LAND CRUISER STATION WAGON · Service Manual Repair Manual

Repair Manual

INTRODUCTION

HOW TO USE THIS MANUAL

IDENTIFICATION INFORMATION

REPAIR INSTRUCTIONS

FOR ALL OF VEHICLES

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

TERMS

PREPARATION

CLUTCH

MANUAL TRANSMISSION (H151F)

MANUAL TRANSMISSION (R151F)

AUTOMATIC TRANSMISSION (A343F)

AUTOMATIC TRANSMISSION (A442F)

TRANSFER (Full-Time 4WD Type)

TRANSFER (Part-Time 4WD Type)

PROPELLER SHAFT

SUSPENSION AND AXLE

BRAKE

STEERING

SUPPLEMENTAL RESTRAINT SYSTEM

BODY ELECTRICAL

BODY

WINCH

AIR CONDITIONING

SERVICE SPECIFICATIONS

STANDARD BOLT

CLUTCH

MANUAL TRANSMISSION (H151F)

MANUAL TRANSMISSION (R151F)

AUTOMATIC TRANSMISSION (A343F)

AUTOMATIC TRANSMISSION (A442F)

TRANSFER (Full-Time 4WD Type)

TRANSFER (Part-Time 4WD Type)

PROPELLER SHAFT

SUSPENSION AND AXLE

BRAKE

STEERING

SUPPLEMENTAL RESTRAINT SYSTEM

BODY ELECTRICAL

BODY

WINCH

AIR CONDITIONING

DIAGNOSTICS

AUTOMATIC TRANSMISSION (A343F)

AUTOMATIC TRANSMISSION (A442F)

ACTIVE HEIGHT CONTROL SUSPENSION & SKYHOOK TEMS

ABS & HYDRAULIC BRAKE BOOSTER POWER SUPPLY SYSTEM

POWER TILT AND POWER TELESCOPIC STEERING COLUMN

SUPPLEMENTAL RESTRAINT SYSTEM

POWER SEAT CONTROL SYSTEM

WIRELESS DOOR LOCK CONTROL SYSTEM

THEFT DETERRENT SYSTEM

CRUISE CONTROL SYSTEM (1FZ-FE, 1HD-T)

CRUISE CONTROL SYSTEM (2UZ-FE, 1HD-FTE)

ENGINE IMMOBILISER SYSTEM (2UZ-FE)

BODY CONTROL SYSTEM

MULTIPLEX COMMUNICATION SYSTEM

AIR CONDITIONING SYSTEM

CLUTCH

TROUBLESHOOTING

CLUTCH PEDAL

CLUTCH MASTER CYLINDER

CLUTCH RELEASE CYLINDER

CLUTCH ACCUMULATOR

CLUTCH UNIT

MANUAL TRANSMISSION (H151F)

TROUBLESHOOTING

MANUAL TRANSMISSION UNIT (Gasoline Engine)

MANUAL TRANSMISSION UNIT (Diesel Engine)

MANUAL TRANSMISSION ASSEMBLY

INPUT SHAFT

OUTPUT SHAFT

COUNTER GEAR AND REVERSE IDLER GEAR

FRONT BEARING RETAINER OIL SEAL

OIL PUMP COVER ASSEMBLY

MANUAL TRANSMISSION (R151F)

TROUBLESHOOTING

MANUAL TRANSMISSION UNIT

MANUAL TRANSMISSION ASSEMBLY

INPUT SHAFT

OUTPUT SHAFT

COUNTER GEAR AND REVERSE IDLER GEAR

FRONT BEARING RETAINER OIL SEAL

TRANSFER ADAPTOR

AUTOMATIC TRANSMISSION (A343F)

AUTOMATIC TRANSMISSION SYSTEM

SPEEDOMETER DRIVEN GEAR

VEHICLE SPEED SENSOR

O/D DIRECT CLUTCH SPEED SENSOR

ATF TEMPERATURE SENSOR

NEUTRAL START SWITCH

VALVE BODY ASSEMBLY

PARKING LOCK PAWL

AIR COOLED OIL COOLER

FLOOR SHIFT ASSEMBLY

AUTOMATIC TRANSMISSION UNIT

TORQUE CONVERTER AND DRIVE PLATE

AUTOMATIC TRANSMISSION (A442F)

AUTOMATIC TRANSMISSION SYSTEM

SPEEDOMETER DRIVEN GEAR

VEHICLE SPEED SENSOR

ATF TEMPERATURE SENSOR (2UZ-FE)

ATF TEMPERATURE SENSOR (2UZ-FE, 1HD-FTE)

ATF TEMPERATURE SWITCH (1FZ-FE, 1HD-T, 1HZ)

NEUTRAL START SWITCH

VALVE BODY ASSEMBLY (2UZ-FE, 1HD-FTE)

VALVE BODY ASSEMBLY (1FZ-FE, 1HD-T, 1HZ)

THROTTLE CABLE (1FZ-FE, 1HD-T, 1HZ)

AIR COOLED OIL COOLER (2UZ-FE)

AIR COOLED OIL COOLER (1FZ-FE, 1HZ, 1HD-T, 1HD-FTE)

FLOOR SHIFT ASSEMBLY

AUTOMATIC TRANSMISSION UNIT (1FZ-FE)

AUTOMATIC TRANSMISSION UNIT (2UZ-FE)

AUTOMATIC TRANSMISSION UNIT (1HZ, 1HD-T, 1HD-FTE)

TORQUE CONVERTER AND DRIVE PLATE

TRANSFER (Full-Time 4WD Type)

TRANSFER SYSTEM

TROUBLESHOOTING

TRANSFER UNIT

TRANSFER ASSEMBLY

INPUT SHAFT

IDLER GEAR

CENTER DIFFERENTIAL

FRONT EXTENSION HOUSING

REAR EXTENSION HOUSING

MOTOR SHIFT CONTROL SYSTEM

TRANSFER (Part-Time 4WD Type)

TRANSFER SYSTEM

TROUBLESHOOTING

TRANSFER UNIT

TRANSFER ASSEMBLY

OUTPUT SHAFT

INPUT SHAFT

IDLER GEAR

FRONT EXTENSION HOUSING

REAR EXTENSION HOUSING OIL SEAL

TRANSFER SHIFT LEVER ASSEMBLY

ONE TOUCH 2-4 SELECTOR SYSTEM

PROPELLER SHAFT

TROUBLESHOOTING

PROPELLER SHAFT ASSEMBLY

SPIDER BEARING

SUSPENSION AND AXLE

TROUBLESHOOTING (Rigid Front Suspension)

TROUBLESHOOTING (Independent Front Suspension)

TIRE AND WHEEL

FRONT WHEEL ALIGNMENT (Rigid Front Suspension)

FRONT WHEEL ALIGNMENT (Independent Front Suspension)

FRONT AXLE HUB (Rigid Front Suspension)

FRONT AXLE HUB (Independent Front Suspension)

FREE WHEEL HUB

FRONT WHEEL HUB BOLT (Rigid Front Suspension)

FRONT WHEEL HUB BOLT (Independent Front Suspension)

STEERING KNUCKLE (Independent Front Suspension)

STEERING KNUCKLE AND AXLE SHAFT (Rigid Front Suspension)

FRONT DRIVE SHAFT (Independent Front Suspension)

FRONT DIFFERENTIAL REAR OIL SEAL (Rigid Front Suspension)

FRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (Independent Front Suspension)

FRONT DIFFERENTIAL CARRIER (Rigid Front Suspension)

FRONT DIFFERENTIAL CARRIER (Independent Front Suspension)

FRONT SHOCK ABSORBER (Independent Front Suspension)

COIL SPRING AND FRONT SHOCK ABSORBER (Rigid Front Suspension)

FRONT TORSION BAR SPRING (Independent Front Suspension)

FRONT UPPER SUSPENSION ARM (Independent Front Suspension)

FRONT LOWER SUSPENSION ARM (Independent Front Suspension)

FRONT LATERAL CONTROL ROD (Rigid Front Suspension)

FRONT LEADING ARM (Rigid Front Suspension)

FRONT STABILIZER BAR (Rigid Front Suspension)

FRONT STABILIZER BAR (Independent Front Suspension)

REAR AXLE SHAFT (Rigid Front Suspension)

REAR AXLE SHAFT (Independent Front Suspension)

REAR AXLE HUB (Rigid Front Suspension)

REAR WHEEL HUB BOLT (Rigid Front Suspension)

REAR WHEEL HUB BOLT (Independent Front Suspension)

REAR DIFFERENTIAL FRONT OIL SEAL

REAR DIFFERENTIAL CARRIER

REAR DIFFERENTIAL CARRIER (w/ Diff. Lock)

REAR DIFFERENTIAL CARRIER (w/ LSD)

DIFFERENTIAL LOCKING SYSTEM (Rigid Front Suspension)

DIFFERENTIAL LOCKING SYSTEM (Independent Front Suspension)

COIL SPRING AND REAR SHOCK ABSORBER (Rigid Front Suspension)

COIL SPRING AND REAR SHOCK ABSORBER (Independent Front Suspension)

REAR LATERAL CONTROL ROD (Rigid Front Suspension)

REAR LATERAL CONTROL ROD (Independent Front Suspension)

REAR UPPER AND LOWER CONTROL ARM (Rigid Front Suspension)

REAR UPPER AND LOWER CONTROL ARM (Independent Front Suspension)

REAR STABILIZER BAR (Rigid Front Suspension)

REAR STABILIZER BAR (Independent Front Suspension)

ACTIVE HEIGHT CONTROL SYSTEM (Independent Front Suspension)

ACTIVE HEIGHT CONTROL PUMP & MOTOR (Independent Front Suspension)

CONTROL VALVE ASSEMBLY (Independent Front Suspension)

HEIGHT CONTROL ACCUMULATOR (Independent Front Suspension)

PUMP ATTENUATOR (Independent Front Suspension)

DAMPING FORCE CONTROL ACTUATOR (Independent Front Suspension)

HEIGHT CONTROL SENSOR (Independent Front Suspension)

BRAKE

BRAKE SYSTEM

TROUBLESHOOTING

BRAKE FLUID (w/ ABS)

BRAKE FLUID (w/o ABS)

BRAKE PEDAL

PARKING BRAKE LEVER

BRAKE MASTER CYLINDER (w/o ABS)

BRAKE BOOSTER ASSEMBLY (w/o ABS)

VACUUM PUMP

FRONT BRAKE PAD

FRONT BRAKE CALIPER

REAR DRUM BRAKE

REAR BRAKE PAD

REAR BRAKE CALIPER

PARKING BRAKE

PROPORTIONING AND BY-PASS VALVE (P & B VALVE) (w/ ABS)

LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) (w/o ABS)

HYDRAULIC BRAKE BOOSTER

FRONT SPEED SENSOR

REAR SPEED SENSOR

STEERING

STEERING SYSTEM

TROUBLESHOOTING

DRIVE BELT

POWER STEERING FLUID

AIR CONTROL VALVE

STEERING WHEEL

TILT STEERING COLUMN

POWER TILT AND POWER TELESCOPIC STEERING COLUMN

POWER STEERING VANE PUMP (1FZ-FE)

POWER STEERING VANE PUMP (2UZ-FE Europe)

POWER STEERING VANE PUMP (2UZ-FE Except Europe)

POWER STEERING VANE PUMP (1HZ)

POWER STEERING VANE PUMP (1HD-T, 1HD-FTE)

POWER STEERING GEAR (Rigid Front Suspension)

POWER STEERING GEAR (Independent Front Suspension)

STEERING LINKAGE

SUPPLEMENTAL RESTRAINT SYSTEM

SRS AIRBAG

STEERING WHEEL PAD AND SPIRAL CABLE

FRONT PASSENGER AIRBAG ASSEMBLY

AIRBAG SENSOR ASSEMBLY

FRONT AIRBAG SENSOR

WIRE HARNESS AND CONNECTOR

BODY ELECTRICAL

BODY ELECTRICAL SYSTEM

POWER SOURCE

IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH

HEADLIGHT AND TAILLIGHT SYSTEM

HEADLIGHT BEAM LEVEL CONTROL SYSTEM

FOG LIGHT SYSTEM

TURN SIGNAL AND HAZARD WARNING SYSTEM

INTERIOR LIGHT SYSTEM

BACK-UP LIGHT SYSTEM

STOP LIGHT SYSTEM

HEADLIGHT CLEANER SYSTEM

WIPER AND WASHER SYSTEM

COMBINATION METER

DEFOGGER SYSTEM

POWER WINDOW CONTROL SYSTEM

POWER DOOR LOCK CONTROL SYSTEM

SLIDING ROOF SYSTEM

POWER SEAT CONTROL SYSTEM

POWER MIRROR CONTROL SYSTEM

SEAT HEATER SYSTEM

AUDIO SYSTEM

ANTENNA

CLOCK

ENGINE IMMOBILISER SYSTEM (2UZ-FE)

ENGINE IMMOBILISER SYSTEM (Except 2UZ-FE)

HORN SYSTEM

BODY

CLIP

SRS AIRBAG

FRONT BUMPER

REAR BUMPER

HOOD

HOOD SUPPORT

FRONT DOOR

REAR DOOR

BACK DOOR (Liftgate Type: Upper Side)

BACK DOOR (Liftgate Type: Lower Side)

BACK DOOR (Swing Type LH)

BACK DOOR (Swing Type RH)

BACK DOOR STAY

FRONT WIPER AND WASHER

REAR WIPER AND WASHER (Liftgate Type)

REAR WIPER AND WASHER (Swing Type LH)

REAR WIPER AND WASHER (Swing Type RH)

BODY OUTSIDE MOULDING

ROOF DRIP SIDE FINISH MOULDING

WINDSHIELD

QUARTER WINDOW GLASS (Fixed Type)

BACK DOOR GLASS (Liftgate Type)

BACK DOOR GLASS (Swing Type LH)

BACK DOOR GLASS (Swing Type RH)

SLIDING ROOF

INSTRUMENT PANEL

ROOF HEADLINING

SIDE STEP

FRONT SEAT (Separate Type: Power Adjuster)

FRONT SEAT (Separate Type: Manual Adjuster)

FRONT SEAT (Bench Type)

REAR NO.1 SEAT (Bench Type)

REAR NO.1 SEAT (Split Type: Single Side)

REAR NO.1 SEAT (Split Type: Double Side)

REAR NO.2 SEAT (Forward-Facing Type)

REAR NO.2 SEAT (Parallel Type)

SEAT BELT

SEAT BELT PRETENSIONER (Electrical Type)

SEAT BELT PRETENSIONER (Mechanical Type)

ROOF RAIL

ROOF RACK

FUEL TANK AND LINE

WINCH

WINCH UNIT

WINCH MOTOR

MAGNET SWITCH NO.1

MAGNET SWITCH NO.2

REMOTE CONTROL SWITCH

AIR CONDITIONING

AIR CONDITIONING SYSTEM

TROUBLESHOOTING (Manual A/C)

DRIVE BELT

MANIFOLD GAUGE SET

REFRIGERANT LINE

FRONT COOLING UNIT

REAR COOLING UNIT

FRONT HEATER UNIT

REAR HEATER UNIT

BLOWER UNIT

COOL BOX

COMPRESSOR AND MAGNETIC CLUTCH

VISCOUS HEATER AND MAGNETIC CLUTCH

CONDENSER

FRONT A/C EVAPORATOR

MAGNETIC VALVE (for Cool Box)

BLOWER MOTOR (for Front A/C)

BLOWER MOTOR (for Cool Box)

BLOWER RESISTOR (for Front A/C)

BLOWER RESISTOR (for Rear Cooler)

BLOWER RESISTOR (for Rear Heater)

BLOWER MOTOR CONTROL RELAY (Auto A/C)

POWER TRANSISTOR (for Rear Cooler)

POWER TRANSISTOR (for Rear Heater)

AIR MIX SERVOMOTOR (Front A/C for LHD)

AIR OUTLET SERVOMOTOR

SOLAR SENSOR

ROOM TEMPERATURE SENSOR (for Front A/C)

ROOM TEMPERATURE SENSOR (for Rear A/C)

AMBIENT TEMPERATURE SENSOR

AIR INLET TEMPERATURE SENSOR

PRESSURE SWITCH

HEATER MAIN RELAY

REAR HEATER RELAY

REAR HEATER HI RELAY (Manual A/C)

CONDENSER FAN RELAY (Dual A/C)

WATER TEMPERATURE CUT RELAY (1HZ, 1HD-T)

BLOWER SPEED CONTROL RELAY (Rear Cooler for Manual A/C)

BLOWER SPEED CONTROL RELAY (Front A/C for LHD)

BLOWER SPEED CONTROL RELAY (Front A/C for RHD)

VISCOUS HEATER RELAY (1HD-FTE)

COOL BOX RELAY

MAGNETIC CLUTCH RELAY

CONDENSER FAN (Dual A/C)

VACUUM SWITCHING VALVE (VSV) (1HZ, 1HD-T)

AIR CONDITIONER CONTROL ASSEMBLY

REAR A/C CONTROL ASSEMBLY (Auto A/C)

REAR A/C CONTROL ASSEMBLY (Manual A/C)

AIR CONDITIONER AMPLIFIER (for Rear A/C)

HEATER AMPLIFIER (w/ Viscous Heater)

COOL BOX CONTROL SWITCH

REAR HEATER CONTROL ASSEMBLY (Manual A/C)

WATER TEMPERATURE CUT SWITCH (1HZ, 1HD-T)

IDLE-UP SWITCH (1HZ, 1HD-T, 1HD-FTE)