AT111-02
D13663
AT0103
D12703
D12704
Bolt
- AUTOMATIC TRANSMISSIONVALVE BODY ASSEMBLY
AT-8
1862 Author: Date:
VALVE BODY ASSEMBLY
ON-VEHICLE REPAIR
1. REMOVE ENGINE NO.2 UNDER COVER
2. DRAIN ATF
3. REMOVE OIL PAN
NOTICE:
Some fluid will remain in the oil pan.
(a) Remove the 20 bolts.
(b) Remove the oil pan gasket.
4. EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect steel particles.
Carefully look at the foreign matter and particles in the pan and
on the magnets to anticipate the type of wear you will find in the
transmission.
Steel (magnetic)...bearing, gear and clutch plate wear
Brass (non-magnetic)...bushing wear
5. REMOVE OIL STRAINER
Remove the 4 bolts, the oil strainer and the O-ring.
NOTICE:
Be careful as some fluid will come out with the oil strainer.
6. DISCONNECT TEMPERATURE SENSOR
(a) Disconnect the 7 solenoid connectors.
(b) Remove 2 bolts and the 2 temperature sensors clamp
from the valve body.
(c) Disconnect the 2 temperature sensor from the valve body.
7. DISCONNECT 7 CONNECTORS FROM SHIFT SOLE-
NOID VALVES
Parts NameParts Number
Pastar UC (Oil Base)08836-00155
Pastar UW (Water Base)08836-001 15
Pastar Gun (For thick application)08836-00091 Parts NameParts Number
Rustop W (Aerosol)08860-00200
Rustop W (1 Milky White)08860-00210
Rustop W (18 Milky White)08860-00230
Rustop B (1 Black)08860-00220
Rustop B (18 Black)08860-00240 Parts NameParts Number
Body Sealer, White (Cartridge Type)08839-00020
Body Sealer, White (Tube Type)08839-00030
Body Sealer, Black (Cartridge Type)08839-00040
ANTI-RUST TREATMENT
When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the re-
quirements of your country.
HINT: For further details, see the description given in Section AR of this manual.
BODY SEALER
Apply body sealer to the
required areas.ANTI-RUST AGENT (WAX)
Apply anti-rust agent to following
sections.
Inside of the hems of the doors
and hood.
Around the hinges of the doors
and hood.
Inside of the welded parts with
boxed cross-section.
Tube Type
Cartridge Type
*The above SSM or equivalent
*The above SSM or equivalent
UNDERCOAT
Apply undercoat to the underbody and
wheel housings.
*The above SSM or equivalent
Spray Gun
Undercoating
(Water base) Undercoating
(Oil base)
INTRODUCTIONIN-14
Lift-Up Type Swing Type: High Strength Sheet Steel
HIGH-STRENGTH STEEL (HSS) PARTS
Generally, High-Strength Steel (HSS) is that which has an intensity value of at 35 kgf/mm2 (343 MPa), and
distinguished from mild steel.
The handling of HSS is the same as for mild steel, but the following should be observed.
1. Panel Hammering: Because HSS is thinner than mild steel, care should be taken to avoid warping dur-
ing hammering operations.
2. Removing Spot Welds: Because HSS is tougher than mild steel, damage will occur more easily to a
regular drill. Therefore, an HSS Spot Cutter is recommended.
Also, use a high-torque drill at low speed, and supply grinding oil to the drill use.
3. Panel welding: Panel welding procedures for HSS are exactly the same as for mild steel. Plug welding
should be done with MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than
specified.
BODY PANEL CONSTRUCTIONCN-4
A19885
1.1 mm
- DIAGNOSTICSENGINE
DI-175
368 Author: Date:
2004 LAND CRUISER (RM1071U)
5 Check spark plug and spark of misfiring cylinder.
PREPARATION:
(a) Remove the ignition coil assembly.
(b) Remove the spark plug.
CHECK:
(a) Check the electrode for carbon deposits.
(b) Check the spark plug type (See page IG-1).
(c) Check electrode gap.
OK:
No large carbon deposit present.
Not wet with gasoline or oil.
Electrode gap: 1.0 to 1.3 mm (0.039 to 0.051 in.)
NOTICE:
If adjusting the gap of a new spark plug, bend only ºthe
base / groundº electrode. Do not touch the tip. Never at-
tempt to adjust the gap on a used plug.
PREPARATION:
(a) Install the spark plug to the ignition coil assembly.
(b) Disconnect the injector connector.
(c) Ground spark plug.
CHECK:
Check if spark occurs while engine is being cracked.
CAUTION:
Always disconnect each injector connector.
NOTICE:
Do not crank the engine for more than 2 seconds.
OK:
Spark occurs across electrode gap.
OK Go to step 8.
NG
2004 LAND CRUISER (EWD548U)
19 E
RELAY
Basically, an electrically operated
switch which may be normally
closed (1) or open (2).
Current flow through a small coil
creates a magnetic field which either
opens or closes an attached switch.
1. NORMALLY
CLOSED
2. NORMALLY
OPEN
SWITCH, MANUAL
Opens and closes
iitth b
SPEAKER
An electromechanical device which
creates sound waves from current
flow.
RELAY, DOUBLE THROW
A relay which passes current
through one set of contacts or the
other.
circuits, thereby
stopping (1) or
allowing (2) current
flow.1. NORMALLY
OPEN
2. NORMALLY
CLOSED
RESISTOR
An electrical component with a fixed
resistance, placed in a circuit to
reduce voltage to a specific value.SWITCH, DOUBLE THROW
A switch which continuously passes
current through one set of contacts
or the other.
RESISTOR, TAPPED
A resistor which supplies two or
more different non adjustable
resistance values.SWITCH, IGNITION
A key operated switch with several
positions which allows various
circuits, particularly the primary
ignition circuit, to become
operational.
RESISTOR, VARIABLE or RHEOSTAT
A controllable resistor with a variable
rate of resistance.
Also called a potentiometer or
rheostat.
SENSOR (Thermistor)
A resistor which varies its resistance
with temperature.SWITCH, WIPER PARK
Automatically returns wipers to the
stop position when the wiper switch
is turned off.
(Reed Switch Type)
SENSOR, SPEED
Uses magnetic impulses to open
and close a switch to create a signal
for activation of other components.TRANSISTOR
A solidstate device typically used as
an electronic relay; stops or passes
current depending on the voltage
applied at ºbaseº.
SHORT PIN
Used to provide an unbroken
connection within a junction block.WIRES
Wires are always drawn as
straight lines on wiring
diagrams.
Crossed wires (1) without a
black dot at the junction are
tj i d
(1) NOT
CONNECTED
SOLENOID
An electromagnetic coil which forms
a magnetic field when current flows,
to move a plunger, etc.
j
not joined;
crossed wires (2) with a
black dot or octagonal ( )
mark at the junction are
spliced (joined)
connections.
(2) SPLICED
B04939
Delivery
Pipe
Lower
Intake
Manifold O-Ring
Grommet
Injector
Insulator
B04898B05006B04991
Type A
Type BPush
Pull Push
Pull
Disconnect
B05012
Type A Type B
S05382
RetainerType A only SF-4
- SFISFI SYSTEM
1703 Author: Date:
2004 LAND CRUISER (RM1071U)
(e) Install the injector to the delivery pipe and lower intake
manifold as shown in the illustration.
Before installing the injector, spindle oil or gasoline must
be applied on the place where the delivery pipe or the in-
take manifold touches the O-ring of the injector.
(f) Take following precautions to disconnect the fuel tube
connector (quick type):
(1) Check that there is no dirt on the pipe and around
the connector before disconnecting them. If there
is, clean the dirt away.
(2) Be sure to disconnect it with hands.
(3) Type A:
When the connector and the pipe are stuck, push
the clicks of the retainer and pull the connector to
free to disconnect and pull it out. Do not use any tool
at this time.
Type B:
When the connector and the pipe are stuck, turn
and pull the connector to disconnect. Do not use
any tool at this time.
(4) Inspect if there is any dirt or the likes on the seal sur-
face of the disconnected pipe and clean it away.
(5) Prevent the disconnected pipe and connector from
damaging and getting foreign objects by covering
them with a vinyl bag.
(g) Take following precautions to connect the fuel tube con-
nector (quick type):
(1) Do not reuse the retainer removed from the pipe.
(2) Do not use any tool. Use hands to connect the re-
tainer to the pipe.
(3) Check if there is any damage or foreign objects on
the connected part of the pipe.
SA14K-04
F05234
SST
F05235
SST
F05233
Less than 5 mm (0.20 in.)
- SUSPENSION AND AXLEFRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
SA-35
1985 Author: Date:
2004 LAND CRUISER (RM1071U)
REPLACEMENT
1. REMOVE FRONT WHEELS
Torque: 131 N´m (1,340 kgf´cm, 97 ft´lbf)
2. REMOVE FRONT DRIVE SHAFT
(See page SA-26)
3. REPLACE OIL SEAL
(a) Using SST, remove the oil seal.
SST 09308-00010
(b) Coat the hypoid gear oil to a new oil seal periphery.
(c) Using SST and a hammer, install the new oil seal.
SST 09550-00032, 09950-70010 (09951-07100)
(d) Coat the MP grease to the oil seal lip.
4. INSTALL FRONT DRIVE SHAFT
(See page SA-33)
5. FILL DIFFERENTIAL WITH HYPOID GEAR OIL
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
Oil type: Hypoid gear oil API GL-5
Recommended oil viscosity:
Above -18°C (0°F) SAE 90
Below -18°C (0°F) SAE 80W-90 or 80W
Capacity: 1.70 liters (1.80 US qts, 1.50 lmp.qts)
Z06905
Less than 5 mm
(0.20 in.)
- SUSPENSION AND AXLEREAR DIFFERENTIAL FRONT OIL SEAL
SA-97
2047 Author: Date:
2004 LAND CRUISER (RM1071U)
16. FILL DIFFERENTIAL WITH HYPOID GEAR OIL
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
Oil type:
w/o LSD: Hypoid gear oil API GL-5
w/ LSD: Hypoid gear oil LSD API GL-5
Recommended oil viscosity:
Above -18°C (0°F) SAE 90
Below -18°C (0°F) SAE 80W-90 or 80W
Capacity:
w/ Diff. Lock: 3.20 liters (3.38 US qts, 2.82 lmp.qts)
Others: 3.30 liters (3.49 US qts, 2.90 lmp.qts)