Toyota LAND CRUISER Betriebsanleitung

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

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

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