Brake Pedal (For Hydraulic Brake Booster) Installation

Temporarily install the reinforcement set bolt.

for LHD:

1. Install the hydraulic brake booster (LandCruiser RM00000171Q033X.html).
   

for RHD:

1. Install the hydraulic brake booster (LandCruiser RM00000171Q034X.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.

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.

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

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

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

Connect the stop light switch connector.

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

Turn the ignition switch to ON.

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.

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

Repeat the step above until the air is completely bled, and then 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.

With the brake pedal depressed, loosen the bleeder plug of the rear disc brake cylinder RH, continue to hold the brake pedal and allow brake fluid to be drained from the bleeder plug while the pump motor operates.

HINT:

1. Air is bled as the pump motor operates while the brake pedal is being depressed.
   
2. Be sure to release the brake pedal to stop the motor after approximately 100 seconds of continuous operation.
   
3. As brake fluid is continuously drained while the pump operates, it is not necessary to repeatedly depress the brake pedal.
   

When there is no more air in the brake fluid, tighten the bleeder plug, and then release 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.

Turn the intelligent tester on.

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

NOTICE:

To protect the solenoid from overheating, the solenoid operation stops automatically in 4 seconds, and then the solenoid will not respond to commands for an additional 20 seconds.

Repeatedly depress the brake pedal several times, and then, with the brake pedal depressed, turn FR Line on and bleed air.

HINT:

Air returns to the brake master cylinder reservoir together with the brake fluid and is bled from the brake system.

NOTICE:

1. As it is not possible to visually confirm that air is being bled, repeat this step 10 times.
   
2. Do not loosen the bleeder plug.
   

Turn FL Line on and bleed air using the same procedures as for FR.

Turn RR Line on, loosen the bleeder plug of the rear disc brake cylinder RH and drain brake fluid.

HINT:

1. Do not depress the brake pedal.
   
2. As brake fluid is automatically drained while the pump and solenoid operate, it is not necessary to operate the brake pedal.
   

Repeat the step above until the air is completely bled, and then tighten the bleeder plug.

Torque:

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

Turn RL Line on and bleed air from the bleeder plug of the rear disc brake cylinder LH using the same procedure as for the RH side.

Turn the intelligent tester off and turn the ignition switch off.

Inspect for brake fluid leaks.

Check and adjust the brake fluid level (LandCruiser RM0000012XQ041X.html).

Clear the DTCs (LandCruiser RM0000046KV016X.html).

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 RM000001QHK02LX.html).