TOYOTA LAND CRUISER 1998 Factory Repair Manual

BO2820Reference Marks
BO4421
H02865
Primer M
Primer M
Primer M
Adhesive
H05397
aa
b
a - ab - b
Primer GPrimer G a
a
b
BO-56
- BODYWINDSHIELD
2630 Author
: Date
:
2004 LAND CRUISER (RM1071U)
5. POSITION GLASS
(a) Place the glass in the correct position.
(b) Check that all contacting parts of the glass rim are perfect-
ly even.
(c) Place reference marks between the glass and the body.
(d) Remove the glass.
6. CLEAN CONTACT SURFACE OF GLASS
Using cleanser, clean the contact surface which is black-col-
ored area around the entire glass rim.
NOTICE:
Do not touch the glass surface after cleaning it.
7. COAT CONTACT SURFACE OF BODY WITH PRIMER
ºMº
Using a brush, apply Primer M to the exposed part of the body
on the vehicle side.
NOTICE:

Let the primer coating dry for more than 3 minutes.

Do not coat Primer M to the adhesive.

Do not keep remaining Primer M for later use.
8. COAT CONTACT SURFACE OF GLASS WITH PRIMER
ºGº
(a) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
(b) If the primer is coated wrongly to the area not specified by
accident, wipe it off with a clean shop rag before the prim-
er dries.
NOTICE:

Let the primer coating dry for more than 3 minutes.

Do not keep remaining Primer G for later use.

H05398
a
b
a - a
b - b A
B aa a
b
A
B
BO2821Reference Marks
BO3986
N08495
Windshield Glass
Adhesive
- BODYWINDSHIELD
BO-57
2631 Author
: Date
:
2004 LAND CRUISER (RM1071U)
9. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle.
Part No.08850-00801 or equivalent.
HINT:
After cutting off the tip, finish up all adhesive within the time de-
scribed in the table below.
TemperatureTackfree time
35 °C (95 °F)15 minutes
20 °C (68 °F)100 minutes
5 °C (41 °F)8 hours
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive as shown.
A: 12.0 mm (0.472 in.)
B: 8.0 mm (0.315 in.)
10. INSTALL WINDSHIELD GLASS
(a) Position the glass so that the reference marks are lined
up, and press in gently along the rim.
(b) Using a spatula, apply adhesive on the glass rim.
(c) Use a scraper to remove any excess or protruding adhe-
sive.
HINT:
Make sure the dam is attached to the body panel, as shown in
the illustration.
(d) Hold the windshield glass in place securely with a protec-
tive tape or equivalent until the adhesive hardens.

H02665
H16066
Windshield Moulding
Windshield Glass
Body
H07493
5 mm (0.20 in.)
Cutting Area
BO-58
- BODYWINDSHIELD
2632 Author
: Date
:
2004 LAND CRUISER (RM1071U)
NOTICE:
Take care not to drive the vehicle within the time described
in the table below.
TemperatureMinimum time prior to driving the vehicle
35 °C (95 °F)1.5 hours
20 °C (68 °F)5 hours
5 °C (41 °F)24 hours
11. INSPECT FOR LEAK AND REPAIR
(a) Conduct a leak test after the adhesive dried completely.
(b) Seal any leak with sealant.
Part No. 08833-00030 or equivalent.
12. APPLY ADHESIVE TO MOULDING INSTALLATION
AREA
Apply adhesive to the moulding installation area between the
glass and the body.
Part No. 08833-00030 or equivalent.
13. INSTALL UPPER OUTSIDE MOULDING
Place a new moulding onto the body and tap it by hand.
14. INSTALL OUTSIDE NO. 2 MOULDING
(a) Using an air riveter with nose piece No. 4, install 4 new riv-
ets and the outside No. 2 moulding.
HINT:
Before using the air riveter with nose piece No. 4, cut 5 mm
(0.20 in.) from the edge of nose piece No. 4 as shown in the il-
lustration.

H02440
Riveter
Mandrel
H02441
Riveter
Riveter
H02442
Riveter
H04845
A
B
H21532
- BODYWINDSHIELD
BO-59
2633 Author
: Date
:
2004 LAND CRUISER (RM1071U)
NOTICE:

Do not prize a riveter. It could damage the riveter and
cause loose fitting and mandrel bend.

Do not tilt the riveter when fasten the rivet to the mate-
rial to avoid loose fitting.

Do not allow gap spacing between the rivet head and
the material.

Do not allow gap spacing between the materials.
(b) Use the same manner described above to the other side.
15. INSTALL COWL TOP VENTILATOR LOUVERS
(a) Install the cowl top ventilator louver LH.
(b) Install the cowl top ventilator louver RH.
16. INSTALL HOOD TO COWL TOP SEAL
17. INSTALL WIPER ARMS
(a) Operate the wiper motor once and turn the wiper switch
OFF.
(b) Install the wiper arms and tighten the nuts by hand.
(c) Adjust the installation positions of the wiper arms to the
positions as shown in the illustration.
A: Approx. 33 mm (1.30 in.)
B: Approx. 21 mm (0.83 in.)
(d) Torque the nuts.
Torque: 20 N´m (204 kgf´cm, 15 ft´lbf)
(e) Install the 2 wiper arm head caps.
18. INSTALL INNER REAR VIEW MIRROR
(a) Install the inner rear view mirror with the 2 screws.
(b) Connect the connector.
19. INSTALL FRONT SIDE OF ROOF HEADLINING
20. INSTALL ASSIST GRIPS
21. INSTALL OVERHEAD CONSOLE BOX
Connect the connector, then install the overhead console box
with the bolt.
22. INSTALL HOLDER
Install the holders with the screws.

H18904
BO-60
- BODYWINDSHIELD
2634 Author
: Date
:
2004 LAND CRUISER (RM1071U)
23. INSTALL DOUBLE VISOR
Install the double visors with the screws.
24. INSTALL SUN VISOR
(a) Install the sun visors with the screws, then connect the
connectors.
(b) Install the caps.
25. INSTALL FRONT PILLAR GARNISH
(a) Install the front pillar garnish.
(b) Use the same manner described above to the other side.
26. INSTALL FRONT ASSIST GRIP
(a) Install the front assist grip with the 2 screws, then install
the 2 assist grip plugs.
(b) Use the same manner described above to the other side.
27. INSTALL FRONT DOOR OPENING TRIMS

BO4IU-01
H18904
H21423
4 Clips
H21532
BO-52
- BODYWINDSHIELD
2626 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REMOVAL
1. REMOVE FRONT DOOR OPENING TRIMS
2. REMOVE FRONT ASSIST GRIP
(a) Using a screwdriver, remove the 2 assist grip plugs, then
remove the 2 screws and the front assist grip.
HINT:
Tape up the screwdriver tip before use.
(b) Use the same manner described above to the other side.
3. REMOVE FRONT PILLAR GARNISH
(a) Using a screwdriver, remove the front pillar garnish.
HINT:
Tape up the screwdriver tip before use.
(b) Use the same manner described above to the other side.
4. REMOVE SUN VISOR
(a) Using a screwdriver, remove the caps.
HINT:
Tape up the screwdriver tip before use.
(b) Remove the screws, then disconnect the connectors.
(c) Remove the sun visors.
5. REMOVE DOUBLE VISOR
Remove the screws and the double visors.
6. REMOVE HOLDER
Remove the screws and the holders.
7. REMOVE OVERHEAD CONSOLE BOX
(a) Remove the bolt.
(b) Using a screwdriver, remove the overhead console box,
then disconnect the connector.
HINT:
Tape up the screwdriver tip before use.
8. REMOVE ASSIST GRIPS
9. PULL DOWN FRONT SIDE OF ROOF HEADLINING
10. REMOVE INNER REAR VIEW MIRROR
(a) Disconnect the connector.
(b) Unfasten a screw, and remove the other screw and the in-
ner rear view mirror.
11. REMOVE WIPER ARMS
(a) Remove the 2 wiper arm head caps and the 2 nuts.
(b) Remove the 2 wiper arms.
12. REMOVE HOOD TO COWL TOP SEAL
13. REMOVE COWL TOP VENTILATOR LOUVERS
(a) Remove the cowl top ventilator louver RH.

H05392
H05393
Protective Tape
Adhesive Tape
H16045
Windshield Moulding
Windshield Glass
Body
- BODYWINDSHIELD
BO-53
2627 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(b) Remove the cowl top ventilator louver LH.
14. REMOVE OUTSIDE NO. 2 MOULDING
(a) Using a screwdriver, remove the outside No. 2 moulding.
HINT:
Tape up the screwdriver tip before use.
(b) Using a drill of less then ù 4 mm (0.16 in.).
(c) Gently and vertically put the drill to the rivet and cut the
rivet flanges.
NOTICE:

Prizing the hole with a drill can lead to damage to the
rivet hole or breaking the drill.

Take cafe as the cut rivet is hot.
(d) Even if flange is taken off, continue drilling and push out
remaining fragments with the drill.
(e) Using a heat light, heat the moulding to 20 - 30 °C (68 -
86 °F).
NOTICE:
Do not heat the moulding excessively.
(f) Tie both piano wire ends to wooden blocks or similar ob-
jects.
(g) Cut the adhesive tape by pulling the piano wire as shown.
NOTICE:

If reusing the moulding, take care not to damage the
moulding.

Do not damage the body.
HINT:
Apply protective tape to the outer surface to keep the surface
from being scratched.
(h) Remove the moulding.
(i) Use the same manner described above to the other side.
15. REMOVE OUTSIDE UPPER MOULDING
Using a knife, cut off the moulding as shown in the illustration.
NOTICE:
Do not damage the body with the knife.

BO5232
Protective Tape
Windshield
GlassBody
BO1689
Protective Tape Plastic Sheet
BO-54
- BODYWINDSHIELD
2628 Author
: Date
:
2004 LAND CRUISER (RM1071U)
16. REMOVE WINDSHIELD GLASS
(a) Push piano wire through between the body and glass
from the interior.
(b) Tie both wire ends to wooden blocks or similar objects.
HINT:
Apply protective tape to the outer surface to keep the surface
from being scratched.
NOTICE:
When separating the glass, take care not to damage the
paint and interior and exterior ornaments. To prevent
scratching the safety pad from scratching when removing
the windshield, place a plastic sheet between the piano
wire and the safety pad.
(c) Cut the adhesive by pulling the piano wire around it.
(d) Remove the windshield glass.
NOTICE:
Leave as much of the adhesive on the body as possible
when cutting the glass.

BR12E-07
F06425
TOYOTA
Hand-held
Tester
DLC3
BR-4
- BRAKEBRAKE FLUID
2140 Author
: Date
:
2004 LAND CRUISER (RM1071U)
BRAKE FLUID
BLEEDING
HINT:

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

When bleeding, keep the amount of the fluid within the
line of reservoir between Min. and Max.
NOTICE:

Do not let brake fluid remain on painted surfaces.
Wash it off immediately.

With the reservoir cap removed, when depressing the
brake pedal, the fluid will spray.
1. FILL RESERVOIR WITH BRAKE FLUID
Fluid: SAE J1703 or FMVSS NO. 116 DOT3
2. In case of using TOYOTA hand-held tester:
BLEED HYDRAULIC BRAKE BOOSTER
HINT:
If the hydraulic brake booster has been disassembled, discon-
nect the brake line from the hydraulic brake booster or if the res-
ervoir becomes empty, bleed the hydraulic brake booster.
(a) 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 light and stroke becomes longer.
(b) Turn the ignition switch ON, check that the pump stops af-
ter approx. 30 to 40 sec.
NOTICE:
When the pump does not stop, repeat step (a) and (b) again.
(c) With the ignition switch remained ON, depress the brake
pedal more than 20 times.
(d) Observe the procedure in step 4 and bleed the right and
left front brake caliper.
(e) Holding the brake pedal depressed, bleed the right and
left rear brake caliper.
HINT:
It is not necessary to depress the pedal continuously, as brake
fluid flows out by first depressing.
(f) Connect TOYOTA hand-held tester.
(1) Turn the ignition switch OFF, connect the TOYOTA
hand-held tester to DLC3.
(2) Turn the ignition switch ON and select ºAIR BLEED-
INGº on the TOYOTA hand-held tester.
HINT:
Please refer to the TOYOTA hand-held tester operator's manu-
al for further details.

F04459F09169F09632
w/ ABS Only:
w/ ABS & BA & TRAC & VSC Only:
- BRAKEBRAKE FLUID
BR-5
2141 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(g) Bleed right front brake line.
(1) Select ºFR LINEº on the TOYOTA hand-held tester.
(2) With ºFR LINEº turned ON with the TOYOTA hand-
held tester, depress the brake pedal and hold it to
bleed the right front brake caliper.
(3) Repeat step (2) until there are no more air bubbles
in the fluid.
(h) Bleed left front brake line.
(1) Select ºFL LINEº on the TOYOTA hand-held tester.
(2) With ºFL LINEº turned ON with the TOYOTA hand-
held tester, depress the brake pedal and hold it to
bleed the left front brake caliper.
(3) Repeat step (2) until there are no more air bubbles
in the fluid.
(i) w/ ABS & TRAC & VSC only:
Bleed rear brake line.
(1) Select ºRR LINEº on the TOYOTA hand-held tester.
(2) With ºRR LINEº turned ON with the TOYOTA hand-
held tester, bleed the left and right rear brake cali-
per.
(j) Disconnect the TOYOTA hand-held tester from DLC3.
(k) Clear the DTC (See page DI-505).
3. In case of using ABS actuator checker (SST):
BLEED HYDRAULIC BRAKE BOOSTER
HINT:
If the hydraulic brake booster has been disassembled, discon-
nect the brake line from the hydraulic brake booster or if the res-
ervoir becomes empty, bleed the hydraulic brake booster.
(a) Disconnect the 2 connectors from the hydraulic brake
booster.