Steering Wheel Freeplay
1. CHECK THAT STEERING WHEEL FREEPLAY IS CORRECT With the vehicle stopped and tires pointed straight ahead, rock the steering wheel gently back and forth with light finger pressure. Freeplay should not exceed the maximum Maximum play 40 mm 1.57 in. If incorrect, adjust or repair as required. b Turn the adjusting screw clockwise to decrease wheel freeplay and counterclockwise to increase it. NOTE Turn the adjusting screw in small increments and check the wheel freeplay between each adjustment....
Remove Door Trim
a Insert a screwdriver between the trim retainers and door panel to pry it loose. NOTE Tape the screwdriver tip before use. Disconnect the connector from the switch. b Partly tear off the service hole cover and disconnect the inside handle link from the door lock. 7. REMOVE INSIDE DOOR LOCK CONTROL a Disconnect the link from the door lock. c Remove the bolt and door lock control. 8. REMOVE OUTER AND INNER WEATHERSTRIP
Replace Light Control Switch And Headlight Dimmer Switch
a Remove the terminals from the connector. See page BE-3 b Remove the light control switch. c Remove the headlight dimmer switch. d Install the headlight dimmer switch. e Insert the spring into the lever and install the lever with the pin. f Place the ball on the spring, position the lever at HI and install the plate. g Insure that the switch operates smoothly. h Install the terminals to the connector. See page BE-3
POWER STEERING OnVehicle Inspection CHECKING DRIVE BELT DEFLECTION
Drive belt deflection at 10 kg 22.0 lb, 98 N New belt 7 - 9.5 mm 0.28 - 0.37 in. Used belt 8 - 10 mm 0.31 - 0.39 in. 3B Engine New belt 13 - 17 mm 0.51 - 0.67 in. Used belt 16 - 22 mm 0.63 - 0.87 in. 2H Engine New belt 6.5 - 8.5 mm 0.26 - 0.33 in. Used belt 7 - 9 mm 0.28 - 0.35 in. NOTE New belt refers to a new belt which has never been used. Used belt refers to a belt which has been used on a running engine for 5 minutes or more. After installing the drive belt, check that it fits properly in...
Check And Adjustment Of Clutch Pedal
1. CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height FJ HJ BJ 60 series 181 mm 7.13 in. FJ-HJ 70 series 186 mm 7.32 in. 2. IF NECESSARY, ADJUST PEDAL HEIGHT Loosen the lock nut and turn the stopper bolt or clutch switch until the height is correct. Tighten the lock nut. NOTE After adjusting the pedal height, check and adjust the pedal free play and push rod play or booster air valve stroke.
Remove Shift Fork Shaft
a Using a pin punch and hammer, drive out the slotted spring pin. b Remove the shift fork shaft from the shift fork. NOTE Use a set of soft jaws in the vise to protect the shift fork. 16. REMOVE TRANSFER INPUT GEAR BEARING, POWER TAKE-OFF DRIVE GEAR AND SPACER a Using SST, remove the transfer input gear bearing. SST 09950-20016 b Remove the power take-off drive gear and spacer. Using SST, remove the transfer input gear. SST 09950-20016 18. REMOVE O-RING FROM TRANSMISSION OUTPUT SHAFT ATM 19....
Install Transmission Assembly
a Install the guide pin in the torque converter. b Align the guide pin with one of the drive plate holes. c Align two sleeves on the block with the converter housing. d Temporarily install one bolt. CAUTION Be careful not to tilt the transmission forward because the torque converter could slide out. e Install the nine transmission mounting bolts. Torque 8 mm bolt 185 kg-cm 13 ft-lb, 18 Nm 10 mm bolt 380 kg-cm 27 ft-lb, 37 N m 12 mm bolt 730 kg-cm 53 ft-lb, 72 N-m
Installation Of Transmission
1. MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR Set up a dial indicator and measure the drive plate runout. If runout exceeds 0.20 mm 0.0079 in. or if the ring gear is damaged, replace the drive plate. If installing a new drive plate, note the orientation of spacers and tighten the bolts. Torque 3F engine 890 kg-cm 64 ft-lb, 87 N-m 2H engine 1,000 kg-cm 72 ft-lb, 98 N-m 2. MEASURE TORQUE CONVERTER SLEEVE RUNOUT a Temporarily mount the torque converter to the drive plate. Set up a dial...
Check Torque Converter Installation
Using calipers and a straight edge, measure from the installed surface to the front surface of the transmission housing. 3F engine 16.5 mm 0.650 in. or more 2H engine 41.2 mm 1.622 in. or more CAUTION Install the converter horizontally to prevent oil seal from damage.
Replacement Of Brake Pads
2. INSPECT PAD LINING THICKNESS Check the pad thickness through the cylinder inspection hole and replace pads if not within specification. Standard thickness 10.0 mm 0.394 in. Minimum thickness 1.0 mm 0.039 in. 4. CHECK ROTOR DISC THICKNESS See step 2 on page BR-41 5. CHECK ROTOR DISC RUNOUT See step 3 on page BR-41
Inspection Of Low Oil Pressure Warning
1. INSPECT WARNING LIGHT OPERATION a Disconnect the connector from the pressure switch. Connect the wire harness side connector terminal and body ground. b Turn the Ignition switch or starter switch on. Check that the warning light lights. If operation is not correct, remove and test the bulb. 2. INSPECT WARNING SWITCH OPERATION a Check that there Is continuity between the terminal and body ground with the engine stopped. b Check that there is no continuity between the terminal and body ground...
Heater
Heater circuit breaker OFF Heater relay faulty Heater blower switch faulty Heater blower resistor faulty Heater blower motor faulty Wiring or ground faulty Check relay Check switch Check resistor Replace motor Repair as necessary Replace valve Repair dampers Repair ducts Replace radiator Repair control ui Front Heater Blower Switch INSPECTION OF HEATER BLOWER SWITCH
Troubleshooting Fmc
I Magnetic clutch does not engage ' a A C fuse blown d Temp, control resistor faulty i Heater relay faulty j Circuit braker faulty k Pressure switch faulty I Compressor does not rotate properly b Compressor faulty I Expansion valve faulty i Fusible plug on receiver blown or clog Replace fuse and check f j Check magnetic clutch Check A C switch i Check resistor Check thermistor Check amplifier Repair as necessary Check refrigerant pressui Check heater relay Check circuit braker Check pressure...
Remove Ignition Key Cylinder
a Place the ignition key at the ACC position. b Push down the stop key with a thin rod, and pull out the key cylinder. 5. REMOVE UPPER BRACKET WITH MAIN SHAFT FROM BREAKAWAY BRACKET a Remove the support reinforcement with two bolts. b Loosen the broken bolt by tapping the chisel. d Disconnect the upper bracket from the breakaway bracket. 7. REMOVE MAIN SHAFT FROM UPPER BRACKET a Using SST, compress the main shaft and upper bracket.
Install Door Lock
Connect the connector to the door lock solenoid and install the door lock with the three screws and bolt, w o door lock solenoid Install the door lock with the three screws. Install the door lock cylinder with the retainer and connect the control link to it. Install the outside handle with the two bolts and connect the control link to it. 5. CONNECT INSIDE LOCKING CONTROL LINK TO DOOR LOCK Install the rear lower frame with two bolts, w o soft top Install the rear lower frame with bolt.
Inspection Of Pressure Switch
a Connect the hoses of the manifold gauge set to the compressor service valves and observe the gauge reading. b The gauge reading must be more than 2.1 kg cm 30 psi, 206 kPa when the ambient temperature is higher than 0 C 32 F . If the pressure is less than 2.1 kg cm2 30 psi, 206 kPa , charge the refrigerant. a Remove the glove box. Ex. Dual A C b Disconnect the lead wires of the A C harness. c Using an ohmmeter, check the continuity between the two terminals of the pressure switch. The...
Install Shift Shaft With Clutch Hub To Retainer
a Install the spring and locking ball to the retainer. b Using a pin punch, depress the locking ball, install the shift shaft into the retainer. 4. INSTALL OUTPUT GEAR INTO GEAR CASE 5. INSTALL NEW GASKET AND CLUTCH HUB WITH SHIFT SHAFT AND RETAINER TO GEAR CASE a Place a new gasket on the gear case. b Install the clutch hub with shift shaft and retainer into the gear case. 6. INSTALL SHIFT LEVER SUPPORT Torque 195 kg-cm 14 ft-lb, 19 N m 7. INSTALL COUNTER SHAFT GEAR, NO. 1 COUNTER GEAR AND...
Refrigerant Container
a When the refrigerant container is empty, close the pressure valves. b Remove the can tap valve from the container. c Attach the can tap valve to a new refrigerant con- d Purge the air from the center hose by barely opening the low pressure valve and loosening the valve disc. e Make a hole in the sealed tap of the new container and charge the system. CAUTION Be careful not to overcharge the refrigerant as it could cause failure of the bearings and belt. 7. WHEN SYSTEM IS FULLY CHARGED,...
Torque Specifications Bsv
Tilt steering support x Breakaway brack Tilt steering support stopper bolt Tilt steering support x Upper bracket Breakaway bracket x Column tube Column hole cover x Column tube Main shaft x Intermediate shaft Column hole cover x Body Breakaway bracket x Body Steering wheel x Main shaft Intermediate shaft No.1 x No.2 Upper bracket x Column tube Column hole cover x Body Column tube x Body Steering wheel x Main shaft Main shaft x Intermediate shaft Intermediate shaft x Worm shaft Worm bearing...
Install Door Glass
a Incline the door glass and install it to the window regulator. b w o ventilator window type Install the two glass channel mounting bolts. 12. w o Ventilator Window type INSTALL CLIP b Install the division bar se 12. w o Ventilator Window type INSTALL CLIP
Mechanical Winch Specifications
Input gear bushing Input gear x Shaft oi Drive shaft runout Spider bearing axial pla gt Snap ring thicknesses 38.000 - 38.0 38.4 mm 38.000 - 38.0 38.4 mm 38.000 - 38.0 38.3 mm 38.000 - 38.0
Inspect Disassembled Parts
Inspect the disassembled parts for wear, rust or damage. 2. MEASURE BRAKE SHOE LINING THICKNESS Standard thickness 6.5 mm 0.256 In. Minimum thickness 1.5 mm 0.059 in. If the shoe lining is less than minimum or shows signs of uneven wear, replace the brake shoes. NOTE If any of the brake shoes have to be replaced, replace all of the brake shoes In order to maintain even braking. 3. MEASURE BRAKE DRUM INSIDE DIAMETER Standard inside diameter 295.0 mm 11.614 in. Maximum inside diameter 297.0 mm...
At At At
Drag, binding or tie-U on 1-2, 2-3 or 3-OD Valve body faulty Transmission faulty Throttle cable out of adjustment Throttle cable and cam faulty Accumulator pistons faulty Valve body faulty Transmission faulty Throttle cable out of adjustment Throttle cable faulty Governor faulty Valve body faulty Transmission faulty Remedy Adjust throttle cable Inspect throttle cable and gt Inspect accumulator pistor Inspect valve body Disassemble and inspect tn Adjust throttle cable Inspect throttle cable...
Adjust Door Lock Striker Cco
a Check that the door fit and door lock linkages are adjusted correctly. b Adjust the door lock striker by loosening the screws. a Do not disassemble the damper because the cylinder is filled with pressurized gas. b If the damper is to be replaced, drill a 2.0 3.0 mm 0.079 - 0.118 in. hole in the bottom of the removed damper cylinder to completely release the high-pressure gas before disposing of it. c When drilling, chips may fly out so work carefully. d The gas is colorless, odorless and...
Removal Of Frp Top
1. REMOVE BOTH QUARTER PANEL NAME PLATES Using a screwdriver, pry out the name plate from the 1. Tape the screwdriver tip before use. 2. Be careful not to damage the FRP top and name plate. 2. REMOVE ROOF HEADLINING FRONT MOULDING AND NO. 1 TRIM a Remove both quarter trim belt hole covers. b Pry loose the clips with a screwdriver and remove the NOTE Tape the screwdriver tip before use. 4. REMOVE QUARTER TRIM POCKET Remove the five bolts and the pocket.
Disassembly Of Brake Booster
2. SEPARATE FRONT AND REAR BODIES a Place the matchmarks on the front and rear bodies. CAUTION Be careful not to tighten the two nuts of c Turn the front body, clockwise until the front and rear bodies separate. d Loosen the upper left and right nuts of the SST, and insert pieces of wood between the front body and upper plate. CAUTION Be careful that pieces of wood do not contact the rear body. e Evenly tighten the four booster mounting nuts to separate the front and rear bodies. f Remove the...
Remove Shift Lever
b Remove the cotter pin and shift lever shaft. c Remove the shift lever with two bushings. d Remove the shift shaft pin from the shift shaft. 11. REMOVE COUNTER SHAFT, NO. 1 COUNTER GEAR AND COUNTER SHAFT GEAR a Using a brass bar and hammer, drive out the counter shaft from the gear case. b Remove the No. 1 counter gear and counter shaft c Remove the O-ring from the counter shaft.
That Throttle Valve Opens Fully
If the throttle valve does not open fully, adjust the accelerator link. 2. CHECK AND ADJUST THROTTLE CABLE a Check that the throttle cable is installed correctly and not bending. b When the throttle valve is fully closed, adjust the cable housing so that the distance between the end of the boot and the stopper on the cable is correct. Distance 0.5 - 1.5 mm 0.020 - 0.059 in. c 2H engine only - Fully depress the accelerator, measure the cable stroke. Cable stroke 33 1 mm 1.30 0.04 in. If not...
Removal Of Sun Roof
1. DISCONNECT BATTERY CABLE FROM NEGATIVE TERMINAL 4. REMOVE SUN ROOF OPENING TRIM Remove the three screws and the drive motor. 7. REMOVE GUIDE RAIL COVER 70, 73, 75 Series Remove the one bolt from the inside and the two screws from the outside, then remove the guide rail cover. 60, 62 Series Remove the three screws from the outside, then remove the guide rail cover.
Torque Specifications Oza
Reclining seat adjuster x Seat cushior Reclining seat adjuster x Seat back Reclining seat adjuster x Seat cushion er support x Seat back er support x Seat cushior r support x Seat cushior Seat track x Body Rear bench seat 70, 73, 75 series Seat cushion lock x Seat leg Seat cushion bracket x Seat cushioi Seat cushion bracket x Body Seat back lock x Seat back Seat back lock x Seat cushion Seat cushion lock x Seat cushion Seat cushion lock striker x Body Seat cushion hinge x Seat cushion Seat...
Dead Radio And Tape Player
a No power to radio or tape player, or power but n sound. Short circuit or broken wire in power source wii harness Loose connectors behind radio and tape player Broken wire in speaker wire harness Improperly installed radio or tape player Defective radio or tape player
Installation Of Power Steering Pump
Place the PS pump in position and install mount bolts. 3B and 2H Engine Place the PS pump in position and torque mount bolts. Torque 3B Engine 375 kg-cm 27 ft-lb, 37 N-m 2H Engine 2. INSTALL PULLEY AND DRIVE BELT a Install the woodruff key, pulley and set nut. Adjust the drive belt tension and torque mount bolts. Torque 400 kg-cm 29 ft-lb, 39 N-m Drive belt tension at 10 kg 22.0 lb, 98 N - -- m 0.28 - 0.37 in. n 0.31 - 0.39 in. Turn the adjust bolt until the belt tension is the specified value....
Troubleshooting Eii
Leak in brake system Master cylinder faulty Air in brake system Wheel cylinder faulty Piston seals worn or damaged I Rear brake automatic adjuster faulty Parking brake out of adjustment Parking brake wire binding Booster push rod out of adjustment Return spring faulty Brake line restricted Wheel cylinder or caliper piston st Automatic adjuster broken ter cylinder faulty sr grease on linings Brake shoes distorted, linings won j Drum or disc out of round Return spring faulty Wheel cylinder faulty...
Removal Of Valve Body
1. MAKE PLATE TO RETAIN ACCUMULATOR PISTONS A retainer is helpful for holding accumulator pistons in the case during removal and installation of the valve body. The plate may be made from aluminum or plastic. 2. REMOVE TRANSMISSION AND TRANSFER UNDER-COVERS To help prevent contamination, clean the exterior of the transmission. Remove the drain plug and drain fluid into a suitable con-
Inspection Of Water Temperature Gauge
1. INSPECT RECEIVER GAUGE OPERATION a Disconnect the connector from the sender gauge. Connect the positive lead from the voltmeter to terminal and connect the negative lead from the voltmeter to body ground. b Turn the ignition switch or starter switch on. Check that the meter needle vibrates near the 3.5V position. If voltage value is not correct, remove and test the receiver 2. MEASURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals 1 and 2. If resistance value is not...
Sst Pof
7. IF NECESSARY, REPLACE FRONT OUTPUT SHAFT OIL SEAL a Using a screwdriver, remove the oil seal. b Using SST, drive in a new oil seal. SST 09316-60010 c Apply MP grease to the oil seal lip. 8. IF NECESSARY, REPLACE FRONT DRIVE SHIFT FORK SHAFT OIL SEAL a Using a screwdriver, remove the oil seal. b Using SST, drive in a new oil seal. SST 09608-20011 c Apply MP grease to the oil seal lip. 9. IF NECESSARY, REPLACE TRANSMISSION REAR OIL SEAL a Using a screwdriver, remove the transmission rear oil b...
Components Lrc
NOTE Remove and install the fixed type of side window on the back door glass with the same procedure. See page BO-66 a From inside of vehicle, stuff lip of weatherstrip under flange with screwdriver. b Push the glass out to remove. a From the outside of the vehicle, cut off the weatherstrip lip with a knife. b Pull the side window outwards and remove the side window. c Remove the remaining weatherstrip. REMOVAL OF SIDE WINDOW 60,62.73,75 Series
Inspect Input Shaft And Bearing
Check for wear or damage. 10. IF NECESSARY, REPLACE INPUT SHAFT BEARING a Using snap ring pliers, remove the snap ring. b Using SST and a press, remove the bearing. SST 09950-00020 c Using a press, install a new bearing. CAUTION Do not press in the bearing outer race. d Select a snap ring that will allow minimum axial play and install it on the shaft. Standard play 0 - 0.10 mm 0 - 0.0039 in. Thickness mm in. 3.20-3.31 0.1260-0.1303 3.31 -3.42 0.1303 - 0.1346
Replacement Of Fuse
Install a new fuse with the correct amperage. 1. Turn off all electrical components and the ignition switch before replacing a fuse. Do not exceed the fuse amp rating. 2. Always use a fuse puller for removing and inserting a fuse. Remove and insert straight in and out without twisting. Twisting could force open the terminals too much, resulting in a bad connection. If a fuse continues to blow, a short circuit is indicated. The system must be checked by a qualified technician.
Removal Of Windshield
b Windshield mouldings See page BO-46 2. REMOVE WINDSHIELD If reusing the weatherstrip a Working from the vehicle outside with a screwdriver, loosen the weatherstrip lip from the body. b From inside of vehicle, stuff lip of weatherstrip under flange with screwdriver. c Push the glass out to remove. a From the outside, cut off the weatherstrip Hp with a knife.
Install Differential Cover
a Install the new gasket and differential cover to the axle housing. b Install the ten nuts and washers. Torque 130 kg-cm 9 ft-lb, 13 N-m INSTALL PARKING BRAKE CABLE CLAMP 6. INSTALL BRAKE DRUM AND WHEEL 7. FILL DIFFERENTIAL WITH GEAR OIL Hypoid gear oil API GL-5 Above 18 C 0 F SAE90 Below 18 C 0 F SAE 80W or 80W-90 Capacity 2.5 liters 2.6 US qts, 2.2 Imp. qts NOTE With LSD fill In hypoid gear oil LSD, SAE 90 API GL-5 REAR AXLE SHAFT AND AXLE HUB Full-floating Type COMPONENTS I kg-cm ft-lb,...
Remove Door Glass 1
a w o ventilator window type Remove two glass channel mounting bolts. b Incline the door glass and pull it upward. a w o venti lator wi ndow type Remove the two equalizer arm bracket mounting bolts. Disconnect the connector from the motor and remove the four bolts, w o power window Remove the three bolts. c Remove the regulator through the service hole. 14. w o Ventilator Window type REMOVE FRONT LOWER FRAME Remove the two bolts and front lower frame, w o soft top Remove the two screws, two...
Remove Inside Handle
b Slide forward and pull off the inside handle. c Disconnect the link from the Inside handle. a w soft top Remove the screw and service cover. b Insert a screwdriver between the t door panel to pry it loose. NOTE Tape the screwdriver tip before use. Disconnect the connector from the switch. 6. REMOVE INNER AND OUTER WEATHERSTRIP a Using a screwdriver, remove the inner weatherstrip. b Pull off the outer weatherstrip. 8. DISCONNECT INSIDE OPENING CONTROL LINK FROM DOOR LOCK Remove the ventilator...
Br 1
Brake shoes distorted, linings worn or glazed, drums worn Disc brake pads worn Piston frozen in caliper Brake booster faulty king I On drum brakes brake shoes binding ces at backing plate ledges On drum brakes-backing plate ledges wo I On drum brakes-loose or missing hold-down spring Replace pads Repair caliper Repair booster Repair as necessary
Disassembly Of Transfer
1. REMOVE DIAPHRAGM CYLINDER ELECTRICAL SHIFT TYPE See page TF-5 2. REMOVE TRANSFER FRONT DRIVE SHIFT LEVER MECHANICAL SHIFT TYPE a Remove the transfer front drive shift lever. Using SST, remove the 4WD indicator switch. SST 09817-16011 4. REMOVE L4 POSITION SWITCH ELECTRICAL SHIFT TYPE REMOVE PLUGS, SPRINGS AND LOCKING BALLS Mechanical Shift Type Remove the plugs and, using a magnetic finger, remove the springs and locking balls. Remove the plug and, using a magnetic finger, remove the spring...
75 Series Land Cruiser Ignition Lock Removal
I kg-cm ft-lb, N-m Specified Non-reusable part
Remove Instrument Panel
a Remove the following parts EC Running light relay Norway Saudi Arabia Seat belt warning buzzer Australia Preheating timer BJ, HJ Canada b Remove the three wiring harness clamps from the instrument panel. c Remove the steering column upper support. d Remove the twelve bolts and the instrument panel.
Removal Of Tarpaulin
1. UNPEEL MAGIC TAPE AROUND TARPAULIN SPARS 3. UNZIP FOUR ZIPPERS TWO EACH SIDE Release the burglary prevention cock and unzip the zipper. 4. REMOVE TWO BACK DOOR OPENING TRIM CORNER JOINTS AND THREE OPENING TRIMS 5. UNPEEL FIVE STRIPS OF MAGIC TAPE ABOVE BACK DOOR UNPEEL TWELVE STRIPS OF MAGIC TAPE OUTSIDE VEHICLE SIX EACH SIDE , AND UNHOOK FOUR SNAPS TWO EACH OUTSIDE UNPEEL TWELVE STRIPS OF MAGIC TAPE OUTSIDE VEHICLE SIX EACH SIDE , AND UNHOOK FOUR SNAPS TWO EACH OUTSIDE
Troubleshooting Ddk
Oil level too high or wrong grade j Oil seal worn or damaged j Companion flange loose or damaged Oil level low or wrong grade Excessive backlash between pinion anc Ring, pinion or side gears worn or chip gt n shaft bearing worn Wheel bearing worn Differential bearing loose or worn Tires worn or improperly inflated Alignment in Wheel bearing adjusted tc Steering linkage loosen or worn Steering gear out of adjustment ihicle overloaded Shock absorber worn out Springs weak s improperly inflated...
Performance Test
a Close the HI and LO hand valves. b Connect the high pressure hose to the discharge service valve of the compressor. c Connect the low pressure hose to the suction service valve of the compressor. 2. RUN ENGINE AND OPERATE AIR CONDITIONER a Run the engine at 2,000 rpm. b Set the blower switch at HI, A C switch or temp, control switch ON, temperature control at COO L, and air flow control at VENT. c Keep all windows and doors open. a Place a dry bulb thermometer in the cool air outlet. b Place...