Bleeding the Brake System

BRAKE FLUID BLEEDING

HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air from the system.

NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.






1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3
2. BLEED MASTER CYLINDER

HINT: If the master cylinder was disassembled or if the reservoir becomes empty, bleed the air from the master cylinder.

a. Disconnect the brake lines from the master cylinder.
SST 09023 - 00100






b. Slowly depress the brake pedal and hold it.






c. Block off the outlet plug with your finger, and release the brake pedal.
d. Repeat (b) and (c) 3 or 4 times.






3. BLEED BRAKE LINE
a. Connect the vinyl tube to the caliper.
b. Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down.
SST 09751-36011
c. At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal.
d. Repeat (b) and (c) until all the air in the fluid has been bled out.
Torque: (Bleeder plug) 11 Nm (110 kgf-cm, 8 ft. lbs.)
e. Repeat the procedure on the previous page to bleed the air out of brake line for each wheel.
4. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3

LOAD SENSING PROPORTIONING AND BY-PASS VALVE ON-VEHICLE INSPECTION






1. SET REAR AXLE LOAD
Rear axle load (includes vehicle weight):
Standard cab: 950 kg (2,094 lb)
Access cab:
5VZ-FE engine: 1,000 kg (2,205 lb)
2UZ-FE engine: 1,050 kg (2,315 lb)






2. INSTALL LSPV GAUGE (SST) AND BLEED AIR
SST 09700-29018






3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf-cm, 2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE
Rear brake pressure: 5,110 + 490 kPa (52.1 + 5 kgf/cm2, 741 + 71 psi)

HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure after holding the specified fluid pressure for 2 seconds. If the brake pressure is incorrect, adjust the fluid pressure.






4. IF NECESSARY, ADJUST FLUID PRESSURE
a. Loosen the lock nut.
b. Adjust the length of the shackle No. 2.
Low pressure: Lengthen A
High pressure: Shorten A
Initial set: 120 mm (4.72 inch)
Adjustment range: 112 - 128 mm (4.41 - 5.04 inch)

HINT: One turn of the nut changes the fluid pressure as shown in the following specification.

7.4 kPa (0.76 kgf/cm, 11 psi)
c. Torque the lock nut.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)






d. If the pressure cannot be adjusted by the shackle No. 2, raise or lower the valve body.
Low pressure-Lower body
High pressure-Raise body
e. Torque the nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
f. Adjust the length of the shackle No. 2 again.
If it cannot be adjusted, inspect the valve body.






5. IF NECESSARY, CHECK VALVE BODY
a. Assemble the valve body in the uppermost position.

HINT: When the brakes are applied, the piston will move down about 0.8 mm (0.03 inch). Even at this time, the piston should not make contact with the load sensing spring or move it.











b. In this position, check the rear brake pressure.
If the measured value is not within the standard, replace the valve body.