Brake Pedal (For Vacuum Brake Booster) Installation

Temporarily install the set bolt.

for LHD:

1. Install the brake booster assembly (LandCruiser RM000002WLP059X.html).
   

2. Install the brake master cylinder sub-assembly (LandCruiser RM000002WEZ07BX.html).
   

for RHD:

1. Install the brake booster (LandCruiser RM000002WLP059X.html).
   

2. Install the brake master cylinder sub-assembly (LandCruiser RM000002WEZ07BX.html).
   

3. Install the brake actuator assembly (LandCruiser RM0000034UV02VX.html).
   

Install the brake pedal support sub-assembly with the 4 nuts.

Torque:

14 N*m{145 kgf*cm, 10 ft.*lbf}

Install the brake pedal support reinforcement set bolt.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Apply a light coat of lithium soap base glycol grease to the inner surface of the hole on the brake pedal lever.

for LHD:
Set the master cylinder push rod clevis in place, insert the push rod pin from the left side of the vehicle and then install a new clip.

for RHD:
Set the master cylinder push rod clevis in place, insert the push rod pin from the right side of the vehicle and then install a new clip.

Apply a light coat of lithium soap base glycol grease to the inner surface of the hole on the brake pedal support sub-assembly.

Install the brake pedal return spring to the brake pedal support sub-assembly.

Connect the brake pedal load sensing switch connector.

Install the stop light switch assembly (LandCruiser RM000003QJQ01EX_01_0002.html).

Connect the stop light switch connector.

Install the lower No. 1 instrument panel airbag assembly (LandCruiser RM000003YPT039X.html).

Remove the brake master cylinder reservoir filler cap assembly.

Add brake fluid until the fluid level is between the MIN and MAX lines of the reservoir.

Using a union nut wrench, disconnect the 2 brake tube from the master cylinder.

Slowly depress and hold the brake pedal.

Block the tube holes with your fingers, and then release the brake pedal.

Remove your fingers, slowly depress and hold the brake pedal, block the tube holes with your fingers again, and then release the brake pedal. Repeat this step 3 or 4 times.

Using a union nut wrench, connect the 2 brake tubes to the brake master cylinder assembly.

Torque:

20 N*m{199 kgf*cm, 14 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (LandCruiser RM000003YMD00TX.html).

Loosen the bleeder plug of the front brake cylinder RH.

Repeatedly depress the brake pedal and bleed the air from the bleeder plug of the front brake cylinder RH.

NOTICE:

Add fluid as necessary so that the fluid in reservoir does not decrease below the MIN level.

After air is completely bled out, tighten the bleeder plug while depressing the brake pedal.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

Bleed the air from the bleeder plug of the front disc brake cylinder LH using the same procedure as for the RH side.

Loosen the bleeder plug of the rear brake cylinder RH.

Repeatedly depress the brake pedal and bleed the air from the bleeder plug of the rear brake cylinder RH.

NOTICE:

Add fluid as necessary so that the fluid in the reservoir does not decrease below the MIN level.

After the air is completely bled out, tighten the bleeder plug while depressing the brake pedal.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

Bleed the air from the bleeder plug of the rear disc brake cylinder LH using the same procedure as for the RH side.

Turn the ignition switch off and connect the intelligent tester to the DLC3.

Turn the ignition switch to on and turn the tester on.

NOTICE:

Do not start the engine.

Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Air Bleeding.

Select and run "Inhalation" from the Air Bleeding screen on the intelligent tester.

NOTICE:

Follow the prompts on the tester screen to bleed the air for both wheels (front and rear) on the right side.

Loosen the bleeder plug of the right front wheel.*1

Using the intelligent tester, operate the actuator.

HINT:

1. To protect the actuator, the operation stops automatically.
   
2. Make sure the brake pedal is released.
   

Check the intelligent tester screen to confirm that the operation stopped.

Tighten the bleeder plug.*2

Repeat the procedures above from *1 to *2 until the air is completely bled out.

Tighten the bleeder plug.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

Bleed the air for the right rear wheel using the same procedure as for the right front wheel.

Select and run "Decrease" from the Air Bleeding screen on the intelligent tester.

NOTICE:

Follow the prompts on the tester screen to bleed the air for all 4 wheels.

Loosen the bleeder plug of the right front wheel.*3

Using the intelligent tester, operate the actuator and at the same time fully depress and hold the brake pedal.

HINT:

To protect the solenoids, the actuator operation stops automatically in 4 seconds. When operating the actuator repeatedly, follow the prompts on the tester screen and wait for 20 seconds or more between each operation.

NOTICE:

1. At this time, the brake pedal becomes difficult to depress. However, be sure to hold the brake pedal in the fully depressed position until brake fluid comes out of the bleeder plug.
   
2. Do not repeatedly depress the brake pedal, hold the brake pedal in the fully depressed position.
   

Tighten the bleeder plug and release the brake pedal.*4

Repeat the procedures above from *3 to *4 until the air in completely bled out.

Tighten the bleeder plug.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

Bleed the air for the other 3 wheels using the same procedure as for the right front wheel.

Repeat the procedure in which air is bled from the brake line by repeatedly depressing the brake pedal.

NOTICE:

Repeat this step for each wheel until air is completely bled out.

Inspect for brake fluid leaks.

Inspect fluid level in reservoir (LandCruiser RM000000SRG05FX_03_0006.html).

Check and clear the DTCs (LandCruiser RM000000XHV0KEX.html for VSC).

Fill the reservoir with brake fluid.

Brake fluid:

SAE J1703 or FMVSS No. 116 DOT 3

NOTICE:

for Hydraulic Brake Booster:

As brake fluid may overflow when fluid is released from the brake actuator, do not leave the brake fluid can in the reservoir filler opening when adding brake fluid.

Remove the bleeder plug cap of the release cylinder.

Connect a vinyl tube to the bleeder plug.

Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

Repeat the previous 2 steps until all the air in the fluid is completely bled.

Tighten the bleeder plug.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

Install the bleeder plug cap.

Check that all the air has been bled from the clutch line.

Check the fluid level.
If the brake fluid level is low, check for leaks and inspect the disc brake pad. If necessary, refill the reservoir with brake fluid after repair or replacement.

Brake fluid:

SAE J1703 or FMVSS No. 116 DOT 3

Check and adjust brake pedal (LandCruiser RM000002W8X06QX.html).