TOYOTA LAND CRUISER 1998 Factory Repair Manual

BR0K2-03
F05358
F05002
- BRAKEFRONT SPEED SENSOR
BR-69
2205 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REMOVAL
REMOVE SPEED SENSOR
(a) Disconnect the speed sensor connector.
(b) Remove the resin clip and 4 clamp bolts holding the sen-
sor harness from the steering knuckle and upper arm.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(c) Remove the speed sensor installation bolt and speed
sensor from the steering knuckle.
Torque: 8.0 N´m (82 kgf´cm, 71 in.´lbf)

BR0K8-20
F17443Non-reusable part N´m (kgf´cm, ft´lbf) : Specified torque

Gasket
Hydraulic Brake
Booster Assembly
LH Lower PanelFluid Level Warning
Switch Connector
No. 2 Heater to
Register Duct
Cowl Side TrimLower No. 1 Panel
15 (155, 11)
15 (155, 11)
PinClip
w/ ABS & BA &
TRAC & VSC Only:
Front Door Scuff Plate
5.0 (51, 44 in.´lbf)
ABS ECU or
ABS & BA &
TRAC & VSC
ECU
w/ ABS & BA & TRAC & VSC Only:
Master Cylinder Pressure Sensor Connector
15 (155, 11)
BR-58
- BRAKEHYDRAULIC BRAKE BOOSTER
2194 Author
: Date
:
2004 LAND CRUISER (RM1071U)
COMPONENTS

F13209
Reservoir Set Screw
Accumulator Bracket
No. 1 Pump
Bracket Actuator No. 1 TubeAccumulator

O-ring
Silencer Tube Grommet
PistonCylinder Boot
Clevis Reservoir Cap
No. 2 Pump
Bracket SleeveCollar
Booster Pump MotorCushion
Actuator Hose
Non-reusable part N´m (kgf´cm, ft´lbf) : Specified torque


25 (260, 19)
Cushion Fluid Level Warning Switch
Connector Clamp
Hydraulic Brake
Booster
Spring
15 (155, 11)

Wire Harness
Reservoir
1.7 (17.5, 15.2 in.´lbf)
54 (550, 36)
Washer
Master Cylinder
Pressure Sensor
81 (830, 60)
w/ ABS & BA
& TRAC & VSC:


- BRAKEHYDRAULIC BRAKE BOOSTER
BR-59
2195 Author
: Date
:
2004 LAND CRUISER (RM1071U)

F04472
SST
SST
BR12D-05
F04473
SST
F13233
30 mm
Deeper
Socket BR-62
- BRAKEHYDRAULIC BRAKE BOOSTER
2198 Author
: Date
:
2004 LAND CRUISER (RM1071U)
DISASSEMBLY
1. PLACE HYDRAULIC BRAKE BOOSTER IN VISE
Using SST, set the hydraulic brake booster in vise.
SST 09630-00014 (09631-00142),
09950-60010 (09951-00180, 09951-00190)
2. REMOVE FLUID LEVEL WARNING SWITCH CONNEC-
TOR CLAMP
(a) Disconnect the connector.
(b) Remove the bolt and clamp.
3. REMOVE RESERVOIR AND GROMMETS
(a) Remove reservoir cap.
(b) Remove the 3 set screws and pull out the reservoir.
Torque: 1.7 N´m (17.5 kgf´cm, 15.2 in.´lbf)
(c) Remove the 3 grommets.
4. REMOVE CLEVIS AND CYLINDER BOOT
(a) Loosen the lock nut, then remove the clevis and lock nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(b) Remove the cylinder boot.
5. REMOVE BRAKE ACTUATOR TUBE NO. 1
Using SST, remove the brake actuator tube No. 1.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
6. REMOVE BOOSTER PUMP AND ASSEMBLY
(a) Remove the actuator hose.
(b) Remove the 4 screws and wire harness from the booster
and pump.
(c) Remove the 2 bolts, accumulator bracket.
(d) Remove the 2 bolts and booster pump motor assembly.
(e) Remove the bolt and No. 1 pump bracket.
(f) Remove the 2 washers, 2 cushions, 2 collars and sleeve.
(g) Remove the 2 bolts and No. 2 pump bracket.
(h) Remove the cushion from No. 2 pump bracket.
7. ABS & BA & TRAC & VSC only:
REMOVE MASTER CYLINDER PRESSURE SENSOR
Using 30 mm deeper socket wrench and remove the oil pres-
sure sensor.
Torque: 81 N´m (830 kgf´cm, 60 ft´lbf)
NOTICE:
If replacing the master cylinder pressuer sensor, since the
sensor is non-reusable, use a sensor of the supply part No
shown below.
PART NO: 89637-30050

F04478Pin
F04503
SST
- BRAKEHYDRAULIC BRAKE BOOSTER
BR-63
2199 Author
: Date
:
2004 LAND CRUISER (RM1071U)
8. REMOVE PISTON
(a) Pressing the piston in with a screwdriver, use a pin or an
equivalent to push the snap ring from the hole in the body
then remove it with another screwdriver.
(b) Remove the piston, pulling straight out, not at an angle.
NOTICE:

If pulled out and installed at an angle, there is a possi-
bility that the cylinder bore could be damaged.

At the time of reassembly, be careful not to damage
the rubber lips on the pistons.
9. REMOVE ACCUMULATOR FROM BOOSTER PUMP
(a) Using SST, remove the accumulator.
SST 09318-12010
Torque: 54 N´m (550 kgf´cm, 36 ft´lbf)
(b) Remove the silencer tube, spring and O-ring.

BR0TH-09
F04504
BA
A: 20 mm (0.791 in.)
B: 30 mm (1.18 in.)
- BRAKEHYDRAULIC BRAKE BOOSTER
BR-65
2201 Author
: Date
:
2004 LAND CRUISER (RM1071U)
DISPOSAL
DISPOSAL METHOD OF ACCUMULATOR
(a) Place the accumulator in a vise, cover it with a cloth over.
(b) Using a saw, then cut the accumulator body slowly.
CAUTION:
Do not cut at a place except a stretch.
(c) When the outer body of the accumulator is cut, gas dis-
charges.

BR120-08
F06051
1
2 BR-64
- BRAKEHYDRAULIC BRAKE BOOSTER
2200 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSPECTION
INSPECT HYDRAULIC BRAKE BOOSTER PUMP MOTOR
OPERATION
(a) Connct the positive (+) lead from the battery to terminal
1 of pump motor, and the negative (-) lead to terminal 2.
(b) Check that the pump motor operation.

BR0KD-04
- BRAKEHYDRAULIC BRAKE BOOSTER
BR-67
2203 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-60).
HINT:

After installation, fill the brake reservoir with brake fluid and bleed brake system (See page BR-4).

Check for leaks.

F04470
Brake Pedal Effort Gauge
SST
SST
BR12B-07
BR-40
- BRAKEHYDRAULIC BRAKE BOOSTER
2176 Author
: Date
:
2004 LAND CRUISER (RM1071U)
HYDRAULIC BRAKE BOOSTER
ON-VEHICLE INSPECTION
1. CHECK HYDRAULIC BRAKE BOOSTER FLUID PRES-
SURE CHANGE
(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 light and stroke becomes longer.
(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):
Front brake pressureRear brake pressure
2,700 kPa (27.5 kgf/cm2, 391 psi)
or more0 kPa (0 kgf/cm2, 0 psi)
At 343 N (35 kgf, 77 lbf):
Front brake pressureRear brake pressure
3,950 kPa (40 kgf/cm2, 568 psi)
or more0 kPa (0 kgf/cm2, 0 psi)
(e) w/ ABS only, 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 pressureRear brake pressure
1,618 - 2,795kPa
(16.5 - 28.5 kgf/cm2, 234 - 405 psi)
1,716 - 2,893 kPa
(17.5 - 29.5 kgf/cm2, 249 - 419 psi)
At 98 N (10 kgf, 22 lbf):
Front brake pressureRear brake pressure
4,413 - 5,624 kPa
(45 - 57 kgf/cm2, 639 - 809 psi)
3,187 - 4,364 kPa
(32.5 - 44.5 kgf/cm2, 462 - 632 psi)
At 147 N (15 kgf, 33 lbf):
Front brake pressureRear brake pressure
7,208 - 8,436 kPa
(73.5 - 85.5 kgf/cm2, 1,043 - 1,214 psi)
4,609 - 5,786 kPa
(47 - 59 kgf/cm2, 667 - 838 psi)
At 196 N (20 kgf, 44 lbf):
Front brake pressureRear brake pressure
9,905 - 11,082 kPa
(101 - 113 kgf/cm2, 1,434 - 1,604 psi)
6,031 - 7,208 kPa
(61.5 - 73.5 kgf/cm2, 873 - 1,044 psi)

I24672
TOYOTA Hand-held Tester
- BRAKEHYDRAULIC BRAKE BOOSTER
BR-41
2177 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(f) w/ ABS & TRAC & VSC ECU only, 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 pressureRear brake pressure
1,618 - 2,795kPa
(16.5 - 28.5 kgf/cm2, 234 - 405 psi)
1,716 - 2,893 kPa
(17.5 - 29.5 kgf/cm2, 249 - 419 psi)
At 98 N (10 kgf, 22 lbf):
Front brake pressureRear brake pressure
4,413 - 5,624 kPa
(45 - 57 kgf/cm2, 639 - 809 psi)
4,609 - 5,786 kPa
(47 - 59 kgf/cm2, 668 - 839 psi)
At 147 N (15 kgf, 33 lbf):
Front brake pressureRear brake pressure
7,208 - 8,436 kPa
(73.5 - 85.5 kgf/cm2, 1,043 - 1,214 psi)
7,502 - 8,679 kPa
(76.5 - 88.5 kgf/cm2, 1,088 - 1,259 psi)
At 196 N (20 kgf, 44 lbf):
Front brake pressureRear brake pressure
9,905 - 11,082 kPa
(101 - 113 kgf/cm2, 1,434 - 1,604 psi)
10,346 - 11,523 kPa
(105.5 - 117.5 kgf/cm2,
1,501 - 1,671 psi)
2. w/ ABS only,
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 light and stroke becomes longer.
(c) 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-64).
(d) 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 ºACTIVE TESTº mode on the TOYOTA
hand-held tester.
HINT:

Please refer to the TOYOTA hand-held tester operator's
manual for further details.