Accu TOYOTA LAND CRUISER 1998 Factory Repair Manual

27 Noise NOISE PRODUCED BY VIBRATION OR SHOCK WHILE DRIVING
No
Ye s Is radio assembly properly installed?
Noise is produced from static eletricity accumulating in the vehicle body. With vehicles stationary lightly tap each system.
Is noise produced?Install properly.
Each system faulty. Is speaker properly installed?
No
No Ye s
Ye s
28 Noise NOISE PRODUCED WHEN ENGINE STARTS
NoYe s Whistling noise which becomes high-pitched when
accelerator strongly depressed, disappears shortly
after engine stops.Generator noise.
A/C noise.
Fuel gauge noise.
Horn noise.
Ignition noise.
Turn signal noise.
Washer noise.
Engine coolant temp. gauge noise.
Wiper noise. Whining noise occurs when A/C is operating.
Scratching noise occurs during sudden acceleration, driving on rough
roads or when ignition switch is turned ON.
Clicking sound is heard when horn button is pressed, then
released. Whirring/grating sound is heard when pushed
continuously.
Murmuring sound stops when engine stops.
Tick-tack noise occurs in co-ordination with blinking
offlasher.
Noise occurs during window washer operation.
Scratching noise occurs while engine is running,
and continues a while even after engine stops.
Scraping noise in line with wiper beat.
Other type of noiseYe s
Ye s
Ye s
Ye s
Ye s
Ye s
Ye s
Ye s No
No
No
No
No
No
No
No
BE-168
- BODY ELECTRICALAUDIO SYSTEM
2541 Author
: Date
:
2004 LAND CRUISER (RM1071U)

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.

BR0TI-09
F05529ABC BR-66
- BRAKEHYDRAULIC BRAKE BOOSTER
2202 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See
page BR-62).
INSTALL ACCUMULATOR BRACKET
When installing the accumulator bracket, adjust to secure the
clearance shown in the illustration on the left.
Standard clearance:
A + B: 4.1 mm (0.161 in.) or less
C: 0.3 - 3.8 mm (0.012 - 0.150 in.)
HINT:
Secure more than 0.3 mm (0.012 in.) clearance for A and B
each.

- 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.

Component to be alignedSection of repair manual for
relevant model
Front WheelsSuspension and Axle (SA) section
Rear WheelsSuspension and Axle (SA) section
Plopeller ShaftPropeller Shaft (PR) section
AIRBAG SENSOR ASSEMBLY

Never reuse the airbag sensor assembly involved in a collision when the SRS has deployed.

The connectors to the airbag sensor assembly should be connected or disconnected with the sensor
mounted on the floor. If the connectors are connected or disconnected while the airbag sensor as-
sembly is not mounted to the floor, it could cause undesired ignition of the supplemental restraint sys-
tem.

Work must be started after 90 seconds from the time the ignition switch is turned to the ºLOCKº posi-
tion and the negative (-) terminal cable is disconnected from the battery, even if only loosening the
set bolts of the airbag sensor assembly.
WIRE HARNESS AND CONNECTOR

The SRS wire harness is integrated with the cowl wire harness assembly and floor wire harness as-
sembly. The wires for the SRS wire harness are encased in a yellow corrugated tube. All the connec-
tors for the system are also a standard yellow color. If the SRS wire harness becomes disconnected
or the connector becomes broken due to an accident, etc., repair or replace it as shown on page.
2. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in section BR of the repair manual for the relevant model year when handling brake sys-
tem parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC
system.
3. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions
given in the repair manual for the relevant model during alignment and section Dl of this manual.
4. COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to the body panels. Strictly ob-
serve the following precautions to prevent damaging these components and the body panels during
handling.

Before repairing the body panels, remove their components or apply protective covers over the com-
ponents.

Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body
to ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
INTRODUCTIONIN-8

mm (in.)
(Three-Dimensional Distance)
Hole dia.
7 (0.28)
12y7 (0.47y0.28)
Name
Frame side rail working hole
Wire harness installation hole Symbol
D, d
E, e Hole dia.
12 (0.47) nut
8 (0.31) nut
16y16 (0.63y0.63)
Name
Winch installation nut
Accumulator installation nut
Frame side rail standard hole Symbol
A, a
B, b
C, c
FRAME DIMENSION-Upper Face
UZJ100 series
w HDJ100, 101 series w FZJ100 series
BODY DIMENSIONSDI-14

mm (in.) Imaginary
Standard
Line
(Two-Dimensional Distance)
Hole dia.
7 (0.28)
12y7 (0.47y0.28)
Name
Frame side rail working hole
Wire harness installation hole Symbol
D, d
E, e Hole dia.
12 (0.47) nut
8 (0.31) nut
16y16 (0.63y0.63)
Name
Winch installation nut
Accumulator installation nut
Frame side rail standard hole Symbol
A, a
B, b
C, c
FRAME DIMENSION-Upper Face
UZJ100 series
w HDJ100,101 series w FZJ100
series (Cont'd)
BODY DIMENSIONSDI-15