Toyota Land Cruiser 1988 Operating instructions

TOYOTA
1988 Land Cruiser
Repair Manual
• Engine
• Chassis
• Body
• Electrical
• Specifications

FOREWORD
This manual contains maintenance and repair procedures for
the 1988 LAND CRUISER.
Applicable model: FJ62 series
The manual
is divided into 17 sections and 4 appendixes with
a thumb index for each section at the edge of the pages.
For other service specifications and repair procedures of the
1988Land Cruiser than those listed
in this manual, refer to the
following manuals;
Manual Name Pub. No.
• Land Cruiser (Hea_vy-Duty) ~hassis
36262E
& Body Repair Manual
• A440F, A440L Automatic Transmission 36264E
Repair Manual
• 1988 Model.New Car Features NCF024U
All information in this manual is based on the latest product
information at the time
of publication. However, specifica-
tions and procedures
are subject to change without notice.
TOYOTA MOTOR CORPORATION

1988 TOYOTA LAND CRUISER
REPAIR
MANUAL
NOTE: The following screen toning letters sections refer to
the LAND CRUISER (Heavy-Duty)
REPAIR MANUAL FOR
CHASSIS AND BODY (Pub. No. 36262E).
INTRODUCTION IIIID
MAINTENANCE h!Jr!W
ENGINE MECHANICAL l@~tJI
EMISSION CONTROL SYSTEMS 1:(11
EFI SYSTEM liD
COOLING SYSTEM llt•J
LUBRICATION SYSTEM llll
IGNITION SYSTEM 11mJ
STARTING SYSTEM l'.il
CHARGING SYSTEM lij:l
AUTOMATICTRANSMISSION
FRONT
AXLE AND SUSPENSION
REAR AXLE AND SUSPENSION
BRAKE SYSTEM
@1987 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be
reproduced or copied, in whole or in part,
without the written permission of Toyota
Motor Corporation.
BODY ELECTRICAL SYSTEM
BODY
AIR CONDITIONING SYSTEM
SERVICE SPECIFICATIONS
STANDARD BOLTTORQUE SPECIFICATIONS
SST
AND SSM
ELECTRICALWIRING DIAGRAMS -•~• -

IN-1
INTRODUCTION
Page
HOW TO USE THIS MANUAL . . . . . . •. . . . . . . . •. . IN-2
IDENTIFICATION INFORMATION . •. . .. . . . . .. ••• IN-4
GENERAL REPAIR INSTRUCTIONS •. . . . . . . . . ••. • IN-4
PRECAUTIONS FOR VEHICLES EQUIPPED WITH
A CATALYTIC CONVERTER .................. IN-7
VEHICLE LIFT
AND SUPPORT LOCATIONS IN-8
ABBREVIATIONS USED IN THIS MANUAL . . •. •• IN-10

IN-2
INTRODUCTION -How to Use This Manual
Fuel Hose
Ikg-em (ft-lb, N-m) I: Specified torque
+ Non-reusable part
HOW TO USE THIS MANUAL
To assist you in finding your way through the manual, the Sec-
tion Title and major heading are given at the top of every page.
An INDEX
is provided on the first page of each section to guide
you
to the item to be repaired.
At the beginning of each section, PRECAUTIONS are given
that pertain
to all repair operations contained in that section.
Read these precautions before starting any repair task.
TROUBLESHOOTING tables are included for each system to
help you diagnose the system problem and find the cause. The
repair
for each possible cause is referenced in the remedy col-
umn to quickly lead you to the solution.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the components and shows how the parts fit
together.
Example:
Fuel Pump Bracket
j35 (30 in.-lb, 3.4)I
__ .,
- I
I
~ Clip
0
------Fuel Hose
e
~ '
Fuel Pump Filter
------+Clip
~-------Rubber Cushion
FA0555

INTRODUCTION -How to Use This Manual
IN-3
Illustration:
what to do and where
The procedures are presented in a step-by-step format:
• The illustration shows what to do and where to do it.
• The task heading tells what to do.
• The detailed text tells how to perform the task and gives
other information such
as specifications and warnings.
Example:
~ Task heading: what to do
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a) Place SST and a dial indicator onto the overdrive
brake piston
as shown in the figure.
SST 09350-30020 (09350-06120)
/ ~
Set part No. Component part No.
/Detail text: how to do it
(b) Measure the stroke applying and releasing the com-
pressed air (4 - 8 kg/cm2, 57 - 114 psi or 392 -
785 kPa) as shown in the figure.
Piston
stroke: 1.40- 1.70 mm (0.0551 - 0.0669 in.)
----Specification
This format provides the experienced technician with a FAST
TRACK to the information needed. The upper case task heading
can be read at a glance and only when necessary, the text
below
it provides detailed information. Important specifications
and warnings always stand out in bold type.
REFERENCES
References have been kept to a minimum. However, when they
are required you are given the page to go to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text in
the applicable step. You never have to leave the procedure to
look up your specs. All specifications are also found in Appen-
dix A, specifications, for quick reference.
WARNINGS, CAUTIONS, NOTES:
• WARNINGS are presented in bold type, and indicate there is
a possibility
of injury to you or other people.
• CAUTIONS are also presented in bold type, and indicate the
possibility of damage to the components being repaired.
• NOTES are separated from the text but do not appear in
bold. They provide additional information to help you effi-
ciently perform the repair.

IN-4
3F-E Engine
INTRODUCTION -Identification Information, General Repair Instructions
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped on the cowl panel
: of the engine compartment. This number is also stamped on
I
!m top of the instrument panel and the driver's door post.
I
I
I
I
IN0013
IN0037
ENGINE SERIAL NUMBER
The engine serial number is stamped on the right side of the
cylinder block.
GENERAL REPAIR INSTRUCTIONS
1. Use, seat and floor covers to keep the vehicle clean and
prevent damage.
2. During disassembly, keep parts in order
to facilitate
reassembly.
3. Observe the following:
(a) Before performing electrical work, disconnect the
negative cable from the battery terminal.
(b) If it is necessary to disconnect the battery for inspec-
tion or repair, always disconnect the cable from the
negative
(-) terminal which is grounded to the vehi-
cle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nutand raise the cable straight up
without twisting it or prying it.
(d) Clean the battery terminal posts and cable terminals
with a shop rag. Do
not scrape them with a file or
other abrasive object.
(e) Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation. Do
not use a hammer to tap the terminal onto the post.
(f)
Be sure the cover for the positive (+)terminal is pro-
perly in place.
4. Check hose
and wiring connectors to make sure that they
are secure and correct.

INTRODUCTION - General Repair Instructions
IN-5
IN0036
5. Non-reusable parts
(a) Always replace cotter pins, gaskets, 0-rings and oil
seals etc. with new ones.
(b) Non-reusable parts are indicated in the component
illustrations by the ... , symbol.
6. Precoated parts
Precoated parts
are the bolts and nuts, which have been
coated with a seal lock adhesive at the factory.
(a) If a precoated part is tightened, loosened or caused
to move in any way,
it must be recoated with the
specified adhesive.
(b) Recoating of precoated parts
(c)
(1) Clean off the old adhesive from the bolt, nut or
installation part threads.
(2) Dry with compressed air.
(3) Apply the specified seal lock adhesive to the
bolt or nut threads.
Precoated parts
are indicated in the component
illustrations by the "*" symbol.
7. When necessary, use a sealer on gaskets to prevent leaks.
8. Carefully observe all specifications for bolt tightening tor-
ques. Always use a torque wrench.
9. Use of special service tools (SST) and special service
materials (SSM) may
be required, depending on the nature
of the repair. Be sure to use SST and SSM where specified
and follow the proper work procedure. A list of SST and
SSM can be found at the back of this manual.
1 0. When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the fuse amp rating
or
use one of a lower rating.
11. Care must be taken when jacking up and supporting the
vehicle.
Be sure to lift and support the vehicle at the
proper locations
(See pages IN-8, 9).
(a) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to
ensure safety.
(b) After the vehicle is jacked up, be sure to support it on
stands. It
is extremely dangerous to do any work on
the vehicle raised on jack alone, even for a small job
that can be finished quickly.

IN-6
INTRODUCTION -General Repair Instructions
WRONG CORRECT
;:::
-~-'
IN0002
12. Observe the following precautions to avoid damage to the
parts:
(a) Do not open the cover or the case of the ECU
unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by static
electricity.)
(b) To disconnect vacuum hoses, pull on the end, not the
middle
of the hose.
(c) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(d) Be careful not to drop electrical components, such as
sensors or relays. If they are dropped on a hard floor,
they should be replaced and
not reused.
(e) When steam cleaning an engine, protect the IIA, from
water.
(f) Never use an impact wrench to remove or install ther-
mo switches or thermo sensors.
(g) When checking continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
(h) When using a vacuum gauge, never force the hose
onto a connector
that is too large. Use a step-down
adapter instead. Once the hose has been stretched,
it
may leak.
13. Tag hoses before disconnecting them:
(a) When disconnecting vacuum hoses, use tags to iden-
tify how they should be reconnected.
(b) After completing a job, double check that the
vacuum hoses are properly connected. A label on the
floor pan shows the proper layout.

INTRODUCTION -Precautions for Vehicles Equipped with a Catalytic Converter IN-7
PRECAUTIONS FOR VEHICLES EQUIPPED WITH A
CATALYTIC CONVERTER
WARNING: If large amounts of unburned gasoline flow
into the converter. it may overheat and create a fire hazard.
To
prevent this. observe the following precautions and
explain
them to your customer.
1. Use only unleaded gasoline.
2. Avoid prolonged idling.
Avoid running the engine at idle speed
for more than 20
minutes.
3.
Avoid spark jump test.
(a) Spark jump test only when absolutely necessary. Per-
form this test
as rapidly as possible.
(b) While testing. never race the engine.
4.
Avoid prolonged engine compression measurement.
Engine compression tests must be made as rapidly as
possible.
5. Do
not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra
load on the converter.
6.
Avoid coasting with ignition turned off and prolonged
braking.
7. Do
not dispose of a used catalyst along with parts con-
taminated
with gasoline or oil.

IN-8
-
Front \
i
\
l
INTRODUCTION -Vehicle Lift and Support Locations
VEHICLE LIFT AND SUPPORT LOCATIONS
JACK POSITION ----------·
Front . . . . . . .. Under the front differential
Rear . . . . . . . . Under the rear differential
SCREW TYPE JACK POSITION -----0
SUPPORT POSITION
Safety stand ............................ ~
IN0041
IN0042

INTRODUCTION -Abbreviations Used in This Manual IN-9
ABBREVIATIONS USED IN THIS MANUAL
A/C
AI
ALH
ASV
A!T, ATM
ATF
BTDC
BVSV
DP
ECU
EFI
EGR
ESA
EVAP
EX
Ex.
FIPG
IG
IN
ISC
Max.
MP
0/S
PCV
PS
SSM
SST
STD
S/W
TDC
TWC
U/S
vcv
vsv
VTV
w/
w/o
Air Conditioner
Air Injection
Automatic Locking Hub
Air Switching Valve
Automatic Transmission
Automatic Transmission Fluid
Before Top
Dead Center
Bimetal Vacuum Switching Valve
Dash Pot
Electronic Controlled Unit
Electronic
Fuel Injection
Exhaust
Gas Recirculation
Electronic Spark Advance
Evaporative (Emission Control)
Exhaust (manifold, valve)
Except
Formed
in Place Gasket
Ignition
Intake (manifold, valve)
Idle Speed Control
Maximum
Multipurpose
Oversize
Positive Crankcase Ventilation
Power Steering
Special Service Materials
Special Service Tools
Standard
Switch
Top Dead Center
Three-way Catalyst
Undersize
Vacuum Control Valve
Vacuum Switching Valve
Vacuum Transmitting Valve
With
Without

-MEMO-

MA-1
MAINTENANCE
Page
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . MA-2
MAINTENANCE OPERATIONS . . . . . . . . .. .. . . MA-4
GENERAL MAINTENANCE .................. MA-14
l®t!t
GENERAL NOTES:
• Every service item in the periodic maintenance list must be
performed.
• Failure to do even one item can cause the engine to run
poorly
and increase exhaust emissions.

MA-2
MAINTENANCE- Maintenance Schedule
MAINTENANCE SCHEDULE
Maintenance operations: A = Check and adjust if neces-
sary;
R = Replace, change or lubri-
cate;
I = Inspect and correct or re-
place if necessary
NORMAL CONDITION SCHEDULE
1\ Senrice lnwval Maintenance services beyond 60,000 miles
(96,000 km) should be performed at the same
(Odometer reading or months, intervals shown
in each maintenance schedule.
See page
System whichever comes first) Miles x 1,000 10 15 20 30
40
45 50 60 (item No.)
\
Km X 1,000 16 24 32 48 64 72 80 96
Maintenance items Months
12
18 24 36 48 54 60 72
ENGINE Valve clearance* A A A A
MA-6
(item 12)
Drive belts'1l I I MA-4
(item 1)
Engine oil and oil filter* R R R R R R MA-5
(item 5)
Engine
coolantC
2l R
MA-5
(item 6)
Exhaust pipes and mountings I I
MA-6 (item 10)
FUEL Air Filter* R R
MA-5 (item 4)
Fuel lines and connections I I MA-6
(item 9)
Fuel tank cap gasket R MA-6 (item 8)
IGNITION Spark plug** R R MA-4
(item 2)
EVAP Charcoal canister California only I
MA-5 (item 7)
EXHAUST Oxygen sensors* Except california R(5) MA-6 (item 11)
BRAKES Brake lining and drums I I I I MA-7
(item 13)
Brake pads and discs I I I I
MA-8
(item 15)
Brake line pipes and hoses
I I I I
MA-7
(item 1 ;3)
CHASSIS Steering linkage I I I I MA-8
(item 16)
Ball joints and dust covers I I I I
MA-8 (item 16)
Front wheel bearing and thrust bush
grease
R R MA-1 0 (item
21 )
Steering knuckle and chassis grease'3' R R R R MA-11 (item 22)
Propeller shaft grease<
3l R R R R MA-11 (item 22)
Automatic transmission, transfer (4WD), differential
MA-8
(item 17)
and steering gear box oil'4l I I I I
MA-9 (item 19)
MA-1 0 (item 20)
Bolts and nuts on chassis and body I I I I MA-12 (item 23)
Maintenance services indicated by a star (*) or asterisk ( *) are required under the terms of the Emission Control
Systems Warranty (ECSW). See Owner's Guide or Warranty Booklet for complete warranty information.
* For vehicle sold in California
* For vehicle sold outside California
NOTE:
(1) After 60,000 miles (96,000 km) or 72 months, inspect every 10,000 miles (16,000 km) or 12 months.
(2) After 60,000 miles (96,000
km) or 72 months. replace every 30,000 miles (48,000 km) or 36 months.
(3) If the propeller shaft
has been immersed in water. it should be re-greased within daily.
(4) Inspect the steering gear box for oil
leakage only.
(5) Replace at 80,000 miles (128,000 km) only.

MAINTENANCE- Maintenance Schedule
MA-3
Follow the severe condition schedule if vehicle is operated mainly under one or more of the following severe
conditions:
• Towing a trailer, using a camper or car top carrier.
• Repeat short trips less than 5 miles (8 km) and outside temperatures remain below freezing.
• Extensive idling and I or low speed driving for a long distance such as police, taxi or door-to-door delivery
use.
• Operating on dusty, rough muddy or salt spread roads.
SEVERE CONDITION SCHEDULE
N""'"' '"'"""'
Maintenance services beyond 60,000 miles (96.000 km) should be
Odometer reading or months, performed at the
same intervals shown in each maintenance schedule.
System whichever comes first) Miles x 1,000 5 7.5
10 15 20 22.5 25
30 35 37.5
40 45 50 52.5 55 60
See page
\
Km x 1.000 8
12 16 24 32 36 40 48 56 60 64 nl8o
84 88 96 (item No.)
Maintenance items Months 6 9 12
18
24 27 30 36 42
45 48 54 60 63 66 72
ENGINE Valve clearance* A A A A
MA-6
(item 12)
Orive belts<
1
> I I MA-4
(item 1)
Engine oil and oil filter*
R R A R R R A R R A R R MA-5
(item 5)
Engine coolant<2> R
MA-5 (item 6)
Exhaust pipes and mountings I I I I
MA-6
(item 10)
FUEL
Air Filter*<3l I I I I I R I I
:I
I I R
MA-5 (item 3, 4
Fuel lines and connections I I
MA-6 (item 9)
Fuel tank cap gasket R MA-6
(item 8)
IGNITION Spark
plug** R R MA-4
(item 2)
EVAP Charcoal canister California only I
MA-5
(item 7)
EXHAUST Oxygen sensors* Except california R(7)
MA-6 (item 11)
BRAKES Brake lining and drums I I I I I I I I
MA-7
(item 13)
Brake pads and discs I I I I I I I I
MA-8
(item 15)
Brake line pipes and hoses I I I I
MA-7 (item 13)
CHASSIS Steering linkage I I I I I I I I
MA-8
(item 16)
Ball joints and dust covers I I I I I I I I MA-8
(item 16)
Automatic transmission. transfer. differential
MA-8
(item 17)
steering gear box
oil<
4> R R R R
MA-9
(item 19)
MA-10 (item 20)
Front wheel bearing grease R R MA-10 (item
21 )
Steering knuckle and chassis grease<
5> R R R R R R R R MA-11 (item 22)
Propeller shaft
grease<
5l R R R R R R R R MA-11 (item 22)
Bolts and nuts on chassis and
body<
6> I I I I I I I I
MA-12 (item 23)
Maintenance services indicated by a star (*) or asterisk ( *) are required under the terms of the Emission Control
Systems Warranty (ECSW). See Owner's Guide or Warranty Booklet for complete warranty information.
* For vehicle sold in California
For vehicle sold outside California
NOTE:
(1) After 60,000 miles (96,000 km) or 72 months, inspect every 10,000 miles (16,000 km) or 12 months.
(2) After 60,000 miles (96,000 km) or 72 months, replace every 30,000 miles (48,000 km) or 36 months.
(3) Applicable when operating mainly on dusty roads. If not, follow the normal condition schedule.
(4) Inspect the steering gear box for oil leakage only.
(5) If the propeller shaft has been immersed in water, it should be re-greased within daily.
(6) Applicable when operating mainly on rough and/or muddy roads. If not, follow the normal condition schedule.
(7) Replace at 80,000 miles (128,000 km) only.

MA-4 MAINTENANCE- Maintenance Operation
CORRECT WRONG
f;m;:~~
ce
~?f~·
1
Clearan
1
Nippondenso
CORREC/
j
\
MA0035
MA0488 MA0489
CH0554
IG0268
IG0004
MAINTENANCE OPERATIONS
ENGINE
Cold Engine Operations
1. INSPECT DRIVE BELTS
2.
(a) Visually check the belt for cracks, oiliness or wear.
Check that the beltdose nottouch the bottom of the
pulley groove.
If necessary, replace the drive belt.
(b) Using a belt tension gauge, check the drive belt
tension.
Belt tension gauge:
Nipp.ondenso BTG-20 (95506-00020) or
Borroughs
No. BT-33-73F
Drive belt tension:
Alternator Used belt
New belt
PS Pump Used belt
(Air Pump) New belt
A/ C Used belt
New belt
100 ± 20 lb
145 ± 25 lb
100 ± 20 lb
145 ± 25 lb
80 ± 20 lb
125 ± 25 lb
If necessary, adjust the drive belt tension.
NOTE:
• When checking the tension, be sure the gauge is on
the belt protrusion. (ex. A/C drive belt).
• "New belt" refers to a belt which has been used less
than 5 minutes on a running engine.
• "Used belt" refers to a belt which has been used on a
running engine for 5 minutes or
more.
• After replacing the drive belt, check that it fits properly
in the ribbed grooves, especially in the places difficult
to
see.
• After installing a new belt,run the engine for about 5
minutes and then recheck the tension.
REPLACE
SPARK PLUGS
(a) Disconnectthe high-tension cords
of the spark plug
at the boot. Do not pull on the cords.
(b)
Remove the spark plugs.
(c) Set the gap
on the new plugs.
Correct electrode gap: 0.8 mm (0.031 in.)
Recommended spark plugs: NO W16EXR-U
NGK BPR5EY

MAINTENANCE- Maintenance Operations
MA-5
-~Air
A ,JL";e
c
...,_L-......1
Air should flow through freely and no
charcoal should
come out.
EC1 106
3. INSPECT AIR FILTER
(a) Visually check that the air cleaner element is not
excessively dirty, damaged or oily.
If
necessary, replace the air cleaner element.
(b)
Clean the element with compressed air.
First blowfrom inside thoroughly, then blow offthe out-
side of the element.
4. REPLACE
AIR FILTER
Replace the used air cleaner element with a new one.
5. REPLACE ENGINE OIL AND OIL FILTER
(See page
LU-4)
6.
Oil grade: API grade SF or SF/CC, multigrade,
fuel-efficient and recommended
viscosity oi I.
Engine oil capacity:
Drain and refill
w/o Oil filter change
7.0 liters (7.4 US qts, 6.2 Imp. qts)
w/ Oil filter change
7.8 liters (8.2 US qts, 7.0 Imp. qts)
REPLACE ENGINE COOLANT
(a) Drain the coolant from radiator and engine drain
cocks.
(b)
Close the drain cocks.
(c) Fill system with coolant.
Coolant capacity:
wl Front heater
17.5 liters (18.5 US qts, 15.4 Imp. qts)
w I Front and rear heaters
19.5 liters (20.6 US qts, 17.2 Imp. qts)
Use agood brand of ethylene-glycol base coolant, mixed
according to the manufacturer's instructions.
7.
CALIFORNIA VEHICLES ONLY:
INSPECT CHARCOAL CANISTER
(a) Disconnectthe hoses to the charcoal canister. Label
the hoses for correct installation.
(b) Plug pipe A with your finger and blow compressed
air (3
kg I cm
2 ,43
psi or 294 kPa) through pipe B
(fuel tank side).
• Check that air comes out of the bottom pipe C
without resistance.
• Check that no activated charcoal comes out.
If necessary, replace the charcoal canister.
NOTE: Do not attempt to wash the charcoal.
(c) Connect the hoses to the charcoal canister.