Toyota land cruiser 1998 2007 brake hệ thống thắng xe trên land cruiser đời 1998 2007

HỆ THỐNG THẮNG XE TRÊN LAND CRUISER ĐỜI 1998-2007

TOYOTAHand-heldTester

brake lines is suspected, bleed the air from the system

line of reservoir between Min and Max

2 In case of using TOYOTA hand-held tester:

BLEED HYDRAULIC BRAKE BOOSTER

HINT:

If the hydraulic brake booster has been disassembled, nect the brake line from the hydraulic brake booster or if the res-ervoir becomes empty, bleed the hydraulic brake booster

more than 40 times

HINT:

When a pressure in power supply system is released, reactionforce becomes light and stroke becomes longer

af-ter approx 30 to 40 sec

NOTICE:

When the pump does not stop, repeat step (a) and (b) again.

pedal more than 20 times

left front brake caliper

left rear brake caliper

HINT:

It is not necessary to depress the pedal continuously, as brakefluid flows out by first depressing

hand-held tester to DLC3

BLEED-ING” on the TOYOTA hand-held tester

HINT:

Please refer to the TOYOTA hand-held tester operator’s

hand-held tester, depress the brake pedal and hold it tobleed the right front brake caliper.

in the fluid

hand-held tester, depress the brake pedal and hold it tobleed the left front brake caliper

in the fluid

Bleed rear brake line

hand-held tester, bleed the left and right rear brake per

3 In case of using ABS actuator checker (SST):

BLEED HYDRAULIC BRAKE BOOSTER

HINT:

If the hydraulic brake booster has been disassembled, nect the brake line from the hydraulic brake booster or if the res-ervoir becomes empty, bleed the hydraulic brake booster

booster

-BRAKE BRAKE FLUID

brake booster side wire harness via the sub-wire harness(SST), as shown in the chart below

HINT:

Connect the connector with the label of ”AIR BLEED” attached

to the connector of actuator checker

posi-tive (+) terminal and the black cable to the negaposi-tive (-) minal

more than 40 times

When the pump does not stop, repeat step (d) and (e) again.

pedal more than 20 times

left front wheel caliper

left rear brake caliper

HINT:

the ”FRONT RH” position.

brake pedal and hold it to bleed the right front brakecaliper

NOTICE:

Do not keep the MAIN switch pushed in for more than 10 sec When operating it continuously, set the interval of more than 20 sec.

in the fluid

the ”FRONT LH” position

brake pedal and hold it to bleed the left front brakecaliper

NOTICE:

Do not keep the MAIN switch pushed in for more than 10 sec When operating it continuously, set the interval of more than 20 sec.

in the fluid

Bleed right rear brake line

switches, bleed the right rear brake caliper

NOTICE:

Do not keep the MAIN switch pushed in for more than 10 sec When operating it continuously, set the interval of

BR-8

-BRAKE BRAKE FLUID

brake line

har-ness (SST) from the actuator

bleeder plug with the pedal held down

bleeder plug, then release the brake pedal

out

each wheel

Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)

5 CHECK FLUID LEVEL IN RESERVOIR

more than 40 times

F08309

Pedal PadBrake Pedal

Return Spring

Cowl Side Trim

Lower No 1 Panel

Install the brake pedal assembly and temporarily fasten the 2bolts.

(See page BR-67 )

4 TIGHTEN 2 BOLTS OF BRAKE PEDAL BRACKET Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR-4 )

(See page BR-9 )

Pedal height from asphalt sheet:

183.7 - 193.7 mm (7.232 - 7.626 in.)

If the pedal height is incorrect, adjust it

2 IF NECESSARY, ADJUST PEDAL HEIGHT

LH lower panel and No 2 heater to register duct (See

No 2 and No 3 covers, steering wheel, combinationswitch, column upper and lower covers, steering column

SR-29)

light switch

Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)

the stop light switch to lock the nut in the position wherethe stop light goes off

- 0.59 in.), check that stop light lights up

col-umn upper and lower covers, combination switch, ing wheel, steering wheel lower No 2 and No 3 covers,

lower No 1 panel, cowl side trim and scuff plate (See

40 times until there is no more pressure left in the booster

resis-tance begins to be felt, then measure the disresis-tance, asshown

Pedal freeplay: 1.0 - 6.0 mm (0.039 - 0.236 in.)

Pedal Reserve Distance

BR-10

-BRAKE BRAKE PEDAL

If incorrect, check the stop light switch clearance If the ance is OK, then troubleshoot the brake system

clear-Stop light switch clearance: 1.9 mm (0.075 in.)

HINT:

The freeplay to the 1st point of resistance is due to the play tween the clevis, pedal link and pin It is 1.0 - 6.0 mm (0.039 -0.236 in.) on the pedal

With the engine running, depress the pedal and measurethe pedal reserve distance, as shown

Pedal reserve distance at 490 N (50 kgf, 110.1 lbf): More than 116 mm (4.57 in.)

If the reserve distance is incorrect, troubleshoot the brake tem

It is very important to keep parts and the area clean when repairing the brake system.

If the vehicle is equipped with a mobile communication system, refer to the precautions in the

IN section.

N·m (kgf·cm, ft·lbf) : Specified torque

Lithium soap base glycol grease

Disc brake grease

Anti-squeal Shim

123 (1,250, 90)

x5

Outer BearingThrust Washer

Oil seal

BR-18

-BRAKE FRONT BRAKE CALIPER

FRONT BRAKE CALIPER

COMPONENTS

Using a screwdriver, remove the 4 cylinder boot set rings and

4 cylinder boots from the caliper

one side

from the cylinder

CAUTION:

Do not place your fingers in front of the piston when using compressed air.

Using a screwdriver, remove the 4 piston seals from the der

Using a ruler, measure the pad lining thickness.

Standard thickness: 11.5 mm (0.453 in.) Minimum thickness: 1.0 mm (0.039 in.)

Replace the pad if the pad’s thickness is at the minimum or if

it shows signs of uneven wear

Using a micrometer, measure the disc thickness

Standard thickness: 32.0 mm (1.260 in.) Minimum thickness: 30.0 mm (1.181 in.)

Replace the disc if the thickness of the disc is at the minimumthickness or less Replace the disc or grind it on a lathe if it isscored or is worn unevenly

Using a dial indicator, measure the disc runout at a position 10

mm (0.39 in.) from the out side edge

Maximum disc runout: 0.07 mm (0.0028 in.)

If the bearing play and axle hub runout are not abnormal, place the disc or grind it on an ”On-Car brake lathe”

re-HINT:

Before measuring the runout, confirm that the front bearing

4 IF NECESSARY, REPLACE DISC

Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)

BR0JO-06 -

BRAKE FRONT BRAKE CALIPER

BR-23

INSTALLATION

Installation is in the reverse order of removal (See page BR-19 ).

HINT:

then disconnect the flexible hose from the caliper.

4 REMOVE CLIP AND 2 PINS

5 REMOVE 2 PAD RETAINER CLIPS

RETAINERS

Disc brake grease

2 INSPECT PAD LINING THICKNESS

Check the pad thickness through the caliper inspection holeand replace the pads if they are not within the specification

Minimum thickness: 1.0 mm (0.039 in.)

3 REMOVE CLIP AND 2 PINS

4 REMOVE 2 PAD RETAINER CLIPS

RETAINERS NOTICE:

The pad retainer clip and clip can be used again provided that they have sufficient rebound, no deformation, cracks

or wear, and have had all rust, dirt and foreign particles cleaned off.

6 CHECK DISC THICKNESS AND DISC RUNOUT (See page BR-21 )

NOTICE:

When replacing worn pads, the anti-squeal shims must be replaced together with the pad.

equiva-lent

HINT:

is a possibility of opposite piston fling out

and push in the piston while letting some brake fluid cape

11 DEPRESS BRAKE PEDAL SEVERAL TIMES

12 CHECK THAT FLUID LEVEL IS AT MAX LINE

-BRAKE FRONT SPEED SENSOR

FRONT SPEED SENSOR

COMPONENTS

REMOVE SPEED SENSOR

sen-sor harness from the steering knuckle and upper arm

Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

sensor from the steering knuckle

Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

Cowl Side Trim

Lower No 1 Panel

15 (155, 11)

15 (155, 11)

Pin

Clip

w/ ABS & BA &

TRAC & VSC Only:

Front Door Scuff Plate

w/ ABS & BA & TRAC & VSC Only:

Master Cylinder Pressure Sensor Connector

Reservoir Set Screw

Accumulator Bracket

No 1 PumpBracketActuator No 1 Tube

Accumulator

O-ringSilencer Tube

Grommet

Piston

Cylinder Boot

ClevisReservoir Cap

No 2 PumpBracket

SleeveCollar

Booster Pump Motor

-BRAKE HYDRAULIC BRAKE BOOSTER

DISASSEMBLY

1 PLACE HYDRAULIC BRAKE BOOSTER IN VISE

Using SST, set the hydraulic brake booster in vise

09950-60010 (09951-00180, 09951-00190)

2 REMOVE FLUID LEVEL WARNING SWITCH TOR CLAMP

Torque: 1.7 N·m (17.5 kgf·cm, 15.2 in.·lbf)

Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)

Using SST, remove the brake actuator tube No 1

Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)

and pump

7 ABS & BA & TRAC & VSC only:

REMOVE MASTER CYLINDER PRESSURE SENSOR

Using 30 mm deeper socket wrench and remove the oil sure sensor

pres-Torque: 81 N·m (830 kgf·cm, 60 ft·lbf) NOTICE:

If replacing the master cylinder pressuer sensor, since the

equivalent to push the snap ring from the hole in the bodythen remove it with another screwdriver.

Torque: 54 N·m (550 kgf·cm, 36 ft·lbf)

F04504

A: 20 mm (0.791 in.)B: 30 mm (1.18 in.)

-BRAKE HYDRAULIC BRAKE BOOSTER

BR-65

DISPOSAL

DISPOSAL METHOD OF ACCUMULATOR

CAUTION:

Do not cut at a place except a stretch.

dis-charges

1 of pump motor, and the negative (-) lead to terminal 2.

BR0KD-04 -

BRAKE HYDRAULIC BRAKE BOOSTER

BR-67

INSTALLATION

Installation is in the reverse order of removal (See page BR-60 ).

HINT:

-BRAKE HYDRAULIC BRAKE BOOSTER

HYDRAULIC BRAKE BOOSTER

ON-VEHICLE INSPECTION

1 CHECK HYDRAULIC BRAKE BOOSTER FLUID SURE CHANGE

Battery positive voltage: 10 - 14 V

more than 40 times

Depress the brake pedal and check fluid pressure

motor has stopped

TOYOTA Hand-held Tester

-BRAKE HYDRAULIC BRAKE BOOSTER

BR-41

motor has stopped

2 w/ ABS only,

In case of using TOYOTA hand-held tester:

INSPECT HYDRAULIC BRAKE BOOSTER TION

Battery positive voltage: 10 - 14 V

more than 40 times

If the pump motor does not operate, check and replace the wire

DLC3

hand-held tester

HINT:

-BRAKE HYDRAULIC BRAKE BOOSTER

OFF automatically for 2 sec after every solenoid hasbeen turned ON

tester

with the TOYOTA hand-held tester, depress thebrake pedal with stable force and check that thepedal cannot be depressed

HINT:

To protect the solenoids, TOYOTA hand-held tester turns OFFautomatically for 2 sec after every solenoid has been turnedON

If the pedal can be depressed, replace the hydraulic brakebooster

NOTICE:

When operating it continuously, set the interval of more than 20 sec.

brake pedal again and check that the brake pedalcan be depressed

If the pedal cannot be depressed, replace the hydraulic brakebooster

hand-held tester

with the TOYOTA hand-held tester, depress thebrake pedal with stable force and check that thebrake pedal cannot be depressed

HINT:

To protect the solenoids, TOYOTA hand-held tester turns OFFautomatically for 2 sec after every solenoid has been turnedON

If the pedal can be depressed, replace the hydraulic brakebooster

are OFF, check that the brake pedal can be pressed

de-If the pedal cannot be depressed, replace the hydraulic brakebooster

and holding the brake pedal with stable force, turnthe SFRH and SFRR solenoids ON simultaneously.HINT:

-BRAKE HYDRAULIC BRAKE BOOSTER

BR-43

pedal can be depressed

If the pedal cannot be depressed, replace the hydraulic brakebooster

and holding the brake pedal with stable force, turnthe SFLH and SFLR solenoids ON simultaneously.HINT:

To protect the solenoids, TOYOTA hand-held tester turns OFFautomatically for 2 sec after every solenoid has been turnedON

are OFF, check that the brake pedal can be pressed

de-If the pedal cannot be depressed, replace the hydraulic brakebooster

tester and depress the brake pedal with stableforce, and rotate the right rear wheel by hand andcheck it

HINT:

OFF automatically for 2 sec after every solenoid hasbeen turned ON

acti-vated and judgement cannot be made properly So rotatethe wheel as slowly as possible

However if the wheel rotates again, the function worksnormally

If the rear wheels stop, replace the hydraulic brake booster

OFF, after depressing the brake pedal with stableforce and stop the rear right wheel by hand andcheck it

If the rear wheel rotate, replace the hydraulic brake booster

”SRH” and ”SRR” ON simultaneously

by hand and check it

HINT:

OFF automatically for 2 sec after every solenoid has

TOYOTA Hand-held Tester

BR-44

-BRAKE HYDRAULIC BRAKE BOOSTER

acti-vated and judgement cannot be made properly So rotatethe wheel as slowly as possible

3 w/ ABS & TRAC & VSC only,

In case of using TOYOTA hand-held tester:

INSPECT HYDRAULIC BRAKE BOOSTER TION

Battery positive voltage: 10 - 14 V

more than 40 times

HINT:

When a pressure in power supply system is released, reactionforce becomes light and stroke becomes longer

If the pedal does not become to be light to depress, check andreplace the brake line and hydraulic brake booster

opera-tion noise

If the pump motor does not operate, check and replace the wire

DLC3

hand-held tester

HINT:

manual for further details

OFF automatically 2 sec after every solenoid has beenturned ON

tester

with the TOYOTA hand-held tester, depress the

brake pedal again and check that the brake pedalcan be depressed.

If the pedal cannot be depressed, replace the hydraulic brakebooster

hand-held tester

with the TOYOTA hand-held tester, depress thebrake pedal with stable force and check that thebrake pedal cannot be depressed

are OFF, check that the brake pedal can be pressed

de-If the pedal cannot be depressed, replace the hydraulic brakebooster

and holding the brake pedal with stable force, turnthe SFRH and SFRR solenoids ON simultaneously.HINT:

To protect the solenoids, TOYOTA hand-held tester turns OFFautomatically 2 sec after every solenoid has been turned ON

pedal can be depressed

If the pedal cannot be depressed, replace the hydraulic brakebooster

and holding the brake pedal with stable force, turnthe SFLH and SFLR solenoids ON simultaneously.HINT:

To protect the solenoids, TOYOTA hand-held tester turns OFFautomatically 2 sec after every solenoid has been turned ON

-BRAKE HYDRAULIC BRAKE BOOSTER

pedal can be depressed

If the pedal cannot be depressed, replace the hydraulic brakebooster

the rear wheels by rotating them by hand

hand-held tester

the TOYOTA hand-held tester, and check that therear wheel does not rotate by hand

HINT:

When rotating the wheel fast, the fail-safe function is activatedand judgement cannot be made properly So rotate the wheel

as slowly as possible

If the rear wheels rotate, replace the hydraulic brake booster

check that the rear wheels by rotating them byhand

HINT:

OFF automatically 2 sec after every solenoid has beenturned ON

acti-vated and judgement cannot be made properly So rotatethe wheel as slowly as possible

NOTICE:

When operating it continuously, set the interval of more than 20 sec.

If the rear wheels stop, replace the hydraulic brake booster

TOYO-TA hand-held tester

simulta-neously with the TOYOTA hand-held tester, andcheck that the right rear wheel by rotating it by hand.HINT:

OFF automatically 2 sec after every solenoid has beenturned ON

acti-vated and judgement cannot be made properly So rotatethe wheel as slowly as possible

-BRAKE HYDRAULIC BRAKE BOOSTER

BR-47

that the right rear wheel by rotating it by hand.HINT:

OFF automatically 2 sec after every solenoid has beenturned ON

acti-vated and judgement cannot be made properly So rotatethe wheel as slowly as possible

If the right rear wheel stop, replace the hydraulic brake booster

”SRRH” and ”SRRR” ON simultaneously

rear wheel by rotating it by hand

TOYO-TA hand-held tester

TOYO-TA hand-held tester, and check that the left rearwheel by rotating it by hand

HINT:

When rotating the wheel fast, the fail-safe function is activatedand judgement cannot be made properly So rotate the wheel

as slowly as possible

If the rear wheels stop, replace the hydraulic brake booster

that the left rear wheel by rotating it by hand.HINT:

OFF automatically 2 sec after every solenoid has beenturned ON

acti-vated and judgement cannot be made properly So rotatethe wheel as slowly as possible

However if the wheel rotates again, the function worksnormally

If the left rear wheel stop, replace the hydraulic brake booster

”SRLH” and ”SRLR” ON simultaneously

HINT:

To protect the solenoids, TOYOTA hand-held tester turns OFFautomatically 2 sec after every solenoid has been turned ON

wheel by rotating it by hand

HINT:

When rotating the wheel fast, the fail-safe function is activated

-BRAKE HYDRAULIC BRAKE BOOSTER

4 w/ ABS only,

In case of using ABS actuator checker (SST):

INSPECT HYDRAULIC BRAKE BOOSTER TION

Battery positive voltage: 10 - 14 V

boost-er

brake booster side wire harness via the sub-wire harness(SST), as shown in the following chart

HINT:

Connect the connector with the label of ”FRONT” attached tothe connector of actuator checker

posi-tive (+) terminal and the black cable to the negaposi-tive (-) minal