ABS TOYOTA LAND CRUISER 1998 Factory Owner's Guide

F02827
F04707
BR-54
- BRAKEHYDRAULIC BRAKE BOOSTER
2190 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(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 ºSA2º 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
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 ºLHº position.
(2) Push and hold in the MAIN push switch and ºSA1º
switch simultaneously, depress and hold the brake
pedal with stable force.
NOTICE:
Do not keep the MAIN push switch and ºSA1º switch
pushed down for more than 10 sec. When operating it con-
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 ºSA1º 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.

F02829
F02830
F02831
- BRAKEHYDRAULIC BRAKE BOOSTER
BR-55
2191 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(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
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
ºFRONTº to ºREARº.
(m) Place ºSHEET Gº of ºREARº 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 ºLº position.
(2) Push and hold the ºSA3º switch and ºSTRº switch
simultaneously.
NOTICE:

Do not keep the ºSTRº switch pushed down for more
than 10 sec.

Do not keep the ºSA3º switch pushed down for more
than 5 sec.

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 ºSA3º switch and ºSTRº 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 ºRHº 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 343 N (35
kgf, 77 lbf), record the fluid surface in the reservoir
tank of the hydraulic brake booster.

F02832
BR-56
- BRAKEHYDRAULIC BRAKE BOOSTER
2192 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(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 ºLº 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 ºLHº 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 343 N (35
kgf, 77 lbf), record the fluid surface in the reservoir
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 ºLº 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.

BR12C-05
F04456
F08307
BR-60
- BRAKEHYDRAULIC BRAKE BOOSTER
2196 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REMOVAL
NOTICE:
Before starting the work, make sure that the ignition switch
is OFF and depress the brake pedal more than 40 times.
HINT:
When a pressure in power supply system is released, reaction
force becomes light and stroke becomes longer.
NOTICE:

As high pressure is applied to the brake actuator tube
No. 1, never deform it.

Until the work is over, do not turn the ignition switch
ON.
1. DRAW OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
2. REMOVE SCUFF PLATE, COWL SIDE TRIM, LOWER
NO. 1 PANEL, LH LOWER PANEL AND NO. 2 HEATER
TO REGISTER DUCT (See page BO-81)
3. REMOVE ABS OR ABS & TRAC & VSC ECU
Remove the 2 nuts and ABS or ABS & TRAC & VSC ECU.
Torque: 5.0 N´m (51 kgf´cm, 44 in.´lbf)
4. w/ ABS only:
DISCONNECT 4 CONNECTORS
5. w/ ABS & TRAC & VSC only:
DISCONNECT 5 CONNECTORS

F04455
SST
F08308
SST
F06413
- BRAKEHYDRAULIC BRAKE BOOSTER
BR-61
2197 Author
: Date
:
2004 LAND CRUISER (RM1071U)
6. w/ ABS only:
DISCONNECT BRAKE LINES
Using SST, disconnect the 3 brake lines.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
7. w/ ABS & TRAC & VSC only:
DISCONNECT BRAKE LINES
Using SST, disconnect the 4 brake lines.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
8. REMOVE CLIP AND CLEVIS PIN
9. REMOVE HYDRAULIC BRAKE BOOSTER ASSEMBLY
(a) Remove the 4 booster installation nuts.
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
(b) Remove the booster assembly and gasket.

- BRAKETROUBLESHOOTING
BR-3
2139 Author
: Date
:
2004 LAND CRUISER (RM1071U) Noise from brakes
1. Pad (Cracked or distorted)
2. Installation bolt (Loose)
3. Disc (Scored)
4. Pad support plate (Loose)
5. Sliding pin (Worn)
6. Pad (Dirty)
7. Pad (Glazed)
8. Tension or return spring (Faulty)
9. Anti-squeal shim (Damaged)
10.Shoe hold-down spring (Damaged)BR-15
BR-24
BR-18
BR-27
BR-21
BR-30
BR-24
BR-27
BR-15
BR-24
BR-15
BR-24
BR-33
BR-15
BR-24
BR-33
Noise from hydraulic brake booster
(Abnormal pump motor operation noise)Accumulator bracket clearance (Out of adjustment)BR-66
Brake warning light lights up*1
(Parking brake pedal released)
1. Brake fluid level
2. Hydraulic brake booster power supply system (Faulty)-
BR-40
Brake warning light lights up and brake warning buzzer sounds*2Hydraulic brake booster power supply system (Faulty)BR-40
ABS warning light lights up*31. Anti - lock brake system (Faulty)
2. Hydraulic brake booster power supply system (Faulty)-
BR-40
*1, *3: The light may stay on for about 60 seconds after the engine is started. It is normal if it goes out after
a while.
*
2, *3: Depressing the brake pedal repeatedly may turn on the warning light and buzzer. It is normal if the
light goes off and the buzzer stops sounding after a few seconds.
*
3: While ABS warning light is ON.

ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
SSM Special Service Materials
w/ with
w/o without
5. ECU (ELECTRONIC CONTROL UNIT)
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all
equipped with memory function, it is not possible to make a record of the memory contents. So when the
operation is finished, it will be necessary to explain this fact to the customer, and request the customer to
adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80°C (176°F).
NOTICE: If it is possible the ambient temperature may reach 80° (176°F) or more, remove the ECUs
from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
INTRODUCTIONIN-9

CodeMaterial
nameHeat*
resistant
temperature
limit °C (°F)Resistance to
alcohol or gasolineNotes
AASAcrylonitrile
Acrylic Styrene80
(176)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease.)Avoid gasoline and
organic or aromatic
solvents.
ABSAcrylonitrile
Butadiene Styrene80
(176)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease.)Avoid gasoline and
organic or aromatic
solvents.
AESAcrylonitrile
Ethylene Styrene80
(176)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease.)Avoid gasoline and
organic or aromatic
solvents.
ASAAcrylonitrile
Styrene
Acrylate80
(176)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease.)Avoid gasoline and
organic or aromatic
solvents.
CABCellulose
Acetate80
(176)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease.)Avoid gasoline and
organic or aromatic
solvents.
EPDMEthylene
Propylene100
(212)Alcohol is harmless.
Gasoline is harmless if applied only
for short time in small amounts.Most solvents are
harmless but avoid
dipping in gasoline,
solvents, etc.
FRPFiber
Reinforced
Plastics180
(356)Alcohol and gasoline are
harmless.Avoid alkali.
EVAEthylene
Acetate70
(158)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease).Avoid gasoline and
organic oraromatic
solvents.
PAPolyamide
(Nylon)80
(176)Alcohol and gasoline are
harmless.Avoid battery acid.
PBTPolybutylene
Terephthalate160
(320)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PC
Polycarbonate120
(248)Avoid gasoline, brake
fluid, wax, wax removers
and organic solvents.
Avoid alkali. Alcohol is harmless.
HANDLING PRECAUTIONS
1. The repair procedure for plastic body parts must conform with the type of plastic material.
2. Plastic body parts are identified by the codes in the following chart.
3. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding,
painting etc.), consideration must given to the property of the plastic.
*Temperatures higher than those listed here may result in material deformation during repair.
PLASTIC BODY PARTSPP-2

Parts Name
Code
Radiator Grille
ABS
Front Bumper Cover
TSOP
Fog Light
PC/PP
Front Turn Signal Light
PMMA/PC/AAS
Side Turn Signal Light
SAN/AAS
Cowl Top Ventirator Louver
TSOP
Outer Rear View Mirror
ABS
Outside Moulding (Fender, Front & Rear Door, Quarter)
TSOP
Outside Handle (Front & Rear Door)
PC
Rocker Panel Moulding
TSOP
Side Door Step Plate Cover (Front, Rear)
PP
Quarter Ventirator Louver
PPO/PA
Rear Combination Light
PMMA/PP/AAS
Rear Light
PMMA/PP
Back Door Outside Moulding
TSOP
License Plate Light
PC
License Plate Light Cover
AAS
Back Door Outside Handle
POM
Rear Bumper Cover
TSOP
Reflex Refrector
PMMA/ABS
Rear Fog Light
PC/PP
Outer Under Rear View Mirror
PC/PBT
Roof Moulding
PVC
LOCATION OF PLASTIC BODY PARTS
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPP-4

(Three-Dimensional Distance)
mm (in.)
Hole dia.
18.5 (0.728)
30 (1.18)
18.5 (0.728)
18.5 (0.728)
16 (0.63)
70 (2.76) Name
Lower control arm installation hole-inner
Body mounting hole
Upper control arm installation hole-inner
Lateral control rod installation hole-front
Body mounting hole
Body mounting hole Symbol
G, g
H, h
I, i
J
K, k
L, l Hole dia.
24 (0.94)
16.5 (0.650)
24 (0.94)
60 (2.36)
18.5 (0.728)
30 (1.18) Name
Body mounting bole
Lateral control rod installation hole-rear
Shock absorber installation hole
Body mounting hole
Leading arm installation hole-inner
Body mounting hole Symbol
A, a
B
C, c
D, d
E, e
F, f
FRAME DIMENSION
FZJ105 series (RHD)
w HZJ105 series (RHD)
BODY DIMENSIONSDI-10