
booster.
(i) Inspect the right front solenoid operation.
(1) Turn the selector switch to ºRHº position.
(2) Push and hold in the MAIN push switch and ºSA2º
switch simultaneously depress and hold the brake
pedal with stable force.
NOTICE:
Do not keep the MAIN push switch and ºSA2º switch
pushed down for more than 10 sec. When operating it con-
tinuously, set the interval of more than 20 sec.

F02829
F02831
- BRAKEHYDRAULIC BRAKE BOOSTER
BR-51
2187 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(6) Depress and hold the brake pedal with stable force,
push and hold in MAIN push switch.
NOTICE:
Do not keep the MAIN push switch pushed down for more
than 10 sec. When operating it continuously, set the inter-
val of more than 20 sec.
(7) Check that the brake pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake
booster.
(8) Release the MAIN push switch, and check that the
brake pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(9) Release the brake pedal.
(k) Turn the ignition switch OFF, then reconnect the connec-
tor of sub- wire harness from the one with label of
ºFRONTº to ºREARº.
(l) Place ºSHEET Gº of ºREARº on the actuator checker.
(m) Jack up and support the vehicle.
(n) Start the engine and run it at idle.
(o) Inspect the rear solenoid operation.
(1) Turn the selector switch to ºRHº position.
(2) Depress the brake pedal several times and release
the pedal when the pump begins rotating. Wait until
the pump stops.
(3) Turn the ignition switch OFF.
(4) Depress the brake pedal with a force of 343 N (35
kgf, 77 lbf), record the fluid surface in the reservoir
tank of the hydraulic brake booster.
(5) Press the MAIN push switch for 10 sec., and check
that the fluid surface in the reservoir tank of the hy-
draulic brake booster dose not rise up at this time.
If the fluid surface level rises up, replace the hydraulic brake
booster.
NOTICE:
Do not press MAIN push switch for more than 10 sec. When
operating the switch continuously, do it an interval of more
than 20 sec.
(6) Release the brake pedal and check that brake ped-
al is not hard to depress.
If pedal is hard to depress, replace the hydraulic brake booster.
(7) Start the engine and run it at idle.
(8) Depress the brake pedal.
(9) Release the parking brake lever and shift the shift
lever to ºLº position.
(10) Once, release the brake pedal. After depressing the
brake pedal with stable force, then push and hold
MAIN push switch.

F04706
F02828
- BRAKEHYDRAULIC BRAKE BOOSTER
BR-53
2189 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(e) Place ºSHEET Gº (SST) of ºFRONTº on actuator checker.
SST 09990-00240
(f) Turn the ignition switch OFF, depress the brake pedal
more than 40 times.
HINT:
When a pressure in power supply system is released, reaction
force becomes light and stroke becomes longer.
(g) Check that the brake pedal becomes light to depress.
If the pedal does not become to be light to depress, check and
replace the brake line and hydraulic brake booster.
(h) Turn the ignition switch ON, check the pump motor opera-
tion noise.
If the pump motor does not operate, check and replace the wire
harness and pump motor (See page BR-64).
(i) Inspect the front TRAC & VSC solenoid operation.
(1) Push in and hold the ºSA1º and ºSA2º switches si-
multaneously, depress strongly and hold the brake
pedal with stable force.
NOTICE:
Do not keep the ºSA1º and ºSA2º pushed down for more
than 10 sec. When operating it continuously, set the inter-
val of more than 20 sec.
(2) Check that the brake pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake
booster.
(3) Release the ºSA1º switch and check that the brake
pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(4) Release the ºSA2º switch and check that the brake
pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(j) Inspect the right front ABS solenoid operation.
(1) Turn the selector switch to ºRHº position.
(2) Push and hold in the MAIN push switch and ºSA2º
switch simultaneously, depress and hold the brake
pedal with stable force.
NOTICE:
Do not keep the MAIN push switch and ºSA2º switch
pushed down for more than 10 sec. When operating it con-
tinuously, set the interval of more than 20 sec.