Land Cruiser 70 Manual
Land Cruiser 70 Manual
Land Cruiser 70 Manual
II .................................................................................................. 2
Manual Information ....................................................................................................... 2
Vehicle Details .............................................................................................................. 2
Installation of SIBS
II Brakes ...................................................................................... 3
Safety Labels ................................................................................................................ 3
Storage of SIBS
II Brakes ........................................................................................... 3
1. General..................................................................................................................... 4
1.1. Introduction ......................................................................................................... 4
1.2. More About SIBS
II ............................................................................................ 5
2. Installation Tools Required .................................................................................... 6
2.1. Special Tools Rear SIBS
II ............................................................................. 6
3. Pre-Installation Inspection ..................................................................................... 8
3.1. Recommendations .............................................................................................. 8
3.2. Your SIBS
II Kit ................................................................................................. 8
4. Pre-Installation Checks .......................................................................................... 9
4.1. Preparation ......................................................................................................... 9
4.2. Installation and Setup Sequence ........................................................................ 9
4.3. Rear Brake Assy; SIBS
Brakes .................................................................................... 64
9. Safety ..................................................................................................................... 65
9.1. Pre-Service Inspection ...................................................................................... 65
10. Servicing ............................................................................................................ 67
10.1. Correct fluid use for the SIBS
Fluid ............................................................ 68
10.3. Changing the SIBS
Fluid .............................................................................. 68
SIBS
II) for the TOYOTA LANDCRUISER 70 series (post March 2007 models). The manual
details how to install and configure the SIBS
II
The SIBS
II system on Toyota Land Cruiser 70 Series (post March 2007 models). All
information contained in this manual is based on the latest SIBS
product information
available at the time of publication. Advanced Braking Pty Ltd reserves the right to
change the manual at any time without prior notice.
This manual should be read in conjunction with the appropriate Toyota manual for
further information on removal of any standard Toyota components.
Vehicle Details
The 70 Series Toyota Land Cruiser vehicles are available in the following variants:
71 Series (Short Wheel Base)
76 Series (4 door Wagon)
78 Series (Troop Carrier)
79 Series (Cab Chassis or Utility).
Two engines are available:
1VD (V8 Turbo Diesel) for Australian markets
1HZ (I6 Diesel) for remaining markets.
Check the vehicle model number (located on the under bonnet VIN plate) to ascertain
full specification of your vehicle. Vehicles sold in Australia have a Q within the model
number (e.g. VDJ79R-TJMRSQ3). Please note that G spec vehicles are not covered in
the scope of this manual due to the different rear axle configuration.
3
mportant nformation
8B8
II Brakes
SIBS II
must be installed by a qualified tradesperson who has been trained for this
purpose by ABT; this is a requirement for ADR compliance of the vehicle. Specific
experience in the installation of braking systems and electromechanical experience is
also a prerequisite for the installation of SIBS II
.
Safety Labels
Advanced Braking Pty Ltd provides customers with Safety Labels that are required to be
placed prominently in any vehicle fitted with SIBS
II Brakes
All SIBS
units are protected against corrosion and may be stored for up to 3 months
before installation. Plugs are fitted in the brake fluid inlet ports of housings and should
be kept in place during storage and shipment to prevent corrosion.
Any SIBS
that remain unfitted for a period longer than 3 months must be inspected
thoroughly before use. Please remove all silica gel sachets from the brake assemblies
prior to installation.
HZJ 79
Series
VDJ 78
Series
VDJ 79
Series
81
4
8B8
II brake is a fully enclosed, single rotor, high-speed wet disc brake providing
greater safety, reliability and durability than a conventional dry brake in a compact
package. The grooves in the SIBS
pads are orientated to efficiently remove the oil from
the pad-rotor interface and maximise the available friction.
The SIBS
II brake.
Figure 2: Exploded view of SIBS
II Rear Brake
81
81
5
1. General
8B8
II
Your SIBS
II brake set comprises of two individual rear brakes. Each fully sealed brake
consists of a sliding rotor, specially designed braking pads and a quantity of specifically
formulated SIBS
pistons
are applied by disc springs and released by hydraulic pressure from a standalone
electro-hydraulic pump unit. This system is referred to as an Electronically Modulated,
Mechanically Applied (EMMA
II
The following equipment is required for the installation of a full SIBS brake set together
with routine maintenance and adjustment of the braking system.
Figure 5: Dowel/ Guide Pins
Fabricate from M10 x 1.5 studding
Only required when stripping the brake.
Figure 6: Bearing Installation Tools
Toyota P/N; 09608-35014
Figure 7: Rear Axle Bearing Lock Nut Wrench
Toyota P/N; 09509-25011
Figure 8: LSPV Gauge Set
Toyota P/N; 09709-29018
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7
3. nspection
8B8
II brake units from their packaging and carefully check that the kit
contains all parts listed on the delivery document. Familiarise yourself with each part
and understand where it should be fitted. Keep parts and work area clean at all times.
WARNING:
The internal components of a SIBS
Brake Clean.
3.1. Recommendations
Inspect each brake and supplied items against the packing list included in
the shipment.
Ensure all items are included as described.
Ensure all components remain in their original packaging until required for
assembly.
Ensure vehicle stub shafts are clean, free from rust, dirt and corrosion. It is
recommended that repair sleeves are fitted to the axle seal running faces.
Thoroughly read this manual and familiarise yourself with the tools required;
familiarise yourself also with the parts of the brake and the process required
to fit each brake and the control system.
Ensure complete cleanliness of all brake components and the working
environment around the vehicle.
Ensure no contamination of the brake assemblies occurs during installation.
Follow the points in the manual as described, if you are not sure
check the manual or contact ABT Customer Service.
Ensure a lifting table or hoist is used to move and position the brakes.
3.2. Your SIBS
II Kit
Figure 14: SIBS
II Installation Kit
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9
4. Pre-nstallation Checks
8B8
harness into the cabin (Section 6) should be re-used to plug the hole in the
cabin floor left after removing the hand brake lever.
4) The required amount of SIBS
II kit;
1) Rear housing (left and right)
2) Rear Expansion Chambers
3) EMMA
system
6) Bleeding of the service brake system
Drawing 24-0817 (Section 4.3) shows an exploded view of a SIBS
variants.
NOTE:
Refer to Appendix for complete SIBS
Rear Brakes
5. Fitting Procedure - 8B8
Rear Brakes
Verify that the pre-installation checks in Section 4 have been completed prior to this
section.
5.1. Rear Brake Assemblies (Left & Right hand side)
Description: The SIBS
fitment)
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13
8B8
Rear Brakes
5.1.4. If the axle flange is in as new condition, apply Loctite
515 to both
sides of an OE Toyota rear spindle gasket and install on to the rear spindle.
Figure 16: Prepared gasket face Figure 17: Loctite
515 may be applied directly to the axle flange. Silicon sealants should
not be used.
2. Check the condition of the wheel bearing seal running surface. If the surface shows signs
of degradation (e.g. corroded or worn) repair using a speed-sleeve (ABT P/N: 15-1284).
Prepare with a
fine rotary wire
brush
Inspect condition
of wheel bearing
seal running
surface
Spacers (P/N; 24-2867)
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14
8B8
Rear Brakes
5.2. Fitting the SIBS
II unit over the stub axle. Align the mounting holes and locate the
housing evenly and firmly against the axle flange; Figure 22.
5.2.3. Fit the 4 wheel end washers and retaining locknuts to the SIBS
II mounting studs
at the rear of the flange and torque to 81 Nm (60 ft-lb) in a diagonal pattern. This
procedure should be repeated three times over a 5 minute period, allowing the
anaerobic sealant to distribute evenly and set; Figure 23.
Figure 22: Fitting the housing & hub complete Figure 23: Secure the SIBS
II housing (81Nm)
5.2.4. Continue to Section 5.3.6.
Figure 19: SIBS
II assembly
being removed from box using
hoist and lifting eye
Figure 20: Housing fitted
complete with hub using lifting
hoist and lifting eye.
Figure 21: SIBS
II lifting eye,
ABT P/N: 24-2870
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15
8B8
Rear Brakes
5.3. Fitting the SIBS
II unit over the stub axle. Align the mounting holes and locate the
housing evenly and firmly against the axle flange; Figure 22.
5.3.2. Fit the 4 wheel end washers and retaining locknuts to the SIBS
II mounting studs
at the rear of the flange and torque to 81 Nm (60 ft-lb) in a diagonal pattern. This
procedure should be repeated three times over a 5 minute period, allowing the
anaerobic sealant to distribute and set; Figure 23.
5.3.3. Fit the inner V-seal seal to the hub as shown in; Figure 24.
5.3.4. Install the hub assembly by lifting over the axle shaft and engaging the hub
splines into the centre of the brake rotor. Take care not to damage the rear bearing
cartridge seal against the axle shaft during this operation.
Figure 24: Inner V-seal installed before hub fitment Figure 25: Outer V-lip seal installation
5.3.5. Tap the hub assembly fully home using a plastic or hide mallet if required.
5.3.6. Fill the wheel bearing cavity with a high temperature, lithium soap EP bearing
grease and fit the outer wheel bearing and retaining collar in accordance with the Toyota
manual and specifications detailed therein.
5.3.7. Fit the outer hub V-seal; Figure 25. The thin lip is fitted toward the brake and
square edge on the hub.
5.3.8. Fill the cavity behind the V-seal using the grease nipple located on the hub face.
A high temperature, Lithium soap EP bearing grease should be used to prevent
washout. Fill the cavity until grease begins to appear from behind the V-seal and repeat
this procedure every turn of the hub for one full revolution.
CAUTION:
Ease the inner hub seal over the stub axle with extreme caution to avoid damaging the seal
lip. Lubricate the seal with wheel bearing grease prior to assembly. Ensure that no bearing
grease or differential oil enters the SIBS
Rear Brakes
5.3.9. Install the axle half shafts in accordance to Toyota manual specifications and top
up the differential oil as required.
5.3.10. Remove the lowermost retractor bolt and screw the pad wear indicator piston
into the piston thread (Torque; 10 Nm); Figure 26. Use Loctite
Rear Brakes
5.4. Rear Service and EMMA Brake Lines
Description: There are two sets of Stainless Steel lines to be fitted across the rear
axle. The thin lines (3/16) replace the standard steel Toyota service brake lines to
provide greater corrosion resistance. The second set of larger lines (1/4) carry the ATF
fluid used by the EMMA pump to release the park brake.
5.4.1. Using a 10mm spacer, fit the rear axle EMMA Tee piece adapter (P/N; 02-
6018) above the Toyota service brake Tee connector on the RH axle tube; Figure 28.
5.4.2. Replace the OE cross axle service brake lines with the Stainless Steel lines
supplied with the SIBS
II Tee piece and RH service line Figure 29: Cross axle service line to LH brake
Figure 30: Mounting position 1 - LH lines Figure 31: Mounting position 2 - LH lines
OE Service brake Tee
EMMA Tee connector
1
1
2
2
Breather Hose
EMMA Line (1/4) - Bottom
Service line (3/16) - Top
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18
8B8
Rear Brakes
Figure 32: Mounting position 3 - LH lines Figure 33: Mounting position 3 - LH lines
Figure 34: Mounting position - RH lines Figure 35: Mounting position - RH lines
NOTE:
Stainless Steel brake lines are harder and less malleable than conventional steel or copper
brake lines. Stainless Steel lines may require a higher torque to be applied at the unions in
order to seat properly and provide a robust seal.
EMMA Line (1/4)
Service line (3/16)
EMMA Line (1/4) - Bottom
Service line (3/16) - Top
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8B8
Rear Brakes
5.5. Rear Expansion Chambers & Breather
Description: The rear expansion chambers connect to each SIBS
Rear Brakes
5.5.3. Mount the SIBS
Rear Brakes
5.5.5. Route the vent line along the chassis rail securing with P-clips; Figure 43.
5.5.6. Route vertically at the front RH corner of the tray; Figure 44.
5.5.7. Fit the vent filter pot bracket in a raised position on the front face of the tray;
Figure 45.
5.5.8. Fit the vent hose to the bottom barb of the vent filter pot and secure the pot
within the 50 mm saddle mounting bracket; Figure 45.
IMPORTANT:
Working upwards from the brake to the bottom of the chamber, check that the red hoses
have not formed any U shaped bends that could hold fluid. Blockage of the breather may
allow pressure to build within each brake resulting in premature seal failure.
Figure 43: HZJ/ VDJ 79 Series mounting location.
Figure 44: HZJ/ VDJ 79 Series mounting location. Figure 45: Fit the black breather link hose
Vent hose
Cab
Tray
Load Sensing
Proportional Valve
(LSPV)
Expansion
chambers
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22
8B8
Rear Brakes
5.6. Hydraulic Installation
Description: This section details the installation of the hydraulic supply hoses along the
vehicle chassis. The hoses run from the EMMA pump at the front of the vehicle to the
rear axle mounted Tee piece connecting the left and right hand wheel ends.
5.6.1. Fit the EMMA Supply Hose (Hose 2) to the axle Tee adapter (P/N; 02-6018)
Figure 48.
5.6.2. Fit the bulkhead union and locknut (P/N; 01-5180) on the RH chassis rail;
Figure 49.
5.7. EMMA Hose Routing (HZJ)
Route the EMMA Supply Line (Hose 1) along the RH chassis rail and cross to the left
chassis rail using first available cross member (behind gear box - HZJ) to continue
forward and connect to EMMA pump unit via the LH inner wheel arch. Fit P-clips at
the locations indicated below.
Figure 46: HZJ Hose Routing
NOTE:
The Spiral Guard should be removed in the area of each P-clip to allow a secure grip on the
hose and prevent fretting; Figure 98.
EMMA Pump
EMMA Pump
1
2
3
4 5 6 7
8
Bulkhead Union
(P/N; 01-5180)
EMMA Tee
adapter
(P/N; 02-6018)
P-clip mounting locations
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23
8B8
Rear Brakes
5.8. EMMA Hose Routing (VDJ)
5.8.1. Clamp the pipe at the intervals indicated using the 8mm P-clips provided.
5.8.2. Run the EMMA Supply Line the full length of the RH chassis rail on the outer
face using the x3 step mounts to affix the x3 P-clips (2, 3 and 4) labelled below. For
positions 5 & 6 use drill through the panels adjacent to the seam weld and secure with
M6 fasteners. Enter the under bonnet area via the triangular opening located in the inner
wheel arch. The line is then taken across the bulkhead to the EMMA pump.
Figure 47: VDJ Hose Routing
NOTE:
The Spiral Guard should be removed in the area of each P-clip to allow a secure grip on the
hose and prevent fretting; Figure 98.
EMMA Pump
EMMA Pump
1
2 3 4
5
6
7
8
Bulkhead Union
(P/N; 01-5180)
EMMA Tee
adapter
(P/N; 02-6018)
P-clip mounting locations
Step Mounting Points
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24
8B8
Rear Brakes
5.8.3. Tighten all hydraulic supply lines ensuring all hoses are free from stress and
twists. Hoses should be positioned to allow smooth axle articulation and be positioned
to avoid contact or abrasion against other parts of the vehicle.
Figure 48: Fit link hose to the EMMA axle Tee
Figure 49: Fit the bulkhead union and locknut
EMMA Axle
Tee adapter
(P/N; 02-6018)
Bulkhead Union
(P/N; 01-5180)
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25
8B8
brakes independently
from the applied service brakes. When the EMMA
pump unit.
Figure 50: SIBS
II operator interface
86
26
8B8
connections. Deutsch
II.
This allows the emergency brake interlock features to be disabled above 40km/h to
prevent the risk of unintended brake application at speed. This optional system is plug
and play and integrates directly with the SIBS
II control system.
6.3. SIBS
II 1
2 02-7074 HARNESS - CABIN CONTROL - SIBS
II 1
3 02-7075 HARNESS - EMMA PUMP CONTROL - SIBS
II 1
5 02-7077 SKT - DEUTSCH JUMPER DT4 - SIBS
II 1
6 02-7078 PLUG - DEUTSCH BLANKING DT4 - SIBS
II 1
02-7089 SKT - DEUTSCH BLANKING DT2 - SIBS II 1
7 02-7079 HARNESS - POWER BOX - SIBS
II 1
8 02-7080 HARNESS - POWER BOX EXT - SIBS
II 1
9 02-7076 HARNESS - EMMA PUMP POWER - SIBS
II 1
10 02-7094 HARNESS - FUSE EMMA PUMP SIBS II 1
11 02-7101 HARNESS - EMMA PUMP POWER DIODED SIBS II 1
12 02-7081 HARNESS - AXLE MANIFOLD - SIBS
II HSI 1
13 02-7082 HARNESS - HIGHWAY SPEED ISOLATION CONTROL - SIBS
II HSI 1
14 02-7085 CONTROL MODULE - HIGHWAY SPEED ISOLATION - SIBS
II HSI 1
02-0092
02-0095
02-0091
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27
8B8
Pump Familiarisation:
Figure 53: SIBS
Pump Installation:
Description: This section details the process for installing the electro hydraulic pump
that releases the Park and Emergency brake. The pump is located under the bonnet
and is controlled by the Control Box.
IMPORTANT:
The vehicle electrical system must be disabled before starting the EMMA instillation.
Operation of the pump at this time may cause injury or damage to equipment.
Disconnect the Earth (-ve) terminal from the vehicle battery.
Some operations in the following procedure require the use of power tools; ensure the
appropriate safety precautions are taken.
6.11.1. Remove the grommet located on the LH (passenger side) foot well. Re-use
the grommet to plug the hole in the cabin floor from removing the hand brake cable.
6.11.2. Using a step drill, enlarge the hole to 30mm; Figure 55.
6.11.3. Retain the original grommet and use this to fill the handbrake cable hole.
6.11.4. Feed the 3 Deutsch
II Harness Assemblies
Description: The SIBS
II harnesses are
not backward compatible with original SIBS
harnesses
are not forward compatible with SIBS
II
harnesses, vehicle requirements and system options;
ABT P/N Description STD HSI STD HSI
CONTROL BOX ASSY - SIBS II
02-7084
02-7084 CONTROL BOX ASSY - SIBS II
02-7074 HARNESS - CABIN CONTROL - SIBS II
02-7075 HARNESS - EMMA PUMP CONTROL - SIBS II
02-7076 HARNESS - EMMA PUMP POWER - SIBS II
02-7077 PLUG - DEUTSCH JUMPER - SIBS II
02-7078 SOCKET - DEUTSCH BLANKING - SIBS II
02-7079 HARNESS - POWER BOX - SIBS II
HARNESS - POWER BOX EXT - SIBS II
02-7080
02-7080 HARNESS - POWER BOX EXT - SIBS II
02-7081 HARNESS - AXLE MANIFOLD - SIBS II HSI
02-7082 HARNESS - HIGHWAY SPEED ISOLATION CONTROL - SIBS II HSI
02-7085 CONTROL MODULE - HIGHWAY SPEED ISOLATION - SIBS II HSI
HARNESS ASSY HSI KIT - SIBS II
02-0092
HARNESS ASSY KIT - SIBS II
02-0091
HZJ VDJ
6.12.1. Become familiar with the component parts of the SIBS
II harness into
the Black cable.
6.13.4. On completion of a secure joint, use self-amalgamating insulation tape to ensure
the joint and second diode is completely insulated; Figure 75.
6.13.5. Locate the Green/ Red (Gn/ Rd) Speed input cable within the centre blue multi-
plug and remove a 10mm section of the protective insulation, again, the OE wiring
harness should not be cut.
6.13.6. Solder splice the Pink (Pk) Speed Pick-up cable from the SIBS
II harness into
the Green/ Red cable. On completion of a secure joint, use self-amalgamating
insulation tape to ensure the joint is completely insulated; Figure 76.
Figure 74: Instrument cluster multi-plug Figure 75: Solder splice the door switch diode and
speed sensor cables.
Figure 76: Use self-amalgamating insulation tape
to seal the joint.
Figure 77: Connect the 12 pin Cabin Control
harness within the glove box.
Green/ Red =
Speed sensor
Black = Door switch
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42
8B8
II
harness into the Black/ White (Bk/ We) cable of D28; Figure 80.
Figure 78: Location of Diode D28 VDJ 2007 > 2009
IMPORTANT
The door interlock must be connected across diode D28 in order for the feature to activate
correctly from all doors. Attempting to connect at the instrument cluster will result in actvation
from the passenger door only.
IMPORTANT
The OE cables should not be cut or compromised. Strip and remove 10mm of the cable
sheath and solder the diodes from the Brown/ Green SIBS
II harness into the Black (Bk) cable at the multi-plug; Figure 85.
6.15.5. Solder splice the second diode branch into the Black and White (Bk/ We) cable;
Figure 85.
Figure 81: Use self amalgamating insulation tape
to seal the joint.
Figure 82: Disconnect the x2 multi-plugs and
remove the cluster.
Figure 83: Take the LH multi-plug. Figure 84: Locate the Black and Black/ White
cables for the door interlock.
Black cable for Passenger Door(s)
Black & White cable for Drivers Door
Green & Red cable Speed sensor
86
45
8B8
II harness into
the Green/ Red cable. On completion of a secure joint, use self-amalgamating
insulation tape to ensure the joint is completely insulated; Figure 76
6.15.8. Refit the multi-plugs into the instrument cluster and make good by refitting the
cluster and surrounding fascia. See TBN-053 for further detail if required.
6.15.9. Refit the kick panel in the passenger foot well.
6.15.10. Refit the plastic cover located between the dash board and in the LH corner
of the windscreen.
6.15.11. Moving back to the glove box connect the 12 pin Deutsch plug; Figure 77 and
carefully conceal the harness connections together with any excess wiring into the
recess at the rear of the glove box cavity.
6.15.12. Refit the glove box liner and the door.
6.15.13. Locate the Power Box harness P/N; 02-7079; Figure 87.
Figure 85: Solder splice into the Black and Black/
White multi-plug cables.
Figure 86: Insulate the joints with self-
amalgamating insulation tape.
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46
8B8
II Operator Interface:
6.16.1. SIBS
II - Standard Operation:
The SIBS
II Operator Interface
NOTE:
The brake will automatically re-apply as soon as the Manual Release push button is
released. The Manual Release is an emergency overide function only.
Operator Button
Park Brake application &
Emergency Stop
Brake Applied
Manual Release
Push Button
+
Brake Released
indicator LED
Highway Speed Isolation (HSI)
indicator
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49
8B8
II:
Emergency operation of the EMMA
II 3 Modes of Operation:
The 3 critical operating states of the braking system are clearly communicated to the
operator via LED and audible indicators. The 3 states of the brake are communicated
as follows:
When the GREEN LED is ON, the brakes are RELEASED; Figure 95.
When the RED LED is Flashing, the brakes are in the process of APPLYING
or RELEASING; Figure 96. A pulsing audible alert accompanies the flashing
red LED to signify that the brake is in transition between the applied and
released state.
When the RED LED is ON, the brakes are APPLIED; Figure 97.
Figure 95: Brake RELEASED indication
Figure 96: Brake TRANSITION indication
Figure 97: Brake APPLIED indication
1
2
3
86
51
8B8
II to prevent
unintended brake application above a predetermined vehicle speed (i.e. for highway
vehicles).
86
52
8B8
ATF reservoir.
6.17.6. Check the level of brake fluid in the master cylinder whilst bleeding this should
not fall below 1/3 full.
6.17.7. Remove any clamps on the rear service line.
Figure 98: Fit P-clips as shown Figure 99: Bleed screw locations Rear Housing
IMPORTANT:
Failure to purge air from the EMMA
pump is designed for intermittent use only; when bleeding do not run
continuously for more than 10 seconds.
IMPORTANT:
Use only SAE J1703 or FMVSS No. 116 DOT 3 brake fluid
Rear Service Brake bleed
screws Brake Fluid
EMMA Brake bleed screws (ATF)
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53
8B8
interlock features
to eliminate any risk of unintended application of the emergency brake at speed (i.e. due
to a door opening or sudden hydraulic fluid loss). The intervention of the HSI feature is
indicated by illumination of a small green LED indicator on the control box. The system
has 2 states of operation;
When the GREEN LED is illuminated, the HSI system is Active and interlock
functions are Disabled; Figure 100.
When the GREEN LED is off, the HSI system is Disabled and the SIBS II
interlock functions are Active; Figure 101.
Fitment of the Highway Speed Isolation (HSI) system is achieved with an optional kit;
ABT P/N; 02-0092. The kit consists of a hydraulic solenoid manifold to be mounted on
the rear axle and supplementary electrical hardware that is plug and play with the
standard SIBS
II
harness. These are located behind the glove compartment; Figure 104 and Figure 105.
7.3.2. Remove the blanking and jumper plug.
7.3.3.
7.3.4.
7.3.5.
7.3.6.
7.3.7. Select HSI harness P/N; 02-7082 and plug into the Standard SIBS
II vehicle
harness. The additional HSI harness contains a switching relay and a twin channel
speed control module; Figure 106.
Figure 104: HSI connections Figure 105: Remove blanking plug and jumper
Figure 106: HSI control harness Figure 107: HSI solenoid plug
Blanking plugs
Speed control
module
87
57
8B8
brake
8.3.2. With the EMMA
brake fully releases and vehicle should begin to roll.
8.3.6. Use the service brakes to halt the vehicle.
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62
8B8
Brakes
The additional mass of the SIBS
(Rear) 30.0 kg
89
65
9. 8afety
8B8
II braking system
Pump Reservoir Use only Automatic Transmission Fluid (ATF, DEXRON III)
SIBS
Cooling Fluid
Figure 122: EMMA Pump ATF Reservoir
Figure 123: SIBS
Fluid
10.2.1. Refer to SIBS
fluid.
10.2.3. SIBS
fluid must be disposed of responsibly in accordance with all
Regulatory and Environmental legislation.
10.3. Changing the SIBS
Fluid
10.3.1. Drain the SIBS
Maintenance 8chedule
The maintenance intervals described below are for SIBS
fluid into a measuring jug. If the volume is less than 800ml per
brake, check for external leaks around the brake housings and internal leaks within the
differential housing and wheel hub.
10.4.10. Check the SIBS
fluid to the level plug and refit the drain plug using a
new sealing washer.
10.4.13. Grease the V-seal (grease nipple located on the front face of the hub).
Lubricate with a grease gun using a high temperature, Lithium soap based grease until
grease begins to appear from behind V-seal. Repeat this procedure every turn of the
hub for one full revolution.
810
70
10. 8ervicing
8B8
and remove the complete assembly from the axle. The inner
housing may need to be tapped with a copper mallet to free it from the axle.
In the absence of a hoist and lifting eye, the brake may be removed as follows:
10.5.8. Remove two housing bolts from the brake assembly and replace with two
guide bolts; Figure 125.
10.5.9. Remove the ten remaining housing bolts. These bolts must be renewed.
10.5.10. Remove the outer housing, hub and rotor as one assembly. Ensure the inner
brake pads remain in the inner housing during this operation; Figure 125.
10.5.11. To install a service exchange rear assembly, refer to Section 5 for procedure.
Figure 125: Use guide pins to support withdrawal
of outer housing
Figure 126: Inspect rotor surface and splines for
wear
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10. 8ervicing
8B8
& EMMA
TROUBLESHOOTING GUIDE
Issue/ Description Possible Cause Solution
Brake pedal soft/
spongy
Air in the service brakes
Bleed the brakes
Leak in the service brake
system
Inspect for leaks
Booster/ master cylinder out
of adjustment.
Adjust booster output pushrod
according to Toyota manual.
Brake pedal hard/
excessive force
required to operate
brakes/ reduced
braking performance
Pads and/ or rotor surface
contaminated.
Change SIBS
& EMMA
TROUBLESHOOTING GUIDE
Issue / Description Possible Cause Solution
EMMA piston leaking
Locate which rear brake is
affected by inspecting rear brakes
for loss of ATF and/ or using
infrared thermometer to determine
hottest brake. Strip brake,
measure components and check
for oversized pads or rotor.
Inspect for leaking EMMA piston,
change seals as required.
Insufficient hydraulic
pressure to release
EMMA brakes
Put vehicle on hoist and release
EMMA brake. Check for free
spinning hubs. One side or both?
If both sides: check pressure in
EMMA circuit should be >
700psi (Standard Duy) >1500psi
(Heavy Duty), if pressure is
insufficient, change pressure
switch.
If only on one side: check
hydraulic hoses for kinks (change
as required); strip brake, measure
components and check for
oversized pads or rotor.
Vehicle pulls to one
side during braking
Generally due to reduced
effectiveness in one brake;
brake steer. Vehicle will
pull to the side with the
more effective front brake.
If vehicle is fitted with rear only
SIBS
& EMMA
TROUBLESHOOTING GUIDE
Issue / Description Possible Cause Solution
Brakes shudder at
the end of a braking
event
Indicates additive package
of oil is depleted.
First occurs on cold brake
applications.
If shudder persists after more
than first three brake applications,
change SIBS
& EMMA
TROUBLESHOOTING GUIDE
Issue / Description Possible Cause Solution
Fail Safe EMMA
Brake System
EMMA brake will
not release
Door is not closed properly
or door switch has failed
if door interlock is fitted.
Hint: Check control box for
RED/ GREEN LED if this
is not illuminated the
system may not be armed
as the interlock is
activated.
Close door.
Inspect/ replace the door switch.
EMMA brake
engages
unexpectedly.
Note: Door should
not be opened whilst
operating the vehicle.
Check door interlock
Close door. Inspect/ replace
door switch.
Control box not
functioning no LED
indicators.
Electrical continuity lost/
control box malfunction.
Check for good earth continuity
on EMMA pump bracket.
Check connections to Toyota
power outlet box.
Replace control box.
Reduced park brake
(EMMA)
performance
Hydraulic fluid slow to
release
Adjust relief valve to reduce
delay in EMMA brake
application
Inspect and clean EMMA
filter.
Brake pads worn Strip rear brakes. Measure pads
and replace pads or install
shims contact ABT for shim
kit.
Failure of EMMA
hose
Rubbing of hose.
Check routing of hoses. Use
Spiral guard where some
rubbing cannot be avoided, refer
to manual for correct
recommended hose routing.
Consider installing Heavy Duty
Hoses contact ABT for details.
811
84
11. Troubleshooting
8B8
& EMMA
TROUBLESHOOTING GUIDE
Issue / Description Possible Cause Solution
Impact damage Check routing of hoses. Use
Spiral guard where some
rubbing cannot be avoided, refer
to manual for correct
recommended hose routing.
Consider installing Heavy Duty
Hoses contact ABT for details.
Failure occurs to long
supply hose between axle
tee piece and chassis
mount
Install Heavy Duty Hoses. If
problem persists contact ABT.
EMMA brake slow to
engage
Blocked or partially
blocked EMMA filter
Inspect and replace
Relief valve set too high Adjust as per Section 8.5
Kinked hose Inspect and replace
Pump runs but brakes
to not release
Leak in system failed
hydraulic hose or leak
inside brake.
Check fluid level in hydraulic
tank if it is falling inspect for
leaks. Change hoses as
required. If leaking inside brake
is suspected disconnect & plug
the hydraulic suppy hose to one
side and see if problem is
removed, restore connection and
inspect other side.
If leak is inside the brake
remove and rebuild as per
Section 8.6.
Solenoid valve not closing
path back to tank.
Check coil for correct operation
valve can be heard to click
when coil is energised. Inspect
solenoid valve for correct
operation remove and inspect
for valve or seat damage.
Pump internal relief valve
bypassing
Pump internal check valve by-
passing. Remove valve and
clean.
Check valve is located on pump
body beneath 7/8 hex plug
note check valve used is on the
firewall side of the pump. See
Section 6.6 and the following
schematic.
811
85
11. Troubleshooting
8B8
& EMMA
TROUBLESHOOTING GUIDE
Issue / Description Possible Cause Solution
Pump worn not
developing suffiient
pressure
Replace pump. Note consider
EMMA service exchange
refer TBN-041.
Pump does not run
when brake release
called for. Control
box functioning
normally.
Note: Ensure control box is functioning correctly hold down
Manual Release button and operate with red operator button
Relay fault Check continuity of relay when
EMMA brake release is called
for thin red wire to relay should be
+12V.
Circuit breaker tripped Note: circuit breakers are
installed to protect the system.
Chock the vehicle before re-
setting circuit breaker as pump
may run & release the EMMA
brake unexpectedly.
Check battery and circuit breaker
cables are energised.
Pressure switch faulty Check function of pressure
switch: remove blue and grey
wires from Deutsch
connector
and short out wires on harness
side if pump runs then pressure
switch has failed OPEN.
If no change then pressure switch
is not at fault.
811
86
11. Troubleshooting
8B8
& EMMA
TROUBLESHOOTING GUIDE
Issue / Description Possible Cause Solution
Pump motor failed Check power is getting to pump
blue/white wire of pump.
Check earth to pump.
Replace hydraulic unit if pump
has failed.
Note: consider service exchange
for EMMA unit, refer TBN-041.
Pump runs and does
not shut off
Note: pump is
designed for
intermittent use only.
Shut pump off after
~10s to prevent
damage.
Brakes release pump
can be heard to strain and
will relieve pressure via
internal relief valve.
Pressure switch failed closed.
System generates more than
minimum required pressure
(~700psi/ 1500psi for Heavy
Duty).
Check function of switch by
removing blue and black wires of
pressure switch from the Deutsch
connector this should shut
pump off.
If switch is found to be faulty
remove and replace.
Brakes partially release
solenoid valve not
functioning
Check coil for correct operation
valve can be heard to click when
coil is energised. Inspect
solenoid valve for correct
operation remove and inspect
for valve or seat damage.
Brakes do not release
pump internal check valve
by-passing.
Remove valve and clean.
Check valve is located on pump
body beneath 7/8 hex plug note
check valve used is on the firewall
side of the pump.
812
87
12. M8D8
8B8
MSDS
812
88
12. M8D8
8B8
MSDS
812
89
12. M8D8
8B8
MSDS
812
90
12. M8D8
8B8
MSDS
813
91
13. 8ervice Record
8B8
II assembly being removed from box using hoist and lifting eye ....... 14
Figure 20: Housing fitted complete with hub using lifting hoist and lifting eye. .............. 14
Figure 21: SIBS
MSDS ............................................................................. 87
Figure 141: Page 2 of SIBS
MSDS ............................................................................. 88
Figure 142: Page 3 of SIBS
MSDS ............................................................................. 89
Figure 143: Page 4 of SIBS
MSDS ............................................................................. 90
Figure 144: Service Record Sheet ................................................................................ 91
815
95
8B8