1996 TOYOTA LAND CRUISER brake light

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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DI5K4−03
Vehicle Brought to Workshop
Customer Problem Analysis
Check DTC and Freezes Frame Data (Pre−check)
Record or Print DTC and Freezed Frame Data
DI−131
Clear DTC and Freezed Frame Data DI−131
Visual Inspection
Setting the Check Mode Diagnosis
DI−131
1
Items insideare titles of pages in this manual, with the
page number indicated in the bottom portion. See the indicated
pages for detailed explanations.
Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3.
If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the
scan tool/TOYOTA hand− held tester, inspect DLC3
DI−131
2
3
4
5
6
symptom does not occur
Problem Symptom Confirmation8
7Symptom Simulation
symptom occurs
DTC Check
DI−131 OK Code
11Preliminary Check
DTC ChartMechanical System Tests
Manual Shifting Test
OK
OK
Chapter 1
(Electronic) Chapter 2
(On−Vehicle)OKChapter 3
(Off
−Vehicle)OK
Matrix Chart of Problem Symptoms
− DI−147
Circuit
InspectionStop Light Signal
 O/D Cancel Signal Check
NG
Parts Inspection
NG
NG NG
Identification of ProblemRepairConfirmation TestEnd
NG
NG
12
NG13
14
15 16
17
9
10
DI−153 − DI−185
18
DI−130
DI−143
DI−131
DI−131
DI−131
DI−147 DI−147
DI−147
P.IN−18
Step 2, 3, 4, 6, 9, 15, 18:
Diagnostic steps permitting the use of the TOYOTA
hand−held tester or TOYOTA brake− out−box.
−
DIAGNOSTICS AUTOMATIC TRANSMISSION
DI−129
296
Author: Date:
1996 LAND CRUISER (RM451U)
AUTOMATIC TRANSMISSION
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following page.
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DI−136
−
DIAGNOSTICS AUTOMATIC TRANSMISSION
1996 LAND CRUISER (RM451U)
If the lock−up is defective:
Lock−up solenoid is stuck.
Lock−up control valve is stuck.
Lock−up signal value is stuck.
(2) In the same way, check the shock and slip at the 1 → 2, 2 →3 and 3 → O/D up−shift.
Evaluation:
If the shock is excessive:
Line pressure is too high.
Accumulator is defective.
Check ball is defective. (3) Run at the D position lock −up or O/D gear and check for abnormal noise and vibration.
HINT:
The check for the cause of abnormal noises and vibration must be made with \
extreme care as it could also
be due to loss of balance in the propeller shaft, differential, torque converter clutch, etc.
(4) While running in the D position, 2nd, 3rd and O/D gears, check to see that the\
possible kick −down
vehicle speed limits for 2 →1, 3 → 2 and O/D →3 kick−downs conform to those indicated on
the automatic shift schedule.
(5) Check for abnormal shock and slip at kick −down.
(6) Check for the lock −up mechanism.
Drive in D position, O/D gear, at a steady speed (lock −up ON) of about 95 km/h (59 mph).
Lightly depress the accelerator pedal and check that the engine RPM does not change
abruptly.
If there is a big jump in engine RPM, there is no lock −up.
(b) 2 position test. Shift into the 2 position and, while driving with the accelerator pedal held \
constantly at the full throttle
valve opening position, push in one of the pattern selectors and check the fo\
llowing points:
HINT:
When the 2nd start switch is on, there is no 1 → 2 up−shift and 2 →1 down−shift.
(1) Check to see that the 1 → 2 up− shift takes place and that the shift point conforms to the automatic
shift schedule.
HINT:
There is no O/D up−shift and lock−up in the 2 position. (2) While running in the 2 position and 2nd ge ar, release the accelerator pedal and check the engine
braking effect.
Evaluation:
If there is no engine braking effect:
2nd coast brake is defective. (3) Check for abnormal noise at acceleration and deceleration, and for shock at up −shift and down −
shift.
(c) L position test. (1) While running in the L position, check to see that there is no up −shift to 2nd gear.
(2) While running in the L position, release the accelerator pedal and check the engine braking ef- fect.
Evaluation:
If there is no engine braking effect:
1stand reverse brake is defective. (3) Check for abnormal noise during acceleration and deceleration.
(d) R position test. Shift into the R position and fully depress the accelerator pedal and ch\
eck for slipping.
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Q07310Control Shaft Lever(b)
(c)
Q07311
Neutral Basic Line
Bolt
Groove
−
DIAGNOSTICS AUTOMATIC TRANSMISSION
DI−139
1996 LAND CRUISER (RM451U)
(3) Return the control shaft lever 2 notches to N posi-
tion.
(4) Set the shift lever to N position.
(5) While holding the shift lever lightly toward the R
position side, adjust the control rod nut.
(6) Tighten the control rod nut.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(7) Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to
D position and reverses when shifting it to the R
position.
(g) Inspec and adjust park/neutral positoin switch. Check that the engine can be started with the shift lever
only in the N or P position, but not in other positions.
If not as stated above, carry out the following adjustment proce-
dure.
(1) Loosen the park/neutral position switch bolt and set
the shift lever to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolt.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) For continuity inspect of the park/neutral position
switch, see page DI−169 .
(h) Check the idle speed. Idle speed:
650 ± 50 rpm (In N position and air conditioner OFF)
7. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed. The object of this test is to check the overall performance of the transmis\
sion and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the that at normal operating ATF temperature 50 − 80°C (122 − 176° F).
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should always be carried out in pairs. One technician should\
observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doin\
g the test.
(1) Chock the 4 wheels.
(2) Connect an OBD II scan tool or TOYOTA hand−held tester to the DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
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DI5LU−01
ABS Check SheetInspector ’sName :
Customer ’s Name Date Vehicle
Brought In Registration Year
Registration No.
Frame No.
Odometer Reading / /
/ /
Date Problem First Occurred
Frequency Problem Occurs / /
ContinuousIntermittent ( times a day)
ABS does not operate.
ABS does not operate efficiently.
ABS Warning Light
Abnormal
Remains ONDoes not Light Up
DTC Check1st Time
2nd Time Normal Code
Malfunction Code (Code )
Normal CodeMalfunction Code (Code )
Symptoms km
miles
−
DIAGNOSTICS ANTI−LOCK BRAKE SYSTEM
DI−189
1996 LAND CRUISER (RM451U)
CUSTOMER PROBLEM ANALYSIS CHECK
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R04751
DI5LV−02
F00006
DLC1Short Pin
F00007
DLC1
E1Tc
DI−190
−
DIAGNOSTICS ANTI−LOCK BRAKE SYSTEM
1996 LAND CRUISER (RM451U)
PRE−CHECK
1. DIAGNOSIS SYSTEM
(a) Check the indicator.
When the ignition switch is turned ON, check that the ABS
warning light goes on for 3 seconds.
HINT:
If the indicator check result is not normal, proceed to trou-
bleshooting for the ABS warning light circuit (See page
DI−230 ).
When the transfer is in L position (center dif ferential lock),
the ABS does not operate and the ABS warning light
stays ON.
(b) Check the DTC. (1) Confirm that the center differential is free.
(2) Disconnect the short pin from the DLC1.
(3) Using SST, connect terminals Tc and E
1 of the
DLC1.
SST 09843−18020
(4) Turn the ignition switch ON.
(5) Read the DTC from the ABS warning light on the combination meter.
HINT:
If no code appears, inspect the diagnostic circuit or ABS
warning light circuit (See page DI−233 or DI−230 ).
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R01346
Normal Code
0.25 sec.
0.25 sec.
2 sec.
ON
OFF
ON
OFF 0.5 sec. 0.5 sec.
Code 11 and 21
4 sec.
1.5 sec.
2.5 sec.
Code 11 Code 21
BR1804
F00006DLC1 Short Pin
−
DIAGNOSTICS ANTI−LOCK BRAKE SYSTEM
DI−191
1996 LAND CRUISER (RM451U)
As an example, the blinking patterns for normal code and
codes 11 and 21 are shown in the illustration.
(6) Code are explained in the code table on page
DI−196 .
(7) After completing the check, disconnect terminals Tc
and E
1, and turn off the display.
If 2 or more malfunctions are indicated at the same time the low-
est numbered DTC will be displayed 1st.
(c) Clear the DTC.
(1) Confirm that the center differential is free.
(2) Using SST, connect terminals Tc and E
1 of the
DLC1 and remove the short pin from the DLC1.
SST 09843−18020
(3) Turn the ignition switch ON.
(4) Clear the DTC stored in ECU by depressing the
brake pedal 8 or more times within 3 seconds.
(5) Check that the warning light shows the normal
code.
(6) Remove the SST from the terminals of the DLC1.
SST 09843−18020
(7) Connect the short pin to the DLC1.
HINT:
Cancellation can also be done by removing the ECU −B fuse,
but in this case, other memory systems will also be cancelled
out.
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