1996 TOYOTA LAND CRUISER Vacuum system

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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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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P22417
Exhaust
Gas
Intake Air
Chamber EGR
Valve
VSV
EGR
Vacuum
Modulator
ECM
Throttle
valve
P22426
BR
From Battery R/B No.2
R−Y
2
222
2
2
Y−R
EFI Main
Y−R
1
2
43
REA2
EZ1
EB12 7
VSV for EGR 21
YYL
−W
EZ14
EGR Gas T emp.
Sensor
21
G−Y
BR−BE7 E4
E4
E5 3
22
19
9
THG
E1
EGR
E2 5V
MRLY
ECM
R
EB
EFI
1
Relay
B+
E01
−
DIAGNOSTICS ENGINE
DI−69
1996 LAND CRUISER (RM451U)
DTC P0401 Exhaust Gas Recirculation Flow Insufficient
Detected
CIRCUIT DESCRIPTION
The EGR system recirculates exhaust gas, which is controlled to the proper \
quantity to suit the driving condi-
tions, into the intake air mixture to slow down combustion, reduce the combust\
ion temp. and reduce NOx
emissions. The amount of EGR is regulated by the EGR vacuum modulator ac\
cording to the engine load.
If even one of the following conditions is fulfilled, the VSV is
turned ON by a signal from the ECM.
This results in atmospheric air acting on the EGR valve, closing
the EGR valve and shutting off the exhaust gas (EGR cut− off).
Under the following conditions, EGR is cut to maintain driveabil-
ity.
Before the engine is warmed up.
During deceleration (throttle valve closed).
Light engine load (amount of intake air very small).
Engine racing.
DTC No.DTC Detecting ConditionTrouble Area
P0401
After the engine is warmed up and run at 80 km/h (50 mph)
for 3 to 5 minutes, the EGR gas temperature sensor value
does not exceed 38° C (100.4°F) above the ambient air tem-
perature. (2 trip detection logic) EGR valve stuck closed
 Short in VSV circuit for EGR
 Open in EGR gas temp. sensor circuit
 EGR hose disconnected
 ECM
WIRING DIAGRAM
DI5PK−02
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A00170
System : ON
System : OFF Air
GE
Air GE
P22963
P22964
−
DIAGNOSTICS ENGINE
DI−73
1996 LAND CRUISER (RM451U)
5 Check the VSV for EGR.
PREPARATION:
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand−held tester to the DLC3.
(c) Turn ignition switch ON and TOYOTA hand −held tester
main switch ON.
(d) Select the ACTIVE TEST mode on the TOYOTA hand −
held tester.
CHECK:
Check operation of VSV, when it is operated by the TOYOTA
hand −held tester.
OK:
EGR system is ON:
Air does not flow from pipe G to pipe E.
EGR system is OFF:
Air from pipe G is flowing out through pipe E.
OK Go to step 7.
NG
6 Check operation of the VSV for EGR (See page SF−60).
NG Replace VSV for EGR.
OK
Check for open in harness and connector be-
tween VSV and ECM (See page IN−28).
7 Check EGR vacuum modulator (See page EC−11 ).
NG Repair or replace.
OK
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DI−80
−
DIAGNOSTICS ENGINE
1996 LAND CRUISER (RM451U)
DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected
CIRCUIT DESCRIPTION
Refer to DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) on page DI−69.
DTC No.DTC Detecting ConditionTrouble Area
P0402
EGR gas temp. sensor value is high during EGR cut −off when
engine is cold (Race engine at about 4,000 rpm without load so
that vacuum is applied to port E)
(2 trip detection logic) EGR valve stuck open
 EGR VSV open malfunction
 Open in VSV circuit for EGR
 Short in EGR gas temp. sensor circuit
 ECM
EGR valve is always open (2 trip detection logic)
Refer to DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) for the System Check Driving
Pattern and Wiring Diagram.
INSPECTION PROCEDURE
TOYOTA hand −held tester
1 Connect the TOYOTA hand −held tester and read EGR gas temp. value.
PREPARATION:
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand−held tester to the DLC3.
(c) Turn ignition switch ON and push the TOYOTA hand −held tester main switch ON.
CHECK:
Read EGR gas temp. on the TOYOTA hand−held tester.
OK:
EGR gas temp.: 150° C (302°F) or less (Not immediately after driving)
HINT:
If there is a short circuit, the TOYOTA hand−held tester indicates Approx. 157.5°C (315.5°F).
OK Go to step 4.
NG
DI5PL−02
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EC−8
−
EMISSION CONTROL EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
1996 LAND CRUISER (RM451U)
16. REMOVE TVV FROM CYLINDER HEAD
(a) Disconnect the 2 vacuum hoses.
(b) Remove the TVV.
17. INSPECT TVV OPERATION
(a) Cool the TVV to below 45° C (113°F) with cool water.
(b) Check that air flows from pipe J to the air filter.
(c) Heat the TVV to above 64° C (147°F) with hot water.
(d) Check that air flows from pipe J to pipe K.
If operation is not as specified, replace the TVV.
18. REINSTALL TVV
(a) Apply adhesive to 2 or 3 threads of the TVV, and install it.
Adhesive:
Part No. 08833 −00070, THREE BOND 1324
or equivalent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(b) Reconnect 2 vacuum hoses.
19. REFILL WITH ENGINE COOLANT
20. REMOVE INTAKE MANIFOLD STAY
21. REMOVE VCV
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EC0107
Orange PipeBlack Pipe
−
EMISSION CONTROL EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC−9
1996 LAND CRUISER (RM451U)
22. INSPECT VCV
(a) Apply vacuum above 9.3 kPa (70 mmHg, 2.76 in.Hg) to
pipe S.
(b) Blow air into pipe Y and check that air comes out of pipe Z.
(c) Stop the applied vacuum.
(d) Blow air into pipe Y and check that air does not come out
of pipe Z.
If operation is not as specified, replace the VCV.
23. REINSTALL VCV
24. INSTALL INTAKE MANIFOLD STAY Torque: 36 N·m (360 kgf·cm, 26 ft·lbf)
25. REMOVE INTAKE MANIFOLD STAY
26. REMOVE CHECK VALVE
27. INSPECT CHECK VALVE
(a) Check that air flows from the orange pipe to the black pipe.
(b) Check that air does not flow from the black pipe to the
orange pipe.
If operation is not as specified, replace the check valve.
28. REINSTALL CHECK VALVE
HINT:
Reinstall the check valve with the black pipe facing the VCV
side.
29. INSTALL INTAKE MANIFOLD STAY Torque: 36 N·m (360 kgf·cm, 26 ft·lbf)
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