Toyota LAND CRUISER Operating manual

CAUTION
Thismanualdoesnotincludeallthenecessaryitemsaboutrepairandservice,thismanualismade
forthepurposeoftheuseforthepersonswhohavespecialtechniquesandcertifications.Inthe
casesthatnon-specializedoruncertified techniciansperformrepairorserviceonlyusingthismanu-
alorwithoutproperequipmentortool,thatmaycausesevereinjurytoyou orotherpeoplearound
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.

FOREWORD
Thissupplementhasbeenpreparedtoprovideinformation
coveringgeneralservicerepairsforthechassisandbodyof
theTOYOTALANDCRUISER(Hardtop,CanvasTopandSta-
tionWagon)whichunderwentchangesinAugust,1992.
Applicablemodels:
Hardtop& CanvasTopRJ70,73,77series
LJ70,72,73,77,79series
FZJ7O,73,75series
PZJ70,73,75series
HZJ7O,73,75series
StationWagonFZJ8Oseries
HZJ80series
HDJ80series
Fortheservicespecificationsandrepairproceduresofthe
abovemodelotherthanthoselistedinthissupplement,refer
tothefollowingmanuals.
©2004TOYOTAMOTORCORPORATIONA)|informatjoninthismanua|isbasedonthelatestproductin-
Allrightsreserved.Thisbookmaynotbeformationatthetimeofpublication.However,specifications
reproducedorcopied,inwholeorinpart,andproceduresaresubjecttochangewithoutnotice,
withoutthewrittenpermissionofToyota
MotorCorporation.
FirstPrinting:Sep.17,199201-920917-00
26thPrinting:Jan.7,200426-040107-02-2TOYOTAMOTORCORPORATION

INTRODUCTION
CLUTCH
MANUALTRANSMISSION
AUTOMATICTRANSMISSION
TRANSFER
PROPELLERSHAFT
SUSPENSIONANDAXLE
BRAKESYSTEM
BODYELECTRICALSYSTEM
AIRCONDITIONINGSYSTEM
ELECTRICALWIRINGDIAGRAMS

IN-1
INTRODUCTION
HOWTOUSETHISMANUALIN-2
IDENTIFICATIONINFORMATIONIN-5
GENERALREPAIRINSTRUCTIONSIN-6
PRECAUTIONIN-9
VEHICLELIFTANDSUPPORTLOCATIONS••IN-16
Hardtop& CanvasTopIN-16
StationWagonIN-18
ABBREVIATIONSUSEDINTHISMANUAL•••IN-19
STANDARDBOLTTORQUE
SPECIFICATIONSIN-20

IN-2INTRODUCTION- HOWTOUSETHISMANUAL
HOWTOUSETHISMANUAL
IN002-09
INDEX
AnINDEXisprovidedonthefirstpageofeachsectiontoguideyoutotheitemtoberepaired.
Toassistyouinfindingyourwaythroughthemanual,theSectionTitleandmajorheadingare
givenatthetopofeverypage.
GENERALDESCRIPTION
Atthebeginningofeachsection,a GeneralDescriptionisgiventhatpertainstoallrepair
operationscontainedinthatsection.
Readtheseprecautionsbeforestartinganyrepairtask.
TROUBLESHOOTING
TROUBLESHOOTINGtablesareincludedforeachsystemtohelpyoudiagnosetheproblemand
findthecause.
PREPARATION
PreparationliststheSST(SpecialServiceTools),recommendedtools,equipment,lubricantand
SSM(SpecialServiceMaterials)whichshouldbepreparedbeforebeginningtheoperationand
explainsthepurposeofeachone.
REPAIRPROCEDURES
Mostrepairoperationsbeginwithanoverviewillustration.Itidentifiesthecomponentsand
showshowthepartsfittogether.
Example:
FillerCap
Float
ReservoirTank
Grommet
ClevisPin
GasketClip
Slotted
SpringPin
Specifiedtorque
Non-reusablepart
Piston
PushRod
Washer
SnapRingLockNut
Clevis

INTRODUCTION- HOWTOUSETHISMANUALIN-3
Theproceduresarepresentedina step—by—stepformat:
•Theillustrationshowswhattodoandwheretodoit.
•Thetaskheadingtellswhattodo.
•Thedetailedtexttellshowtoperformthetaskandgivesotherinformationsuchas
specificationsandwarnings.
Example:
Thisformatprovidestheexperiencedtechnicianwitha FASTTRACKtotheinformationneeded.
Theuppercasetaskheadingcanbereadata glancewhennecessary,andthetextbelowit
providesdetailedinformation.Importantspecificationsandwarningsalwaysstandoutinbold
type.
REFERENCES
Referenceshavebeenkepttoa minimum.However,whentheyarerequiredyouaregiventhe
pagetoreferto.
SPECIFICATIONS
Specificationsarepresentedinboldtypethroughoutthetextwhereneeded.Youneverhaveto
leavetheproceduretolookupyourspecifications.Theyarealsofoundattheendofeachsection,
forquickreference.

INTRODUCTION- HOWTOUSETHISMANUAL
SIUNIT
TheUNITSgiveninthismanualareprimarilyexpressedaccordingtotheSIUNIT(lnternational
SystemofUnit),andalternatelyexpressedinthemetricsystemandintheEnglishSystem.
Example:
Torque:30Nm(310kgfcm,22ftlbf)
CAUTIONS,NOTICES,HINTS:
•CAUTIONSarepresentedinboldtype,andindicatethereisa possibilityofinjurytoyouor
otherpeople.
•NOTICESarealsopresentedinboldtype,andindicatethepossibilityofdamagetothe
componentsbeingrepaired.
•HINTSareseparatedfromthetextbutdonotappearinbold.Theyprovideadditional
informationtohelpyouperformtherepairefficiently.
IN-4

INTRODUCTION- IDENTIFICATIONINFORMATIONIN-5
IDENTIFICATIONINFORMATION
VEHICLEIDENTIFICATIONNUMBER
Thevehicleidentificationnumberisstampedontheoutersur-
faceofthefrontrightsideframe.Thisnumberisalsostamped
onthemanufacturer'snameplate.
A:VehicleIdentificationNumber
B:Manufacturer'sNamePlate
ENGINESERIALNUMBER
Theengineserialnumberisstampedontherightsideofthe
cylinderblock.

IN-6INTRODUCTION- GENERALREPAIRINSTRUCTIONS
GENERALREPAIRINSTRUCTIONS
INOO5-09
1.Usefender,seatandfloorcoverstokeepthevehicle
cleanandpreventdamage.
2.Duringdisassembly,keeppartsintheappropriate
ordertofacilitatereassembly.
3.Observethefollowing:
(a)Beforeperformingelectricalwork,disconnect
thenegativecablefromthebatteryterminal.
(b)Ifitisnecessarytodisconnectthebatteryfor
inspectionorrepair,alwaysdisconnectthecable
fromthenegative(—)terminalwhichisgrounded
tothevehiclebody.
(c)Topreventdamagetothebatteryterminalpost,
loosentheterminalnutandraisethecablestr-
aightupwithouttwistingorpryingit.
(d)Cleanthebatteryterminalpostsandcableter-
minalswitha cleanshoprag.Donotscrapethem
witha fileorotherabrasiveobjects.
(e)Installthecableterminaltothebatterypostwith
thenutloose,andtightenthenutafterinstalla-
tion.Donotusea hammertotaptheterminal
ontothepost.
(f)Besurethecoverforthepositive(+)terminalis
properlyinplace.
4.Checkhoseandwiringconnectorstomakesurethat
theyaresecureandcorrect.
5.Non—reusableparts
(a)Alwaysreplacecotterpins,gaskets,O—ringsand
oilsealsetc.withnewones.
(b)Non—reusablepartsareindicatedinthecom-
ponentillustrationsbythe"•"symbol.
6.Precoatedparts
Precoatedpartsareboltsandnuts,etc.thatare
coatedwitha seallockadhesiveatthefactory.
(a)Ifa precoatedpartisretightened,loosenedor
causedtomoveinanyway,itmustberecoated
withthespecifiedadhesive.

INTRODUCTION- GENERALREPAIRINSTRUCTIONSIN-7
(b)Whenreusingprecoatedparts,cleanofftheold
adhesiveanddrywithcompressedair.Then
applythespecifiedseallockadhesivetothebolt,
nutorthreads.
(c)Precoatedpartsareindicatedin thecomponent
illustrationsbythe"^k" symbol.
7.Whennecessary,usea sealerongasketstoprevent
leaks.
8.Carefullyobserveallspecificationsforbolttightening
torques.Alwaysusea torquewrench.
9.Useofspecialservicetools(SST)andspecialservice
materials(SSM)mayberequired,dependingonthe
natureoftherepair.BesuretouseSSTandSSM
wherespecifiedandfollowtheproperworkproce-
dure.A listofSSTandSSMcanbefoundinthe
preparationpartatthefrontofeachsectioninthis
manual.
10.Whenreplacingfuses,besurethenewfusehasthe
correctamperagerating.DONOTexceedtheratingor
useonewitha lowerrating.
IllustrationSymbolPartNameAbbreviation
FUSE
FUSE
MEDIUMCURRENTFUSE
M-FUSE
HIGHCURRENTFUSE H-FUSE
FUSIBLELINKFL
CIRCUITBREAKERCB
Fuse
EqualAmperageRating

IN-8INTRODUCTION- GENERALREPAIRINSTRUCTIONS
11.Caremustbetakenwhenjackingupandsupporting
thevehicle.Besuretoliftandsupportthevehicleat
theproperlocations(SeepagesIN—16to18).
(a)Ifthevehicleistobejackeduponlyatthefront
orrearend,besuretoblockthewheelsatthe
oppositeendinordertoensuresafety.
(b)Afterthevehicleisjackedup,besuretosupport
itonstands.Itisextremelydangeroustodoany
workona vehicleraisedona jackalone,evenfor
asmalljobthatcanbefinishedquickly.
12.Observethefollowingprecautionstoavoiddamageto
theparts:
(a)DonotopenthecoverorcaseoftheECUunless
absolutelynecessary.(IftheICterminalsare
touched,theICmaybedestroyedbystaticele-
ctricity.)
(b)Todisconnectvacuumhoses,pullontheend,not
themiddleofthehose.
(c)Topullapartelectricalconnectors,pullonthe
connectoritself,notthewires.
(d)Becarefulnottodropelectricalcomponents,
suchassensorsorrelays.Iftheyaredroppedon
ahardfloor,theyshouldbereplacedandnot
reused.
(e)Whensteamcleaninganengine,protectthe
distributor,airfilter,andVCVfromwater.
(f)Neveruseanimpactwrenchtoremoveorinstall
temperatureswitchesortemperaturesensors.
(g)Whencheckingcontinuityatthewireconnector,
insertthetesterprobecarefullytopreventter-
minalsfrombending.
(h)Whenusinga vacuumgauge,neverforcethe
hoseontoa connectorthatistoolarge.Usea
step—downadapterinstead.Oncethehosehas
beenstretched,itmayleak.
13.Taghosesbeforedisconnectingthem:
(a)Whendisconnectingvacuumhoses,usetagsto
identifyhowtheyshouldbereconnected.
(b)Aftercompletinga job,doublecheckthatthe
vacuumhosesareproperlyconnected.A label
underthehoodshowstheproperlayout.
WRONGCORRECT
WRONGCORRECT

INTRODUCTION- PRECAUTIONIN-9
PRECAUTION
moo*-01
FORVEHICLESEQUIPPEDWITHA CATALYTICCONVERTER
CAUTION:Iflargeamountsofunburnedgasolineflowintotheconverter,itmayoverheatandcreate
afirehazard.Topreventthis,observethefollowingprecautionsandexplainthemtoyourcustomer.
1.Useonlyunleadedgasoline.
2.Avoidprolongedidling.
Avoidrunningtheengineatidlespeedformorethan20minutes.
3.Avoidsparkjumptest.
(a)Performsparkjumptestonlywhenabsolutelynecessary.Performthistestasrapidlyaspossible.
(b)Whiletesting,neverracetheengine.
4.Avoidprolongedenginecompressionmeasurement.
Enginecompressiontestsmustbedoneasrapidlyaspossible.
5.Donotrunenginewhenfueltankisnearlyempty.
Thismaycausetheenginetomisfireandcreateanextraloadontheconverter.
6.Avoidcoastingwithignitionturnedoffandprolongedbraking.
7.Donotdisposeofusedcatalystalongwithpartscontaminatedwithgasolineoroil.
FORVEHICLESWITHANAUDIOSYSTEM
WITHBUILT-INANTI-THEFTSYSTEM
AudioSystemdisplayingthesign" ANTI— THEFT
SYSTEM"shownonthelefthasa built-inanti-theft
systemwhichmakestheaudiosystemsoundlessif
stolen.
Ifthepowersourcefortheaudiosystemiscuteven
once,theanti—theftsystemoperatessothatevenif
thepowersourceisreconnected,theaudiosystem
willnotproduceanysoundunlesstheIDnumber
selectedbythecustomerisinputagain.Accordingly,
whenperformingrepairsonvehiclesequippedwith
thissystem,beforedisconnectingthebatterytermi-
nalsorremovingtheaudiosystemthecustomer
shouldbeaskedfortheIDnumbersothatthetech-
niciancaninputtheIDnumberafterwards,orelsea
requestmadetothecustomertoinputtheIDnumber.
ForthemethodtoinputtheIDnumberorcancelthe
anti—theftsystem,refertotheOwner'sManual.
CassetteTapeSlotCover

IN-10INTRODUCTION- PRECAUTION
WHENSERVICINGFULL-TIME4WD
VEHICLES
Thefull—time4WDLandCruiserStationWagonis
equippedwiththemechanicallocktypecenterdif-
ferentialsystem.Whencarryingoutanykindofser-
vicingortestingona full—time4WDinwhichthe
frontorrearwheelsaremadetorotate(brakingtest,
speedometertest,on—vehiclewheelbalancing,etc.),
orwhentowingthevehicle,besuretoobservethe
precautionsgivenbelow.Ifincorrectpreparationsor
testproceduresareused,thetestcannotbesuc-
cessfullycarriedout,andmaybedangerousaswell.
Therefore,beforebeginninganysuchservicingor
test,besuretocheckthefollowingitems:
(1)Centerdifferentiallocktype
(2)(w/oABS)
Centerdifferentialmodeposition(FREEorLOCK)
(3)Whetherwheelsshouldbetouchinggroundor
jackedup
(4)Transmissiongearposition
(5)Transfergearposition(HorL)
(6)Maximumtestingvehiclespeed
(7)Maximumtestingtime
Alsobesuretoobservethefollowingcautions:
(1)Neveraccelerateordeceleratethevehiclesud-
denly.
(2)Observetheothercautionsgivenforeachindi-
vidualtest.
BeforeBeginningTest
Duringtestswitha braketesterorchassisdyna-
mometer,suchasbrakingforcetestsorspeedometer
tests,ifonlythefrontorrearwheelsaretoberotated,
itisnecessarytosetthepositionofthecenterdif-
ferentialtotheFREEpositionortotheLOCKposition
dependingonthetypeoftestbeingperformed.
(1)(w/oABS)
Selectthepositionofthecenterdifferentialby
pushingthecenterdifferentiallockswitchwith
thetransferselectleverto"H"position.
(2)Afterselectingtheposition,confirmtheopera-
tionofindicatorlight.

INTRODUCTION- PRECAUTIONIN-11
HINT:
•(w/oABS)
Movethevehiclebackwardorforwardslightlyif
theindicatorlightdoesnotoperatecorrectly
whenthecenterdifferentiallockswitchisturned
ONorOFF.
•Whenthetransferselectleverisputin"L"posi-
tion,thecenterdifferentialisputinLOCKcon-
ditionregardlessofthepositionofthecenter
differentiallockswitch.
•TransferH L GearShiftingProcedure:
Whenshifting,alwaysputtheshiftleverofthe
automatictransmissioninP orN range.Inother
ranges,thegearsofthetransferclash,andswi-
tchingcannotoccur.
(w/oABS)
CAUTIONSWHENCENTERDIFFERENTIALCON-
TROLSWITCHISTURNEDON
•Operatetheswitchonlywhenallfourwheelsare
stoppedorwhendrivingwiththewheelsina
straightline.
•Neveroperatetheswitchunderthefollowing
conditions.
(1)Whenanytireisslipping.
(2)Whenanytireisspinningfreely.
(3)Whenswervingorcornering.
IndicatorLight(
DIFFLOCK
3FF
[f~~\\
Rotate^
1\
SwitchOFF
i|\
o;
Rotate
)
IN0338INO3O3
FREEPosition
CenterDifferential
Lock
Control
Switch
OFF
Indicator
Light
OFF
Transfer
Select
Lever
H
Wheel
Aliftedwheelcanberotated
evenifonlyonewheelislifted
up,aslongastransmissionisin
Nrange.

IIM-12
INTRODUCTION- PRECAUTION
LOCKPosition
BrakingForceTest(VehicleSpeed:Below
0.5km/hor0.3mph)
Whenperforminglow— speedtypebraketester
measurements,observethefollowinginstructions.
(1)PutthecenterdifferentialinFREEposition.
•ShiftthetransferselectlevertoH position.
•(w/oABS)
TurnthecenterdifferentiallockswitchtoOFF
andcheckthatthecenterdifferentiallockindi-
catorlightgoesoff.
(2)ShiftthetransmissionshiftlevertoN range.
(3)Idletheengine,operatethebrakeboosterand
performthetest.
CenterDifferential
LockTransfer
Select
LeverWheel
Control
Switch
Indicator
Light
ON
OFF
ON
ON
H
L
Aliftedwheelcannotbero-
tatedifonlyonewheelislifted
up,eveniftransmissionisinN
range.

INTRODUCTION- PRECAUTIONIN-13
SpeedometerTestorOtherTests
(UsingSpeedometerTesterorChassis
Dynamometer)
(1)(w/oABS)
Removethefrontpropellershaft,putthecenter
differentialinLOCKposition,thenputtherear
wheelsonthetesterrollerandperformthetest.
(2)(w/ABS)
ShiftthetransferselectlevertoH position,jack
upthefrontwheels,thenputtherearwheelson
thetesterrollerandperformthetest.
(3)Whenperformingtests,observethefollowing
precautions.
•(w/oABS)
Checkthatthecenterdifferentialissecurelyin
LOCKcondition.
•Confirmthatthevehicleissecurelyimmobilised.
•Neveroperatethebrakessuddenly,suddenly
drivethewheels,orsuddenlydecelerate.
On—VehicleWheelBalancing
Whendoingon—vehiclewheelbalancingona full-
time4WDvehicle,topreventthewheelsfromrot-
atingatdifferentspeedsorindifferentdirections
fromeachother(whichcouldleadtodamagetothe
centerdifferentialortransfergears),alwaysbesure
toobservethefollowingprecautions:

IN-14INTRODUCTION- PRECAUTION
(1)Allfourwheelsshouldbejackedup,clearingthe
groundcompletely.
(2)(w/oABS)
ThecenterdifferentialshouldbeintheLOCKpo-
sitionwiththetransfergearinH position.
(3)(w/ABS)
ShiftthetransferselectlevertoH position.
(4)Theparkingbrakelevershouldbefullyreleased.
(5)Noneofthebrakesshouldbeallowedtodrag.
(6)Thewheelsshouldbedrivenwithboththeengine
andthewheelbalancer.
HINT:Whendoingthis,becarefuloftheotherwheels,
whichwillrotateatthesametime.
(7)Avoidsuddenacceleration,decelerationandbra-
king.
(8)Carryoutthewheelbalancingwiththetransmission
in"D"or"3"range.

INTRODUCTION- PRECAUTIONIN-15
WHENTOWINGFULL-TIME4WDVEHICLES
1.Useoneofthemethodsshownbelowtotowthevehicle.
2.Whenthereistroublewiththechassisanddrivetrain,usemethod(flatbedtruck)ormethod
(2)(slingtypetowtruckwithdollies)
3.RecommendedMethods:
EmergencyMethod:
HINT:Donotuseanytowingmethodsotherthanthoseshownabove.
Forexample,thetowingmethodshownbelowisdangerous,sodonotuseit.
TowingMethod
Condition
Parking
Brake
Transmission
ShiftLever
Position
Transfer
ShiftLever
Position
(w/oABS)
Center
Differential
LockSwitch
Center
Differential
FREE
/Normal\
\Driving/
OFF"H"PositionApplied"P"Range
Released
"N"Range"N"PositionOFF
OFF
"N"Position"N"Range Released
TowingwithRope
Sling-TypeTowTruck
(Frontwheelsmustbeableto
rotatefreely)
Sling-TypeTowTruckwith
Dollies
FlatBedTruck
HINT:Donottowthevehicleata speedfasterthan45km/h(30mph)ora
distancegreaterthan80km(50miles).
Duringtowingwiththistowingmethod,thereisa dangerofthedrivetrain
heatingupandcausingbreakdown,orofthefrontwheelsflyingoffthe
dolly.

IN16INTRODUCTION- VEHICLELIFTANDSUPPORTLOCATIONS
(Hardtop& CanvasTop)
VEHICLELIFTANDSUPPORTLOCATIONS
(Hardtop& CanvasTop)