Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota 4Runner 1996-2003 Approved SIL techinfo.toyota.com ileaf 02toyrm 02toypdf 02rmsour 2002 024runne br hbb ovi
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BR-26
BRAKE - HYDRAULIC BRAKE BOOSTER
HYDRAULIC BRAKE BOOSTER
Effort Gauge BR123-03
ON-VEHICLE INSPECTION
1. CHECK HYDRAULIC BRAKE BOOSTER FLUID PRES-
SURE CHANGE
SST
(a) Inspect the battery positive voltage.
Battery positive voltage: 10 - 14 V
(b) Turn the ignition switch OFF, depress the brake pedal
more than 40 times.
HINT:
When a pressure in power supply system is released, reaction
SST force becomes heavy and stroke becomes shorter.
(c) Install LSPV gauge (SST) and brake pedal effort gauge,
bleed air.
SST 09709-29018
(d) When booster does not operate:
Depress the brake pedal and check fluid pressure.
At 245 N (25 kgf, 55 lbf):
F13929 Front brake pressure Rear brake pressure
2,100 kPa (21 kgf/cm2, 305 psi)
0 kPa (0 kgf/cm2, 0 psi)
or more
At 343 N (35 kgf, 77 lbf):
Front brake pressure Rear brake pressure
3,100 kPa (32 kgf/cm2, 450 psi)
0 kPa (0 kgf/cm2, 0 psi)
or more
(e) When booster operate:
(1) Turn the ignition switch ON and wait until the pump
motor has stopped.
(2) Depress the brake pedal and check fluid pressure.
At 49 N (5 kgf, 11 lbf):
Front brake pressure Rear brake pressure
1,000 - 2,200 kPa 1,200 - 2,400 kPa
(10.2 - 22.4 kgf/cm2, 145 - 319 psi) (12.2 - 24.4 kgf/cm2, 174 - 348 psi)
At 98 N (10 kgf, 22 lbf):
Front brake pressure Rear brake pressure
3,400 - 4,600 kPa 3,800 - 5,000 kPa
(34.7 - 46.9 kgf/cm2, 493 - 667 psi) (38.7 - 51.0 kgf/cm2, 551 - 725 psi)
At 147 N (15 kgf, 33 lbf):
Front brake pressure Rear brake pressure
5,600 - 6,800 kPa 6,000 - 7,200 kPa
(57.1 - 69.3 kgf/cm2, 812 - 986 psi) (61.2 - 73.4 kgf/cm2, 870 - 1,044 psi)
At 196 N (20 kgf, 44 lbf):
Front brake pressure Rear brake pressure
7,800 - 9,000 kPa 8,200 - 9,400 kPa
(79.5 - 91.8 kgf/cm2, 1,131 - 1,305 psi) (83.6 - 95.9 kgf/cm2, 1,189 - 1,363 psi)
2002 4RUNNER (RM887U)
Author : Date : 1333
BR-27
BRAKE - HYDRAULIC BRAKE BOOSTER
2. In case of using TOYOTA hand-held tester:
INSPECT HYDRAULIC BRAKE BOOSTER OPERA-
TION
(a) Inspect the battery positive voltage.
Battery positive voltage: 10 - 14 V
(b) Turn the ignition switch OFF, depress the brake pedal
more than 40 times.
HINT:
When a pressure in power supply system is released, reaction
force becomes heavy and stroke becomes shorter.
(c) Check that the brake pedal becomes heavy to depress.
If the pedal does not become to be heavy to depress, check and
replace the brake line and hydraulic brake booster.
(d) Turn the ignition switch ON, check the pump motor opera-
tion noise.
If the pump motor does not operate, check and replace the wire
harness and pump motor (See page BR-42 ).
TOYOTA Hand-held Tester
(e) Connect the TOYOTA hand-held tester.
(1) Connect the TOYOTA hand- held tester to the
DLC3.
(2) Turn the ignition switch ON.
(3) Select the "ACTIVE TEST" mode on the TOYOTA
hand-held tester.
HINT:
DLC3 S Please refer to the TOYOTA hand-held tester operator's
F13739 manual for further details.
S To protect the solenoids, TOYOTA hand-held tester turns
OFF automatically 2 sec. after every solenoid has been
turned ON.
(f) Inspect the front TRAC & VSC solenoid operation.
(1) Select "SA1" and "SA2" on the TOYOTA hand-held
tester.
(2) With "SA1" and "SA2" turned ON simultaneously
with the TOYOTA hand-held tester, depress the
brake pedal with stable force and check that the
pedal cannot be depressed.
HINT:
To protect the solenoids, TOYOTA hand-held tester turns OFF
automatically 2 sec. after every solenoid has been turned ON.
If the pedal can be depressed, replace the hydraulic brake
booster.
NOTICE:
When operating it continuously, set the interval of more
than 20 sec.
(3) Once, release the brake pedal.
2002 4RUNNER (RM887U)
Author : Date : 1334
BR-28
BRAKE - HYDRAULIC BRAKE BOOSTER
(4) When the solenoids are OFF, after depressing the
brake pedal again and check that the brake pedal
can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(g) Inspect the front ABS solenoid operation.
(1) Select "SFRH" and "SFLH" on the TOYOTA hand-
held tester.
(2) With "SFRH" and "SFLH" turned ON simultaneously
with the TOYOTA hand-held tester, depress the
brake pedal with stable force and check that the
brake pedal cannot be depressed.
HINT:
To protect the solenoids, the TOYOTA hand-held tester turns
OFF automatically 2 sec. after every solenoid has been turned
ON.
If the pedal can be depressed, replace the hydraulic brake
booster.
(3) Once, release the brake pedal when the solenoids
are OFF, check that the brake pedal can be de-
pressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(4) Once, release the brake pedal. After depressing
and holding the brake pedal with stable force, turn
the SFRH and SFRR solenoids ON simultaneously.
HINT:
To protect the solenoids, the TOYOTA hand-held tester turns
OFF automatically 2 sec. after every solenoid has been turned
ON.
(5) When the solenoids are OFF, check that the brake
pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(6) Once, release the brake pedal. After depressing
and holding the brake pedal with stable force, turn
the SFLH and SFLR solenoids ON simultaneously.
HINT:
To protect the solenoids, the TOYOTA hand-held tester turns
OFF automatically 2 sec. after every solenoid has been turned
ON.
(7) When the solenoids are OFF, check that the brake
pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(h) Jack up and support the vehicle.
(i) Release the parking brake lever.
(j) Shift the transfer shift lever to "N" position and check that
the rear wheels by rotating them by hand.
(k) Inspect the rear TRAC & VSC solenoid operation.
2002 4RUNNER (RM887U)
Author : Date : 1335
BR-29
BRAKE - HYDRAULIC BRAKE BOOSTER
(1) Select the "SA3" and "STR" on the TOYOTA hand-
held tester.
(2) Turn the "SA3" and "STR" ON simultaneously with
the TOYOTA hand-held tester, and check that the
rear wheels does not rotate by hand.
HINT:
When rotating the wheel fast, the fail-safe function is activated
and judgement cannot be made properly. So rotate the wheel
as slowly as possible.
If the rear wheels rotate, replace the hydraulic brake booster.
(3) Turn the "SA3" and "STR" OFF simultaneously, and
check that the rear wheels by rotating them by
hand.
HINT:
S To protect the solenoids, the TOYOTA hand-held tester
turns OFF automatically 2 sec. after every solenoid has
been turned ON.
S When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly. So rotate
the 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.
(l) Inspect the right rear ABS solenoid.
(1) Select the "SA3", "STR" and "SRRH", on the TOYO-
TA hand-held tester.
(2) Turn the "SA3", "STR" and "SRRH" ON simulta-
neously with the TOYOTA hand-held tester, and
check that the right rear wheel by rotating it by hand.
HINT:
S To protect the solenoids, the TOYOTA hand-held tester
turns OFF automatically 2 sec. after every solenoid has
been turned ON.
S When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly. So rotate
the wheel as slowly as possible.
S When solenoid is OFF, the wheel might stop temporarily.
However if the wheel rotates again, the function works
normally.
If the rear wheels stop, replace the hydraulic brake booster.
(3) Turn the "SA3", "STR" and "SRRH" OFF, and check
that the right rear wheel by rotating it by hand.
HINT:
S To protect the solenoids, the TOYOTA hand-held tester
turns OFF automatically 2 sec. after every solenoid has
been turned ON.
S When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly. So rotate
the wheel as slowly as possible.
2002 4RUNNER (RM887U)
Author : Date : 1336
BR-30
BRAKE - HYDRAULIC BRAKE BOOSTER
If the right rear wheel stop, replace the hydraulic brake booster.
(4) Depress the pedal with stable force, then turn the
"SRRH" and "SRRR" ON simultaneously.
(5) When the solenoids are ON, check that the right
rear wheel by rotating it by hand.
(m) Inspect the left rear ABS solenoid operation.
(1) Select the "SA3", "STR" and "SRLH" on the TOYO-
TA hand-held tester.
(2) Turn the "SA3", "STR" and "SRLH" ON with the
TOYOTA hand-held tester, and check that the left
rear wheel by rotating it by hand.
HINT:
When rotating the wheel fast, the fail-safe function is activated
and judgement cannot be made properly. So rotate the wheel
as slowly as possible.
If the rear wheels stop, replace the hydraulic brake booster.
(3) Turn the "SA3", "STR" and "SRLH" OFF and check
that the left rear wheel by rotating it by hand.
HINT:
S To protect the solenoids, the TOYOTA hand-held tester
turns OFF automatically 2 sec. after every solenoid has
been turned ON.
S When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly. So rotate
the wheel as slowly as possible.
S When solenoid is OFF, the wheel might stop temporarily.
However if the wheel rotates again, the function works
normally.
If the left rear wheel stop, replace the hydraulic brake booster.
(4) Depress the pedal with stable force, then turn the
"SRLH" and "SRLR" ON simultaneously.
HINT:
To protect the solenoids, the TOYOTA hand-held tester turns
OFF automatically 2 sec. after every solenoid has been turned
ON.
(5) When the solenoids are ON, check that the left rear
wheel by rotating it by hand.
HINT:
When rotating the wheel fast, the fail-safe function is activated
and judgement cannot be made properly. So rotate the wheel
as slowly as possible.
(n) Lower the vehicle.
(o) Disconnect the TOYOTA hand-held tester.
2002 4RUNNER (RM887U)
Author : Date : 1337
BR-31
BRAKE - HYDRAULIC BRAKE BOOSTER
3. In case of using ABS actuator checker (SST):
INSPECT HYDRAULIC BRAKE BOOSTER OPERA-
TION
(a) Inspect the battery positive voltage.
Battery positive voltage: 10 - 14 V
(b) Disconnect the 2 connectors from hydraulic brake boost-
er.
(c) Connect the ABS actuator checker (SST) to the hydraulic
F13920 brake booster side wire harness via the sub-wire harness
S (SST), as shown in the following chart.
SST 09990-00150, 09990-00480
HINT:
Connect the connector with the label of "FRONT" attached to
the connector of ABS actuator checker.
(d) Connect the red cable of the checker to the battery posi-
tive (+) terminal and the black cable to the negative (-) ter-
minal.
ABS Actuator Checker (SST)
Sub-wire Harness S (SST)
FRONT
REAR
Hydraulic Brake
Booster
AIR BLEED
F02821
(e) Place "SHEET G" (SST) of "FRONT" on ABS actuator
checker.
SST 09990-00240
(f) Turn the ignition switch OFF, depress the brake pedal
more than 40 times.
HINT:
When a pressure in power supply system is released, reaction
force becomes heavy and stroke becomes shorter.
(g) Check that the brake pedal becomes heavy to depress.
2002 4RUNNER (RM887U)
Author : Date : 1338
BR-32
BRAKE - HYDRAULIC BRAKE BOOSTER
If the pedal does not become to be heavy to depress, check and
replace the brake line and hydraulic brake booster.
(h) Turn the ignition switch ON, check the pump motor opera-
tion noise.
If the pump motor does not operate, check and replace the wire
harness and pump motor (See page BR-42 ).
(i) Inspect the front TRAC & VSC solenoid operation.
(1) Push in and hold the "SA1" and "SA2" switches si-
multaneously, depress strongly and hold the brake
pedal with stable force.
NOTICE:
Do not keep the "SA1" and "SA2" pushed down for more
than 10 sec. When operating it continuously, set the inter-
val of more than 20 sec.
F04706 (2) Check that the brake pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake
booster.
(3) Release the "SA1" switch and check that the brake
pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(4) Release the "SA2" switch and check that the brake
pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(j) Inspect the right front ABS solenoid operation.
(1) Turn the selector switch to "RH" position.
(2) Push and hold in the MAIN push switch and "SA2"
switch simultaneously, depress and hold the brake
pedal with stable force.
NOTICE:
Do not keep the MAIN push switch and "SA2" switch
pushed down for more than 10 sec. When operating it con-
F02828 tinuously, set the interval of more than 20 sec.
(3) Check that the brake pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake
booster.
(4) Release the MAIN push switch and "SA2" switch si-
multaneously and check that the brake pedal can
be depressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(5) Release the brake pedal.
2002 4RUNNER (RM887U)
Author : Date : 1339
BR-33
BRAKE - HYDRAULIC BRAKE BOOSTER
(6) Depress and hold the brake pedal with stable force,
push and hold in MAIN push switch.
NOTICE:
Do not keep the MAIN push switch pushed down for more
than 10 sec. When operating it continuously, set the inter-
val of more than 20 sec.
(7) Check that the brake pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake
F02827 booster.
(8) Release the MAIN push switch, and check that the
brake pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(9) Release the brake pedal.
(k) Inspect the left front ABS solenoid operation.
(1) Turn the selector switch to "LH" position.
(2) Push and hold in the MAIN push switch and "SA1"
switch simultaneously, depress and hold the brake
pedal with stable force.
NOTICE:
Do not keep the MAIN push switch and "SA1" switch
pushed down for more than 10 sec. When operating it con-
F04707 tinuously, set the interval of more than 20 sec.
(3) Check that the brake pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake
booster.
(4) Release the MAIN push switch and "SA1" switch si-
multaneously, and check that the brake pedal can
be depressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(5) Release the brake pedal.
(6) Depress and hold the brake pedal with stable force,
push and hold in MAIN push switch.
NOTICE:
Do not keep the MAIN push switch pushed down for more
than 10 sec. When operating it continuously, set the inter-
val of more than 20 sec.
(7) Check that the brake pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake
F02829 booster.
2002 4RUNNER (RM887U)
Author : Date : 1340
BR-34
BRAKE - HYDRAULIC BRAKE BOOSTER
(8) Release the MAIN push switch, and check that the
brake pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake
booster.
(9) Release the brake pedal.
(l) Turn the ignition switch OFF, then reconnect the connec-
tor of sub- wire harness from the one with label of
"FRONT" to "REAR".
(m) Place "SHEET G" of "REAR" on the actuator checker.
(n) Jack up and support the vehicle.
(o) Start the engine and run it at idle.
(p) Inspect the rear TRAC & VSC solenoid.
(1) Release the parking brake lever and shift the shift
lever to "L" position.
(2) Push and hold the "SA3" switch and "STR" switch
simultaneously.
NOTICE:
S Do not keep the "STR" switch pushed down for more
than 10 sec.
F02830 S Do not keep the "SA3" switch pushed down for more
than 5 sec.
S When operating it continuously, set the interval of
more than 20 sec.
(3) Check that the rear wheels stop.
If the rear wheels rotate, replace the hydraulic brake booster.
(4) Release the "SA3" switch and "STR" switch simulta-
neously.
(5) Check that the rear wheels rotate.
If the rear wheels stop, replace the hydraulic brake booster.
(q) Inspect the right rear ABS solenoid.
(1) Turn the selector switch to "RH" position.
(2) Depress the brake pedal several times and release
the brake pedal when the pump begins rotating.
Wait until the pump stops.
(3) Turn the ignition switch OFF.
(4) Depress the brake pedal with a force of 490 N (50
kgf, 110 lbf), record the fluid surface in the reservoir
F02831 tank of the hydraulic brake booster.
2002 4RUNNER (RM887U)
Author : Date : 1341
BR-35
BRAKE - HYDRAULIC BRAKE BOOSTER
(5) Press the MAIN push switch for 10 sec., and check
that the fluid surface in the reservoir tank of the hy-
draulic brake booster does not rise up at this time.
If the fluid surface level rises up, replace the hydraulic brake
booster.
NOTICE:
Do not press MAIN push switch for more than 10 sec. When
operating the switch continuously, do it an interval of more
than 20 sec.
(6) Start the engine and run it at idle.
(7) Depress the brake pedal.
(8) Release the parking brake lever and shift the shift
lever to "L" position.
(9) Once, release the brake pedal. After depressing the
brake pedal with stable force, then push and hold
MAIN push switch.
(10) Check that the right rear wheel rotates.
If the right rear wheel stops, replace the hydraulic brake boost-
er.
(r) Inspect the left rear ABS solenoid.
(1) Turn the selector switch to "LH" position.
(2) Depress the brake pedal several times and release
the brake pedal when the pump begins rotating.
Wait until the pump stops.
(3) Turn the ignition switch OFF.
(4) Depress the brake pedal with a force of 490 N (50
kgf, 110 lbf), record the fluid surface in the reservoir
F02832 tank of the hydraulic brake booster.
(5) Press the MAIN push switch for 10 sec., and check
that the fluid surface in the reservoir tank of the hy-
draulic brake booster does not rise up at this time.
If the fluid surface level rises up, replace the hydraulic brake
booster.
NOTICE:
Do not press MAIN push switch for more than 10 sec. When
operating the switch continuously, do it an interval of more
than 20 sec.
(6) Start the engine and run it at idle.
(7) Depress the brake pedal.
(8) Release the parking brake lever and shift the shift
lever to "L" position.
(9) Once, release the brake pedal. After depressing the
brake pedal with stable force, then push and hold
MAIN push switch.
(10) Check that the left rear wheel rotates.
If the left rear wheel stops, replace the hydraulic brake booster.
(s) Stop the engine and lower the vehicle.
2002 4RUNNER (RM887U)
Author : Date : 1342
BR-36
BRAKE - HYDRAULIC BRAKE BOOSTER
(t) Remove the "SHEET G" (SST) and disconnect the actua-
tor checker (SST) and sub-wire harness S (SST) from the
hydraulic brake booster.
(u) Connect the 2 connectors to the actuator.
(v) Clear the DTC (See page DI-224 ).
2002 4RUNNER (RM887U)
Author : Date : 1343
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