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Table Of Contents - Toyota LAND CRUISER Service Manual Supplement

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Owner's manual (623 pages)

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Repair manual (19 pages)

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Owner's manual (576 pages)

Table Of Contents

Table of Contents

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Table of Contents

Table Of Contents5

General Description6

Troubleshooting6

Repair Procedures6

How To Use This Manual6

Specifications7

How To Use This Manual In7

Cautions, Notices, Hints8

Identification Information9

Vehicle Identification Number9

Engine Serial Number9

General Repair Instructions10

Before Beginning Test14

Free Position15

Lock Position16

Braking Force Test16

Speedometer Test Or Other Tests17

On —Vehicle Wheel Balancing17

Precaution In17

When Towing Full-Time 4Wd Vehicles19

Vehicle Lift And Support Locations20

Hardtop & Canvas Top20

Station Wagon22

Abbreviations Used In This Manual23

Standard Bolt Torque Specifications24

How To Determine Bolt Strength24

Specified Torque For Standard Bolts25

Clutch Master Cylinder27

Clutch Master Cylinder Removal27

Master Cylinder Disassembly28

Master Cylinder Inspection28

Master Cylinder Installation29

Install Reservoir Tank29

Install Master Cylinder29

Connect Clutch Line Union29

Manual Transmission30

(Hardtop & Canvas Top) Description31

Transmission Removal And Installation33

Transmission Removal34

Remove Transfer Shift Lever34

Remove Speedometer Cable35

Remove Clutch Release Cylinder35

Remove Starter35

Remove Front Exhaust Pipe35

Remove Stabilizer Braket Set Bolts36

Support Transmission36

Remove Crossmember36

Remove Transmission36

Remove Engine Rear Mounting37

Remove Transfer From Transmission37

Transmission Installation38

Install Engine Rear Mounting38

Install Transmission To Engine38

Install Crossmember38

Install Stabilizer Bracket Set Bolts39

Install Front Exhaust Pipe39

Install Starter39

Install Clutch Release Cylinder39

Install Speedometer Cable40

Fill Transmission With Gear Oil41

Tighten Fan Shroud41

Install Transfer Shift Lever41

Install Transmission Shift Lever41

Output Shaft Disassembly43

Inspect Each Gear Thrust Clearance43

Inspect Each Gear Oil Clearance43

Remove Ball Bearing And First Gear43

Output Shaft Assembly Inspection46

Inspect Output Shaft46

Output Shaft Component Parts Inspection46

Inspect Synchronizer Ring For 2Nd Gear47

Output Shaft Assembly48

Inspect Fifth Gear Thrust Clearance49

Install Third Gear And Hub Sleeve No.2 Assembly49

Install Snap Ring49

Inspect Third Gear Thrust Clearance50

Install Second Gear And Hub Sleeve No.1 Assembly50

Inspect Second Gear Thrust Clearance51

Install First Gear51

Install Ball Bearing51

Service Specifications53

Torque Specifications54

Sst (Special Service Tools)56

Automatic Transmission71

(Station Wagon) Description72

Function Of Components75

Hydraulic Control System78

Electronic Control System79

Function Of Tcm80

Control Of Shift Timing80

Control Of Overdrive80

Control Of Lock-Up System80

A/T. Fluid Temperature Warning System81

A/T. P. (Automatic Transmission Parking) Indicator81

Diagnosis System87

Check "O/D Off" Indicator Light87

Read Diagnostic Code88

Diagnostic Codes89

Cancel Out Diagnostic Code90

Troubleshooting Flow-Chart91

Diagnostic Code 4191

Diagnostic Code 4291

Diagnostic Code 6192

Diagnostic Code 6292

Diagnostic Code 6392

No.2 Speed Sensor Circuitry92

Diagnostic Code 6493

Diagnostic Code 6593

Diagnostic Code 8693

Diagnostic Code 8894

Engine Speed Sensor Circuitry94

Preliminary Check95

Check Fluid Level95

Check Fluid Condition95

Inspect Throttle Cable96

Inspect Transmission Shift Lever Range96

Inspect Neutral Start Swtich97

Inspect Idle Speed (N Range)97

Manual Shifting Test98

Electronic Control Circuit99

Electronic Control Components101

Troubleshooting Flow - Chart102

Trouble No.2 Shift Point Too High Or Too Low103

Trouble No.3 No Up-Shift To Overdrive (After Warm-Up)104

Terminal Voltage Inspection106

Inspect Throttle Position Sensor Signal106

Inspect Brake Signal106

Inspect Each Upshift Position106

Electronic Control Componenets107

Inspect Voltage Of Ect Ecu107

Inspect Solenoid109

Check Solenoid Seals110

Inspect Throttle Position Sensor110

Check The Lock-Up Solenoid Valve110

Inspect No.2 Speed Sensor111

Inspect Pattern Select Switch111

Inspect O/D Switch111

Inspect Neutral Start Switch111

A/T Fluid Temperature Warning System Circuit112

Inspect A/T Fluid Temperature Warning Light112

Inspect A/T Fluid Temperature Sensor112

Measure Stall Speed113

Time Lag Test115

Measure Time Lag115

Hydraulic Test117

Measure Line Pressure117

2 Range Test120

L Range Test121

R Range Test121

Automatic Shift Schedule123

Troubleshooting Matrix Chart126

Valve Body Removal128

Drain Transmission Fluid128

Remove Oil Pan Protector128

Remove Oil Pan And Gasket128

Remove Oil Strainer129

Remove Valve Body129

Valve Body Installation129

Install Magnets In Pan131

Install Oil Pan131

Install Drain Plug131

Fill Transmission With Atf132

Throttle Cable Removal133

Remove Frame Crossmember Set Bolts133

Remove Throttle Cable Clamp133

Remove Throttle Cable133

Throttle Cable Installation134

Install Four Center Support Apply Gasket134

If Throttle Cable Is New, Paint Mark On Inner Cable134

Connect Throttle Cable134

Assembly Removeal And Installation136

Disconnect Throttle Cable138

Assembly Removal And Installation139

Disconnect Two Oil Cooler Tubes141

Remove Engine Under Cover142

Remove Six Torque Converter Mounting Bolts142

Remove Transmission Assembly143

Torque Converter Cleaning146

Torque Converter And Drive Plate Inspection146

Remove Oil Filler Tube151

Service Date156

Torque Specification158

(Hf2Av For Station Wagon With Abs) Description160

Transfer Disassembly163

Remove Motor Actuator163

Remove Output Gear163

Remove Screw Plug, Spring And Ball163

Remove Transfer Indicator Switches164

Remove Power Take-Off Case164

Remove Front Extension Housing164

Separate Shift Fork No.2 And Fork Shaft165

Remove Rear Extension Housing165

Remove Retainer165

Remove Case Cover166

Separate Front Case And Rear Case166

Component Parts170

Input Shaft Assembly170

Disassembly Of Input Shaft Assembly170

Assembly Of Input Shaft Assembly172

Install Front Ball Bearing172

Install Input Gear172

Install Rear Ball Bearing173

Idler Gear Assembly174

Disassembly Of Idler Gear Assembly174

Assembly Of Idler Gear Assembly175

Center Differential Assembly177

Disassembly Of Center Differential Assembly177

Remove Front Drive Gear Piece178

Remove Front Taper Roller Bearing178

Front Extension Housing Assembly186

Disassembly Of Front Extension Housing Assembly186

Remove Front Output Shaft187

Remove Dust Deflectors187

Remove Oil Seal187

Remove Ball Bearing187

Assembly Of Front Extension Housing Assembly188

Rear Extension Housing Assembly190

Disassembly Of Rear Extension Housing Assembly191

Assembly Of Rear Extension Housing Assembly195

Check Tip Clearance Of Driven Rotor195

Check Side Clearance Of Oil Pump195

Install Dust Deflectors196

Install Oil Seal196

Install Rear Output Shaft196

Install Speedometer Drive Gear197

Install Oil Pump Plate Separator197

Install Center Differential Control Coupling Assembly197

Install Driven Rotor198

Install Drive Rotor198

Install Oil Pump Cover198

Transfer Assembly199

Install Two Bearing Races To Front Case199

Install Oil Receiver To Front Case199

Assemble Shift Fork No.1 And Fork Shaft200

Install Input Shaft Assembly200

Install Oil Strainer To Rear Case201

Assemble Front Case And Rear Case201

Install Case Cover202

Install Retainer203

Install Rear Extension Housing203

Assemble Shift Fork No.2 And Fork Shaft204

Install Front Extension Housing204

Install Power Take-Off Case205

Install Transfer Indicator Switches205

Install Ball, Spring And Screw Plug205

Install Output Gear206

Install Motor Actuator206

Motor Shift Control System207

System Inspection207

Inspect Shift Lever Position207

Parts Inspection208

Inspect Center Differential Lock Control Relay208

Propeller Shaft211

Suspension And Axle215

Front Differential216

Wheel Alignment217

Primary Inspection217

Front Wheel Alignment218

Inspect Caster218

Inspect Toe-In218

Adjust Toe-In218

Inspect Wheel Angle219

Brake System223

Recommended Tools224

Brake Pedal Check And Adjustment226

Master Cylinder Removal228

Remove Master Cylinder Boot231

Remove Reservoir Cap And Strainer231

Remove Reservoir231

Master Cylinder Assembly232

Install Two Pistons232

Install No.2 Piston Stopper Bolt233

Install Reservoir233

Install Reservoir Cap233

Connect Brake Lines234

Load Sensing Proportioning And By-Pass Valve (Lsp & Bv)235

Fluid Pressure Check And Adjustment236

Set Rear Axle Load236

Lsp & Bv Removal237

Lsp & Bv Assembly Disassembly238

Lsp & Bv Inspection239

Lsp & Bv Assembly239

Lsp & Bv Installation240

Install Valve Bracket240

Install Lsp & Bv Assembly240

Connect Shackle No.2 To Bracket240

Set Valve Body241

Anti-Lock Brake System (Abs) Br-2O242

System Parts Location243

Wiring Diagram244

Diagnosis System Inspection246

Diagnostic Codes Clearing249

Clear Diagnostic Codes249

"Abs" Warning Light Comes On.250

Speed Sensor And Deceleration Sensor Diagnosis System256

Inspect Battery Voltage256

Check That Warning Light Turns On256

Inspect Speed Sensor Signal Change257

Diagnostic Code259

Deceleration Sensor Operation Diagnosis System260

Inspect Sensor Detection Point260

Inspect Sensor Operation261

Abs Actuator262

Abs Actuator Removal And Installation262

Main Points Of Removal And Installation263

Abs Actuator Inspection264

Inspect Brake Actuator Operation265

Inspect For Other Wheels265

Push Sub Motor Switch266

Connect Connectors266

Control Relay267

Control Relay Inspection267

Front Speed Sensor268

Front Speed Sensor Inspection268

Front Speed Sensor And Sensor Rotor Serrations Inspection269

Inspect Sensor Installation269

Visually Inspect Sensor Rotor Serrations269

Front Speed Sensor Removal270

Front Speed Sensor Installation270

Front Speed Sensor Air Gap Adjustment271

Rear Speed Sensor273

Rear Speed Sensor Inspection273

Rear Speed Sensor And Sensor Rotor Serrations Inspection274

Rear Speed Sensor Removal275

Rear Speed Sensor Installation275

Anti-Lock Brake System Circuit277

Body Electrical System280

(Hardtop, Canvas Top & Station Wagon) Wiper And Washer System281

Combination Meter Parts Location282

Meter Circuit283

Shift Position Indicator286

Speedometer System289

Speed Sensor Inspection289

Tachometer System290

Fuel Gauge System290

Tachometer Inspection290

Fuel Receiver Gauge Inspection290

Fuel Sender Gauge Inspection291

Fuel Level Warning System291

Inspect Warning Light291

Inspect Warning Switch291

Water Temperature Gauge System292

Water Temperature Receiver Gauge Inspection Operation292

Voltmeter System293

Inspect Voltmeter (On-Vehicle)293

Oil Pressure Gauge System294

Oil Pressure Receiver Gauge Inspection294

Oil Pressure Sender Gauge Inspection294

Brake Warning System295

Brake Warning Light Inspection295

Parking Brake Switch Inspection295

Open Door Warning System295

Seat Belt Warning System296

Door Courtesy Switch296

Seat Belt Warning Inspection296

Seat Belt Buckle Switch Inspection296

Engine Oil Level Warning System298

Meter Illumination Control System298

Inspect Engine Oil Level Sensor298

Power Seat Control System300

Parts Location300

Power Seat Switch302

Power Seat Switch Inspection302

Power Seat Motor304

Slide Motor Inspection304

Circuit Breaker Operation304

Front Vertical Motor Inspection304

Rear Vertical Motor Inspection305

Reclining Motor Inspection305

Motor Operation Passenger' S Seat306

Circuit Breaker Operation Driver' S Seat306

Circuit Breaker Operation Passenger's Seat306

Lumbar Support Motor Inspection Motor Operation307

Cruise Control System308

Connector Diagrams309

Main Switch Operation310

Control Switch Operation310

Speed Control Operation310

Manual Cancel Operation310

System Description310

Power Source Circuit314

Cruise Control Indicator Circuit315

Control Switch Circuit316

Actuator Circuit317

Speed Sensor Circuit319

Stop Light Switch Circuit320

Parking Brake Switch Circuit322

Neutral Start Switch Circuit323

Ect Solenoid No.2 Circuit (With A/T)323

Idl Signal Circuit324

Cruise Control Ecu Circuit325

Control Switch Inspection326

Stop Light Switch Inspection326

Cruise Control Actuator Inspection327

Control Link Assembly Adjustment328

Adjust Control Link Assembly328

Extra (Sub) Tank System329

Sub Fuel Switch332

Inspect Sub Fuel Switch332

Inspect Fuel Pump Operation332

Fuel Level Switch333

Fuel Sender Gauge334

Fuel Solenoid Valve334

Fuel Pump Control Ecu335

Satellite Navigation System338

Wiring Diagrams339

Air Conditioning System341

Electrical Wiring Diagram342

Inspect Drive Belt Tension350

Refrigeration Lines351

Compressor Removal352

Magnet Clutch Disassembly353

Cooling Unit Disassembly354

Air Conditioner Amplifier355

Inspect Amplifier Circuit356

On-Vehicle Inspection362

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Table of Contents

Troubleshooting