Toyota Land Cruiser 70 2017 Series User manual

BBG
2017September
Pub. No. BBGJ1007
BODY BUILDER’S GUIDE
Land Cruiser 70 series

INTRODUCTION
This guidebook contains descriptions of various basic matters required for and cautions to be exercised when
body-building or making alterations to the base vehicles in cab and chassis conditions.
All body-builders are requested to use this guidebook in design and conducting their body-building and alteration
work, always keeping in mind the direct or indirecteffect that the body-building or alteration job is expected to have
on the component parts and the system of the base vehicles.
The description in this guidebook is aimed at the vehicles manufactured in and after September, 2017. Note that
all the vehicles manufactured subsequently may be covered by different descriptions due to specification changes,
etc. This guidebook does not contain any service data or any description on methods of repair.
C&A Operations Division
TOYOTA MOTOR CORPORATION
Nisshin Education & Training Center
5-210, Sakae
Nisshin City, Aichi Prefecture
JAPAN 470-0113

CONTENTS
【1】BASIC MATTERS FOR BODY-BUILDING AND ALTERATIONS ································ 1
1. Compliance with laws and regulations ·············································································· 1
2. Securing basic performance and safety requirements ························································ 1
[1] Vehicle width ·········································································································· 2
[2] Rear overhang ········································································································ 2
[3] Limitation of front axle load ratio (when loaded with cargo) ············································· 3
[4] Height of gravity center ····························································································· 3
[5] Weight ··················································································································· 5
3. No alterations to important safety parts ············································································ 7
4. Preparation of operation manual and/or maintenance & inspection manual and their
installation on vehicles ···································································································· 7
5. Establishing after-sale service system ·············································································· 7
6. Model structure ··············································································································· 8
[1] Meaning of model code ···························································································· 8
[2] List of vehicle models ······························································································· 9
【2】DAMAGE WARNINGS ON MECHANISMS AND SYSTEMS
IN BODY-BUI LDING OR MAKING ALTERATIONS ··············································· 10
1. Engine and engine compartment ···················································································· 10
2. Frames ·························································································································· 10
3. Suspension ·····················································································································11
[1] Front suspension ···································································································· 11
[2] Rear suspension ···································································································· 11
[3] Tire ······················································································································ 11
[4] Bound limit of tire and differential················································································ 11
[5] Data for calculating the ground clearance of frame reference line ·································· 12
4. Body ····························································································································· 25
[1] Building and alterations to rear body and deck ··························································· 25
[2] Securing rear wheel house space ············································································ 28
[3] Protection against thermal effect of exhaust system ···················································· 28
5. Brake ···························································································································· 29
[1] Readjustment of LSPV ··························································································· 29
6. Drive units ···················································································································· 34
[1] Transmission ········································································································ 34
[2] Propeller shaft ······································································································ 34
7. Exhaust pipe ················································································································· 34
8. Battery ·························································································································· 35
[1] Wiring precautions ································································································· 35
[2] Change of battery mounting position ········································································ 35
[3] No overlaid connection of battery cables····································································· 36
[4] Replacement battery cable······················································································· 36
[5] Serviceability ········································································································ 36

9. Fuel tank ······················································································································· 37
[1] Addition and relocation of fuel tank ··········································································· 37
[2] Fuel tank position (steel tank) ·················································································· 37
[3] Serviceability·········································································································· 37
10. Spare tire carrier ·········································································································· 38
[1] General preventive measures ·················································································· 38
[2] Preventive measure for addition or alteration to spare tire carrier of wind-up type ············ 39
[3] Mounting position···································································································· 40
[4] Spare tire carrier handle··························································································· 41
11. Electrical wirings ········································································································· 43
[1] Consideration of existing vehicle wirings ··································································· 43
[2] Wiring addition ······································································································ 45
[3] Fuse ···················································································································· 49
[4] Switch ················································································································· 49
[5] Power supply ········································································································ 50
[6] Electrical wiring diagrams ······················································································· 51
12. Mounting rear combination lamp ·················································································· 52
13. License plate and license lamp ····················································································· 53
14. Reflector ····················································································································· 53
【3】DRAWINGS ····································································································· 54
1. Cab & Chassis drawing ··································································································· 54
2. Frame drawing ·············································································································· 58
3. Exhaust pipe drawing ···································································································· 64
4. Fuel tank installation-related drawings (Drawings for fuel tank) ········································ 68
5. Rear combination lamp-related chart ·············································································· 70
6. License lamp-related chart ····························································································· 71
7. Alternator output characteristic ······················································································ 73
【4】MAJOR TECHNICAL SPECIFICATIONS ····························································· 75

【1】-1. Compliance with laws and regulations, 【1】-2. Securing basic performance and safety requirements
1
【1】 BASIC MATTERS FOR BODY-BUILDING AND
ALTERATIONS
1. Compliance with laws and regulations
Body builders are required to design and fabricate their vehicles in such a manner that the vehicles built or
altered by them conform to the laws and regulations including safety and exhaust gas standards applied to
finished vehicles of their respective countries.
In making alterations to vehicles, care should be taken to design and fabricate them in such a manner as to
·
satisfy various related laws and regulations with an ample allowance.(Such laws and regulations always
represent the minimum limit of requirements to be met by the particular body-building or alteration work.)
Be sure that the materials used for body-building or alterations sufficiently meet the legal requirements, the
·
performance and safety standards, and that the resulting vehicle should be as lightweight as possible.
After body-building or alteration work is complete, check to see whether the materials or parts used for such
·
work are produced as designed and satisfy predetermined performance requirements and functions, and also
whether they contain no defects.
2. Securing basic performance and safety requirements
All body-builders are required to make sure that the inherent functions of the base vehicle are not lost by the
particular body-building or alterations. Also, make sufficient study to make sure that any changes of the
standard parts are free of functional problems from both technical and safety points of view.
The forward field of view should not be blocked by the body-building or alterations.
·
The chassis should not be damaged by the body-building or alterations.
·
No difference in weight between right and left wheels should occur due to the body-building or alterations.
·
All body-building jobs should be conducted in a manner avoiding local concentration of the load on the
·
chassis frame. In order to distribute the load over the frames, all the wheels should be located on the same
plane without distorting the frame.
The materials and parts involved in the body-building or alteration work should be designed and fabricated to
·
facilitate the inspection and maintenance of the chassis parts after they are mounted on the vehicles.
Limitations are set for the length, width, height and weight of the parts mounted according to the particular base
vehicle.Any restrictions which may be imposed in each country should be complied with.

【1】-2. Securing basic performance and safety requirements
2
[1] Vehicle width
In order to secure safe drive，the width of a mounted part should be 60 mm maximum as measured from the
outermost point of the cab of the base vehicle (not including the outside mirror).
[2] Rear overhang
The rear overhang should be as shown in the following depending on the body style and the length of the
wheelbase of the base vehicle.
Body style Rear overhang
Vehicle with cargo not protruding
from rear end
Ex: Van
Vehicle with cargo protruding from rear end
Ex: Cargo truck
The rear overhang is defined as the horizontal distance from the rear axle center to the rear end.

【1】-2. Securing basic performance and safety requirements
3
[3] Limitation of front axle load ratio (when loaded with cargo)
In order to secure running safety, the ratio of the load exerted on the front axle should be set as follows
(Distribute the cargo weight uniformly over the whole vehicle).
20%X100%
weightvehicleTotal weightaxleFront
ratio(%)loadaxleFront:Limit ≧








[4] Height of gravity center
The height of gravity center after body-building or alterations (unloaded vehicle) should be within the tolerance
shown in the table below. Install heavy building components in the vicinity of gravity center.
Models Gravity center height after
building or alteration Gravity center height of base vehicle (C&C)
GRJ79L-TJMRK3 Less than 1000 700
HZJ79L-TJMRS3 ↑↑
VDJ79R-TJMRYQ3 ↑↑
VDJ79R-TJMNYQ3 ↑↑
VDJ79R-DKMRYQ3 ↑730

【1】-2. Securing basic performance and safety requirements
4
Example calculation of gravity center height
·
How to determine vertical gravity center
Weight =
W (kg) Vertical gravity center = H (m) Moment (W x H) (kg-m)
Chassis w/cab 800 0.555 800 x 0.555 = 444.00
Built or
attache
d part
Floor joist
①45 565 +
2
155
= 6 42.5 ≒0.640 45 x 0.640 = 28.80
Rear body
floor ②70 565 + 155 +
2
70
= 755 ≒0.755 70 x 0.755 = 52.85
Rear body
front ③30 565 + 155 +
2
1200
= 1320 ≒1.320 30 x 1.320 = 39.60
Rear body
side ④130 565 + 155 +
2
1200
= 1320 ≒1.320 130 x 1.320 = 171.60
Rear body
tail ⑤45 565 + 155 +
2
1200
= 1320 ≒1.320 45 x 1.320 = 59.40
Rear body
roof ⑥35 565 + 155 + 70 + 1130 +
2
50
= 1945 ≒1.945 35 x 1.945 = 68.08
Total 355
Subtotal
(Vehicle weight) 1155 864.33
Gravity center height
Gravity center height
weighVehicle
momentTotal
1155
864.33

= 0.7483 →0.748 m
Related dimensions

【1】-2. Securing basic performance and safety requirements
5
[5] Weight
(1) Weight check
Measure and determine the curb weight of the built or altered vehicle. Take a measurement of the front axle
weight and the rear axle weight separately. (Each value must not be more than their respective tolerances.)
Curb weight
Overall vehicle weight
Overall front axle weight + Overall rear axle weight
With all optional parts, equipment and the rear
body with the fuel tank filled up
With all optional parts, equipment and the rear
body with the fuel tank filled up
+
All passengers and cargo to
full capacity
U-090 U-091

【1】-2. Securing basic performance and safety requirements
6
(2) Relation between building or alteration weight and load （Example)
Model
Item VDJ79R-T JMRYQ3
C.W. of base vehicle (C&C) 2,165 ~ 2,220
Special equipment, accessories,
permanent attachments A
Total weight of passengers, cargos and
baggages B
G.V.W. of finished vehicle 3,400
In the case where the weight of the finished vehicle [C.W. of base vehicle (C&C) + A] increases, the maximum
allowable load is reduced as the G.V.W. is fixed.
C.W. of base
vehicle (C&C)
Weight of built
or altered
equipment
Passengers
and cargo G.V.W.
2,165 ~ 2,220 + A + B ≦3,400
(3) Relation between overall vehicle weight and maximum allowable axle weight
(F) = Front axle weight after building or alteration ≦Front G.A.W.R.
(R) = Rear axle weight after building or alteration ≦Rear G.A.W.R.
(F) + (R) ≦G.V.W.
Refer to Major Technical Informations.

【1】-3. No alterations to important safety part 【1】-4. Preparation of operation manual and/or maintenance &
inspection manual and their installation on vehicles 【 1 】 -5. Establishing afte
r
-sale service system
7
3. No alterations to important safety parts
The important safety parts and components (such as the front axle，steering-related and brake-related parts)
must not be modified (either by welding，reinforcement，machining，heating or otherwise).
4. Preparation of operation manual and/or maintenance &
inspection manual and their installation on vehicles
In the event that thebody-building or alterations cause a change in the procedure for operation, maintenance, ·
inspection or adjustment of the standard vehicle, an operation manual should be prepared and installed on
the vehicle.
An operation manual and/or a maintenance & inspection manual specifying the procedure for the operation,
·
maintenance, inspection and adjustment including inspection intervals of the particular building or alterations
should be prepared and installed in the vehicle.
5. Establishing after-sale service system
Take adequate care to establish an after-sale service system for the parts built or altered.

【1】-6. Model structure
8
6. Model structure
[1] Meaning of model code
Basic ModelCode
GRJ79 : 1GR
-
FE E/G
HZJ79 : 1HZ E/G
VDJ79 : 1VD-FTV E/G
Super Long Wheel Base
Steering Position
R : Right Hand Drive
L : Left Hand Drive
BodyType
T : Single Cab Pick Up
D : Double Cab Pick Up
V
DJ79 R T- J M R Y Q 3
Package Model
3 : Cab & Chassis
Model
Destination
Blank : General Countries
Q : Australia
Door
J : 2 door
K : 4 door
Transmission
M : 5M/T-Floo
r
Grade
R : STD
N : LX
EngineType
K : DOHC and EFI
S : Diesel
Y : Common-rail Diesel

【1】-6. Model structure
9
[2] List of vehicle models
Destination General Australia
Wheel Base Super Long
Body Type Pick Up
Grade STD STD LX
Steering Position
Engine Transmission LHD RHD RHD
1GR-FE 5M/T GRJ79L-
TJMRK3
1HZ 5M/T
HZJ79L-
TJMRS3
1VD-FTV 5M/T VDJ79R- TJMRYQ3
DKMRYQ3
VDJ79R-
TJMNYQ3

【2】-1. En
g
ine and en
g
ine compartment 【2】-2. Frames
10
【2】 DAMAGE WARNINGS ON MECHANISMS AND SYSTEMS
IN BODY-BUILDING OR MAKING ALTERATIONS
1. Engine and engine compartment
Engine & Component must notbe modified.
2. Frames
The frame must not be modified.
·
When doing conversion, use standard deck mounts of frame. (see frame drawing)
·

【2】-3. Suspension
11
3. Suspension
[1] Front suspension
Don't alter the component parts of the front suspension in any event. Also, don't change the specifications as it
would adversely affect the vehicle performance.
[2] Rear suspension
①Don' alter the component parts of the rear suspension in any event. Also, don' change the specifications as
it would adversely affect the performance and propeller shaft function.
②In building ormaking alterations to the vehicle, take adequate care not to damage the leaf spring.Should the
leaf spring be damaged, change the whole assembly. (Don't change individual spring plate units, and don't
reuse spring plates.)
[3] Tire
Don't use any tire or disc wheel other than specified for the particularvehicle.
[4] Bound limit of tire and differential

【2】-3. Suspension
12
[5] Data for calculating the ground clearance of frame reference line
The ground clearance of the frame reference line should be calculated using the following formulae.
X = HF + TF
Y = HR + TR
Z = Y+ ሺY-Xሻ× L2
L1
X Ground clearance of frame reference line at front wheel center line (mm)
Y Groundclearance of frame reference line above rear wheel center line (mm)
Z Ground clearance of frame reference line of frame rear end (mm)
WF Front axle load (N)
WR Rear axle load (N)
L1Wheelbase (mm)
L2Frame rear overhang (mm)
TF Front tire radius (mm)
TR Rear tire radius (mm)
HF Distance from front wheel center to frame reference line (mm)
HR Distance from rear wheel center to frame reference line (mm)

【2】-3. Suspension
13
(1) How to determine the distance from wheel center to frame reference line
The distance from the wheel center to the frame reference line should be determined by calculating the
single-wheel sprung loads and then either by reading from the spring characteristic curve or calculating
according to the following equations.
Wf = WF - W1
2
Wr = WR - W2
2
HF = H0Wf
K
HR = H0Wr
K
Wf Single-wheel sprung load (front wheel) (N)
Wr Single-wheel sprung load (rear wheel) (N)
WF Front axle load (N)
WR Rear axle load (N)
W1Unsprung load (front axle) (N)
W2Unsprung load (rear axle) (N)
H0Distance from wheel center to frame reference line with 0-N
sin
g
le-wheel sprun
g
load
(
mm
)
K Spring constant (N/mm)
(2) Example of calculation
Let us calculate the frame reference line height from ground, Y, at the rear wheel center after rebuilding using
the model HZJ79L-TJMRS3 as an example. Suppose the rear axle weight after rebuilding as 13000N.
①Obtain the single wheel sprung load for rear wheel, Wr, using the following equation.
ex.
Wr= WR - W2
2= 13000 - 2453
2=5273.5N
1786×70×7-1
1696×70×7-1
1390×70×8-1
1270×70×8-1
1130×70×8-1
1010×70×8-1
830×70×15-1
550×70×15-1

【2】-3. Suspension
14
(3) Spring characteristics curve diagram
Front suspension (1/7) Vehicle Models
·GRJ79L-TJMRK3

【2】-3. Suspension
15
Front suspension (2/7) Vehicle Models
·HZJ79L-TJMRS3

【2】-3. Suspension
16
Front suspension (3/7) Vehicle Models
·GRJ79L-TJMRK3 ·HZJ79L-TJMRS3
(Heavy Duty with winch)