Toyota LAND CRUISER Operating instructions

FOREWORD
Thisrepairmanualhasbeenpreparedtoprovideinformation
coveringgeneralservicerepairsforthechassisandbodyof
theTOYOTALANDCRUISER(StationWagon).
Applicablemodels:FJ80series
HZJ80series
HDJ80series
Fortheservicespecificationsandrepairproceduresofthe
abovemodelotherthanthoselistedinthismanual,refertothe
followingmanuals.
ManualName
3FEngineRepairManual
3F-EEngineRepairManualSupplement
1PZ,1HZ,1HD-TEngineRepairManual
A441L,A440F,A442FAutomatic
TransmissionRepairManual
LandCruiserStationWagonElectrical
WiringDiagram
LandCruiserStationWagonNewCar
Features
Pub.No.
36253E
RM134E
RM172E
RM188E
EWD090F
NCF064E
Allinformationinthismanualisbasedonthelatestproductin-
formationatthetimeofpublication.However,specifications
andproceduresaresubjecttochangewithoutnotice.
TOYOTAMOTORCORPORATION

CAUTION
Thismanualdoesnotincludeallthenecessaryitemsaboutrepairandservice,thismanualismade
forthepurposeoftheuseforthepersonswhohavespecialtechniquesandcertifications.Inthe
casesthatnon-specializedoruncertifiedtechniciansperformrepairorserviceonlyusingthismanu-
alorwithoutproperequipmentortool,thatmaycausesevereinjurytoyouorotherpeoplearound
andalsocausedamagetoyourcustomer'svehicle.
Inordertopreventdangerousoperationanddamagestoyourcustomer'svehicle,besuretofollow
theinstructionshownbelow.
Mustreadthismanualthoroughly.Itisespeciallyimportanttohavegoodunderstandingallthe
contentswritteninthePRECAUTIONof"IN"section.
Theservicemethodwritteninthismanualisveryeffectivetoperformrepairandservice.When
performingtheoperationsfollowingtheproceduresusingthismanual,besuretousetoolsspe-
cifiedandrecommended.Ifusingnon-specifiedorrecommendedtoolsandservicemethod,
besuretoconfirmsafetyofthetechniciansandanypossibilityofcausingpersonalinjuryor
damagetothecustomer'svehiclebeforestartingtheoperation.
Ifpartreplacementisnecessary,mustreplacethepartwiththesamepartnumberorequivalent
part.Donotreplaceitwithinferiorquality.
Itisimportanttonotethatthismanualcontainsvarious"Cautions"and"Notices"thatmustbe
carefullyobservedinordertoreducetheriskofpersonalinjuryduringserviceorrepair,orthe
possibilitythatimproperserviceorrepairmaydamagethevehicleorrenderitunsafe.Itisalso
importanttounderstandthatthese"Cautions"and"Notices"arenotexhaustive,becauseitis
importanttowarnofallthepossiblehazardousconsequencesthatmightresultfromfailureto
followtheseinstructions.

TOYOTALANDCRUISER
(StationWagon)
REPAIRMANUAL
FORCHASSIS& BODY
INTRODUCTION
CLUTCH
MANUALTRANSMISSION
AUTOMATICTRANSMISSION
TRANSFER
PROPELLERSHAFT
SUSPENSIONANDAXLE
BRAKESYSTEM
STEERING
BODYELECTRICALSYSTEM
BODY
WINCH
AIRCONDITIONINGSYSTEM
SERVICESPECIFICATIONS
STANDARDBOLTTORQUESPECIFICATIONS
SSTANDSSM
ELECTRICALWIRINGDIAGRAMS
©2001TOYOTAMOTORCORPORATION
Allrightsreserved.Thisbookmaynotberepro-
ducedorcopied,inwholeorinpart,without,the
writtenpermissionofToyotaMotorCorporation.
FirstPrinting:Feb.28,199001-900228-00
28thPrinting:May29,200128-010529-05-2

Page
HOWTOUSETHISMANUALIN-2
IDENTIFICATIONINFORMATIONIN-4
GENERALREPAIRINSTRUCTIONSIN-4
PRECAUTIONSFORVEHICLESEQUIPPED
WITHA CATALYTICCONVERTERIN-7
PRECAUTIONSFORVEHICLESWITHANAUDIO
SYSTEMWITHBUILT-INANTI-THEFTSYSTEM....IN-7
PRECAUTIONSWHENSERVICINGFULL-TIME
4WDVEHICLESIN-8
PRECAUTIONSWHENTOWINGFULL-TIME
4WDVEHICLESIN-13
VEHICLELIFTANDSUPPORTLOCATIONSIN-14
ABBREVIATIONSUSEDINTHISMANUALIN-15
IN-1
INTRODUCTION

IN-2INTRODUCTION- HowtoUseThisManual
HOWTOUSETHISMANUAL
Toassistyouinfindingyourwaythroughthemanual,the
SectionTitleandmajorheadingaregivenatthetopofevery
page.
AnINDEXisprovidedonthefirstpageofeachsectionto
guideyoutotheitemtoberepaired.
Atthebeginningofeachsection,PRECAUTIONSaregiven
thatpertaintoall repairoperationscontainedinthatsection.
Read these precautions before starting any repair task.
TROUBLESHOOTINGtablesareincludedforeachsystemto
helpyoudiagnosetheproblemandfindthecause.Therepair
foreachpossiblecauseisreferencedintheremedycolumnto
quicklyleadyoutothesolution.
REPAIRPROCEDURES
Mostrepairoperationsbeginwithanoverviewillustration.It
identifiesthecomponentsandshowshowthepartsfitto-
gether.
Example:
PressurePortUnion
700(51,69)
ReservoirTank
420(30,41)
O-Ring
FlowControlValve
Spring
130(9,13)SnapRing
420(30,41)
O-Ring
FrontHousing
WaveWasher
RearPlate
CamRing
Rotor
OilSeal
RearHousing
O-Ring
VanePlate
FrontPlate
O-Ring
PumpShaft
StraightPinSnapRing
Specifiedtorque
Non-reusablepart
kg-cm(ft-lb,N-m)
SR3955

INTRODUCTION- HowtoUseThisManualIN-3
Theproceduresarepresentedina step-by-stepformat:
•Theillustrationshowswhat todoandwhere todoit.
•Thetaskheadingtellswhat todo.
•Thedetailedtexttellshow toperformthetaskandgives
otherinformationsuchasspecificationsandwarnings.
Example:
Task heading : what to do
21.CHECKPISTONSTROKEOFOVERDRIVEBRAKE
(a)PlaceSSTanda dialindicatorontotheoverdrive
brakepistonasshowninthefigure.
SST09350-30020(09350-06120)
Set part No. Component part No.
Detailed text: how to do task
(b)Measurethestrokeapplyingandreleasingthecom-
pressedair(4— 8 kg/cm2,57— 114psior392—
785kPa)asshowninthefigure.
Pistonstroke:1.40- 1.70mm(0.0551- 0.0669in.)
Specification
Thisformatprovidestheexperiencedtechnicianwitha FAST
TRACKtotheinformationneeded.Theuppercasetaskhead-
ingcanbereadata glancewhennecessary,andthetextbe-
lowitprovidesdetailedinformation.Importantspecifications
andwarningsalwaysstandoutinboldtype.
REFERENCES
Referenceshavebeenkepttoa minimum.However,when
theyarerequiredyouaregiventhepagetoreferto.
SPECIFICATIONS
Specificationsarepresentedinboldtypethroughoutthetext
whereneeded.Youneverhavetoleavetheproceduretolook
upyourspecifications.TheyarealsofoundinAppendixA,for
quickreference.
CAUTIONS,NOTICES,HINTS:
•CAUTIONSarepresentedinboldtype,andindicatethereis
apossibilityofinjurytoyouorotherpeople.
•NOTICESarealsopresentedinboldtype,andindicatethe
possibilityofdamagetothecomponentsbeingrepaired.
•HINTSareseparatedfromthetextbutdonotappearin
bold.Theyprovideadditionalinformationtohelpyoueffi-
cientlyperformtherepair.
Illustration:
what to do and where

INTRODUCTION— IdentificationInformation,GeneralRepairInstructions
IN-4
IDENTIFICATIONINFORMATION
VEHICLEIDENTIFICATIONNUMBER
Thevehicleidentificationnumberisstampedontheoutersur-
faceofthefrontrightsideframe.Thisnumberisalsostamped
onthemanufacturer'snameplate.
A:VehicleIdentificationNumber
B:Manufacturer'sNamePlate
ENGINESERIALNUMBER
Theengineserialnumberisstampedontherightsideofthe
cylinderblock.
GENERALREPAIRINSTRUCTIONS
1.Use,fenderseatandfloorcoverstokeepthevehicle
cleanandpreventdamage.
2.Duringdisassembly,keeppartsintheappropriateorder
tofacilitatereassembly.
3.Observethefollowing:
(a)Beforeperformingelectricalwork,disconnectthe
negativecablefromthebatteryterminal.
(b)Ifitisnecessarytodisconnectthebatteryforin-
spectionorrepair,alwaysdisconnectthecablefrom
thenegative(—)terminalwhichisgroundedtothe
vehiclebody.
(c)Topreventdamagetothebatteryterminalpost,
loosentheterminalnutandraisethecablestraight
upwithouttwistingorpryingit.
(d)Cleanthebatteryterminalpostsandcableterminals
witha shoprag.Donotscrapethemwitha fileor
otherabrasiveobject.
(e)Installthecableterminaltothebatterypostwiththe
nutloose,andtightenthenutafterinstallation.Do
notusea hammertotaptheterminalontothepost.
(f)Besurethecoverforthepositive( + ) terminalis
properlyinplace.
4.Checkhoseandwiringconnectorstomakesurethatthey
aresecureandcorrect.
IN0345
3Fand3F-EEngines
1HZand1HD-TEngines
IN0037
IN0294
FI1066

INTRODUCTION— GeneralRepairInstructionsIN-5
5.Non-reusableparts
(a)Alwaysreplacecotterpins,gaskets,O-ringsandoil
sealsetc.withnewones.
(b)Non-reusablepartsareindicatedinthecomponent
illustrationsbythesymbol.
6.Precoatedparts
Precoatedpartsareboltsandnuts,etc.thatarecoated
witha seallockadhesiveatthefactory.
(a)Ifa precoatedpartistightened,loosenedorcaused
tomoveinanyway,itmustberecoatedwiththe
specifiedadhesive.
(b)Recoatingofprecoatedparts
(1)Cleanofftheoldadhesivefromthebolt,nutor
threads.
(2)Drywithcompressedair.
(3)Applythespecifiedseallockadhesivetothe
boltornutthreads.
(c)Precoatedpartsareindicatedinthecomponentillus-
trationsbythesymbol.
7.Whennecessary,usea sealerongasketstoprevent
leaks.
8.Carefullyobserveallspecificationsforbolttightening
torques.Alwaysusea torquewrench.
9.Useofspecialservicetools(SST)andspecialservicema-
terials(SSM)mayberequired,dependingonthenature
oftherepair.BesuretouseSSTandSSMwherespeci-
fiedandfollowtheproperworkprocedure.A listofSST
andSSMcanbefoundatthebackofthismanual.
10.Whenreplacingfuses,besurethenewfusehasthecor-
rectamperagerating.DONOTexceedtheratingoruse
onewitha lowerrating.
11.Caremustbetakenwhenjackingupandsupportingthe
vehicle.Besuretoliftandsupportthevehicleatthe
properlocations(SeepageIN-14).
(a)Ifthevehicleistobejackeduponlyatthefrontor
rearend,besuretoblockthewheelsattheopposite
endinordertoensuresafety.
(b)Afterthevehicleisjackedup,besuretosupportit
onstands.Itisextremelydangeroustodoanywork
ona vehicleraisedona jackalone,evenfora small
jobthatcanbefinishedquickly.
SealLockAdhesive
IN0036
EqualAmperageRating
BE1367

IN-6INTRODUCTION— GeneralRepairInstructions
12.Observethefollowingprecautionstoavoiddamageto
theparts:
(a)DonotopenthecoverorcaseoftheECUunlessab-
solutelynecessary.
(IftheICterminalsaretouched,theICmaybede-
stroyedbystaticelectricity.)
(b)Topullapartelectricalconnectors,pullonthecon-
nectoritself,notthewires.
(c)Becarefulnottodropelectricalcomponents,such
assensorsorrelays.Iftheyaredroppedona hard
floor,theyshouldbereplacedandnotreused.
(d)Whencheckingcontinuityatthewireconnector,in-
sertthetesterprobecarefullytopreventterminals
frombending.
(e)Todisconnectvacuumhoses,pullontheend,not
themiddleofthehose.
(f)Whensteamcleaninganengine,protectthedistrib-
utor,coil,airfilterandVCVfromwater.
(g)Neveruseanimpactwrenchtoremoveorinstall
temperatureswitchesortemperaturesensors.
(h)Whenusinga vacuumgauge,neverforcethehose
ontoa connectorthatistoolarge.Usea step-down
adapterinstead.Oncethehosehasbeenstretched,
itmayleak.
13.Taghosesbeforedisconnectingthem:
(a)Whendisconnectingvacuumhouses,usetagsto
identifyhowtheyshouldbereconnected.
(b)Aftercompletinga job,doublecheckthatthevac-
uumhosesareproperlyconnected.A labelunder
thehoodshowstheproperlayout.
WRONG CORRECT
IN0252
WRONGCORRECT
IN0253
Example
IN0002