Toyota Land Cruiser 70 2017 Series Builder's Manual
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Toyota Land Cruiser 70 2017 Series Builder's Manual

Toyota Land Cruiser 70 2017 Series Builder's Manual

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

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Summary of Contents for Toyota Land Cruiser 70 2017 Series

  • Page 1 2017 September BODY BUILDER’S GUIDE Land Cruiser 70 series Pub. No. BBGJ1007...
  • Page 2 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...

  • Page 3: Table Of Contents

    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 ·····························································································...
  • Page 4 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 ····································································································...

  • Page 5: 1】 Basic Matters For Body-Building And Alterations

    【1】-1. Compliance with laws and regulations, 【1】-2. Securing basic performance and safety requirements 【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.

  • Page 6: Vehicle Width

    【1】-2. Securing basic performance and safety requirements [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.

  • Page 7: Limitation Of Front Axle Load Ratio (When Loaded With Cargo)

    【 1 】 -2. Securing basic performance and safety requirements [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).
  • Page 8 【1】-2. Securing basic performance and safety requirements · Example calculation of gravity center height How to determine vertical gravity center Weight = Vertical gravity center = H Moment (W x H) W (kg) (kg-m) Chassis w/cab 0.555 800 x 0.555 = 444.00 Floor joist 45 x 0.640 = 28.80 = 6 42.5 ≒...

  • Page 9: Weight

    【1】-2. Securing basic performance and safety requirements [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...
  • Page 10 【 1 】 -2. Securing basic performance and safety requirements (2) Relation between building or alteration weight and load （Example) Model VDJ79R-T JMRYQ3 Item C.W. of base vehicle (C&C) 2,165 ~ 2,220 Special equipment, accessories, permanent attachments Total weight of passengers, cargos and baggages G.V.W.

  • Page 11: No Alterations To Important Safety Parts

    【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 after-sale service system 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).

  • Page 12: Model Structure

    【 1 】 -6. Model structure 6. Model structure [1] Meaning of model code Basic Model Code Steering Position Body Type GRJ79 : 1GR-FE E/G R : Right Hand Drive T : Single Cab Pick Up HZJ79 : 1HZ E/G L : Left Hand Drive D : Double Cab Pick Up VDJ79 : 1VD-FTV E/G...

  • Page 13: List Of Vehicle Models

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

  • Page 14: 2】 Damage Warnings On Mechanisms And Systems In Body-Building Or Making Alterations

    【2】-1. Engine and engine compartment 【2】-2. Frames 【2】 DAMAGE WARNINGS ON MECHANISMS AND SYSTEMS IN BODY-BUILDING OR MAKING ALTERATIONS 1. Engine and engine compartment Engine & Component must not be modified. 2. Frames · The frame must not be modified. ·...

  • Page 15: Suspension

    【2】-3. Suspension 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 ① Don' 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.

  • Page 16: Data For Calculating The Ground Clearance Of Frame Reference Line

    【 2 】 -3. Suspension [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 Ground clearance of frame reference line at front wheel center line (mm) Y = HR + TR Ground clearance of frame reference line above rear wheel center line (mm) Y-X ×...
  • Page 17 【 2 】 -3. Suspension (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.
  • Page 18 【2】-3. Suspension (3) Spring characteristics curve diagram Front suspension (1/7) Vehicle Models · GRJ79L-TJMRK3...
  • Page 19 【2】-3. Suspension Front suspension (2/7) Vehicle Models · HZJ79L-TJMRS3...
  • Page 20 【2】-3. Suspension Front suspension (3/7) Vehicle Models · GRJ79L-TJMRK3 · HZJ79L-TJMRS3 (Heavy Duty with winch)
  • Page 21 【2】-3. Suspension Front suspension (4/7) Vehicle Models · GRJ79L-TJMRK3 · HZJ79L-TJMRS3 (Heavy Duty without winch)
  • Page 22 【2】-3. Suspension Front suspension (5/7) Vehicle Models · GRJ79L-TJMRK3 · HZJ79L-TJMRS3 (with optional winch)
  • Page 23 【2】-3. Suspension Front suspension (6/7) Vehicle Models · VDJ79R-TJMRYQ3 · VDJ79R-TJMNYQ3...
  • Page 24 【2】-3. Suspension Front suspension (7/7) Vehicle Models · VDJ79R-DKMRYQ3...
  • Page 25 【2】-3. Suspension Vehicle Models Rear suspension (1/3) · GRJ79L-TJMRK3 · HZJ79L-TJMRS3 · VDJ79R-DKMRYQ3...
  • Page 26 【2】-3. Suspension Rear suspension (2/3) Vehicle Models · GRJ79L-TJMRK3 · HZJ79L-TJMRS3 (Heavy Duty)
  • Page 27 【2】-3. Suspension Vehicle Models Rear suspension (3/3) · VDJ79R-TJMRYQ3 · VDJ79R-TJMNYQ3...
  • Page 28 【 2 】 -3. Suspension (4) Static load radius of tire 7.50R16LT 375 ± 7 mm JATMA 225/95R16C 374 mm Static load ETRTO radius 7.50R-16C 265/70R16LT 359 ± 8mm JATMA (5) Tire load table JATMA (kg) Pressure Tire size kgf/cm 3.00 3.25 3.50...

  • Page 29: Body

    【2】-4. Body 4. Body · In order to prevent intrusion of exhaust gas into the cab, surely seal all the holes and apertures in the cab including the floor. · Don't remove the heat insulator from the base vehicle. [1] Building and alterations to rear body and deck (1) Prevention of cargo drop Each customer (driver) is responsible for preventing his/her cargo from falling.
  • Page 30 【2】-4. Body (2) Clearance between cab back and alteration (rear body, deck, etc.) · Single Cab...
  • Page 31 【2】-4. Body · Double Cab Make sure to secure a sufficient clearance between the cab deck and alteration.

  • Page 32: Securing Rear Wheel House Space

    【2】-4. Body [2] Securing rear wheel house space Make sure to secure a required space for the wheel house. Vertical Bound limit of tire +25mm Outer surface of tire +30mm Horizontal inner surface of tire +40mm In attaching the tire chain, secure a larger clearance. [3] Protection against thermal effect of exhaust system With a sufficient clearance secured between the exhaust-related parts and the built or altered parts, measure the temperature as required to see that there is no safety problem.

  • Page 33: Brake

    【2】-5. Brake 5. Brake The brake system and piping must not be modified. [1] Readjustment of LSPV A load sensing proportioning valve (LSPV) is mounted on the base vehicle for stabilizing the brake performance in accordance with the change of load. ·...
  • Page 34 【2】-5. Brake ③ Measurement of hydraulic pressure (a) Depress the brake pedal until the oil pressure in the front wheel cylinder reaches 5.9 Mpa, 7.8 Mpa. · Don't depress the brake pedal a number of times. · When the oil pressure in the front wheel cylinder exceeds 5.9 Mpa, 7.8 Mpa, release the pedal completely and then depress it again (b) After holding the oil pressure in the front wheel cylinder at (5.9 Mpa, 7.8 Mpa) for two seconds, measure the oil pressure in the rear wheel cylinder.
  • Page 35 【2】-5. Brake (b) After the value for the bend point of oil pressure is determined，plot the performance line (a line parallel to the valve unit performance line extending from the bend point of oil pressure), and read the rear wheel cylinder oil pressure at the time when the front wheel cylinder pressure is at 5.9 Mpa, 7.8 Mpa.
  • Page 36 【2】-5. Brake ⑤ Oil pressure adjustment If the oil pressure measurement fails to satisfy the standard value, adjust the oil pressure as follows. (a) Adjust the length of shackle No.2 (Dimension A). When the oil pressure is low, increase the Dimension A. (Turn the shackle counterclockwise.) When the oil pressure is high, decrease the Dimension A.
  • Page 37 【2】-5. Brake (2) LSPV performance curve diagram (3) Static oil pressure curve bend point diagram...

  • Page 38: Drive Units

    【2】-6. Drive units 【2】-7. Exhaust pipe 6. Drive units [1] Transmission ① Sufficient clearance should be provided between transmission and an altered part because the two parts move relatively. ② It is necessary to shift transmission rearward to pull out the clutch spline shaft when removing and reinstalling clutch and transmission.

  • Page 39: Battery

    【2】-8. Battery 8. Battery The battery is an item which, if handled inappropriately, may cause a malfunction of the electrical components of the vehicle or an engine trouble or a fire. Strictly observe the instructions on the battery and battery cable. [1] Wiring precautions ①...

  • Page 40: No Overlaid Connection Of Battery Cables

    【2】-8. Battery [3] No overlaid connection of battery cables Never connect battery cables by overlaying them one on another. [4] Replacement battery cable Replacing the battery cable poses an engine start problem and causes the loss of other key systems. Comply with the following instructions strictly.

  • Page 41: Fuel Tank

    【2】-9. Fuel tank 9. Fuel tank [1] Addition and relocation of fuel tank ① Don't add or relocate a fuel tank. [2] Fuel tank position (steel tank) ① Keep the fuel tank 100 mm minimum away from the exhaust pipe and 200 mm minimum away from the muffler.

  • Page 42: Spare Tire Carrier

    【 2 】 -10. Spare tire carrier 10. Spare tire carrier In order to support the spare tire safely, take the following preventive measures when the spare tire carrier is added or modified. [1] General preventive measures ① Construct the vehicle in such a way as to facilitate the mounting and demounting of the spare tire by a single person.

  • Page 43: Preventive Measure For Addition Or Alteration To Spare Tire Carrier Of Wind-Up Type

    【2】-10. Spare tire carrier [2] Preventive measure for addition or alteration to spare tire carrier of wind-up type (1) How to support tires ① In order to ensure that the spare tire carrier produces a tightening reaction force even in case a punctured tire is stored，construct the spare tire carrier in such a manner that the tire rim can surely rests on the support.

  • Page 44: Mounting Position

    【2】-10. Spare tire carrier [3] Mounting position...

  • Page 45: Spare Tire Carrier Handle

    【2】-10. Spare tire carrier [4] Spare tire carrier handle (1) Rod (2) Handle...
  • Page 46 【2】-10. Spare tire carrier (3) Handle guide hole...

  • Page 47: Electrical Wirings

    【2】-11. Electrical wirings 11. Electrical wirings The electrical wirings of the vehicle are specified taking the operating load and the operating frequency into consideration. When adding wirings for body-building or alterations, make sure that there is no safety problem. [1] Consideration of existing vehicle wirings (1) Interference ①...
  • Page 48 【2】-11. Electrical wirings (3) Mounting and demounting the connector When removing the connector, don't pull the wire harness but by holding the connector body. (4) Heat consideration ① Secure an adequate clearance with the high- temperature parts. ② Measure the temperature whenever required to eliminate the safety problems.

  • Page 49: Wiring Addition

    【2】-11. Electrical wirings [2] Wiring addition (1) Wire harness ① When extending the wiring, use the low-voltage wiring for vehicles specified according to JIS or JASO. (Reference) Features of low-voltage wirings for vehicles · The copper wire is wound with soft vinyl coating ·...
  • Page 50 【2】-11. Electrical wirings · Use a clamp made of rubber or coated with vinyl. · Secure the inter-clamp interval of about 200 mm. · Secure a sufficient clearance between the wiring and moving parts or a sharp object. ② Always use a connector with lock. Don't use a plug-type connector as far as possible. If the use of a plug-type connector is unavoidable, set the female side as the positive power supply (+) in order for the connector not to come off and cause short circuit.
  • Page 51 【2】-11. Electrical wirings ③ When mounting an additional electrical part, always attach a fusible link and the earth. (4) Protection against water and dust ① Install the wiring at a (upper) position where the wiring is not likely to be damaged by water, dust, mud or snow pile, freezing or flying stones, or where it is not buried under dust or sand.
  • Page 52 【2】-11. Electrical wirings (5) Heat consideration Keep the wiring away from the exhaust pipe by 150 mm minimum, and from the muffler by 250 mm minimum. · In cases where the above clearance can not be satisfied, protection against the heat such as a heat insulating plate is required.

  • Page 53: Fuse

    【2】-11. Electrical wirings [3] Fuse ① Fuses of optimum capacity must be used for vehicles considering the operating electrical load and the operating frequency. Don't add any electrical load from accessories to the existing fuses. ② Always be sure to insert a fuse in an added wiring circuit.

  • Page 54: Power Supply

    【2】-11. Electrical wirings [5] Power supply (1) Power supply · Instructions Interpose a subwire (with the wire of more than AV3 from subwire to fuse) between the ignition switch and the vehicle wire harness behind the combination meter to take out power. (2) Connector style and wiring arrangement ·...

  • Page 55: Electrical Wiring Diagrams

    · Tightening torque of nut is required as above for both condition. [6] Electrical wiring diagrams This manual does not contain electrical wiring diagrams. The electrical wiring diagrams are in the Publication MANUAL or Toyota Service Information website. For more details, please consult your nearest Toyota dealer or distributor.

  • Page 56: Mounting Rear Combination Lamp

    【2】-12. Mounting rear combination lamp 12. Mounting rear combination lamp In the case of the cab & chassis model, the rear combination lamp is mounted as a rear combination lamp subassembly (for land transportation) shown in the drawing. Bracket sub-assy Combination rear Lamp assy rear lamp...

  • Page 57: License Plate And License Lamp

    【2】-13. License plate and license lamp, 【2】-14. Reflector 13. License plate and license lamp A provisional license plate and a provisional license lamp are attached to the cab & chassis model being shipped. When attaching an official license plate, conform with the related laws and regulations of the country concerned.

  • Page 58: 3】 Drawings

    3 -1. Cab & Chassis drawing 3 DRAWINGS MODEL GRJ79L-TJMRK3 1-1. Cab & Chassis drawing HZJ79L-TJMRS3 2725 Frame Reference Line (H10+30) 2060 3180 1190 5080...
  • Page 59 3 -1. Cab & Chassis drawing MODEL 1-2. Cab & Chassis drawing VDJ79R-TJMRYQ3 * : Models with 265/70R16 tires 2725 Frame Reference Line (H10+30) 2060 3180 1190 5220...
  • Page 60 3 -1. Cab & Chassis drawing MODEL 1-3. Cab & Chassis drawing VDJ79R-TJMNYQ3 * : Models with 265/70R16 tires 2725 Frame Reference Line (H10+30) 2060 3180 1190 5230...
  • Page 61 3 -1. Cab & Chassis drawing MODEL 1-4. Cab & Chassis drawing VDJ79R-DKMRYQ3 * : Models with 265/70R16 tires 3445 Frame Reference Line (H10+30) 2780 3180 1190 5220...

  • Page 62: Frame Drawing

    3 -2. Frame drawing MODEL 2-1. Frame drawing GRJ79L-TJMRK3 Front wheel center Rear wheel center Reference Point dimension Frame Reference Line (H10+30)
  • Page 63 3 -2. Frame drawing MODEL 2-2. Frame drawing GRJ79L-TJMRK3 Front wheel center Rear wheel center (with fuel sub tank) Reference Point dimension Frame Reference Line (H10+30)
  • Page 64 3 -2. Frame drawing MODEL 2-3. Frame drawing HZJ79L-TJMRS3 Front wheel center Rear wheel center Reference Point dimension Frame Reference Line (H10+30)
  • Page 65 3 -2. Frame drawing MODEL 2-4. Frame drawing HZJ79L-TJMRS3 (with fuel sub tank) Front wheel center Rear wheel center Reference Point dimension Frame Reference Line (H10+30)
  • Page 66 3 -2. Frame drawing MODEL 2-5. Frame drawing VDJ79R-TJMRYQ3 VDJ79R-TJMNYQ3 Front wheel center Rear wheel center Reference Point dimension Frame Reference Line (H10+30)
  • Page 67 3 -2. Frame drawing MODEL 2-6. Frame drawing VDJ79R-DKMRYQ3 Front wheel center Rear wheel center Reference Point dimension Frame Reference Line (H10+30)

  • Page 68: Exhaust Pipe Drawing

    3 -3. Exhaust pipe drawing MODEL 3-1. Exhaust pipe drawing GRJ79L-TJMRK3 Front wheel center Rear wheel center Reference Point dimension Frame Reference Line (H10+30)
  • Page 69 3 -3. Exhaust pipe drawing MODEL 3-2. Exhaust pipe drawing HZJ79L-TJMRS3 Front wheel center Rear wheel center Reference Point dimension Frame Reference Line (H10+30)
  • Page 70 3 -3. Exhaust pipe drawing MODEL 3-3. Exhaust pipe drawing VDJ79R-TJMNYQ3 VDJ79R-TJMRYQ3 Front wheel center Rear wheel center Reference Point dimension Frame Reference Line (H10+30)
  • Page 71 3 -3. Exhaust pipe drawing MODEL 3-4. Exhaust pipe drawing VDJ79R-DKMRYQ3 Front wheel center Rear wheel center Reference Point dimension Frame Reference Line (H10+30)

  • Page 72: Fuel Tank Installation-Related Drawings (Drawings For Fuel Tank)

    3 -4. Fuel tank installation-related drawings (Drawings for fuel tank) MODEL 4-1. Fuel tank installation-related drawings (Drawings for fuel tank) GRJ79L-TJMRK3 HZJ79L-TJMRS3...
  • Page 73 3 -4. Fuel tank installation-related drawings (Drawings for fuel tank) MODEL VDJ79R-TJMRYQ3 VDJ79R-TJMNYQ3 VDJ79R-DKMRYQ3 130L...

  • Page 74: Rear Combination Lamp-Related Chart

    【3】-5. Rear combination lamp-related chart 5. Rear combination lamp-related chart...

  • Page 75: License Lamp-Related Chart

    【3】-6. License lamp-related chart 6-1. License lamp-related chart License Lamp...
  • Page 76 【3】-6. License lamp-related chart MODELS 6-2. License lamp-related chart ALL MODELS License Plate...

  • Page 77: Alternator Output Characteristic

    【 3 】 -7. Alternator output characteristic 7-1. Alternator output characteristic Model 12V-80A GRJ79L-TJMRK3 Model 12V-80A HZJ79L-TJMRS3...
  • Page 78 【 3 】 -7. Alternator output characteristic 7-2. Alternator output characteristic Model 12V-130A VZJ79R-TJMRYQ3 VZJ79R-TJMNYQ3 VDJ79R-DKMRYQ3...

  • Page 79: 4】 Major Technical Specifications

    【 4 】 MAJOR TECHNICAL SPECIFICATIONS 【4】 MAJOR TECHNICAL SPECIFICATIONS Destination General Countries Body Type Single Cab Drive System Model Code GRJ79L-TJMRK3 HZJ79L-TJMRS3 Overall Length 5080 5080 Width 1770 1770 Height 1970 1975 Wheel Base 3180 3180 Tread Front 1515 1515 Rear 1420...
  • Page 80 【 4 】 MAJOR TECHNICAL SPECIFICATIONS Destination Australia Body Type Single Cab Drive System Model Code VDJ79R-TJMRYQ3 VDJ79R-TJMNYQ3 Overall Length 5220 5230 Width 1790, 1870 *1 1790, 1870 *1 Height 1970, 1955 *1 1970, 1955 *1 Wheel Base 3180 3180 Tread Front 1515, 1555 *1...
  • Page 81 【 4 】 MAJOR TECHNICAL SPECIFICATIONS Destination Australia Body Type Double Cab Pick-up Drive System Model Code VDJ79R- DKMRYQ3 Overall Length 5220 Width 1790, 1870*1 Height 1960, 1945*1 Wheel Base 3180 Tread Front 1515, 1555*1 Rear 1420, 1460*1 Fuel Tank Capacity Liters Seating Capacity (OPT) Persons...
  • Page 82 C&A Operations Division TOYOTA MOTOR CORPORATION Nisshin Education & Training Center 5-210, Sakae Nisshin City, Aichi Prefecture JAPAN 470-0113...

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