1996 TOYOTA LAND CRUISER brake system

BR1D6−01
BR−38
−
BRAKE REAR BRAKE CALIPER
1996 LAND CRUISER (RM451U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−34 ).
HINT:
After installation, fill brake reservoir with brake fluid, bleed brake system\
(See page BR−4) and check for
leaks.
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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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BR1DL−01
−
BRAKE ABS ACTUATOR
BR−59
1996 LAND CRUISER (RM451U)
INSTALLATION
Installation is in the reverse order of removal (See page BR−57 ).
HINT:
After installation, fill the brake reservoir with brake fluid, bleed bra\
ke system (see page BR−4) and check
for leaks.
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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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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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DI5LT−02
Vehicle Brought to Workshop
Customer Problem Analysis
P. DI−189
Check and Clear DTC (Pre−check)
P.
DI−190
Items inside are titles of pages in this manual,
with the page number in the bottom portion. See
the indicated pages for detailed explanations.
Problem Symptom ConfirmationSymptom Simulation
P. IN−18

Symptom
does not occur
Symptom
occurs
DTC Check
P. DI−190
Sensor CheckCircuit Inspection
P. DI−201 − DI−235
DTC Chart
P. DI−196
Malfunction codeProblem Symptoms Table
P. DI−200
Check for Fluid Leakage
P. DI−237
Identification of Problem
Normal code
Repair
Confirmation Test
End
1
2
3
4
5
6 7
8 9
10 11 Step 8: Diagnostic steps permitting the use of the
TOYOTA hand−held tester or TOYOTA
breake −out−box.
DI−188
−
DIAGNOSTICS ANTI−LOCK BRAKE SYSTEM
355
Author: Date:
1996 LAND CRUISER (RM451U)
ANTI−LOCK BRAKE SYSTEM
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoooting in accordance with the procedure on the following pages.
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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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