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Toyota 1986 Landcuiser, Repair Manual

The Toyota 1986 Landcruiser Repair Manual is a comprehensive guide to maintaining and servicing your vehicle. Easily download this manual for free from manualshive.com to access detailed instructions and diagrams that will help you keep your Landcruiser running smoothly for years to come.

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Summary of Contents for 1986 Landcuiser

Page 1: ...TOYOTA I8Ir PIIOIJUCI18I DATES 10184 THRU 1110 UA _ _...

Page 2: ...Duty refer to the following repair manuals 3F Engine Repair Manual Pub No 36253E B series Engine Repair Manual Pub No RM035E 2H Engine Repair Manual Pub No 36048E A440l A440F Automatic Transmission R...

Page 3: ...EAR AXLE AND SUSPENSION liB BRAKE SYSTEM IffiI STEERING IIDI BODY ELECTRICAL SYSTEM BODY ImlI WINCH I2D AIR CONDITIONING SYSTEM m I SERVICE SPECIFICATIONS STANDARD BOLT TDRQUE SPECIFICATIONS C 1994 TO...

Page 4: ...IN l INTRODUCTION HOW TO USE THIS MANUAL IN 2 IDENTIFICATION INFORMATION IN4 GENERAL REPAIR INSTRUCTIONS IN4 VEHICLE LIFT AND SUPPORT LOCATION IN 6 ABBREVIATIONS USED IN THIS MANUAL IN 8...

Page 5: ...eginning of each section PRECAUTIONS are given that pertain or slf repair operations contained in that section Read these precautions before starting any repair rask TROUBLESHOOTING tables are include...

Page 6: ...ad the task headings and refer to the detailed text only when he needs it Important specifications and warnillQs always stand out in bold type REFERENCES References have been kept to a minimum However...

Page 7: ...revent damage 2 During disassembly keep parts in order to facilitate re assembly 3 Observe the following a Before performing electrical work disconnect the cable from the battery terminal b If it is n...

Page 8: ...y the specified seal lock adhesive to the bolt or nut threads c Precoated parts are indicated in the component illustrations by the symbol 7 When necessary use a sealer on gaskets to prevent leaks 8 C...

Page 9: ...lift and Support Locations VEHICLE LIFT AND SUPPORT LOCATIONS 60 series II IJ 70 series short Itfr I M Front Under the front differential Rear Under the rear differentia SUPPORT POSITION Safety stand...

Page 10: ...ions IN 7 VEHICLE LIFT AND SUPPORT LOCATIONS Cont d 73seri9S 1mi ddlel riff I 75seriesUo n l Ifi 11 X l JACK POSITION e Front Under the front differential Rear Under the rear differential SUPPORT POSI...

Page 11: ...utomatic Transmission Approximate Automatic Transmission Fluid Circuit Breaker Except Front Fiber Reinforced Plastics Inch Ignition Left hand Left hand Drive Load Sensing Proportioning Valve Maximum M...

Page 12: ...G CHECK AND ADJUSTMENT OF CLUTCH PEDAL OPERATIONAL TEST OF CLUTCH BOOSTER BLEEDING OF CLUTCH SYSTEM CLUTCH MASTER CYLINDER CLUTCH BOOSTER CLUTCH RELEASE CYLINDER CLUTCH UNIT CL Page CL 2 CL 3 CL CL CL...

Page 13: ...eplay CL 3 Clutchboo lerfaully Inspect clutch booster CL 9 Clutch disc lining oily or worn OUI Inspectclulchdisc CL IS Pressure plate faulty Replace pressure plate CL IS Inspect release fork CL IS Clu...

Page 14: ...til the resis tance begins to increase a little Push rod play at pedal top 1 5 mm 0 04 0 20 in 3 2 w Clutch Booster CHECK PEDAL FREEPLAY AND BOOSTER AIR VALVE STROKE Pedal Freeplay Push in on the peda...

Page 15: ...ne time is equal to that with the engine running NOTE If a and b are not as stipulated inspect the vacuum check valve and if necessary the clutch booster also BLEEDING OF CLUTCH SYSTEM NOTE If any wor...

Page 16: ...MOVAL OF MASTER CYLINDER 1 DRAW OUT FLUID WITH SYRINGE 2 DISCONNECT CLUTCH LINE UNION Using SST disconnect the union SST 09751 36011 CL S 3 DISCONNECT CLEVIS FROM CLUTCH PEDAL Remove the clip and clev...

Page 17: ...pB uG oo Inspect the disassembled parts for wear rust or damage I 0 CL 51 SEMBLY OF MASTER CYLINDER 1 COAT PARTS WITH LI THIUM SOAP BASE GLYCOL o GRE ASE 2 INSTALL PISTON INTO CYLINDER 3 INSTAll PUSH...

Page 18: ...Master Cylinder w Clutch Booster COMPONENTS CL 7 REMOVAL OF MASTER CYLINDER DRAW OUT FLUID WITH SYRINGE DISCONNECT CLUTCH LINE UNION Using S5T disconnect the union SST 09751 36011 3 REMOVE MASTER CYLI...

Page 19: ...r damage ASSEMBLY OF MASTER CYLINDER See page CL 7 1 COAT PARTS WI TH LITHIUM SOAP BASE GLYCOL GREASE 2 INSTALL PISTON INTO CYLINDER INSTA LL RESERVOIR TANK Torque 250 kg cm 18 ft lb 25 N m INSTALLATI...

Page 20: ...Specifiedto Que Non euublepart 1 REMOVE MASTER CYLI NDER See page CL 7 2 DISCONNECT VACUUM HOSE FROM CLUTCH BOOSTER 3 REMOVE CLUTCH PIPE AND VACUUM PIPE CLAMP BOLTS 4 DISCONNECT CLEVIS FROM CLUTCH PE...

Page 21: ...ponge element from the boot_ cu o 3 REMOVE SPONGE AND FELT ELEMENT SST J J Using screwdriver remove the E ring and sponge and felt element 4 SEPARATE NO AND NO 2 BOOSTEA BODIES a Put matchmarks on the...

Page 22: ...ragm 7 REMOVE BOOSTER A IR VALVE ASSEMBLY FROM BOOSTER PISTON a Push down the booster air valve in the booster piston and remove the stopper key b Pull off the booster air valve assembly 8 REMOVE REAC...

Page 23: ...e vacuum hose side to the vacuum tank side NOAO Air ruo o SST SST SST SST 2 IF NECESSARY REPLACE BODY SEAL FOR NO 2 BOOSTER BODY a Using SST remove the body sealer SST 09630 00011 09753 30020 and 0961...

Page 24: ...WN BELOW 2 INSTAll BODY SEAL Cl O a Place the TO NO 1 BOO b s cu th odY io po itioo_ STER BODY body seal with the circular ring 3 INSTAll BO OOSTER PI 6 R AIR VALVE ASSEM a Insert the b BlY TO b Push...

Page 25: ...ot to tighten the two nutsof the SST too tightly C d Turn the No 1 booster body counterclockwise until the matchmarks match NOTE If the No 1 booster body is too tight to be turned apply more silicone...

Page 26: ...it on the booster SST 09737 00010 c Adjust the booster push rod length until the push rod lightly touches the pin head Clearance 0 mm 0 in 2 INSTA LL CLUTCH BOOSTER WITH MASTER CYLINDER BRACKET TO BO...

Page 27: ...51 3601 t nect the union b Removethecl CUll cl Loosen and Ip from flexible hose 2 nod mo th 11 1 ho om RE MOVE RE LEASE th DISASS CYLINDER 1 EMBLY OF REL PULL OFF PUSH ROD EASE CYLINDER REMOV E BOOT 3...

Page 28: ...G yro G g ASSEMBLY OF RELEASE CYLINDER See page CL 16 1 COAT PISTON WITH LI THIUM SOAP BASE GLYCOL GREASE AS SHOWN 2 INSTALL PISTON 3 INSTALL BOOT AND INSERT PUSH ROD f SST 09751 36011 c Install the...

Page 29: ...PONENTS ClutehCover CLUTCH UNIT REMOVAL OF 1 REMOVE TRANSMISSION See page MT drain the transmission o 1 NOTE Do not TCH COVER AND OIS er and flywheel 2 REMOVE CLU k 00 h h 0 m h a Place m c bolts one...

Page 30: ...sc 2 INSPECT CLUTCH DISC RUNOU T Using a dial indicator check the disc runout Maximum runout 0 8 mm 0 031 in Ifrunout is excessive replace the disc 3 INSPECT FLYWH EEL RUNOUT Using a dial indicator ch...

Page 31: ...0 6 mm 0 024 in Width 5 0 mm 0 197 in IF NECESSARY REPLACE PRESSURE PLATE a Drill out the rivet heads b Disconnect the retracting springs from the pressure plate e Using a punch drive out the rivets...

Page 32: ...a new release bearing into the hub SST 09315 00021 cl After installing the bearing check that there is no drag on the bearing when it is turned under pressure INSTALLATION OF CLUTCH UNIT See pageCl 1...

Page 33: ...ect SST 09333 00012 5 APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE N LGI NO 2 OR MP GREASE a Apply molybdenum disulphide lithium base grease to the following parts Release fork and hub contact poin...

Page 34: ...n _ Disassembly of Case Cover Assembly H41 Disassembly of Case Cover Assembly H55FJ Inspection of Transmission Components Assembly of Case Cover Assembly H41 Assembly of Case Cover Assembly H55F Assem...

Page 35: ...BLESHOOTING Probl m I notshlh Transmisslonl ulty Hard IOshift or will ISpline Son inputsh ftdirtyorb rred Tr n iuion jumps ITransmission f ulty out of gear Repairil5ne ary Diussembleandinspecttr ns mi...

Page 36: ...move the shift lever boot b Cover the shift lever cap with a cloth c Then pressing down on the shift lever cap rotate it counterclockwise to remove d Remove the shift lever 3 RAISE VEHICLE AND DRAIN O...

Page 37: ...ove the starter 13 REMOVE EXHAUST PIPE 14 JACK UP TRANSMISSION SLIGHTLY Raise the transmission enough to remove the weight from the engine rear support member 15 REMOVE ENGINE REAR SUPPORT MEMBER a Re...

Page 38: ...MANUAL TRANSMISSION H41 and H55F C r m o OMPONENTS MT 5 CueCover__ l__ tl w T o m oo H55F l J f5 Sh ftFm Sh ft Transfer Adapter 5th Shift Fork...

Page 39: ...MT 6 MANUAL TRANSMISSION H41 and H55F T COMPON ransmissions ENTS Con d eNo 2 eg Rolllr InputShft Input Shift 1 l J_ J IpRing L I L p ocklngBall In...

Page 40: ...O T n iuion MPONENTSICon d 1 Loc lullgBaH o CoW ja rseShlh HHd _0 w on ReverseSh t 1Roll o Sh h R slA n nd2 n Sh O Inttr1 n Lodung 6 aIl o I htancl2nd lh ft 0 lRi lh_Pi 0 4 mShlh IR F kSh r S n B C 3r...

Page 41: ...MT 8 MANUAL TRANSMISSION H41 and H55F Transmission S COMPONENTSICont dj 5 5_ Ikg em It tb N mll SpeocifiwtofQUr Noo reuu bl part Precolted pltt...

Page 42: ...SST 09817 16011 REMOVE CASE COVER a Remove the case cover and gasket b Remove the dust boot H55F MT 9 5 REMOVE FIFTH LOCKING BALL AND SPRING H55F a Using SST remove the screw plug SST 09313 30021 b Us...

Page 43: ...um clearance 0 175 0 325 mm 0 0069 0 0128 in 0 125 0 275 mm 0 0049 0 0108 in 0 10 0 30 mm 0 0039 0 01 18 in 1st and 2nd gears 0 35 mm 0 01 38 in 3rd and counter 5th gears 0 30 mm 0 0118 in 8 REMOVE OU...

Page 44: ...hat the teeth of the SST are not damaged b Apply the SST make a gap between 5th gear and the bearing then raise the gear NOTE Make sure the SST is always between 5th gear and the bearing Tighten the S...

Page 45: ...to damage the oil seal 17 REMOVE COUNTER GEAR FRONT BEARING la Using snap ring plier1 remove the snap rings T n move the counter gear front bearing 18 FJ HJ series REMOVE INP UT SHAFT AND BEARING T mo...

Page 46: ...prevent the case from being damaged by the bolts Tighten the two bolts evenly Use bolts with a 12 mm nominal diameter 1 5 pitch and approx 60 mm thread length Reference Part No 90101 12034 19 REMOVE O...

Page 47: ...gear shaft toward the rear b Remove the gear and the woodruff key 22 REMOVE REVERSE SHIFT ARM FROM TRANSMISSION CASE Remove the nut washers Q ring pivot arm and reverse shiharm 23 REMOVE FIRST GEAR T...

Page 48: ...remoV1 the hub sleelle No 2 assembly synchronizer ring 3rd gear 3rd gear bushing needle roller bearing and 2nd gear 27 REMOVE LOCKING BALL Using a magnetic finger remove the locking ball 28 REMOVE FI...

Page 49: ...the locking ball from flying out c Remove the fork shaft shift head interlock roller locking ball and spring 2 REMOVE REVERSE SHIFT HEAD a Using a pin punch and hammer drive out the slotted spring pi...

Page 50: ...ight plug NOTE Cover the service hole with your hand to prevent the locking ban from flying out c Remove the fork shaft shift fork interlock pin locking ball and spring 4 DISASSEMBLE SHIFT HEAD a Comp...

Page 51: ...emove the tight plug from the case cover c Using a pin punch drive out the slotted spring pin from the shift fork d Remove the fork shaft shift fork shift head inter lock roller interlock pin locking...

Page 52: ...ft shift fork interlock roller interlock pin lock ing ball and spring 5 REMOVE SELECT LEVER SHAFT AND SHIFT LEVER HOUSING a Unstak e the lock plate and remove the lock bott from the shift lever housin...

Page 53: ...nsmissions 7 DISASSEMBLE SHIFT HEADS a Using two screwdrivers and a hammer remove the C washer CAUTION Be careful as the plunger will spring out b Remove the plunger and compression spring NOTE Be car...

Page 54: ...sing a dial indicator measure the shaft ru nou t Maximum runout 0 03 mm 0 0012 in 2 INSPECT COUNTER GEAR ANa BEARINGS a Check the gear teeth for wear or damage b Check the bearings for wtlar or damage...

Page 55: ...INSPECT SYNCHRONIZER RINGS OF FIRST AND SECOND GEARS a Check the inner spline for wear or damage Syndlronizer I I G i b Check the raised position of the guide pins for wear or damage Ring Holder I Thr...

Page 56: ...aring CAUTION 00 not press in the bearing outer race d Select a snap ring that will allow minimum axial play and install iton the shaft Standard play 0 0 10 mm 0 0 0039 in Thickn ss mm lin 3 20 3 31 O...

Page 57: ...F NECESSARY REPLACE FIFTH SHIFT ARM OIL SEAL ON TRANSFER ADAPTER H55F a Using a screwdriver pry out the oil seal b Using a socket wrench and hammer drive in a new oil seal Drive in depth 1 0 mm 0 039...

Page 58: ...the spring and locking ball b Insert the fork shaft through the reverse shift head 3 INSTA LL FIRST AND SECOND SHIFT FORK AND SHAFT la Install the spring and locking ball b Coat the interlock roller w...

Page 59: ..._ 5 INSTALL SLOTTED SPRING PINS a Align the pin hole of each shaft with the fork head and the other fork respectively b Using a pin punch and hammer drive in the sloned spring pins until they are flus...

Page 60: ...d torque the plug Torque 190 kg cm 14 ft lb 19 N m 3 INSTALL SELECT LEVER SHAFT AND SHI FT LEVER HOUSING a Insert the shaft thrOllgh the select lever and shift lever housing b Align the holes of the s...

Page 61: ...Install the spring and locking ball Ib Coat the interlock pin with MP grease and install it in the shaft Id Insert the fork shaft through the shift fork and the shift head Id Install the two interloc...

Page 62: ...E1J 10 H41oodH55FT 0 INSTALL TIGHT PL MT 29 Apply liq d UGS the case c erS l o nthe tight plug and d rlve them into MANUAL TRANSMISSION...

Page 63: ...n the bushing notch and locking ball c Apply gear oil to the bushing_ Id Install the 3rd gear on the bushing 3 INSERT CLUTCH HUB NO 2 INTO HUB SLEEVE a Install the clutch hub and shifting keys to the...

Page 64: ...0 30 mm 0 0118 in ASSEMBLE SYNCHRONIZER RING HOLDER Hook the synchronizer ring holder ends to the thrust piece NOTE Align the synchronizer ring holder ends so they are not both facing in the same dire...

Page 65: ...end 12 PUT OUTPUT SHAFT ASSEMBLY INTO TRANSMISSION CASE CAUTION Be careful not to damage the front end of the shaft 13 INSTALL OUTPUT SHAFT CENTER BEARING a Using snap ring pliers install the snap rin...

Page 66: ...rcenter b Install the thrust collar for the front bearing onto the counter gear H55F cl Using S5T drive in the bearing S5T 09316 60010 NOTE When driving in the bearing support the counter gear in rear...

Page 67: ...19 INSTALL STRAIGHT PIN AND COUNTER FIFTH GEAR THR UST WASHER H55FI a Install the straight pin onto the counter shaft b Align the thrust washer slot with the straight pin and install the thrust washer...

Page 68: ...INSTALL SYNCHRONIZER RING AND GEAR SPLlNE PIECE NO 5 H55F a Align the synchronizer ring slots with the shifting keys and place the synchronizer ring on the rear end of the counter 5th gear b Using SS...

Page 69: ...nce 0 30 mm 0 0118 in le Using a punch stake the lock nut 26 INSTALL FRONT BEARING RETAINER WITH A GASKET la Install the front bearing retainer with a gasket b Apply liquid sealer to the bolts c Insta...

Page 70: ...SHIFT ARM AND SHAFT H55F a Install the 5th shift arm shaft through the transfer adapter and install the 5th shift arm b Install the bolt with a lock washer and torque the bolt Torque 380 kll cm 27 ft...

Page 71: ...kg cm 18 ft lb 25 N m 32 INSTALL CASE COVER a Install the dust boot H55F b Install the case cover with a gasket Torque the bolts Torque 400 kg cm 29 ft lb 39 N m 33 INSTALL BACK UP LIGHT SWITCH Using...

Page 72: ...a Position the adjustment mark on the shift arm pivot end toward the front b Temporarily install the shift lever and if the shift lever is catching on something in the selecting direc tion adjust by m...

Page 73: ...INE REAR SUPPORT MEMBER lal Install the bolts to both sides of the member Torque 400 kg cm 29 ft Ib 39 N m bl Install the four bolts to the member Torque 600 kg cm 43 ft lb 59 N m 3 INSTALL EXHAUST PI...

Page 74: ...lever cap and the pin part of the case cover b Cover the shift lever cap with a cloth c Then pressing down on the shift lever cap rotate it clockwise to install d Install the shift lever boot 14 CONN...

Page 75: ...TRANSMISSION TROUBLESHOOTING ATF INSPECTION ADJUSTMENTS TESTS AT Page AT 2 AT S AT 6 AT 7 AUTOMATIC SHIFT DIAGRAM AT 16 ON VEHICLE REPAIR AT 18 REMOVAL OF TRANSMISSION AT 24 INSTALLATION OF TRANSMISS...

Page 76: ...th the inspection as follows Basiedledc I Overhaultr nsmission 1 Preliminary Check a Check the fluid level b Check the throttle cable mark c Check the shift linkage Id Check the neutral start switch e...

Page 77: ...ss mbl and intplCttransmi tion Hlfshengagement Thronleeableout ofldjuilment AdjuH throttle eable AT S into nydriverange V I body or prim ry r ilulltor faulty Inspectv lve body AT la Accumulator piston...

Page 78: ...NoOD 3 J 2or2 1 Throttle uble out of adjustment ThrottltClblt flulty Governorf ulty Valve body faulty Transmipionfaully Thronl uble out 01 adjuUrnerlt Governorf ulty V tlle body flulry Adjust thronll...

Page 79: ...dd fluid Fluid type ATF DEXRON n CAUTION Do not overfilL 2 CHECK FlUID CONDITION If the fluid smells burnt or is black replace it 3 REPLACE FLUID a Remove the drain plug and drain the fluid b Reinstal...

Page 80: ...justing cam Then re check the adjustment ADJUSTMENT OF SHIFT LINKAGE ADJUST FLOOR SHIFT LINKAGE a loosen the nut on the connecting rod b Push the manual lever fully toward the front of the vehicle c R...

Page 81: ...time Stall speed 3F engine 1 85O 150 rpm 2H engine 1 9OO 150 rpm gl Perform the same test in the R range EVALUATION a If the stall speed is the same for both ranges but lower than the specified value...

Page 82: ...ch measure the time it takes from shifting the lever until the shock is felt Time lag Less than 0 7 seconds Id In same manner measure the time lag for N A Time lag Less than 1 2 seconds CAUTION la Per...

Page 83: ...0 35 22 1 33121 1 31 19 1 800 64 40 59 37 57 35 3 500 124 77 1 5 71 1 110 1 68 3 500 rpm it would be safer to do it on rold or using a chassis dynamometer because an on stand test could be hazardous 2...

Page 84: ...ng 3 7 4 3 I 4 5 5 5 153 61 1 64 78 363 4221 441 5391 11 1 13 6 I 14 0 17 0 Slall 1158 193J 1199 2421 1 089 1 334 1 373 1 6671 le If the measured pressures are not up to specified values recheck the t...

Page 85: ...1 2 up shift Governor valve is defective 1 2 shift valve is stuck 2 If there isno 2 3up shift 2 3 shift valve is stuck 3 If there is no 3 0D up shift 3 4 shift valve is stuck t41 If the shift point i...

Page 86: ...oot from the accelera tor Check that after shifting into the 2 range the OD 3 shift takes place immediately afterward and that the 3 2 shift conforms with the specifications in the automatic shift dia...

Page 87: ...n and deceleration and for shock at up shift and down shift c Perform a kick down from 2nd and 3rd gear of the 3 range and check the possible 2 3 2 3 1 kickdowns vehicle speed limit to see if it confo...

Page 88: ...of the 2 range check to see that there is nodown shift to 1st gear c While running in 2nd gear of the 2 range release the accelerator pedal and check the engine braking effect d Check for abnormal noi...

Page 89: ...ise at acceleration and deceleration 5 R RANGE TEST Shift into t he R range and check for slipping while ru nning at full t hronle 6 P RANGE TEST Stop the vehicle on a gradient more than 9 and after s...

Page 90: ...pen fullyelosedl 2 rlnge L rlnge n Size 2 3 3 00 00 3 1 3 2 2 lock up lock up 3 2 2 ON OFF 1 00 16 6 1 SO 16 6 34 41 76 92 120 1 40 11 1301 61 31 40 70 90 65 85 80 91 38 SO 1 50R I6 6 8 21 291 41 57 1...

Page 91: ...80 Ib 2 0 io I 50 90 lOO 10 120 130 140 un h 70 io mph Vehicl Speed km h mphf O rlngehhrottl vllvefully n l fully closed 2 rlll9t L nge Tire Sill 1 2 2 1 3 2 2 1 7 SOR I6 6 8 32 44 68 84 110 129103 12...

Page 92: ...p prevent contamination clean the exterior of the transmission 4 DRAIN TRANSMISSION FLUID Remove the drain plug and drain fluid into a suitable con lainer 5 REMOVE OIL PAN AND GASKET CAUTION Some flu...

Page 93: ...cable from the cam and re move the valve body 8 REMOVE FOUR CENTER SUPPORT APPLY GASKETS INSTALLATION OF VALVE BODY 1 INSTALL FOUR CENTER SUPPORT APPLY GASKETS Install the four center support apply g...

Page 94: ...ue 100 kg cm 7 ft Ib 10 N m 5 INSTALL OIL STRAINER Be sure the strainer is clean Install a new gasket and strainer Torque 5 mm bolt 55 kg cm 48 in lb 5 4 N m 6 mm bolt 100 kg cm 7 ft lb 10 N m 6 INSTA...

Page 95: ...type ATF DEXRON D 10 CHECK FLUID LEVEL See page AT 5 REMOVAL OF THROTTLE CABLE 1 DISCONNECT THROTTLE CABLE a Disconnect the cable housing from the bracket tb Disconnect the cable from the throttle lin...

Page 96: ...H THROTTLE CABLE OUT OF TRANSMISSION CASE Using a 10 mm socket push the throttle cable out_ INSTALLATION OF THROTTLE CABLE 1 INSTALL CABLE IN TRANSMISSION CASE Be wre to push it in all the way 2_ INST...

Page 97: ...cam of valve body bl Pull the inner cable lightly until resistance is felt and hold it c Paint a mark as shown about 4 mm 0 16 in in width dl Pull the inner cable fully measure the cable stroke Cable...

Page 98: ...et b Disconnect the cable from the throttle linkage 5 DISCONNECT CONNECTORS Disconnect the connectOr1located near the starter 6_ REMOVE TRANSFER SHIFT LEVER BOOT la Remove the shift lever knob Ib Remo...

Page 99: ...ft lever with control rod 11 DISCONNECT TRANSMISSION CONTROL ROD e le 7 nd disconnect the control rod from the 12 w OE Z H FF SHIFT LEVER a Remove the knob bunon b Remove the spring c hSi e ehre wrenc...

Page 100: ...ge PR 3 14 REMOVE POWER TAKE OFF DRrvE SHAFT w MECHANICAL WINCH a Remove the engine undercover b Place matchmarks on the yoke and flange cl Remove the bolts and nuts and disconnect the drive shaft fro...

Page 101: ...18 REMOVE STARTER a Oisconnect the connector and cable b Remove the bolt nut and starter 19 REMOVE OIL FILLER TUBE 20 REMOVE SIX TORQUE CONVERTER MOUNTING BOLTS a Remove the end plate hole plug b Turn...

Page 102: ...e exhaust pipe clamp b Remove the three bolts disconnect the front pipe from the tail pipe c Remove the three nuts and front pipe from the ex haustmanifold d Remove the two gaskets 23 REMOVE TRANSMISS...

Page 103: ...Id Draw out the transmission down and toward the rear CAUTION Be careful not to snag the thronle cable or neutral start switch cable Keep the oil pan positioned downward 24 PLACE PAN UNDER CONVERTER H...

Page 104: ...the installation of the converter If excessive runout cannot be corrected replace the torque converter NOTE Mark the position of the converter to ensure cor rect installation b Remove the torque conve...

Page 105: ...transmission for ward because the torque converter could slide out le Install the nine transmission mounting bolts Torque 8 mm bolt 185 kg cm 13 ft lb 18 N m 10 mm bolt 380 kg crn 27 ft Ib 37 N m 12 m...

Page 106: ...pin b Install the six bolts hand tight Turn the crankshaft to gain access c Tighten theboltsevenlv Torque 290 kg cm 21 ft lb 28 N m d Install the end plate hole plug 10 INSTAll Oil FillER TUBE a Inst...

Page 107: ...VE SHAFT Iw MECHANICAL WINCH AT 33 a Align the matchmarks on the joint flange yoke and drive sh8ft b Inst811 the drive shaft cl Install the front and rearbr8cket Id Align the mltchmarks on the drive s...

Page 108: ...Install the shift lever to the transmission b Install the shift rod to the PTO c Install the shift lever boot with the four bolts Id Install the lift lever knob to the shift lever and torque the two...

Page 109: ...pin to the transfer c Install the clip d Install the shift lever boot with the four bolts e Install the shift lever knob 21 INSTAll TRANSMISSION UNDERCOVER AND TRANSFER UNDERCOVER 22 LOWER VEHICLE AND...

Page 110: ...TTERY CABLE TO NEGATIVE TERMINAL 28 FILL TRANSMISSION WITH ATF AND CHECK FLUID LEVEL See page AT 5 Fluid type ATF OEXRONIP D Total capacity 15 0 liten 15 9 US qts 13 2 Imp q1s Drain and refill capacit...

Page 111: ...f Diaphragm Cylinder Inspection of Diaphragm Cylinder Components Assembly of Diaphragm Cylinder Transfer Componenu Disassembly of Transfer Inspection of Transfer Componenu Assembly of Transfer Install...

Page 112: ...HOOTING Problem Remedy P Hlrdtoshiftorwill Splinesoninputshaftdirtyorburred Repair sneeluilry TF J not shift Transf rh lty Oisauembl nd inspe t TF 3 tr nder Tr nsflr jumps out Trilnsfer faulty Disasse...

Page 113: ...SHAFT OIL SEAL DRAIN GEAR OIL FROM TRANSFE R 2 REMOVE TRANSFER UNDERCOVER TF 3 3 REMOVE FRONT AND REAR PROPELLER SHA FTS See page PR 3 4 REMOVE COMPANION FLANGE a Using a hammer and chisel loosen the...

Page 114: ...nion flange b Using SST to hold the companion flange install the companion flange lock nut SST 09330 21 Torque 1 300 kg cm 94ft lb 127 N m c Stake the companion flange lock nut S INSTALL FRONT AND REA...

Page 115: ...nder BodV Co r 1 Suction Tube I XI __ DilPhragm PI te DISASSEMBLY OF DIAPHRAGM CYLINDER p MII REMOVE DIAPHRAGM CYLINDER ASSEMBLY a Remove the diaphragm cylinder assembly from the diaphragm cylinder bo...

Page 116: ...SPECT DIAPHRAGM CYLINDER ASSEMBLY a With at least 400 mm Hg 1 5 75 in Hg 53 3 kPa of vacuum in the diaphragm confirm that the shaft Standard stroke 22 mm 0 87 in b Confirm again on the diaphragm side...

Page 117: ...PHRAGM PUSH ROD Twowashers Twoplates Diaphragm O ring INSPECTION OF DIAPHRAGM CYLINDER COMPONENTS IF NECESSARY REPLACE OIL SEAL a Using a screwdriver remove the oil seal b Using a socket wrench drive...

Page 118: ...M PUSH ROD INTO DIAPHRAGM CYLINDER COVER 4 INSTALL DIAPHRAGM CYLINDER BODY COVER Ins all the diaphragm cylinder body cOller to the diaphragm cylinder coller Torque the bolts Torque 75 kg cm 65 in Ib 7...

Page 119: ...STAll SHIFT LINK LEVER AND STRAIGHT PIN Apply MP grease to shoe and straight pin b Install the shift link lever and straight pin o 0 INSTALL DI APHRAGM CYLINDER ASSEMBLY Install the diaphragm cylinder...

Page 120: ...ring HighlndLowOuterLev r C l r 1 50l33 441 1 DUi Boot _ _ l ocking Ball Oil Sell eo Sorinv f I 1 Oil Se 1 I lL B _ I I r 0000 0 H L L I I O O o H h Lo r Fork Shaft Highlnd low Shift Fork IUI7 18 SniP...

Page 121: ...TRANSFER Transfer TF 11 COMPONENTS Cont d l f i _m D G Space Btlring ATM J I kg em ft lb N mH pt ifiedlo que Non tunblep 1...

Page 122: ...emove the dust boot 3 REMOVE 4WD INDICATOR SWITCH Using SST remove the 4WD indicator switch SST09817 1 6011 4 J I fd 0 m REMOVE L4 POSITION SWITCH ELECTRICAL SHIFT TYPE 5 REMOVE PLUGS SPRINGS AND LOCK...

Page 123: ...AND REAR COMPANION FLANGE a Using a hammer and chisel loosen the staked part of the nut b Using SST to hold the companion flange remove tne companion flange lock nut SST 09330 21 c Remove the companio...

Page 124: ...put shaft rear bearing retainer bl Remove the speedometer drive gear and spacer 12 REMOVE IDLER GEAR SHA FT LOCK PLATE 13 REMOVE TRANSFER REAR CASE al Remove the bolts bl Using a plastic hammer remove...

Page 125: ...nsfer input gear bearing SST 09950 20016 b Remove the power take off drive gear and spacer 17 REMOVE TRANSFER INPUT GEAR Using SST remove the transfer input gear SST 09950 20016 18 REMOVE O R ING FROM...

Page 126: ...pring pin b Remove the shift fork from the shift fork shaft Electrical Shift Type a Remove the retainer spring and shift fork from the shift fork shaft b Using snap ring pliers remove the snap ring 23...

Page 127: ...igh gear Standard clearance MTM 0 10 0 25 mm 0 1 039 0 0098 in ATM 0 15 0 30mm 0 0059 0 0118 in Maximum clearance MTM 0 25 mm 0 0098 in ATM 0 30 mm 0 0118 in b Using a feeler gauge measure the thrust...

Page 128: ...ench remove the follow ing parts Clutch hub Output shaft front bearing Highgear High gear bearing ATM Clutch sleeve 28 REMOVE LOW GEAR FROM REAR OUTPUT SHAFT Using a press remove the following parts O...

Page 129: ...dial indicator measure oil clearance between the high gear and shaft Standard clearance MTM 0 035 0 081 mm 0 0014 0 0032 in ATM 0 019 0 068 mm 0 0007 0 0027 in Maximum clearance MTM 0 081 mm 0 0032 i...

Page 130: ...20011 c Apply MP grease to the pilot bearing 5 IF NECESSARY REPLACE REAR OUTPUT SHAFT FRONT BEAR ING OUTER RACE a Using SST remove the rear output shaft front bearing outer race SST 09514 35011 b Usin...

Page 131: ...10 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...

Page 132: ...new oil seal SST 09316 60010 c Apply MP grease to the oil seal Iip 10 IF NECESSARY REPLACE REAR OUTPUT SHAFT OIL SEAL a Using a screwdriver remove the oil seal b Using SST drive in a new oil seal SST...

Page 133: ...EDOMETER DRIVEN GEAR OIL SEAL a Using SST pull out the oil seal 55T 09921 o xJ10 bl Using SST drive a new oil seal into the sleeve 55T 09201 60011 Oil seal depth 20 mm 0 79 in 13 IF NECESSARY REPLACE...

Page 134: ...TF 24 TRANSFER Transfer d Using SST press in a new bearing SST 09316 00010 e Install the snap ring f Install a new oil seal See page TF 21...

Page 135: ...SHAFT Using S5T press in the foHowing parts Clutch sleeve low gear bearing ATM low gear Output shaft rear bearing 55T09316 6001O 3 INSTAll SNAP RING Select a snap ring that will aHow minimum axial pl...

Page 136: ...NSFER FRONT CASE a Apply MP grease to the oil seal 8 Ib Install the front case with a new gasket to the transfer adapter c Apply liquid sealer to the bolts and install and torque as shown 4 Speed Four...

Page 137: ...a plastic hammer install the rear output shaft front bearing retainer 11 INSTALL IOLER GEAR al Install a new O ring on the idler gear shaft front side groove b Install the idler gear shaft to the tra...

Page 138: ...l the spacer and power take off drive gear to the output shaft 15 INSTALL OUTPUT SHAFT REAR BEARING Using SST and hammer drive in the output shaft bearing SST 09316 600tO 16 INSTALL SHIFT FOR K SHAFT...

Page 139: ...t lever tip with the shift fork shaft groove e Apply liquid sealer to the two bolts and install and torque as shown Torque 650 kg cm 47 ft lb 64 N m d Install and torque the other bolts Torque 17 mm 6...

Page 140: ...New bearing 15 24 7 kg c m 13 0 21 4 in tb 1 5 2 4 N m Reused bearing 7 12 kg cm 6 1 10 4 in Ib 0 7 1 2 N m If the preload is not within specification remove the outer race of the rear output shaft re...

Page 141: ...panion flange lock nut SST 09330 00021 Torque 1 300 kg m 94 ft lb 127 N m c Stake the companion flange lock nut 26 INSTALL TRANSMISSION OUTPUT SHAFT LOCK NUT a Using SST to hold the rear companion fla...

Page 142: ...lb 13 N m 30 INSTALL PLUG SPRING ANO LOCKING BALL Mechanical Shift Type Apply liquid sealer to the plugs and install the locking balls springs and plugs Torque 450 kg cm 33 ft Ib 44 N m Electrical Sh...

Page 143: ...TF 33 LL TRANSFER F HANICAL SHIFT T T DRIVE SHIFT LEV INSTALL DIAP ER ECTRICAL I M CYLINDER page TF 8 TYPE INSTALLATION See page MT 40 or AT TRANSFER...

Page 144: ...Control RellY Tr nlfer Control Switeh ELECTRICAL SHIFT TYPE Wiring Diagram Trlnsierl4Po ition Switeh wo Neutrll Sun Switeh Tr nsnr Parki Control Br Relay Wlrning light WO Tr nsfer Neutr 1 Indicator Po...

Page 145: ...there is no continuity between terminals when the switch is free transfer in H2 position If continuity is not as specified replace the switch Transfer Control Relay INSPECTION OF TRANSFER CONTROL REL...

Page 146: ...ltage across terminals 3 and 4 Check that air flows from port A to port C Check that ai r does not flow from port A to port B b Check that air flows from port A to port B Check that air does not flow...

Page 147: ...rt switch is the N position If operation is not as specified remove and test the bulb and neutral position switch Neutral Start Switch See page AT 6 Transfer Neutral Position Switch INSPECTION OF TRAN...

Page 148: ...from the transmission control computer Connect the terminal 1 wire harness side connector and body ground b Turn the ignition switch or starter switch on Check that the bulb lights If operation is not...

Page 149: ...t the connector on the wire harness side as shown in the table below Check Item Tftter Connection Contirwity 2 5 Voltage 3 BodyGlound Voltag e 6 BodyGroond Contiouity 7 Body Groond Turn ignition lwitc...

Page 150: ...PROPELLER SHAFT PRECAUTIONS TROUBLESHOOTING PROPELLER SHAFT PR p PA 2 PR 2 PR 2...

Page 151: ...n PRE Pcop Sh ft CAUTIONS caref 1 not to grip the as this will cause d f propeller shaft tube TROU BLES m o too t h y h _ Po bI R OTI NG 1 VeYOkeipliMworn plderbe ril liWOrnOrnuck Propelieru lftM lnou...

Page 152: ...the flanges b Remove the four nuts c Remove the propeller shaft INSPECTION OF PROPELLER SHAFT COMPONENTS 1 INSPECT FRONT AND REAR PROPELLER SHAFTS FOR OAMAGE OR RUNOUT If shaft runout is greater than...

Page 153: ...eeve yoke and flange b Slightly tap in the bearing outer races c Using two screwdrivers remove the four snap rings from the grooves Id Using SST push out the bearing from the flange SST 09332 25010 NO...

Page 154: ...oke with a hammer NOTE Remove the bearing on the opposite side in the same procedure ASSEMBLY OF PROPELLER SHAFT See page PR 2j NOTE When replacing the spider be sure that the grease fin ing assembly...

Page 155: ...lange c Fit the new spider into the yoke d Using SST install the new bearings on the spider SST 09332 25010 e Using SST adjust both bearings so that the snap ring grooves are at maximum and equal widt...

Page 156: ...opeller shaft spline and sleeve yoke sliding surface b Align the matchmarks on the sleeve yoke and propel lershaft c Install the propeller shaft into the sleeve yoke INSTALLATION OF FRONT AND REAR PRO...

Page 157: ...se gun pump the MP grease into each fitting until it begins to ftow from around the oil seal NOTE Turn the front propeller shaft until the yoke fitting f ICes the right side of the vehicle and apply g...

Page 158: ...BLESHOOTING FA 2 FRONT WHEEL ALIGNMENT FA 3 FREE WHEEL HUB FA 6 FRONT AXLE HUB FA 12 STEERING KNUCKLE AND AXLE SHAFT FA 17 FRONT DIFFERENTIAL FA 2B FRONT SUSPENSION FA 31 Leaf Spring and Shock Absorbe...

Page 159: ...g linkage 100000n or worn Tighlln or replace tteering linkage Steering gear out 01 adjustment or broken Adjust or rePlir neering gear V hieltoverloaded Shock absorber worn out Sprin jSweak Tires impro...

Page 160: ...f Use the standard bounce test to check that the front absorbers work properly 2 INSTAll WHEel ALIGNMENT EQUIPMENT Follow the specific instructions of the equipment manu facturer 3 CHECK CAMBER AND KI...

Page 161: ...0 04 4 t2 O 16 t O 08 4 1 1 0 16 t 0 04 e Make sure the steering gear is centered f Loosen the nuts holding the clamps to the tie rod g Adjust toe in to the correct value by turning the tie md h Torq...

Page 162: ...ENSION Front Wheel Alignment 7 INSPECT SIDE SUP WITH SIDE SLIP TESTER Sideslip limit Leuthan 3 0 mm m 0 118 in 3 3 ft FA S If the side slip exceeds the limit the toe in or other front wheel alignment...

Page 163: ...FA 6_ _ Wheel Hub o SUSPENSION Free FRONT AXLE AN HUB FREE WHEEL COMPONENTS...

Page 164: ...ing nuts bl Using a brass bar and hammer tap the bolt heads and remove the cone washers cl Pull off the free wheel hub body DISASSEMBLY OF FREE WHEEL HUB 1 REMOVE CONTROL HANDLE FROM FREE WHEEL HUB CO...

Page 165: ...el hub ring and spacer 0 IN SPECTION OF FREE WHEEL HUB INSPECT COVER HANDLE AND SEAL I Temporarily install the handle in the cover and check that the handle moves smoothly and freely 2 INSPECT BODY AN...

Page 166: ...N SPRING IN CLUTCH Install the tension spring in the clutch with the spring end aligned with the initial groove 4 INSTALL FOLLOWER PAWL TO CLUTCH a Place the follower pawl on the tension spring with o...

Page 167: ...p ring 7 INSTALL INNER HUB AND FREE WHEEL HUB RING IN FREE WHEEL HUB BODY a Insert the inner hub and free wheel hub ring in the bod b Using a screwdriver install the snap ring 8 TEMPORARILY INSTA LL C...

Page 168: ...L SNAP RING a Install a bolt in the axle shaft and pull it out b Using snap ring pliers install the snap ring c Remove the bolt 3 APPLY MP GREASE TO INNER HUB SPLINES 4 INSTALL FREE WHEEL HU B COVER W...

Page 169: ...FA 12 Front Axle Hub NO SUSPENSION FRONT AXLE A XlE HUB FRONT A COMPONENTS r o...

Page 170: ...hUb See page FA 7 a Remove the cap from the flange b Using snap ring pliers remove the snap ring c Remove the mounting nuts Id Using a brass bar and hammer tap the bolt heads and remove the cone vashe...

Page 171: ...em for wear or damage 2 REPLACE BEARING OUTER RACE a Using a brass bar and hammer drive out the bearing outer race b Using SST carefully drive in the new bearing outer SST 09608 35013 ASSEMBLY OF FRON...

Page 172: ...nut until it can be turned by hand e Using a spring tension gauge measure the frictional force of the oil seal at the hub bolt 1 Aetighten the adjusting nut Torque 40 70 kg cm 35 60 inAb 4 0 6 8 N m 9...

Page 173: ...ts Torque the nuts Torque 315 kg cm 23 ft lb 31 N m d Install a bolt in the axle shaft and pull it out e Using snap ring pliers install the snap ring f Remove the bolt g Install the cap to the flange...

Page 174: ...USPENSION Steering Knuckle and Axle Shaft FA 17 STEERING KNUCKLE AND AXLE SHAFT COMPONENTS Oil S u i Retl i ner Oust Seal I ktcm Ift lb No mH SpKif e torQue Non reuublel lft Front Axil Hub with Oisc F...

Page 175: ...NUCKLE SPINDLE MOUNTING BOLTS 3 REMOVE DUST SEAL AND DUST COVER 4 REMOVE KNUCKLE SPINDLE Using a brass bar tap the knuckle spindle off of the steer ingknuckle 5 REMOVE AXLE SHAFT Position one flat par...

Page 176: ...of the cone washers and remove them from the knuckle arm Icl Using SST pudl out the knuckle arm and shims from the steering knuckle SST 09606 60020 NOTE Use the SSTwithout a collar Id Using SST push...

Page 177: ...65013 b Using SST press a new bushing into the spindle SST 09608 35013 3 INSPECT BEARING Clean the bearings and outer races and inspect them for wear or damage 4 IF NECESSARY REPLACE BEARING OUTE R RA...

Page 178: ...race from the cage through the large opening f Clean and inspect the joint inner parts for wear or damage g Coat the joint inner parts and inside of the outer shaft with Molybdenum disulphide lithium...

Page 179: ...inner race and cage and install the six bear ingballs in the outer shaft See step c m Pack Molybdenum disulphide lithium base grease in the outer shaft n Install the new snap rings on the inner shaft...

Page 180: ...Using SST remove the oil seal SST 09308 00010 b Coat the knuckle bearings lightly with Molybdenum disulphide lithium base grease cl Mount the SST on the housing with the bearings SST 09634 60013 d Ad...

Page 181: ...e care not to erase the line when dismounting and remounting the SST Make sure that rod D is in the same vertical direction that it was when mounted on the housing le Turn rod 0 and mark another line...

Page 182: ...base grease in the palm of your hand b Pack grease into the bearing and continue until the grease 00181 out from the other side c Do the same around the bearing circumference 4 INSTA LL STEERING KNUC...

Page 183: ...bearing inner race g Remove SST from the knuckle h Install the cone washers to the third arm and torque the nuts Torque 975 kg cm 171 ft lb 96 N m i Install the cone washers to the knuckle arm and tor...

Page 184: ...Pack Molybdenum disulphide lithium base grease into the knuckle to about three fourths of the knuckle 11 INSTALL KNUCKLE SPINDLE DUST COVER WITH NEW GASKETS AND DUST SEAL a Place a new gasket in posit...

Page 185: ...nuts 2 REMOVE COMPANION FLANGE See n ep 2 on page RA 15 3 REMOVE OIL SEAL AND Oil SlINGER a Using SST remove the oil seal from the housing SST 09308 10010 b Remove the oil slinger 4 REMOVE REAR BEARIN...

Page 186: ...TI AL OIL LEVE L Fill with hypoid gear oil if necessary Hypoid gear oil API GL 5 Above _ 18 C OOF SAE 90 Below l SoC 0 F SAE SOW or BOW 90 Capacity 3 0 liters 3 2 US qu 2 6 Imp qts REMOVAL OF FRONT DI...

Page 187: ...ng b Using S5T connect the brake hose at the frame side and install the clip SST 09751 36011 c Install the four clamp to the axle housing with bolts 4 CONNECT PROPELLER SHAFT FLANGE TO COMPANION FLANG...

Page 188: ...ubl p t FRONT SUSPENSION COMPONENTS Leaf Spring and Shock Absorber REMOVAL OF LEAF SPRING AND SHOCK ABSORBER 1 JACK UP AND SUPPORT BODY tal Jack up and support the body on stands b Lower the axle hous...

Page 189: ...ting nuts c Remove the hanger pin d Remove the shackle pin e Remove the leaf spring REPLACEMENT OF LEAF SPRING 1 BENO OPEN SPRING CLIP Using a chisel pry up the spring clip 2 REMOVE CENTER BOLT Hold t...

Page 190: ...ammer bend the spring clip into position INSTALLATION OF LEAF SPRING 1 INSTALL LEAF SPRING a Insert the bushings into the frame and into both ends of the leaf spring b Place the leaf spring in positio...

Page 191: ...ame 3 INSTAll SHOCK ABSORBER a Position the shock absorber and install the bushings retainers and nut_ Torque 260 kg cm 19 ft lb 25 N m b Install the lower mounting bolt Torque 970 kg cm 70 ft Ib 95 N...

Page 192: ...ROM FRAME Remove the nuts cushions and bolts holding both sides of the stabilizer bar to the frame and remove the stabilizer INSTALLATION OF STABILIZER BAR 1 CONNECT STABILIZER BAR TO FRAME Connect th...

Page 193: ...RA 2 Semi floating Type RA 3 REAR AXLE SHAFT AND AXLE HUB Full floating Type RA 8 REAR DIFFERENTIAL RA 15 Conventional Type Differential RA 21 Limited Slip Differential RA 32 REAR SUSPENSION RA 37 Re...

Page 194: ...tween pinion nd ring or ide gear Ring pinion Of lide gun WQm or cnipped Pinion sh ft belring worn Axle shaft bearing worn Oifferenti lbeiringlooseorWQrn Vehicleoverloacltd Shocklbsorberwornout Springs...

Page 195: ...ake Cllmp 1301 13 b parkingBrakeCabte ionShlft l75120 27 51 l 0 I G ff Co REMOVAL OF REAR AXLE SHAFT 1 JACK UP AND SUPPORT VEHICLE 2 REMOVE WHEEL AND BRAKE DRUM RA 3 3 REMOVE DRAIN PLUG AND DIFFERENTI...

Page 196: ...ential b Remove the pinion shaft and spacer NOTE When the pinion shaft is removed the pinion gear and thrust washer will come off also 7 REMOVE AXLE SHAFT LOCK Push the axle shaft to the differential...

Page 197: ...in RA 5 2 INSPECT OIL SEAL AND BEARING FOR WEAR OR DAMAGE If the oil seal and bearing is damaged or worn replace it 3 REPLACE OIL SEAL AND BEARING a Using SST remove the oil seal SST 09308 00010 b Usi...

Page 198: ...all the axle shaft lock to the axle shaft b Pull the axle shaft fully toward the outer side of vehicle 3 INSTA LL PINION SHAFT AND PINION 5PACER a Install the spacer and pinion shaft to the differenti...

Page 199: ...the ten nuts and washers Torque 130 kg cm 9 ft lb 13 N m 5 INSTA LL PARKING BRAKE CABLE CLAMP 6 INSTALL BRAKE DRUM AND WHEel 7 FILL DIFFERENTIA L WITH GEAR OIL Hypoid gear oil API GL 5 Above l8 C O F...

Page 200: ...OilS OilSeal o R OiISeal 1 0 Hub D O R o f I 1 i 1 0 I iN kg cm Ift lb N m Spe ifiedtorque NOrl reusablepart ckNut L i 0 91 Drum REM OVAL OF REAR AXLE SHAFT 1 REMOVE AXLE SHAFT SET NUT Remove the six...

Page 201: ...ION When pulling out the axle shaft be careful not to damage tne oil seal INSPECTION OF REAR AXLE SHAFT COMPONENTS 1 INSPECT REAR AXLE SHA FT Check for wear or damage Maximum runout 0 8 mm O Oll in 2...

Page 202: ...J SST 3 INSTALL CONE WASHER AND SET NUT Install the cone washers and spring washers with six nuts Torque 340 kg cm 25 ft lb 33 N m REMOVAL OF REAR AXLE HUB See page RA 8 1 JACK UP VEHICLE AND REMOVE W...

Page 203: ...Using a magnetic flaw detector or flaw detecting penetrant check for damage or cracks 2 REMOVE OIL SEAL AND INNER BEARING a Using SST remove the oil seal SST 09308 00010 b Remove the inner bearing fro...

Page 204: ...OI L SEAL a Install the inner bearing to the axle hub b Using SST drive in the oil seal to the axle hub SST 09608 35013 c Apply MP grease to the oil seal lip INSTALLATION OF REAR AXLE HUB I eRA INSTAL...

Page 205: ...bearing lock nut SST 09509 25011 Torque 600 kg cm 43 ft Ib 59 N m d Using SST loosen the bearing lock nut until you can rotate itby hand SST 09509 2501 1 e Using iI spring tension gauge measure the fr...

Page 206: ...the holes at right angles to the lock nut i Measure the distance between the top surface of axle housing and the lock nut Standard distance 0 2 0 9 mm 1 0 008 0 035 in If not within specification rein...

Page 207: ...5 ON VEHICLE REPL 1 OtSCON ACEMENT OF DIFFER iA RDPELLER SHAFT OIL SEAL a Place mat FROM b Remove t arks on the flanges our bolts and nuts 2 REMOVE COMPANION a Using a hamm FLANGE the nut er and chise...

Page 208: ...PACER a Using SST remove the front bearing from the drive pinion 55T 09556 30010 b Remove the bearing spacer 5 INSTALL NEW BEARING SPACER AND FRONT BEARING 6 INSTALL OIL SEAL AND OIL SLINGER a Install...

Page 209: ...0 kg cm 65 ft lb 88 N m 10 CHECK DIFFERENTIAL OIL LEV EL Fill with hypoid gear oil if necessary Hypoid gear oil API GL 5 Above 18 Q C W F SAE 90 Below 18 Q C 0 FJ SAESOWor 80W 90 capacity 2 5 liters 2...

Page 210: ...15 0 20 mm 0 0059 0 0079 in NOTE Measure the backlash at three or four places and con firm that it is the same value 3 ADJUST RING GEAR BACKLASH a Remove the two adjusting nut locks b Loosen the beari...

Page 211: ...ferent positions on the ring gear with red lead b Hold the companion flange firmly and rotate the ring gear in both directions c Inspect the tooth pattern FlteContaet K m w b Y 1d I I f VV ToeContlct...

Page 212: ...asket _ j r b g he differential carrier assembly in the axle c Tighten the ten nuts Torque 475 kg cm 34 ft lb 47 N m 2 CONNECT PROPELLER SHAFT TO DIFFERENTIAL a Align the matchmarks on the flanges b T...

Page 213: ...7 DIFFERENTIAL DISASSEMBLY 1 REMOVE COM OF DIFFERENTIAL a Using a ha NION FLANGE the nut er and chisel loosen the T U n SST 0 hold h k d rtof 09330 00021 ge remove the nut T 09950 20016 companion flan...

Page 214: ...010 b Remove the bearing spacer If the front bearing is damaged or worn replace the bearing 4 REMOVE DIFFERENTIAL CASE AND RING GEAR la Plac e matchmarks on the bearing cap and differential Ib Remove...

Page 215: ...new rear bearing on the drive pinion SST 09506 30011 REPLACE DRIVE PINION FRONT AND REAR BEARING OUTER RACE a Using a hammer and brass bar drive out the outer b Using a press and SST drive in a new ou...

Page 216: ...backlash 0 05 0 20 mm 0 0020 0 0079 in Using the table below select thrust washers which will ensure that the backlash is within specification Try to select washers of the same size for both sides Th...

Page 217: ...plates NOTE Stake one claw flush with the flat surface of the nut For the claw contacting the protruding portion of the nut stake only the half on the tightened side i Check the ring gear runout Maxi...

Page 218: ...R a Place the bearing outer races on their respective bear ings Make sure the left and right outer rates are not interchanged b Install the case in the carrier 3 INSTALL ADJUSTING NUTS Install the adj...

Page 219: ...ash loosen the nut SO that backlash is eliminated e Place a dial indicator on the top of the bearing cap on the ring gear side If Adjust the side bearing for zero preload bV tightening the other adjus...

Page 220: ...4 0 6 N m Backlash 0 15 0 20 mm 0 0059 0 0079 in 6 INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PI NION a Coat 3 or 4 teeth at three different positions on the ring gear with red lead b Hold the...

Page 221: ...1 1 50 0 05911 1 55 0 06101 7 REMOVE COMPANION FLANGE See page RA 21 8 REMOVE FRONT BEARING See page RA 22 9 INSTA LL NEW BEARING SPACER AND FRONT BEARING a Install a new bearing spacer on the shaft b...

Page 222: ...used bearing 9 13 kg cm 7 8 11 3 in Ib 0 9 1 3 N m a Ifpreload is greater than the specification replace the bearingspacer b If preload is less than specification retighten the nut 130 kg cm 9 ft lb 1...

Page 223: ...rential RA 31 15 INSTA LL ADJUSTING NUT LOCKS a Select either a No l or No 2 lock whichever will fit the adjusting nuts b Install the lock on the bearing caps Torque 130 kg cm 9 ft lb 13 N m INSTALLAT...

Page 224: ...l N W C d I i s ifJ0 Th rt w I S d Gear I 0 ng J Clutch Plate RH Case LHCase IkQ m Ift lb N mH SpKifie d tQrQu Non r usablepart REMOVAL OF DIFFERENTIAL CASE 1 REMOVE DIFFERENTIAL See page RA 17 2 REMO...

Page 225: ...ing LH retainer Id Side gear le Side gear thrust washer 3 pieces f Clutch plate 3 pieces g Adjusting washer NOTE Keep the disassembled parts in order INSPECTION OF COMPONENTS 1 REPLACE PARTS THAT ARE...

Page 226: ...32 NOTE a Using a rag clean off any foreign matter from the parts b Apply LSD oil to the contact surfaces of the clutch plates and the thrust washers c Degrease the differential case bolts 1 INSTALL...

Page 227: ...etainer Backluh 0 05 0 24 mm 0 0020 0 0094 in If the backlash is not within specification adjust with an adjusting washer of a different thickness Adjusting w8 her thidc ne e mm in Thickneu 2 20 0 086...

Page 228: ...Rear Differential b Tighten the bolts uniformly a little at a time Torque 480 kg cm 35 ft lb 47 N m INSTALLATION OF DIFFERENTIAL 1 INSTALL DIFFERENTIAL CASE IN CARRIER See page RA 26 2 INSTALLATION O...

Page 229: ...D SUSPENSION AearSuspension REAR SUSPENSION COMPONENTS T W h Q I I I I I I I li t W f I B 5li Stab hler Lmk u 92 1 fi7 t U Sh kI PI Q RA 37 11 rr d p_ I Lo lSp l Spol S kI 1 Dlm PI SU hing ro o Spring...

Page 230: ...RA 38 REAR AXLE AND SUSPENSION Rear Suspension FJ BJ HJ 60 series LufSptingComponent Ik9 cmIft lb N m Spe eifiedtorque Non rtusablep rt COMPONENTS ICont d...

Page 231: ...nect the shock absorber from the frame b Disconnect the shock absorber from the spring seat 5 REMOVE U BOlTS a Remove the four U bolt mounting nuts with the spring seat and distance plate b Remove the...

Page 232: ...Drill off the head of the rivet and drive it out b Install a new rivet into the holes of the spring leaf and clip Then rivet with a press 4 INSTAll SPRING CENTER BOLT fal Align the leaf holes and secu...

Page 233: ...m c Hand tighten the bracket pin nut d Place the rear end of leaf spring in the rear bracket and install the shackle pin e Install the plate and hand tighten the nuts 3 INSTALL U BOLT a Install the t...

Page 234: ...the bolt Torque 375 kg cm 27 ft lb 37 N m 5 INSTALL WHEEL AND LOWER VEH ICLE 6 STABILIZE SUSPENSION Bounce the vehicle to stabilize the suspension 7 TIGHTEN SPRING BRACKET PIN AND SHACKLE PIN a Torque...

Page 235: ...bar bracket from the axle housing b Remove the stabilizer bar link with the stabilizer bar from the frame 3 REMOVE STABILIZER BAR LINK FROM STABILIZER BAR REPLACEMENT OF STABILIZER BAR BUSHING 1 REMOV...

Page 236: ...tall the new nut 2 INSTALL STABILIZ ER BAR a Install the cushion and bracket to the stabilizer bar b Temporarilv install the bracket to the axle housing cl Temporarily install the stabilizer link to t...

Page 237: ...OUBLESHOOTING BR 2 CHECKS AND ADJUSTMENTS BR S MASTER CYLINDER BRAKE BOOSTEA VACUUM PUMP FRONT BRAKE Drum Brake Disc Brake REAR BRAKE BR 9 BR 16 BR 25 BR 30 BR 30 BR 37 BR LOAD SENSING PROPORTIONING V...

Page 238: ...linin ilS Brak shoes distorted linin ilS worn or Drum or disc out of round Return spring f lty WhHI cylinder flulty Pistonfrolenin liPfr Disc brlk pad stiddn Brakll grlb chaner Oil or grease on linin...

Page 239: ...drums orrOIOrs if heavily scored Aepl ceasr quired BR 30 44 noisewh T1brlkes applied Caliper 10 wheel Of rotor iT1I rference Squeaiing gro T1iT1g orchillteriT1gT1oise whenb kes f pplied Note Brlke fri...

Page 240: ...e rept c e M required BR 30 44 LOO eOfeXlflIPlrtsinbr kei Rear dnlm adjustment lOO tight Clusingliningloglne Wom d magedor insuffieiently lubrieatedwheelbearil lQl Drum br kes wuk damaged or incorree...

Page 241: ...ake pedal several times until there is no more vacuum left in the booster b Push in the pedal until the beginning of resistance is felt Measure the distance as shown Pedal freeplay 3 6 mm 0 12 0 24 in...

Page 242: ...veral times slowly If the pedal goes down furtherest the first time but gradual Iy rises after the second or third time the booster is airtight b Depress the brake pedal while the engine is running an...

Page 243: ...e pedal several times cl While having an assistant press on the pedal loosen the bleeder plug until fluid starts to runout Then close the bleeder plug d Repeat b and c until there are no more air bubb...

Page 244: ...sembly and or parking brake lever cover ADJUSTMENT OF BRAKE SHOE CLEARANCE FOR DRUM BRAKE TYPE ADJUST BRAKE SHOE CLEARANCE a Jack up and support the vehicle b Remove the shoe adjusting hole plugs from...

Page 245: ...lb N ml l Specified torQue Non reulablepart 1 DISCONNECT LEVEL WARNING SWITCH CONNECTOR 2 TAKE OUT FLUID WITH SYRINGE OR SUCH CAUTION 00 not let brake fluid remain on a painted surface Wash it off imm...

Page 246: ...BR l0 BRAKE SYSTEM Master Cylinder 4 REMOVE MASTER CYLINDER a Remove the four nuts b Remove the master cylinder clamp and gasket from the brake booster...

Page 247: ...Y OF MASTER CYLINDER 1 PLACE CYLINDER IN V ISE 2 REMOVE RESERVOIR AND HOSE a Remove the set bolt from the reservoir b Remove the reservoir with the hose from the master cylinder 3 REMOVE BOOT 4 REMOVE...

Page 248: ...D SPRINGS a Push in the piston with a screwdriver and remove the snap ring with snap dng plief S b Remove the two pistons and springs from the master cylinder If necessary inject compressed air into t...

Page 249: ...s a Insert two springs and pistons straight in not at an angle b Using snap ring pliers install the snap ring 3 INSTAll PISTON STOPPER BOLT AND NEW GASKET Using a screwdriver push the pistons in all t...

Page 250: ...ase on the union A c Install the union through the new O ring d Using a snap ring pliers install the new snap ring e Install the boot 6 INSTA LL RESERVOI R AND HOSE a Connect the hose to union and res...

Page 251: ...age BA 23 4 INSTALL MASTER CYLINDER Install the master cylinder and clamp on the brake booster with foor nuts through the new gasket Torque 130 kg cm 9 ft lb 13 N m 5 CONNECT TWO BRAKE TUBES a Finger...

Page 252: ...R 1 REMOVE MASTER CYLINDER See page BR g 2 DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER 3 REMOVE CLUTCH BOOSTER See page CL 9 4 REMOVE AIR DUCT Remove the two screws and air duct 5 REMOVE PEDAL RETURN SP...

Page 253: ...09753 40010 CAUTION Be careful not to tighten the two nuts of SST too tightly c Turn the front body clockwise until the front and rear bodies separate d Loosen the upper leh and right nuts of the SST...

Page 254: ...a Yise SST 09736 27010 b Put the diaphragm assembly on SST and turn it to separate the yalye body and diaphragm plate Id RemoYe the diaphragm from the plate 7 REMOVE OPERATING ROD FROM VALVE BODY la P...

Page 255: ...r INSPECTION OF BRAKE BOOSTER INSPECT CHECK VALVE OPERATION BR 19 a Check that air flows from the booster side to the hose side b Check that air does not flow from the hose side to the booster side If...

Page 256: ..._ B k B OM t _____________ ASSEMBLY OF Is 8R 17 BRAKE BOOSTER 1 APPLY SILICONE GAEASE TO PARTS SHOWN BELOW 2 INSTALL BODY a Place the bod SEAL TO FRONT BODY b Secure the bo seal In position y seal wit...

Page 257: ...M PLATE a Install the diaphragm to the plate b Insert the valve body to the plate c Mount SST in a vise SST 09736 27010 d Put the diaphragm assembly on SST and turn it to install 6 INSTALL BODY SEAL T...

Page 258: ...ies SST 09753 40010 and 09753 00012 CAUTION Be careful not to tighten the two nuts of the SST too tightly c Assemble the front and rear bodies by turning the front body counterclockwise until the alig...

Page 259: ...0 c Measure the clearance between the booster push rod and pin head SST Clearance 0 mm 0 in d Adjust the booster push rod length until the push rod lightly touches the pin head 2_ INSTALL BRAKE BOOSTE...

Page 260: ...TER CYLINDER See page BR 15 B CONNECT HOSE TO BRAKE BOOSTER 9 FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM See page BR fi 10 CHECK FOR LEAKS 11 CHECK AND ADJUST BRAKE PEDAL See page BR...

Page 261: ...niOll et V tuum Pump OiI OU leIHose O Aing ChedtV ln 750 54 741 c R I G l t Ikoxm lft lb N m 1 Specil td lorque O Aing Non fullbleparl REMOVAL OF VACUUM PUMP 1 DISCONNECT VACUUM HOSES 2 DISCONNECT OI...

Page 262: ...SASSEMBLY OF VACUUM PUMP 1 BR 251 I I _ b Remove the check valve and gasket 2 REMOVE VACUUM PUMP END PLATE Using a pin punch and hammer tap out the dowel pin rearward and remove the end plate 3 REMOVE...

Page 263: ...2 INSPECT ROTOR 13 80 mm 0 5433 in 5 95 mm 0 2343 in 39 98 mm 1 5740 in al Check for wear or damage b Assemble the rotor to the alternator and check the amount of play in the direction of rotor splin...

Page 264: ...blades with round end facing outward NOTE Be sure that the blade and rotor surface are even 2 INSTALL O RING AND END PLATE al Install the O ring into the groove b Place the end plate onto the casing...

Page 265: ...orque 80 kg cm 69 in Ib 7 8 N m 3 INSTALL UNION AND BOLT Install the union and bolt with a new gaskets Torque the bolt Torque 140 k m to ft Ib 14 N m NOTE Be sure to align the alignment pin of union a...

Page 266: ...ied 10rqUf FRONT BRAKE Drum Brake COMPONENTS Sho Hold downSpringPin Bleeder PIUg REMOVAL OF FRONT BRAKE 1 REMOVE WHEEL REMOVE DRUM Remove the screw and then remove the drum NOTE I f the drum cannot be...

Page 267: ...010 BR 31 5 REMOVE BRAKE SHOES AND REAR SIDE RETURN SPRING Slide the shoes and remove them together with the rear side return spring 6 IF NECESSARY REMOVE WHEEL CYLINDER a Remove the brake tube clamp...

Page 268: ...Front Brake Drum Brake 7 IF NECESSARY DISASSEMBLE WHEEL CYLINDER a Remove the following parts from the wheel cylinder Adjusting bolt and nut 800t Cup Spring seat Return spring b Remove the screw and a...

Page 269: ...wear replace the brake shoes NOTE If any of the brake shoes have to be replaced re place all of the brake shoes in order to maintain even braking 3 MEASURE BRAKE DRUM INSIDE OIAMETER Standard inside...

Page 270: ...ion only Returnspring Springseat Cup Boot c nstall the adjusting bolt and nut to the wheel cy linder There are two kinds of adjusting nuts and bolts Use each at the proper location RH wheel cylinder R...

Page 271: ...lb 18 N m 4 INSTALL BRAKE TUBE TO WHEEL CYLINDER After tightening by finger tighten the nut with SST SST 09751 36011 TorQue lSS kg m 11 ft lb 1SN m S INSTALL BRAKE TUBE CLAMP Torque 80 kg cm 69 in lb...

Page 272: ...return spring SST 09703 30010 7 CLEAN LINING AND INNER DRUM WITH SANDPAPER 8 INSTALL DRUM Install the drum with screw 9 FILL BRAKE RESER VOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM See page BR 5 10 C...

Page 273: ...OF BRAKE PADS REMOVE FRONT WHEE L 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 3...

Page 274: ...ll amount of brake fluid from the reservoir b Press in the piston with a hammer handle or such NOTE Always change the pad on one wheel at a time as there isa possibility of the opposite piston flying...

Page 275: ...FRONT WHEEL 2 DISCONNECT BRAKE LINE Using SST disconnect the brake line Uses container to catch the brake fluid SST 09751 36011 3 REMOVE CY LINDER Remove the two mounting bolts and cylinder 4 REMOVE F...

Page 276: ...boot 2 REMOVE PISTON FROM CYLINDER a Prepare the wooden plate as shown in the figure to hold the piston b Place the plate between the pistons and insert a pad at one side c Use compressed air to remo...

Page 277: ...c runout at 10 mm 0 39 in from the outer edge of the rotor disc Maximum disc runout 0 15 mm 0 0059 in If the runout is 9reater than the maximum replace the disc NOTE Before measuring the runout confir...

Page 278: ...O O d 00 I I I 0 000 I I P l ASSEMBLY OF CYLINDER See page BR 37J _ APPLY LITHIUM SOAP BASE GLYCOL GREASE TO PARTS INDICATED BY ARROWS 2 INSTALL PISTON SEAL IN CYLINDER 3 INSTALL PISTON IN CYLINDER 4...

Page 279: ...m 90 ft lb 123 N m 2 INSTALL FOLLOWING PARTS a Two pads b Anti rattlespring c Two anti rattle pins Id Anti rattleclip 3 CONNECT BRAKE LINE Using SST connect the brake line SST 09751 36011 Torque 155 k...

Page 280: ...f the brake drum cannot be removed easily perform the following al Insert a screwdriver through the hole in the backing b plate and hold the automatic adjusting lever away from the adjusting bolt Usin...

Page 281: ...SST 09718 00010 bl Disconnect the parking brake cable from the parking brake bellcrank cl Remove the front shoe with adjuster Id Disconnect the parking brake cable from the front 0 4 REMOVE ADJUSTER F...

Page 282: ...AND DISASSEMBLE PARKING BRAKE BElLCRANK ASSEMBLY a Remove the clip and disconnect the parking brake cable b Remove the two tension springs le Remove the parking brake belle rank assembly with the two...

Page 283: ...be replaced re place all of the brake shoes in order to maintain even braking 3 INSPECT BRAKE LI NING AND DRUM FOR PROPER CONTACT 4 5 6 7 If the contact between the brake lining and drum is in proper...

Page 284: ...hown Assemble t e parts in the correct direction 3S Right Wheel 1 IF NECESSARY ASSEMBLE AND INSTAll PARKING BRAKE BEllCAANK ASSEMBLY a Install the parking brake bellcrank to the crank bracket b Instal...

Page 285: ...NSTALL WHEEL cups and piston P base glycol grease t o the piston b I c e he spring and two p Make su e flanges ISlon cups in the wheel c Install the two of the cups are pointed der pistons boots and s...

Page 286: ...ER TO FRONT SHOE lal Install the adjuster to the adjust lever Ibl Install the adjust lever spring 6 INSTALL FRONT SHOE lal Install the parking brake cable to the parking brake shoe lever Ib Install th...

Page 287: ...ing SST install the tension spring SST 09703 30010 8 CHECK OPERATION OF AUTOMATIC ADJ USTER MECHANISM la Pull the parking brake cable backward as shown and release Check that the adjusting bolt turns...

Page 288: ...f incorrect check the parking brake system 10 IF NECESSARY ADJUST BELLCRANK la Lightly pull the bellcrank in direction A until there is no slack at part B b In this condition turn the adjusting bolt s...

Page 289: ...OI IG COMPONENTS NG VALVE f f if3l Br k Tube lOld SemingProponioning V lvt V B I I loadSens t Pro Ing port on ngValve Cl I I Pine Wutl Q ICoI r 1 o Gl i Pl ltWllher Bushing lOld Sensing Spring Bushing...

Page 290: ...specified pressure Read the value of rear brake pressure two seconds after adjusting the specified fluid pressure 4 RAISE FRONT BRAKE PRESSURE TO 100 kg cm fl 422 psi 9 807 kPa AND CHECK REAR BRAKE PR...

Page 291: ...When the brakes are applied the piston will move down about 1 mm 0 04 in Even at this time the piston should not make contact with or move the load sensing spring bl In this position check the rear b...

Page 292: ...EM lSPV ii f1 REMOVAL OF LSPV ASSEMBLY I See pageBR S3 1 DISCONN ECT BRAKE TUBES SST n SST disconnect the brake tubes from the valve SST 09751 3601 1 2 REMOVE LSPV ASSEMBLY a r t the two bolts and rem...

Page 293: ...the spring from thevalve 3 REMOVE SHACK LE BRACKET a Remove the cotter pin b Remove the nut and remove the shackle bracket two retainer1 two bushings and collar 4 REMOVE SHACKLE NO l AND NO 2 Remove...

Page 294: ...BR 58 BRAKE SYSTEM LSPV INSPECTION OF LSPV INSPECT VALVE PISTON PIN AND LOAD SENSING CONTACT SURFACE FOR WEAR Wear limit 0 7 mm 0 028 in...

Page 295: ...e for the shackle side of the load sensing spring 2 INSTALL SHACKLE NO l AND NO 2 TO LOAD SENSI NG SPRING Install the shackle to the load sensing spring through the twoplatewashel 1 Torque 185 kg cm 1...

Page 296: ...BR 60 BRAKE SYSTEM LSPV b Install the set plate to the valve assembly and tern porarily tighten the two valve body mounting nuts...

Page 297: ...ACKET a Set the dimension A by turning shackle No 2 Initial set 120 mm 4 72 in bl Tighten the lock nut Torque 250 kg m 18 ft lb 25 N m c Install the two bushings and collar to the load sensing spring...

Page 298: ...he valve piston moves down smoothly fb Position the valve body so that the valve piston light ly contacts the load senSing spring c Tighten the valve body mounting nuts Torque 130 kg cm 9 ft lb 13 N m...

Page 299: ...2 CONNECT HOSE AND TUBE a Connect the hose and tube by hand b Using a wrench to hold the hose and SST to hold the tube torque the connection SST 09751 36011 Torque 155 kg cm 11 ft Ib 15 No m c Install...

Page 300: ...TH TILT STEERING STEERI NG COLUMN ASSEMBLY STEERING GEAR HOUSING POWER STEERING On Vehicle Inspection Bleeding of Power Steering System Oil Pressure Check Power Steering Pump Gear Housing STEERING LI...

Page 301: ...ring belt loose Tighten belt SR 32 Fluid level in reservoir low Check reservoir SR 33 Power steering fluid IOlming Check POWef neering fluid SR 33 Power steefingunit f ulty Che kpew ltetrlngunit SR J7...

Page 302: ...HEAD 3 ADJUST STEERING GEA R BOX a Loosen he lock nut tb Turn the adjusting screw clockwise to decrease wheel freeplay and counterclockwise to increase it NOTE Turn the adjusting screw in small increm...

Page 303: ...SR STEERING Steering Column Assembly with TiltStee STEERING 9 WITH TILT S NNGASSEMBLY REMOVAL OF STEERING COlUMN ASSEMBLY l k q em ft lb N m 1 1 DISCONNECT NEGATIVE CABLE FROM BATTEAY...

Page 304: ...2 3 REMOVE STEERING WHEEL a Remove the steering wheel pad b Remove the set nut c Place matchmar1 s on the steering wheel and main shaft d Using SST remove the steering wheel SST 09609 20011 4 REMOVE A...

Page 305: ...olumn Assembly witn Tilt Steering COMPONENTS Intermldi le Sluft No 1 Co No lingSUPPort 1 m J Tilt Llwr __________ Colla No 1 l D _ f e d Support Stopper _ G Te sion Spring Ikv m ft lb N m I S if fll l...

Page 306: ...d tip and remove the spring and cord 2 DISCONNECT INTERMEDIATE SHAFT FROM MAIN SHAFT a Place matehmarks on the intermediate shaft and uni versal joint b Remove the bolt c Remove the snap ring d Pull o...

Page 307: ...racket 6 REMOVE IGNITION SWITCH 7 REMOVE MAIN SHAFT FROM UPPER BRACKET a Using SST compress the main shaft and upper bracket SST 09950 20016 CAUTION Do not tighten the SST too tightly b Using snap rin...

Page 308: ...emove the tilt pawl set bolt g Remove the nut and support stopper bolt with a clamp h Remove the tilt lever set nut i Temporarily install the nut flat with the end of the bolt and tap it with a hammer...

Page 309: ...ng cl Using SST and a hammer drive the bearing into the bracket SST09620 3OQ10 2 IF NECESSARY REPLAC E LOWER BEARING al Using SST and a press remove the lower bearing from the main shaft SST 09527 200...

Page 310: ...d vise press out the yoke side ooter race c Clamp the outer race in a vise and tap off the yoke with a hammer NOTE Remove the other bearing races in the same procedure Id Apply molybdenum disulphide l...

Page 311: ...1 1 225 1 275 10 0482 0 0502 1 275 1 325 10 0502 0 0522 1 1 Using needle nose pliers install tne snap rings NOT E Install the bearing outer races in tne yoke side using the same procedure i Using a na...

Page 312: ...which will eliminate play 17 989 17 996 17 996 18 003 18 003 18 010 18 010 18 017 18 017 _ 18 024 Qult di mele mmOn J 10 7082 0 7085 10 7085 0 7088 0 7088 0 7091 10 7091 0 7093 10 7093 0 7096J b Insta...

Page 313: ...snugly when pressed in by hand None 5 18 Thickness mm On 0 197 0 203 0 495 0 505 0 795 0 805 1 395 1 405 1 195 1 805 0 00780 0080 0 0195 0 0199 0 0313 0 0317 0 0549 0 0553 0 0707 0 0711 b Install the...

Page 314: ...esive and sealant THREE BOND 1324 Part No_ 08833 00070 or equivalent to one or two threads of the bolt end_ NOTE This adhesive will not harden while e posed to air It will act as a sealer or binding a...

Page 315: ...WO SPRINGS AND TWO CORDS a Connect the tension spring and cord and hook the spring to the hanger b Pry the spring end and hook the cord end to the support c Hook the cord to the cord guides 12 CHECK O...

Page 316: ...ft Ib 25 N m 2 INSTALL COMBINATION SWITCH 3 INSTALL COLUMN COVER AND AIR DUCT 4 INSTALL STEERI NG WHE EL a Align matchmarks on the steering wheel and main shaft and install the steering wheel to the m...

Page 317: ...BLY OF STEERING COLUMN ASSEMBLY 1 REMOVE MAIN SHAFT a Turn ignition key to the ACC position b Using snap ring pliers remove the snap ring c Pull out the main shaft 2 REMOVE UPPER BRACKET FROM COLUMN T...

Page 318: ...STEERING Steering Column Assembly SR 19 3 REMOVE COLUMN HOLE COVER FROM COLUMN TUBE a Remove the three bolts b Remove the column hole cover...

Page 319: ...dition and check for abnormal noise If the bearing is worn or damaged replace the upper bracket 2 IF NECESSARY REPLACE MAIN SHAFT LOWER BEARI NG a Remove the dust seal b Using snap ring pliers remove...

Page 320: ...ue 185 kg cm 13 ft lb 18 N m 2 INSTALL UPPER BRACKET TO COLUMN TUBE Install the upper bracket with three bolts See page SR 15 Torque 75 kg cm 65 in Ib 7 4 N m 3 INSTALL MAIN SHAFT TO COLUMN TUBE al Tu...

Page 321: ...Qu ili 1 DISCONNECT I I I A mo IO EAMEDIATE SHAFT b at atchm O the 1 c Remove ft JOint yoke worm shaft and Inter Id o two set bolts f 5hl nnect the intermedi t Okes 2 LOOSEN TM om th wo m AN ARM SET N...

Page 322: ...rt PrKC lledparl DISASSEMBLY OF GEAR HOUSING 1 REMOVE BREATHER PLUG AND DRAIN GEAR OIL 2 DISCONNECT PITM AN ARM FROM GEAR HOUSING a Remove the pitman arm set nut b Using SST disconnect the pitman arm...

Page 323: ...sector shaft 5 REMOVE WO RM BEARING ADJUSTI NG SCREW LOCK NUT UsingSST remove the lock nut SST 09617 60010 6 REMOVE WORM BEARING ADJUSTING SCREW Using SST remove the adjusting screw SST 09616 30020 7...

Page 324: ...ound repair Of replace the worm CAUTION Do not allow the ball nut to hit the end of the worm shaft 2 IF NECESSARY REPLACE WORM BEARING a Using SST remove the both side bearings SST 09950 20016 b Using...

Page 325: ...M SHAFT OIL SEAL a Using a 19 mm socket wrench drive out the oil seal Ib Using a 23 mm socket wrench drive in the oil seaL 4 MEASURE SECTOR SHAFT THRUST CLEARANCE Using a feeler gauge measure the shaf...

Page 326: ...ce the end cover 36 055 36 065 11 4195 1 4199J 36 045 36 055 11 4191 1 41951 36 035 36 045 11 4187 1 4191 36 025 36 035 1 4183 1 4187 NOTE When replacing the end cover replace with one having the same...

Page 327: ...just ing screw until it is snug 55T 09616 30020 b Using a torque meter alld SST measure the bearing preload in both directions Turn the adjusting screw until the preload is correct Preload starting 3...

Page 328: ...b 113N m 7 PLACE WORM SHAFT IN NEUT RAL POSITION a Fully turn the worm shaft while counting the rota tions b Then turn the shaft back half that number The shaft is now in neutral c Place matchmarks on...

Page 329: ...tor shaft with the pitman arm Install the pitman arm and tighten the nut finger tight b Install the backlash gauge Check that the sector shaft has no backlash within 100 degrees of either side of the...

Page 330: ...rm shaft and intermedi ate shaft joint yoke and connect them b Install and torque the two bolts Torque 360 kg cm 26 ft Ib 35 N m 3 INSTALL JOINT PROTECTOR la Install tnejoint protector b Install and t...

Page 331: ...7 in Used belt 8 10 mm 0 31 0 39 in 13B 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 ref...

Page 332: ...ure 80 C 176 F 3 CHECK FOR FOAMING OR EMULSI FICATION NOTE Foaming and emulsification indicate either the existence of air in the system or that the fluid level is too low 4 CHECK FLUID LEVE L IN RESE...

Page 333: ...UID WHILE TURNING STEERING WHEEL FROM LOCK TO LOCK 4 STOP ENGINE S FILL RESERVOIR TANK WITH FRESH FLUID Fluid ATF DEXRON or DEXRONI I U 6 START ENGINE AND RUN IT AT 000 RPM After one or two seconds fl...

Page 334: ...CLOUDY AND DOES NOT RISE OVER MAXIMUM WHEN ENGINE IS STOPPED Measure the flu id level with the engine running Stop the engine and measure the fluid level Maximum rise 5 mm 0 20 in If a problem is fou...

Page 335: ...pm and 3 000 rpm checks If the difference is excessive repair or replace the flow control valve of the PS pump S CHECK PRESSURE READING WITH STEERING WHEel TURNED TO FULL LOCK 8e sure the pressure gau...

Page 336: ...Power Steering Power S t e e ri n gp SFS A 37 REMOVAL OF pump OWER STEERIN _ J lL M r i R H I i i i J i i I t I L j I I 3FEngine 3BEngine i T IT owHSteeringpump 7 T 1Jt r i 1 m Ik Ift Ib N m H f L _ f...

Page 337: ...FROM J LOOSEN DRI VE P RESERVOIR TANK io USh on the drive ULLE Y NUT osen the pulley nu eJt to hold the pulley in piace and 4 REMOV E DRI VE a 1 3Fand BE T Loosen B Engine a 2 L 2H Et i er pulley out...

Page 338: ...teering 6 DISCONNECT PRESSURE HOSE Using SST disconnect the pressure hose SST 09631 22020 7 DISCONNECT RETURN HOSE 8 REMOVE POWER STEERING PUMP SR 39 Remove PS pump mount bolts and remove the PS pump...

Page 339: ...___________________ COMPONENTS 1 i _t 1 DISASSEMBLY OF PO CLAMP POWER STEERI WER STEERING PUMP CAUTION Do not ti9hte U MP IN VISE Ylse more than necessary 2 M INE 2 2 RESERVOIR TANK M ENGINEI ANO O RI...

Page 340: ...plates rotor and cam ring do not fall out 4 REMOVE CAM RING ROTOR AND VANE PLATES CAUTION Be careful not to scratch the cam ring rotor or vane plates 5 REMOVE ROTOR SHAFT a Clamp the front housing in...

Page 341: ...late with pliers as this could damage it b Remove the two O rings from the front housing and rear plate 7 REMOVE PRESSURE PORT UNION REMOVE FLOW CONTROL VALVE AN D SPRING CAUTION Use care not drop scr...

Page 342: ...ing snap ring plier remove the snap ring b Using a press press out the bearing c Using a press press in the bearing d Using snap ring pliers install the snap ring 3 INSPECT ROTOR AND CAM RING Measure...

Page 343: ...W CONTROL VALVE AND MEASURE SPRING a Check the flow control valve for wear or damage b Apply fluid to the valve and check that it falls smoothly into the valve hole by its own weight c Check the flow...

Page 344: ...STEERING Power Steering SR 45 6 IF NECESSARY REPLACE UNION SEAT al Using a screw extractor wrench remove the union seat b Install a oew union seat NOTE Only floating type parts are available...

Page 345: ...L SPRING AND flOW CONTROL VA LVE Push in the spring and valve to the front housing_ 3 INSTAll PRESSURE PORT UNION a Install the two O rings to the pressure port union and the front housing b Install a...

Page 346: ...Align and install large hole of th 2i p rd Ure the letters i OtthhePin e cam ring l 8 INSTALL ROTOR Install the rotor with the letters inscribed f Clng upward 9 INSTALL VANE PLATES Install the vane p...

Page 347: ...0 not tighten the vise too tightly e Evenly tighten the four housing bolts in several passes Torque 470 kg cm 34 ft Ib 46 N m 12 3Band 2H Engine INSTALL SUCTION PORT UNION a Install the suction port u...

Page 348: ...lg Seat DISASSEMBLY OF POWER STEERING PUMP 1 ATIACH SST TO POWER STEERING PUMP AND HOLD POWE R STEERING PUMP SST 09630 00011 2 REMOVE FRONT HOUSING MOUNT BOLTS 3 REMOVE RESERVOIR TANK AND O RING 4 MAR...

Page 349: ...NG a Using a plastic hammer tap off the fired ring b Remove the O ring and side plate 9 REMOVE PRESSURE PORT UN ION 10 REMOVE FLOW CONTROL VALVE AND SPR IN G CAUTION Avoid gripping the rear plate with...

Page 350: ...VE AN D MEASURE SPRING a Check the flow control valve for wear or damage b App y fluid the valve and check that it falls smoothly into the valve hole by its own weight c Check the f ow control vaive f...

Page 351: ...0 512 0 551 in If the spring is not within specification replace it 5 INSPECT FRONT AND REAR HOUSING BUSHING a Check the front and rear bushing for wear or cracks b Measure the clearance between rotor...

Page 352: ...F 3 INSTALL PRESSURE PORT UNION i Install and torque the union Torque 700 kg cm 51 ft Ib 69 N m 4 NIISTALL FLOW CONTROL SPRING SEAT Temporarily install a suitable bolt to the spring seat Push in the...

Page 353: ...lign the marks on the fixed ring and front housing d Temporarilv install the five bolts 9 TIGHTEN FIVE HOUSING BOLTS Evenly tighten the fire housing bolts in several passes Torque 470 kg cm 34 ft Ib 4...

Page 354: ...2 38 and 2H Engine Tum the adjust bolt until the belt tension is the specified value Drive belt tension at 10 kg 22 0 Ib 98 N 138 Engine New belt 13 17 mm 0 51 0 67 in Used belt 16 22 mm 0 63 0 87 in...

Page 355: ...SR S6 STEERING Power Steering 5 FILL RESERVOIR WITH FLUID Fluid ATF DEXRON or DEXRON l n 6 BLEED POWER STEERING 7 CHECK FOR flUID LEAKS...

Page 356: ...2S I7 911 P tm nArm 1 aoo 1131O 1171 1 ONNECT RETURN LINE AND Using SST d PRESSURE SST 0963 2 nect the return and pressure line T 2 DISCONNECT INTERME j _ 3 mo Ih jo OIp o E SHAFT m at atch a kS on th...

Page 357: ...ering 4 DISCONNECT RelAY ROD FROM PITMAN ARM a Remove the cotter pin b Remove the set nut e Using SST disconnect the relay rod from the pit SST 09628 62011 5 REMOVE GEAR HOUSING RemOlle the four nuts...

Page 358: ...OVE PITMAN ARM a Mount the gear housing on 55T and clamp 55T in vise SST 09630 00011 b Using SST remove the pitman arm SST 09628 62011 2 REMOVE END COVER a Remove the adjusting screw lock nut b Remove...

Page 359: ...se Then withdraw the valve body and power piston assembly CAUTION Ensure that the power piston nut does not come off the worm shaft c Remove the Q ring 5 REMOVE POWER PISTON NUT a Mount the valve body...

Page 360: ..._ _____ S TEERING Power Steering 8 REMOVE FOllOWING lal Worm shaft PARTS SR 61 b Thrustbearing c Plate washer d Teflonring e a ring...

Page 361: ...earance is not correct adjust the thrust clear 2 IF NECESSARY ADJUST THRUST CLEARANCE la Using a chisel and hammer remove the lock nut stake Ib Using SST loosen the lock nut SST 09630 0001 1 cl Adjust...

Page 362: ...top end should be installed so that it aligns with the upper end of the housing hole f sing SST install the lower bearing so that it is posi tloned 23 1 mm 0 909 in away from the lower end of the hou...

Page 363: ...k Using SST form the teflon ring SST 09630 00011 I Using SST drive in the oil seal SST 09630 0001 1 4 IF NECESSARY REPLACE ADJUSTING SCREW OIL SEAL a Using a screwdriver drive out the oil seal b Usin...

Page 364: ...remove the two teflon ring NOTE Be careful nOt to damage the control valve b Install the teflon ring to SST and expand it SST 09630 00011 c Install the expanded teflon ring to the control valve and sn...

Page 365: ...and clamp SST in vise SST 09630 00011 3 INSTALL O RING AND TEFLON RING a InstalltheO ring b Form the teflon ring into a heart shape and install it with your finger c Using SST form the teflon ring SS...

Page 366: ...into the holes and turn the worm shaft a little with each insertion Then securely insert the 33 balls into the piston d Install eleven new balls to the ball guide and apply MP grease to the ball guid...

Page 367: ...n the adjusting screw SST 09630 00011 c Turn the worm shaft to right and left and snug down the bearing d Slightly loosen the adjusting screw le Using SST slightly tighten the adjusting screw until th...

Page 368: ...four bolts Torque 470 kg cm 34 ft lb 46 N m 11 ADJUST TOTAL PRELOAQ a Match the alignment mark on the pitman arm and cross shaft and install them b Install and torque the pitman arm set nut Torque 1...

Page 369: ...RING Power Steering f While holding the adjusting screw install and torque the lock nut Torque 470 kg cm 34 ft lb 46 N m g Recheck the total preload 12 STAKE LOCK NUT Using a punch and hammer stake th...

Page 370: ...RMEDIATE SHAFT SR 71 a Align matchmarks on the worm shaft and inter mediate shalt joint yoke and connect them b Install and torque the two bolts Torque 360 kg cm 26 ft lb 35 N m c Install the joint pr...

Page 371: ...II TieRod 1 Cotterp Rel YRod QSc Pc e 1S __ r Y v TIIRod Sid 1 e Rel yRodEnd Pl G N B IISludSeI 1 O Soring SUI Pltm nArmSidlj REMOVE WHEEL DISCONNECT RELAY ROD FROM PITMAN ARM a Remove the cotter pin...

Page 372: ...ering damper from the damper bracket SST 09628 12022 5 DISCONNECT STEERI NG DAMPER FROM RELAY ROD al Remove the nut b Using SST disconnect the steering damper from the relay rod SST 09611 22012 6 DISC...

Page 373: ...ing on the fifth turn Torque turning 10 30 kg cm 8 7 26 0 in lb 1 0 2 9 N m 2 IF NECESSARY REPLACE TIE ROD END a Loosen the tie rod end clamp and remove the tie rod end b Tum the tie rod ends equal am...

Page 374: ...ring seat spring link joint knob and two ball stud seau f Tighten the plug completely 9 loosen the plug 1 1 1 3 turns and install a new cotter pm h Turn the relay rod ends equal amounts into the relay...

Page 375: ...m 54 ft Ib 74 N m 3 CONNECT STEERING DAMPER TO DAMPER BRACKET Torque the nut Torque 750 k cm 54 ft lb 74 N m CONNECT TIE ROD TO KNUCKLE ARM a Torque the nut Torque 925 kg cm 67 ft lb 91 N m b Install...

Page 376: ...CH AND STARTER SWITCH BE 13 LIGHTING BE 14 HEADLIGHT CLEANER BE 21 WIPERS AND WASHERS BE 23 INSTRUMENTS GAUGES AND WARNING LIGHTS BE 28 REA R WINDOW OEFOGGER BE 40 HEATER BE 43 POWER WINDOW BE 51 DOOR...

Page 377: ...YPE CONNECTOR DISCONNECT BULKHEAD TYPE CONNECTOR To remove the connector push the lock levers shown in the figure and pull out INSPECT BULKHEAD TYPE CONNECTOR When checking the continuity or voltage w...

Page 378: ...ectors are shown from the component lide Therefore when inspecting from the body side the left and right terminal connections will be in reverse REPLACEMENT OF FUSE Install a new fuse with the correct...

Page 379: ...the reset hole and push it b Using an ohmmeter check that there is continuity between both terminals of the circuit breaker If there is no continuity replace the circuit breaker 3 INSTAll CIRCUIT BRE...

Page 380: ...gine BODY ELECTRICAL SYSTEM Location of Switches and Relays BE S LOCATION OF SWITCHES AND RELAYS ENGINE COMPARTMENT SWITCHES AND RELAYS Water Temperature Switch W ter Temperature Sender Gau Oil I ssur...

Page 381: ...nd Relays ENGINE COMPARTM RELAYS Cont d ENT SWITCHES AND 3F Engine Wate Te mper ture Switch 70 Series Wiper Lock Switch wl Collapsible Wiper VacuumSwilct1 f Brake Fluid Level Warning Switch FuelSedime...

Page 382: ...BODY ELECTRICAL SYSTEM Location of Switches and Relays BE 7 70 Series LightC lntrol Rheosut ICanada md Allstralial Light Control Switch INSTRUMENT PANEL SWITCHES AND RELAYS One TOllch 2 4 Selector...

Page 383: ...BE S BODY ELECTRICAL SYSTEM Location of Switches and Relays 60 Series INSTRUMENT PANEL SWITCHES AND RELAYS ICont d...

Page 384: ...70 Series BODY ELECTRICAL SYSTEM Location of Switches and Relays BE 9 DRIVER AND PASSENGER COMPARTMENT SWITCHES AND RELAYS C tJb Wiper ContrOl Relay...

Page 385: ...BE 10 BODY ELECTRICA L SYSTEM Location of Switches and Relays 60 Series DRIVER AND PASSENGER COMPARTMENT SWITCHES AND RELAYS ICont d TaillightControl Relav Heitdlight Dimmer Relay...

Page 386: ...70 Series BODY ElECTRICAL SYSTEM Location of Switches and Re ays BE 11 PASSENGER AND LUGGAGE COMPARTMENT SWITCHES AND RELAYS Door Courtesy SwilCh Power Window Door Switch...

Page 387: ...ICAL SYSTEM Location of Switches and Relays 60 Series Counesy Switch PASSENGER AND LUGGAGE COMPARTMENT SWITCHES AND RELAYS ICant d Pow r Window Maner Switch Stop Li htSwitd1 j Door Courtesy Switd1 Doo...

Page 388: ...y between terminals Ignition switch C nad 60 Series Terminalr __ __ __ i i n LOCK O f C ACC o r c o r c ON o r o START o r r c Warning 1 i 1 o IgnitionswitcnIExCanada60Series S Terminal r r__ __ 1__ S...

Page 389: ...r faulty Tumsigrlal hazard switch faulty Tumsignal relay laulty 124V 60 series Wiringorgrourldfauity HAZ HORN fuse blown Turn sigrlal flasher faulty Turnliignal hazard switch faulty Turnsigrlal relay...

Page 390: ...eadlight dimmer lWitch LowS am HighBnm EL IWI 11 T IWI 4 H IAI 0 1 0 1 0 0 6 5 12 Hl Mu HF tR G R YI R W It continuity is not as specified replace the switch REPLACEMENT OF LIGHT CONTROL SWITCH AND HE...

Page 391: ...een terminals 3 and 4 c Check that there is no continuity between terminals 1 and 4 fcontinuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals...

Page 392: ...continuity between terminals 2 and 4 c Check that there is no continuity between terminals 3and4 If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage a...

Page 393: ...inuity is not as specified replace the relay 2 INSPECT RelAY OPERATION a Apply battery oltage across terminals 1 and 3 b Check that there is continuity between terminals 2 and 4 c Check that there is...

Page 394: ...ws and remove the wiper and washer switch cl Remove the turn signal and hazard switch d Install the turn signal and hazard switch e Install the wiper and washer switch f Connect the terminals to the c...

Page 395: ...Turn Signal Relay 24V 60 Series See Rear Fog Light Relay on page BE la Running Light Relay Norway only INSPECTION OF RUNNING LIGHT RELAY INSPECT RUNNING LIGHT RELAY CIRCUIT Disconnect the relay connec...

Page 396: ...Y CIRCUIT a Disconnect the control relay connector and inspect the connector on the wire harness side as shown in the chart below Condition Turn lightcontro switch to HEAD and turn headlight cleaner w...

Page 397: ...Turn wl her switch to ON nd ignition switch ON Novoltlge Continuity Turn ignitionlwitch toON Bltteryvoltage Turn ignition switch to LOCK or ACC No voltage b With terminal 4 on the connector side grou...

Page 398: ...Wiring or IfOUnd flulty Repairasnectullry Washer hose or nozzlaclogged Washer motor faulty Wiper lw tchf ully Wiringorgroundflully Repair as necessary Replace motor Chukswitch Rep lr nneceuilry BE 25...

Page 399: ...to terminal 3 and connect the negative I lead from the battery to terminal 2 b Connect the positive lead from the voltmeter to terminal 1 and connect the negative lead from the voltmeter to terminal...

Page 400: ...e motor body c Check that the motor operates at low speed 2 INSPECT THAT MOTOR OPERATES AT HIGH SPEED a Connect the positive lead from the battery to terminal 1 Connect the negative 1 lead to the moto...

Page 401: ...a Check that there is continuity when the switch is pushed b Check that there is no continuity when the switch is free If continuity is not as specified replace the switch Rear Wiper and Washer Switc...

Page 402: ...INSPECT THAT MOTOR OPERATES STOPPING AT STOP POSITION a Connect the positive lead from the banery to terminal 3 Connect the negative lead to the motor body Operate the motor tb Stop motor operation an...

Page 403: ...warning switch faulty Wiring or ground faulty GAUGE fuse blown Bulb burned out Brake fluid level warning switch faulty Wiring or ground faulty GAUGE fuse blown Bulbburnedoot Wiring or grour ld faulty...

Page 404: ...omputer Ground SpndWlrningBuzzIr QilPressur Sendlr Gauge V euum Switcn Parking BrOlka Switcn oo Brlk Fluid L I Wlrning Switch Ignition Coil or Tl h Sensor ENGINE Fuse CHARGE Fuse 11 Light ContrOl Rh_t...

Page 405: ...MBINATION METER CIRCUIT Wir ngConneetorSide Emission Computer Ground 3 SpeedW rning 8uuer 4 Oil PressureSw tch VlCuumSwitch Plrking8rakeSwitchand 8rake Fluid Ltvel Warning Switch ENGINE Fuse CHARGEFuM...

Page 406: ...ination Meter and Gauge 60 Series COMBINATION METER CIRCUIT No Wirin lConnKtorSidn 2 Oil Pre1lure Sender Gauge 3 GAUGE FUll 6 WlterTtmperltureSenderGlulJI 7 CHARGE Fuse A 8 Hn dlight Dimmer Switch Ter...

Page 407: ...7 If error is excessive replace the speedometer b Check the speedometer for poi nter vibration and abnormal noise NOTE Pointer vibration can be caused by a loose speedometer cable Tachometer ON VH ICL...

Page 408: ...ESISTANCE Measure the resistance between terminals 1 and 2 Resistance ApproK 55n If resistance value is not as specified replace the receiver gauge 3 INSPECT SUB FUEL RECEIVER GAUGE OPERATION a Discon...

Page 409: ...each float position 70 Se ies Float position mmlin 1 2 E 60 Series 76 7 1 3 020 189 817 472 302 4 11 905 mmlin 34 511 358 89 5 3 524 160 516 319 70 Serie S for sub fuel lank Floalposition mmlin l 56...

Page 410: ...on is not as specified replace the solenoid Water Temperature Gauge INSPECTION OF WATER TEMPERATURE GAUGE 1 INSPECT RECEIVER GAUGE OPERATION la Disconnect the connector from the sender gauge Connect t...

Page 411: ...or starter switch on Check that the bulb starts flashing and the gauge pointer deflects If indications are not as specified remove and test the receiver gauge 2 MEASURE RECEI VER GAUGE RESISTANCE Meas...

Page 412: ...ine running NOTE After the engine has started oil pressure should be over 0 3 kg cm 4 3 psi 29 kPa If operation is not correct replace the switch Brake Warning INSPECTION OF BRAKE WARNING 1 INSPECT WA...

Page 413: ...ace the relay 2 INSPECT RELAY OPERATION Connect the positive lead from the battery to terminal 1 and connect the negative I lead from the battery to terminal 3 Then check that there is continuity betw...

Page 414: ...hen the switch is ON float up and when the switch isOF F float down If operation is not correct replace the switch Air Cleaner Warning INSPECTION OF AIR CLEANER WARNING 1 INSPECT WARNING LIGHT OPERATI...

Page 415: ...eckwi H WiringanOgroundl ulty RepairHne e Slry BE 40 BE J BE40 BE 41 m Rear Window Defogger Switch INSPECTION OF REAR WINDOW DEFOGGER SWITCH INSPECT SWITCH CONTINUITY Inspect continuity between the te...

Page 416: ...e as shown Voltage Criteri Approx 5V Okly Nobrelkin wifl Approx IOVo OV Brok nwir NOTE If there are l OV the wire is broken between the center of the wire and positive J end If there is no voltage the...

Page 417: ...TH WHITE GASOLINE 2 PLACE MASKING TAPE ALONG BOTH SIDES OF Broken Wire WIRE TO BE REPAIRED Masking Tape 3 REPAIR DEFOGGER WIRES a Thoroughly mix the repair agent Oupont paste No 4817 b Using a fine ti...

Page 418: ...valve Air dampers broken Repair dampers Air duc ts c 10g9ld Rlpairducn Heater radiator leaking or clogged Replace radiator Heater control unit faulty Repair control unit BE 43 P Front 81 43 BI 46 SE 4...

Page 419: ...ECT RESISTOR CONTINUITY a Check that there is continuity between terminals 1 and 2 b Check th8t there is continuity between terminals 1 and 3 c Check that there is continuity between terminals 1 and4...

Page 420: ...l lever to DEF 3 ADJUST AIR MIX DAMPER Set the air mix damper and control lever to COOL 4 ADJUST WATER VALVE Set the water vallle and control lever to COOl NOTE Place the water vallle lever on COOL an...

Page 421: ...LECTRICAL SYSTEM Heater Rear Heater Blower Switch INSPECTION OF HEATER BLOWER SWITCH INSPECT SWITCH CONTINUITY Inspect the switch continuity between terminals If continuity is not as specified replace...

Page 422: ...g Or clogged Wate w lve f lty Replacewllwe Air dlfTlp8rs broken ReP31irdamptrs Air ducu clogged Repaird X u Heilte ldiato leakingorclogged Replacerldinor Heale COf llrol unit faulty Replir control uni...

Page 423: ...BLOWER RESISTOR INSPECT RESISTOR CONTINUITY a Check that there is continuity between terminals 1 and 2 b Check that there is continuity between terminals 1 and 3 c Check that there is continuity betw...

Page 424: ...or and control lever to DEF 3 ADJUST AIR MIX DAMPER Set the air mix damper and control lever to COOL 4 ADJUST WATER VALVE Set the water valve and control lever to COOl NOTE Place the water valve lever...

Page 425: ...3 b Check that there is no continuity between terminals 2and 4 If continuity is nOt as specified replace the relay 2 INSPECT RELAY OPERATION Check that there is continuity between terminals 2 and 4 wi...

Page 426: ...WITCH INSPECT SWITCH CONTINUITY Check that there is continuity between terminals Window Lock SWiteh If continuity is not as specified replace the switch Power Window Door Switch INSPECTION OF POWER WI...

Page 427: ...uity Turn ignition lwitd l on Battery voltage Turni ilionswitcholf No voltage Continuity Turn master driver side switch to UP Battery voltage Turn master driver side switch 10 DOWN or OFF No voltage T...

Page 428: ...dow switch on UP and check that there is a circuit breaker operation noise within 4 to 40 seconds bJ With the window in the fully closed position hold the switch on DOWN and check that the window begi...

Page 429: ...Check that there is continuity between terminals 1 and 3 b Check that there is no continuity between terminals 2 and 4 If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a A...

Page 430: ...noid Door Lock Solenoid For Back Door INSPECTION OF DOOR LOCK SOLENOID INSPECT SOLENOI D OPERATION al Connect the positive lead from the battery to terminal 1 Connect the negative Iead to terminal 3 C...

Page 431: ...ion Ignition swild OFF Turn ignition switch ON Turn sun rool switch to OPEN Turn sun roof switch to excl pt OPEN Turn sun rool switch to CLOSE Turn sun roof switch anywh r oH CLOSE Turn limit switch O...

Page 432: ...TINUITY a Check that there is continuity between terminals 1 and 2 when the switch is ON b Check that there is no continuity between terminals 1 and 2 when the switch isOFF If continuity is not as spe...

Page 433: ...RADIO AND TAPE PLAYER a No power to radio or tape player or power but no sound Possible causes Blown CIG fuse Short circuit or broken wire in power source wire harness Loose connectors behind radio a...

Page 434: ...BODY ELECTRICAL SYSTEM Radio Stereo Tape Player and Antenna BE 59...

Page 435: ...either one Possible causes Antenna disconnected Antenna plug not properly connected Defectiveantenna Defective antenna cable Defective radio or tape player Reinserlplug Okay I OK nspe 1 anlenn plug L...

Page 436: ...Tape Player and Antenna BE 61 cl No sound from one speaker PO siblecauses Loose speaker connector Broken wire in speaker wire harness Defectivespeaker Defective radio and tape player OK Inspeetconr e...

Page 437: ...mmer Defectiveantenna Defective antenna cable Defectivespeaker Defective radio Q I OK Impectantlnnl clbleand rtplirlSnecfl ry NOTE Adjustment of antenna trimmer 1 Fu Uy lengthen Iheantenna 2 With volu...

Page 438: ...terception Tuner dial not synchronized with station Defectiveantenna Defective antenna cable Speaker improperly installed Vibration sound from components near speaker Defectivespeaker Defective radio...

Page 439: ...speaker Vibration noise from around speaker Defectivespeaker Defectivetapeplayer Tlpebfd f _ yH _ OK NOTE Head cleaning procedure 1 Raise the cassette door with your finger Next using a pencil or lik...

Page 440: ...rmi n l S position UP OFF DOWN 0 0 If continuity is not as specified replace the switch Antenna Motor INSPECTION OF MOTOR INSPECT MOTOR OPERATION a Connect the positive lead from the battery to termin...

Page 441: ...g knob not returned Below 11V 22VI LOO5eorrvsted No voltage Loose or rusted L te roubleandrepairor replace fuse as necessary Repair if necessary or repla eelock Recharge or replace battery Repair Loca...

Page 442: ...of the quartz clock requires a precise digital counter Adjustment must be made in a shop specified by the manufacturer 3 SETTING OF CLOCK a Connect the battery terminal b Check the clock to see that i...

Page 443: ...ROOF INSTRUMENT PANEL 70 73 75 Series 60 62Series TARPAULIN TARPAULIN SPARS FRP TOP ROLL BAR SEAT 70 73 75 Series 60 62 Series SEAT BELT 70 73 75 Series 60 62 Series FUEL TANK AND LINE FRAME OIMENSION...

Page 444: ...hood by loosening the hood side hinge bolts 2 ADJUST FRONT EDGE OF HOOD IN VERTIC AL DIRECTION Adjust the hood by turning the hood cushions 3 ADJUST REAR EDGE OF HOOD IN VERTICAL DIRECTION Adjust the...

Page 445: ...L DIRECTION Adjust the hood by turning the hood cushions ADJUST REAR EDGE OF HOOD IN VERTICAL DIRECTION Disconnect the washer hose and remove the four bolts and hood b Remove the two clips and six scr...

Page 446: ...BO 4 BODY Hood 4 ADJUST HOOD LOCK Adjust the hood lock by loosening the mounting bolts...

Page 447: ...Window Regulator R rr Handle BODY Front Door 60 Series FRONT pOOR 60 Series COMPONENTS with Ventilator Window BO 5 S S...

Page 448: ...OUTER AND INNER WEATHERSTRIP al Pull off the outer weathentrip b Using a screwdriver remove the inner weatherstrip REMOVE REAR VIEW MIRROR 8 REMOVE INSIDE HANDLE a Remove the three screws b Partly lea...

Page 449: ...e hole 13 w o Ventilator Window type REMOVE FRONT LOWER FRAME Remove the two screws bolt and front lower frame 14 REMOVE RE AR LOWER FRAME Remove the bolt and rear lower frame 15 DISCONNECT INSIDE LOC...

Page 450: ...ace of the door lock 2 INSTALL DOOR LOCK w door lock solenoid Connect the connector to the door lock solenoid and in stall the door lock with the th ree screws and bolt w o door lock solenoid Install...

Page 451: ...window type Install the two equalizer arm bracket mounting bolts 10 PLACE DOOR GLASS IN DOOR Insert the door glass in the door cavity 11 w Ventilator Window type INSTALL VENTI LATOR WINDOW a Install t...

Page 452: ...the tape 18 INSTALL INSIDE HANDLE a Connect the link to the door lock b Install the inside handle with the three screws 19 INSTA LL OOOR TRIM a w power window Connect the connector to the switch b In...

Page 453: ...AND i b adjust the door by loosening the body ide SST 09812 00010 2 lg sOR IN LEFT RIGHT AND VERT ICAL Adjust the door by loosening the door side hinge bolts J 3 ADJUST DOOR LOCK STRI KER j s hC r I r...

Page 454: ...nt Door 70 Series FRONT DOOR 70 Series COMPONENTS Soft Top Type Front l ower Frame Door Glass R irviewMirror Glass Olan 1 OuterWeath ntrip OoorHinge Window Regulltor 11 gr V o ItU hD B Front lower Fr...

Page 455: ...im retainers and door panel to pry it loose NOTE Tape the screwdriver tip before use c w power windowl Disconnect the connector from the switch 5 REMOVE REA R VIEW MIRROR 6 REMOVE INNER AND OUTER WEAT...

Page 456: ...window Disconnect the connector from the motor and re move 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...

Page 457: ...e outside handle b Remove the two bolts and outside handle 19 REMOVE DOOR LOCK wl door lock solenoid Remove the three screws bolt and door lock and dis connect the connector from the solenoid w o door...

Page 458: ...ith the three screws J INSTALL DOOR LOCK CYLINDER Install the door lock cylinder with the retainer and con nect the control link to it 4 INSTALL OUTSIDE HANDLE Install the ouuide handle with the two b...

Page 459: ...door glass and install it to the window regulator b w o ventilator window type Install the two glass channel mounting bolts 11 w Ventilator Window type INSTALL VENTILATOR WINDOW a Install the three sc...

Page 460: ...OOR TRIM a w power window Connect the connector b Install the door trim with clips to the inside door panel by tapping c w soft top Install the service cover with screw 20 INSTALL INSIDE HANDLE a Conn...

Page 461: ...2 b adjust the door by loosening the body side SST 09812 00010 M 2 lg sOR IN LEFT RIGHT AND VERTICAL Adjust the door by loosening the door side hinge bolts 01 3 ADJUST DOOR LOCK STRIKER j s etc rr I...

Page 462: ...BO 20 BODY Rear Door REAR DOOR COMPONENTS W d WGI r I DOO G GlilssChilnnel O Y onBa Inne Weatherstnp Window Regulato...

Page 463: ...nector from the switch 5 REMOVE INSIDE HANDLE a Remove the three screws b Partly tear off the service hole cover and disconnect the inside handle link from the door lock REMOVE SERVICE HOLE COVER 7 RE...

Page 464: ...ve the four bolts and window regu lator w o power window Remove the three bolts and window regulator Ib w power window Disconnect the connector from the motor 14 REMOVE DOOR LOCK a w door lock solenoi...

Page 465: ...the door lock 2 INSTALL OUTSIDE HANDLE Install the outside handle with two boll 3 INSTALL DOOR LOCK I _ b w door lock solenoid Connect the connector to the solenoid w door lock solenoid Install the do...

Page 466: ...e lower edge of the service hole cover into the panel slit c Seal the panel slit with cotton tape CAUTION Do not block the trim clip seating with the tape 12 INSTALL INSIDE HANDLE a Connect the link t...

Page 467: ...the door by loosening the body side hinge bolts 2 ADJUST DOOR IN LEFT RIGHT AND VERTICAL DIRECTIONS Adjust the door by loosening the door side hinge bolts 3 ADJUST DOOR LOCK STRIKER lal Check that the...

Page 468: ...PUll HANDLE 2 REMOVE SERVICE HOLE COVER 3 S N g Sd E LOCKING CONTROL LINK 4 REMOVE DOOR LOCK CYLINDER J Di nnect the links from the cylinder s ng a screwdriver remove the E ring and lever c C OIS c 9...

Page 469: ...g e Connect the links to the cylinder 4 CONNECT INSIDE LOCKING CONTROL LINK TO DOOR LOCK 5 CHECK DOOR LOCK OPERATION 6 INSTALL SERVICE HOLE COVER 7 INSTALL PULL HANDLE ADJUSTMENT OF UPPER BACK DOOR 1...

Page 470: ...el to pry it loose NOTE Tape the screwdriver tip before use 2 REMOVE SERVICE HOLE COVER 3 REMOVE DOOR LOCK CONTROL a Disconnect the links from the door lock control _ 4 b Remove the screw and inside h...

Page 471: ...the screw d Connect the links to the door lock control 5 CHECK DOOR LOCK OPERATION 6 INSTAll SERVICE HOLE COVER 7 INSTALL DOOR TRIM Install the door trim with clips to the inside door panel by tapping...

Page 472: ...efore disposing of it Icl When drilling chips may fly out so work carefully Id The gas is colorless odorless and non toxic lel When working handle the damper carefully Never score or scratch the expos...

Page 473: ...BODY Back Door 60 Sef les Swing Out Type BACK DOOR ng Out Type 60 Series SWI COMPONENTS DoorLockStrik er Slid Block Ooor Trim BO 31...

Page 474: ...fore use 4 REMOVE SERVICE HOLE COVER REMOVE INSIDE HANDLE a Remove the three screws and inside handle b Disconnect the link from the inside handle REMOVE DOOR LOCK CYLINDER Disconnect the link from th...

Page 475: ...outside handle with the two bolts b Connect the link to the outside handle INSTALL DOOR LOCK CYLINDER a Install the door lock cylinder with retainer b Connect the link to the cylinder 6 INSTALL INSID...

Page 476: ...VERTICAL DIRECTIONS Adjust the door by loosening the body side hinge bolts 2 ADJUST DOOR IN LEFT RIGHT AND VERTICAL DIRECTIONS Adjust the door by loosening the door side hinge bol ts 3 ADJUST DOOR LO...

Page 477: ...HANDLE a Remove the three screws and inside handle b Disconnect the link from the inside handle 5 DISCONNECT OUTSIDE LOCKING CONTROL LINK FROM LOWER DOOR LOCK REMOVE LOWER DOOR LOCK a Disconnect the l...

Page 478: ...screw5 y 4 INSTAll UPPER DOOR LOCK 1 Install the upper door lock with the three screws 1 b Connect the link to the door lock control 5 INSTALL LOWER DOOR LOCK Install the lower door lock with the two...

Page 479: ...loosening the body side hinge bolts 2 ADJUST DOOR IN LEFT RIGHT AND VERTICAL DIRECTIONS Adjust the door by loosening the door side hinge bolts 3 ADJUST DOOR LOCK STRIKER a Check that the door fit and...

Page 480: ...80 38 BODY Back Door 70 Series Swing Out Type BACK DOOR 70 Series Swing Out Type COMPONENTS Door Trim...

Page 481: ...ver tip before use 5 REMOVE SERV ICE HOLE COVER 6 REMOVE DOOR STOPPER 7 REMOVE DOOR STOPPER BRACKET 8 REMOVE LOWER DOOR LOCK a Disconnect the link from the door lock control b Remove the three bolts a...

Page 482: ...th two screws Ib Install the inside handle with a screw 3 w o Soft Top INSTALL UPPER DOOR LOCK fal Install the upper door lock with the two bolts b Connect the link to the door lock control c Install...

Page 483: ...service hole cover into the panel slit c Seal the panel slit with cotton tape CAUTION Do not block the trim clip seating with the tape 9 INSTALL DOOR TRIM Install the door trim with clips to the insid...

Page 484: ...the pull handle and door trim Ib Peel off the outer ridges of the service hole cover c Adjust the door by loosening the door side hinge bolts 3 ADJUST DOOR lOCK STRIKER la Check that the door fit and...

Page 485: ...crewdriver between the trim retainers and door panel to pry it loose NOTE Tape the screwdriver tip before use REMOVE SERVICE HOLE COVER DISCONNECT INSIDE LOCKING CONTROL LINK FROM DOOR LOCK 6 REMOVE D...

Page 486: ...ailW r b Connect the link to the cylinder 5 CONNECT INSIDE LOCKING CONTROL LI NK TO DOOR lOCK 6 INSTALL SERVICE HOLE COVER a Seal the service hole cover with adhesive b Insert the lower edge of the se...

Page 487: ...DOOR IN LEFT RIGHT AND VERTICAL DIRECTIONS a Remove the pull handle inside handle and door trim bl Peel off the outer ridges of the service hole cover c Adjust the door by loosening the door side hing...

Page 488: ...UTSIDE MOULDING REMOVE WINDSHIELD OUTSIDE MOULDING a Using a screwdriver pull off the joint cover b Using a screwdriver pull off the moulding from the end INSTALLATION OF WINDSHIELD OUTSIDE MOULDING I...

Page 489: ...BODY Moulding Roof D BBC np Moulding 0 47 COMPONENTS 60 SeriesJ Roof Drip Front Side Moulding 70 Series...

Page 490: ...sing SST pull off the joint cover SST 09806 30010 b Using SST pull off the roof drip moulding from both ends SST 09806 30010 INSTALLATION OF ROOF DRIP MOULDING INSTALL ROOF DRIP MOULDING BY HAND Anach...

Page 491: ...BODY Moulding 80 49 Back Door Moulding C O MPONENTS Lift up type Side Moulding __ l JoinlCover Lower Moulding Swing Out type...

Page 492: ...DING REMOVE BACK DOOR MOULDING a Using a screwdriver pull off the joint cover b g a screwdriver pull off the moolding from the INSTALLATION OF BACK DOOR MOULDING INSTALL BACK DOOR MOULDING Using a scr...

Page 493: ...NENTS REMOVAL OF WIN 1 REMOVE FOLl DSH1ELO a Wiper arms OWING PARTS tb Windshield mould I wml Is BO 461 Sun visors and holders 2 REMOVE WINOSHIEL If reusing th 0 tal worldn r herstriP loosen the wea r...

Page 494: ...ce INSTALLATION OF WINDSHIELD See page BO 51 1 CLEAN BODY AND GLASS Using alcohol wipe off any adhesive left on the body or glass 2 INSTALL WEATHERSTRIP ON GLASS a Attach the weatherstrip to the glass...

Page 495: ...le so it pulls the lip over the flange From the outside press the glass along the weatherstrip until the glass is in stalled 4 SNUG DOWN GLASS To snug down the glass tap from the outside with your ope...

Page 496: ...sl URFACE bl Clean off the adh emove the masking tape tape with a clean r l t a ndgi u om the asking Ite gasoline 7 CHECK FOR If necessa WATER LEAKS 8 rv applysealant INSTALL FOLLOWING PAR 5 od hold T...

Page 497: ...s in advance BO 55 w r white ga line UNION CA r AP131 ADHESION P _ CORPORATION OTER IMR i N 366ET CEMEDINEI CO I or such T El DUPONT DE NEMOURS COMPONENTS REMOVAL OF WINDSHIELD 1 MWO E FOLLOWING PARTS...

Page 498: ...c Tie both wire ends to a wooden block or equivalent CAUTION When separating take care not to damage the paint or interior and exterior ornaments To prevent scratching the safety pad when removing th...

Page 499: ...the white gasoline has dried at least 3 minutes NOTE Use AP131 grade primer or such The primer is volatile and will form deposits under humid conditions Therefore always store primer in a cool dry pl...

Page 500: ...ver the flange From the outside press the glass along the weatherstrip until the glass is installed 5 SNUG DOWN GLASS To snug down the glass tap from the OlJtside with your open hand 6 APPLY ADHESIVE...

Page 501: ...15 hours b Clean off the adhesive oozing out from the masking tape with a clean rag saturated in white gasoline 8 CHECK FOR WATER LEAKS If necessary apply adhesive NOTE Use a CEMEDIN E 366ET IM AON SE...

Page 502: ...80 60 70 Series Hard Top IFbc ed Type 73 Serie5 FRP Top BODY Side Window SIDE WINDOW COMPONENTS Lock Retainer S deWindOWGUlrd SuhClip FrameSp cer oh...

Page 503: ...60 62 Series Fb ed Type WHt Germanv onlv Channll Wllthlrstflp BODY Side Window COMPONENTS Cont d Slidjng Typel SMhClip FrilmeSpacer S h CenterWllthtrsttip Wutherstrip B0 61...

Page 504: ...the vehicle cut off the weather strip lip with a knife bl Pull the side window outwards and remove the side window cl Remove the remaining weatherstrip REMOVAL OF SIDE WINDOW 60 62 73 75 Series See pa...

Page 505: ...4 70 Series REMOVE SIDE WINDOW WEATHERSTRIP FROM SASH ASSEMBLY OF SIDE WINDOW See pages eo 60 61 1 70 Series INSTAll SIDE WINDOW WEATHERSTRIP ON SASH AS SHOWN CAUTI ON If the weathentrip has hardened...

Page 506: ...o the contact surface of the weatherstrip lip and to the body flange NOTE Begin installation in the middle of the lower part of the side window cl Hold the window in position on the body d From the in...

Page 507: ...AI Itlngaroundgl u 0 04 x 23 62in l I fO t r iHOline h rll Ig urface b Using alcohol adhesive left onor unleaded gasolin 1 0 Appl b 1 bod d h w p off n Id Install the side o the body ow to the body P...

Page 508: ...BO 66 60 62 Series Swing Out Type Lift up Type 70 73 75 Series BODY Back Door Glass BACK DOOR GLASS COMPONENTS Wutherstrip Back DoorGlan Weathernrip Back Door GIISS Moulding Rear Wiper m...

Page 509: ...p of weatnerstrip under flangewitn screwdriver Ib Pusn tne glass out to remove If using a new weatnerstrip a From outside of tne venicle cut off tne weatnerstrip lipwitn a knife b Pusn tne back door g...

Page 510: ...part b Hold the glass in position on the body Id T pt e n the outside of the glass until it IS securely in 3 CHE K FOR LEAKS I dwater on glass and weath apply sealant where nece s rlP check seal for...

Page 511: ...d Type BACK WINDOW ____C O MvItPONENTS Sliding Type Wutherstrip REMOVAL OF BA REMOVE BACK WINDO K WINDOW BO 69 iUS g the weatherstrip f rom in ide of vehi le st b p e with screwdrive utf hp of weather...

Page 512: ...VE SLICE GLASS Pull apart the channels and remove the two slide glass panes at the center of the glass channel 4 REMOVE FIX FRAME a Remove the four packings b Pull apart the channels and remove the tw...

Page 513: ...e b Pull apart the channels and install the two fixed glass panes with the weatherstrip 3 INSTA LL FIX FRAMES a Apply soapy water to the contact face of the weather strip and to the fix frames b Pull...

Page 514: ...he weatherstrip to the back window CAUTION If the weatherstrip has become hard it may develop leaks Use 8 new one if possible b Insert a cord into the groove of the weatherstrip all the way around wit...

Page 515: ...lip over the flange From the outside press the glass along the weatherstrip until the glass is in stalled d Tap on the outside of the glass until it is securely in place 3 CHECK FOR LEAKS Pouring wat...

Page 516: ...BO 74 Sliding Roof Panel Wind Oefleelor SunRoof pening CO OI SWi h A SWi hCo BODY Sun Roof SUN ROOF COMPONENTS Wulh rtlrip...

Page 517: ...Remove the screw inside CAUTION Be careful not to lose the spring washer or washer c Manually operate the wn roof by inserting a screw driver into the ho eand turning the drive shaft 1V A OJUSTMENT OF...

Page 518: ...roof to th I h ha shoe nuts and mo vlng the 5 TO ADJUST Oifference in 1 Ea R NCE d right front clearance the difference is about 2 m Remove the d m 0 08 in notch on the si five motor and bJ Reinstall...

Page 519: ...NO DEFLECTOR 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 fro...

Page 520: ...AIL c a Loosen the screw b Pull the guide rail rearward to remove REMOVE DRIVE CABLES FROM CABLE GUIDE CASING ASSEMBLY OF ROOF See page BO 74 APPLY MP GREASE TO DRIVE CABLE 2 PLACE DRI V E CABLES INTO...

Page 521: ...ONTO ROOF a Install the sliding roof assembly onto the roof b Tighten the four cable guide casing set screws INSTALL SIDE RAIL COVER 70 73 75 Series Install the side rail cover from the inside with t...

Page 522: ...ION 7 INSTALL CONTROL SWITCH 8 INSTALL SWITCH COVER 9 CONNECT BATTERY CABLE TO NEGATIVE TERMINA L REMOVAL OF SLIDING ROOF PANEL TO REMOVE SLIDING ROOF PANEL ONLY a pun loose the clips and slide the he...

Page 523: ...PineI 8 _ 1llFFpeak m i nish iJ f3 No 2 Side Air Duet e l NO 3Sid NO lS d AirDuet i No 4 Air Duct 6 Air DtKt _ Sid Air Duet r 1 it No 2 R t NO 2lnstrument Clu1ter Finish 1 r egostr CeottrP nel N o 5 R...

Page 524: ...16 I L 16 N I I 0 IP L oO 14 i REMOVAL OF INSTRUMENT PANEL See page BO 81 L 20 L 20 L 10 L 14 1 DISCONNECT BATTERY CABLE FROM NEGATIVE TERMINAL 2 REMOVE STEERING WHEEL 3 REMOVE STEERING COLUMN COVER 4...

Page 525: ...emolle the four screws b Disconnect the connector and antenna cable then remove the radio 10 REMOVE ACCESSORY METER al RemOlle the two screws and the hood bl Disconnect the connector then remove the t...

Page 526: ...n remove the finish panel 14 REMOVE COMBINATION METER lal Remove the four screm b Remove the No 3 side air duct cl Reach in from where the No 3 side air duct has been removed and disconnect the speedo...

Page 527: ...16 REMOVE GLOVE COMPARTMENT DOOR 17 REMOVE SIDE AIR DUCT NOTE The No 4 side air duct must be removed 18 REMOVE INSTRUMENT PANEL SIDE REGISTER 19 REMOVE BOTH SIDE OEFROSTER DUCTS 20 REMOVE ASSIST GRIP...

Page 528: ...W e h V e ps p the safety pad and re NOTE Tape the screwdriver tip before use LJJt 22 REMOVE BOTH SPEAKERS Disconnect the connector b Remove the two nutsand speaker I fJf 23 REMOVE BOTH INSTRUMENT PA...

Page 529: ...Australia Emission control relay Preheating timer BJ HJ Canada Charge light relay Seat belt warning buzzer 8087 b Remove the three wiring harness clamps from the instrument panel c Remove the steering...

Page 530: ...BO 88 BODY Instrument Panel 60 6 2 H ___________ g us J PANEL COMPONENTS...

Page 531: ...STRUMENT PANEL See page BO 88 L 16 5 L 16 8 L 16 1 DISCONNECT BATTERY CABLE FROM NEGATIVE TERMINAL 2 REMOVE STEERING WHEEL 3 REMOVE STEERING COLUMN COVER 4 REMOVE THROTTLE CABLE a Disconnect the throt...

Page 532: ...ble and the connecton then remove the instrument cluster finish panel with the combination meter 8 REMOVE INSTRUMENT CLUSTER FINISH CENTER PANel a Remove the nine screws b Disconnect the connecton and...

Page 533: ...he two screws and the door lock striker Id Remove the two screws and the glove compartment 13 REMOVE RADIO a Remove the switch and control knobs b Remove the two nuu and the plate c Remove the four sc...

Page 534: ...WO CLIPS FROM SAFETY PAD REMOVE FUSE BOX FROM INSTRUMENT PANEL REMOVE HEATER DUCTS 20 REMOVE INSTRUMENT PANEL a Disconnect the control cable indicated left and insert the heater control panel into the...

Page 535: ...Panel SO 62 Seriesl BO 93 21 REMOVE FOllOWING PARTS FROM INSTRUMENT PANEL Switches Nineclips Socket INSTALLATION OF INSTRUMENT PANEL lSee page BO 88l INSTALL PARTS OF INSTRUMENT PANEL IN REVERSE SEQU...

Page 536: ...EEL MAGIC TAPE AROUND TARPAULIN SPARS 70 series 10 places 73 series 15 places 70 Series 73 Series 2 RELEASE FOUR BELTS WRAPPED AROUND TARPAULIN SPARS TWO EACH SIDE 3 UNZIP FOUR ZIPPERS TWO EACH SIDE R...

Page 537: ...JOINTS AND THREE OPENING TRIMS 5 UNPEEL FIVE STRIPS OF MAGIC TAPE ABOVE BACK DOOR MagieTl pe 6 DISCONNECT ROOF SIDE RAI L AS WELL AS TEN SNAPS FIVE EACH SIDE 7 UNPEEL TWELVE STRIPS OF MAGIC TAPE OUTSI...

Page 538: ...the hooks b From the back end of the pipe push the pipe forward so the opposite elld protrude5 a few inches from the service notch and the back end slides out of the service hole c Pull the pipe out b...

Page 539: ...OTH WATER SEALS UP AND OUT OF REAR PILLAR CHANNEL 12_ FLIP UP SIDEWALL ONTO ROOF ABOVE CARGO COMPARTMENT 13 FLIP FOLDED BACK HALF OF TARPAULIN ONTO ROOF ABOVE DRIVER S COMPARTMENT 14 DISCONNECT FOUR C...

Page 540: ...N TO EITHER VEHICLE RIGHT OR LEFT TO FREE FRONT WATER SEAL AND REMOVE TARPAULIN INSTALLATION OF TARPAULIN INSTALL TARPAULIN IN REVERSE SEQUENCE OF REMOVAL NOTE Before installing the tarpaulin adjust t...

Page 541: ...BODY Tarpaulin Spars TARPA U LI N 88CO 99 SPARS COMPONENTS r 1 7JS r CenterTOPCovernrp UlinBo I W I I I I I SideTopCo T P Ii R t I I _ _ __ _ J...

Page 542: ...BO l00 kg cm ft lb N ml Speei il dl0rQUe BODY FRP Top FRP TOP COMPONENTS FRPTop L _ ROOf Wuthernrip...

Page 543: ...rewdriver tip before use REMOVE QUARTER TRIM POCKET Remove the five bolts and the pocket 5 REMOVE FRPTOP Remove the four plugs on the roll bar and the lower rear pillar bolt caps on FRP TOP two each s...

Page 544: ...02 FRP TOP Room Limp SOFT TOP BODY Roll Bar ROLL BAR COMPONENTS Roll S r Rear Edge Proteetor Roll S r Roll Bar CtnlerGarnidl Roll S r fo o h 011 b ft rJ e room lamp inside t h nnectin9 the wire qoart...

Page 545: ...Front Seat Ikg m b N mJ BODY Seat 70 73 75 Series SEAT 73 75 Senes 70 COMPONENTS BO 103...

Page 546: ...80 104 BOOV Seat 70 73 75 Series COMPONENTS Cont d Rear Bench Seat 70 73 Series Seat Cushion Cover 0 6 Seat CustoionP d I ki cm fl Ib N m H SpKifiedlorQue...

Page 547: ...BODY Seat 70 73 75 Series BO l05 COMPONENTSICont d Rear Bench Seat 75 Series fiiiIl Specjfj 1O qu...

Page 548: ...BODY Seat 70 73 75 Series COMPONENTSICon d Rear Parallel Seat 170 Serift 17lSerift 75V rits...

Page 549: ...Rear Parallel Seat 175P S iHI i kQ m Ih lb N mH Spe ciliedlorque BODY Seat 70 73 75 Series COMPONENTS Con dl BO 07...

Page 550: ...Support Co 1 ____________ e e c rr Seat I Seal Cushion Pad I l r 1Iiilf eo_____ w O RltClin ng MltCh I 1 Bushini I J I ii Ier 1 1 J ll mJ2 32J I 11 r L J Se nnerSuPportT I 1 32512 321 J L ____________...

Page 551: ...SPtBlckP8d T r 1 IOClt Ab 7 81 1 1 _ BUlhing Se tBad Lock 01 Selt BIck Cover _ SeatSloPPllrHokf StIIBlckpad llngBand Se 1 Back Lock Slrik r h 7ft Jf k d Seat J C I Seal Panel Ornament hion Sell CUshi...

Page 552: ...Transvene Seat 7 380m_31I ISeflBlck ld Btlshinll q Selt Sick l ock n I s 0000 SNtCushionPtd SeatBaCkCove L3Iom 31 1 I I m OM I L 1 3101 7_ 311 1 LockS V I p hlOO i 1 r 1 115 13 11 1 Parallel Seat Ri...

Page 553: ...BODY Seat Belt 70 73 75 Series Front Seat Belt E LRtype NRtypel i 0 r i 44 1 32 013 32 013 kg m ft Ib NomJ Speeifiedlorque SEAT BELT 70 73 75 Series COMPONENTS BO 111...

Page 554: ...BO 112 Forward Seat Rear Seat Belt ELRtypt Parallel Seat N R type I kq m It Ib Nom 1 Sp Ciliedtorq e BODY Seat Belt 70 73 75 Series COMPONENTSICont d NRtyptl...

Page 555: ...Front Seat Belt ElRtype Rear Seat Belt ELR typel ko m Ih lb N m Speeiliedto qut BODY Seat Belt 60 6 2 Senesl SEAT B E lT 80 113 60 62 Series COMPONENTS...

Page 556: ...BO 114 Rear Seat Belt NRtype Transverse Seat Belt HR type I kSl cm ft lb N m i Spe eiliedtorque BODY Seat Belt 60 62 Series COMPONENTS Con d oo...

Page 557: ...i I Chick Vil _ t Fuel Sender Gau C dI I N 4 L FUII TlnkSuC110n TUbe CO Gask t r75S ul nkS tlV FUll Tl nk L I2tH I Protteto I r I 4OO12IHI I 1 _ 1 400129 H _ GI ket I It 6 DOlln Piug J 400I2931 11 l F...

Page 558: ...80 116 BODY Fuel Tank and line COMPONENTS Con d G k _ _ g 0 e le 1...

Page 559: ...r torque to all tightening parts INSPECT FUEL LI NES AND CONNECTIONS la Inspect the fuel lines and connections for cracks leakage or deformation b Inspect the fuel tank vapor vent system hoses and con...

Page 560: ...80 118 BODY Frame Dimensions FRAME DIMENSIONS FJ SJ70 S in I WlMel baN I 2 310 90 941...

Page 561: ...80DY Frame Dimensions 80 119 FJ BJ73S ie1 I Wheel base I 2 600 n02 36 I...

Page 562: ...BO 120 BODY Frame Dimensions FJ BJ HJ75VS riel I WhHlbuI I 2 980 117 32 I 1 ej r _ I I 1 1 u Cl...

Page 563: ...FJ BJ HJ75PS in I il BODY Frame Dimensions WhHtb H 1 2 980 117 32 BO 121 i __ _ _ I i z _ ill...

Page 564: ...BO 122 FJ 62 Series BJ HJ60Series BODY Frame Dimensions I WhH lbf se I 2 130 107 48 I ci i _ 0 I ggggg lll l i i r i Q i...

Page 565: ...WINCH Chain Wire Power Take off P T O Drive Shaft Winch ElECTRIC WINCH OnNehicle Inspection Chain Wire Winch _ _ Winch Motor with No 2 Magnet Switch Assembly WI P WI 2 WI 2 W 4 WI 12 WI 22 WI 39 WI 39...

Page 566: ...the No 1 bracket support together with the chain wire from the drum 2 REMOVE HOOK HOLOER FROM CHAIN WIRE 3 REMOVE WIRE LOCK a Shift the clutch lever to the lock position b Remove the two bolts and wi...

Page 567: ...ch speed varies according to the gear the transmission is in and the s peed of the engine How ever for your safety and for the long life of the winch it is advised that you operate it slowly In vehicl...

Page 568: ...WI 4 WINCH Mechanical Winch Power Take off P T O COMPONENTS 1 rtJ I Output Sh ft SpiceI 00 s r w 0 ikR m ft lb N m I Specified torque Output Gear NOl HeuMbleplrt P eo Q ilted rt...

Page 569: ...the oil 3 DISCONNECT P T D DRIVE SHAFT WI 5 lal Place matchmarks on the flange of P T O and yoke of drive shaft Ib Remove the four bolts and nuts and discOl1nect the drive shaft 4 DISCONNECT P T D SHI...

Page 570: ...t link lever 2 REMOVE INPUT GEAR AND SHAFT a Remove the lock plate b Using a screwdriver remove the input gear shaft and remove the input gear cl Remove the O ring from the shah 3 REMOVe IDLER SHAFT a...

Page 571: ...d k ust boot and then remove the shift e Remove the dust seal and O ring 5 REMOVE UNIVERSAL JOINT FLANGE a RemoVi the cotter pin b Using SST to hold the flange remove the nut SST 09330 00021 e Remove...

Page 572: ...snap ring b Using a press and l1 mm socket wrench remove the bearing INSPECTION OF P T O COMPONENTS INSPECT INPUT GEAR BUSHING Using calipers measure the bushi ng bore Max imum bore 20 mm 0 791 in If...

Page 573: ...cers c Using a press press the output shaft into the front bearing NOTE Install in proper direction only 3 INSTALL BEARING RETAINER 4 Install a new gasket and bearing retainer with four bolts Torque t...

Page 574: ...s to the shafr b Install the shaft into the case with the lock plate and bolt Torque the bolt NOTE Be careful not to damage the D ring Torque 130 kg cm 19 ft tb 13 N m 9 INSTALL INPUT GEAR AND SHAFT a...

Page 575: ...lts Torque tne bolts Torque A Front side 170 kg cm 12 ft Ib 17 N m B Other side 195 kg cm 14 ft Ib 19 N m 2 CONNECT P T O SHI FT ROD Torque 200 k9 Cm 14 ft Ib 20 N m 3 CONNECT P T O DR IVE SHAFT Align...

Page 576: ...WI 12 WINCH Mechanical Winch Drive S h aft COMPONENTS Ikg em tt Ib N m Non_reusablep r ilitdtorQUe...

Page 577: ...ace the matchmarks on the drive shaft and universal jointor P T C companion flange 4 REMOVE SAFETY LOCK PIN Remove the two cotter pins and safety lock pin 5 DISCONNECT DRIVE SHAFT a Remove the pillow...

Page 578: ...ce the shaft 2 INSPECT SPIDER BEARINGS a Inspect the spider bearings for wear or damage b Check the spider bearing a xial play Bearing all ial play 0 15 mm 0 0059 in If necessary replac1 the spider be...

Page 579: ...remove the four snap rings from the grooves W 3 REMOV E SPIDER BEARINGS fa Using 12 mm and 21 mm socket wrenches and a vise press out the bearing b Clamp the outer bearing race in a vise and tap off...

Page 580: ...cket wrench and vise press out the bearing on the opposite side h Remove the bearing on the opposite side in the same procedure as shown in step f 4 INSTAll SPIDER BEARINGS a Apply molybdenum disulphi...

Page 581: ...ill allow 0 0 15 mm 0 0 0059 in of axial play NOTE Do not reuse the snap rings Snap ring thicknHHS Thicknen mm in 1 20 0 0472 No 1 25 0 0492 1 30 0 0512 b Using a plastic hammer or copper hammer tap t...

Page 582: ...he bolt lock plate and plate washer c Using a brass bar and hammer remove the sleeve yoke d Remove the woodruff key 3 REMOVE PILLOW BLOCK Using a brass bar and hammer drive out the pillow block 4 REMO...

Page 583: ...ng Ibl preu and 24 mm socket wrench press out the 6 INSTALL NEW BEARING 1 1 Using a press and SST install a new bearing SST 09603 35013 Ibl Install the snap ring 7 IN TALL NO 2 DUST SEAL AND NO 2 RETA...

Page 584: ...mer drtve In the No 1 NOTE Be careful not to dam e the retainer 10 INSTALL SLEEVE YOKE a Install the woodruff key bl a brass bar and ham mer drive in the sleeve cl II the washer lock plate and bolt To...

Page 585: ...and torque the bolts and nuts Torque 200 kg em 14 ft Ib 20 N m 2 INSTALL SAFETY LOCK PIN a Align the safety lock pin hole of the universal joint and worm b Install the safety lock pin and two cotter p...

Page 586: ...WI 22 70 73 75 Series 60 62 Series Ikg m It lb N ml l 5pe ifiedtorQue WINCH Mechanical Winch W inch COMPONENTS...

Page 587: ...NECT DRIVE SHAFT See page WI 13 4 70 73 75 Series REMOVE WINCH UNDERCOVER Remove the four bolts and winch undercover 5 70 73 75 Series REMOVE FRONT BUMPER Remove the 16 bolts front bumper and license...

Page 588: ...24 WINCH Mechanical Winch 6 2 60 62 Series REMOVE WINCH ASSEMBLY a Remove the six winch roller bracket bolts b Remove the four winch rear base member bolts c Remove the winch assembly from the vehicl...

Page 589: ...70 73 75 Series 60 62 Series WINCH Mechanical Winch COMPONENTS Rur S se Mtmber j Winch Roller Br I 1 WI 25...

Page 590: ...PI i a k p _ i j End Bracktt I Spring I K SllfCer Clutch levtrPin Key Sp Lowerltv r 1 teh J Wirl ock OiISe 1 GtarCase Ga ket BI Ilhing ___ J I la I No 2 Worm No 1 BeaM AdlUllln9 ShIm No 1 AdJU t a m...

Page 591: ...8 E BRACKET winch roller bracket 1 2 M62 Seriesl DVE WINCH R a Remove the OLLER BRACKET b Remove the r b b ket support bolts otsand Winch roller bracket 2 7073 REf lOV 5 r BAS Remove the four bolts a...

Page 592: ...ever pin and remove the lower lever spring and clutch lever c Using a file file off the staked part of the knob pin d Using a pin punch and hammer tap out the knob pin and remove the lever knob lock p...

Page 593: ...iner and remove the No 1 bearing retainer and No l lldjustingshim c Remove the worm Id Remove the four bolts e Using a plastic hammer lightly tap the bearing re tainer and remove the No 2 bearing reta...

Page 594: ...2 in 2 IF NECeSSARY REPLACE END COVER BRACKET BUSHING al Using a press and 55T press out the bushing SST 09307 30010 bl Using a press and SST press in the new bushing SST 09307 30010 3 INSPECT DRUM BU...

Page 595: ...bore Maximum bore 38 3 mm 1 508 in WI 31 6 IF NECESSARY REPLACE GEAR CASE BUSHING a Using SST remove the bushing SST 09612 65013 b Using a press and SST press in a new bushing SST 09307 30010 NOTE Al...

Page 596: ...30010 NOTE Align the groove of gear case cover and the oil hole of bushing 9 INSPECT WORM BE ARING Inspect for wear or damage 10 IF NECESSARY REPLACE WORM BEARING a Using SST remove the inner bearing...

Page 597: ...etainer e g a press and SST press in the new bearing outer SST 09608 35013 11 REPLACE GEAR CASE OIL SEAL a Using a screwdriver pry out the oil seal b Using SST install a new oil seal SST 09608 35013 1...

Page 598: ...ring retainer with four bolts Torque the bolts Torque 250 kg cm 18 ft lb 25 N m b Put the worm into the gear case c Install the two No 1 adjusting shim and NO l bearing retainer with four bolts Torque...

Page 599: ...and bearing re tainers as shown in step 2 on page WI 33 5 INSTA LL GEAR CASE COVER 6 a Apply seal packing yellow 08826 00012 or such to a new gasket and two lower side bolts b Install a new gasket and...

Page 600: ...in f Using a file file off any tips or jags on the staked part of tne pin 9 INSTALL BRAKE PLATE Install the brake plate with two screws 10 INSTAll END BRACKET WITH CLUTCH LEVER Install the spacer and...

Page 601: ...n 12 2 60 62 Seril 1 INSTALL WINCH ROLLER BRACKET a Install the winch roller bracket with bolts Torque the bolts Torque 250 kg cm 18 ft lb 25 N m b Install the two bracket support bolts Torque the bol...

Page 602: ...clutch lever and lock plate with the lock plate set bolts as shown in step 12 1 b on page WI 37 Standard clearance 0 5 1 5 mm 0 020 0 059 in 2 70 73 75 Series INSTALL FRONT BUMPER Install the front b...

Page 603: ...nector of the No 1 magnet switch Using a voltmeter check the battery voltage between the terminals of the wire harness side connector Using an ohmmeter check the continuity between the terminals of th...

Page 604: ...switch A with the winch remote control switch on the IN position Terminal c 8attery voltage Terminal a and b Continuity cl Using an ohmmeter and voltmeter check operation of magnet swi tch B with the...

Page 605: ...the thermo switch connector is disconnected and turn the ignition switch ON d Install the magnet switch cover 70 73 75 Series See steps 15 16 17 and 19 on pageWI 40 2 CHECK WINCH REMOTE CONTROL SWITC...

Page 606: ...move the wire lock and lock plate from the chain wire INSPECTION OF CHAIN WIRE See page WI 2 INSTALLATION OF CHAIN WIRE 1 INSTAll WIRE LOCK a Insert the chain wire into the wire installation hole of t...

Page 607: ...wire remaining out 3 INSTALL HOO K HOLDER a Set the wire hook in the hook holder and temporarily tighten the wing nut b Wind the chain wire until the hook holder enters the bumper NOTE Due to inertia...

Page 608: ...WI 44 70 73 75 Series 60 62 Series Ttrmmal B W nehAssembly I kg cm It lb N m 1 Spec f edtorQue WINCH Electric Winch Winch COMPONENTS Clamp...

Page 609: ...INCH FLUID 3 70 73 75 Series REMOVE WINCH UNDERCOVER Remove the four bolts and winch undercover 4 DISCONNECT WI RE HARNESS a Disconnect connector for No 1 magnet switch b Disconnect terminal B cl Disc...

Page 610: ...h roller bracket bolts b Remove the two winch c Remove the winch rear base member bolts assembly from the vehicle 7 2 60 62 Series M VE WINCH ASSEMBLY emove the six winch roller bracket bolts b Remove...

Page 611: ...60 62 Series WINCH Electric Winch COMPONENTS rm HookH W Ro k t No 1 Bracket Support 00 i r Winch RotlerBracket _ S f ed torque WI 47...

Page 612: ...rake S laft Spacer One WlyOulch LeverKnob C B klShlflDriven nr r ft III B tR ring i l Lock Pin e aringR PRing I T Clutch Outer Rice Shift L vtr No l Count rGnr o Ring Counter Sh fl Gear ConerPin 1 Shi...

Page 613: ...e four bolu two nuts and winch roller bracket 3 REMOVE REAR BASE MEMBER 60 62 Series Remove the two bolts member spacers and rear base member 70 73 75 Series Remove the two bolts and rear base member...

Page 614: ...CLUTCH SUB ASSEMBLY a Using a pin punch and hammer drive out the slotted spring pin bl Using a plastic hammer lightly tap the gear case cover and remove the brake shaft cl Remove the clutch subassemb...

Page 615: ...ive out the counter shah from the gear case b Remove the No 1 counter gear and counter shaft gear c Remove the O ring from the counter shaft 12 REMOVe SHIFT LEVER SUPPORT Remove the three bolts and su...

Page 616: ...assembly 3 INSPECT DRUM HOUSING BUSHING Using calipers measure the bushing bore Maximum bore 86 0 mm 3 386 in If the btnhing bore is greater than mallimum replace the drum housing assembly 4 INSPECT C...

Page 617: ...AND NO 2 DRUM SPACERS Usir l lcalipers measure the spacer thick ness Minimum t hickness 1 2 mm 0 047 in l 9 INSPECT ONE WAY CLUTCH OPERATION a Innall the brake shaft into the one way clutch b Hold th...

Page 618: ...SSARY REPLACE OIL SEAL a Using a screwdriver pry out the oil seal b Using SST drive in the new oil seal SST 096 35013 13 INSPECT GEAR CASE OIL SEAL Inspect for wear or damage 14 IF NECESSARY REPLACE O...

Page 619: ...ATIC TRANS MISSION FlUID ATF TO PARTS SHOWN BelOW NOTE Before assembling soak new inner discs in auto matic transmission f luid for two hours_ 2 INSTALL CLUTCH HUB THREE E RINGS AND O RING TO SHIFT SH...

Page 620: ...t Gear a Place a new gasket on the gear case Drum b Install the clutch hub with shift shaft alld retainer n o h 6 INSTALL SHIFT LEVER SUPPORT Torque 195 kg cm 14 ft Ib 19 N m 7 INSTAll COUNTER SHAFT G...

Page 621: ...ner disc outer disc inner disc outer disc and spilCtlr NOTE Align the notches and tabs b Install the two clutch outer discs and two inner discs on the brake shaft dri en gear nstall in order dri en ge...

Page 622: ...bolts together with the ground cable as shown Torque the bolts Torque 195 kg cm 14 ft lb 19 N m NOT E Gradually tighten each bolt in several passes in the sequence shown 12 INSTAll WINCH INPUT SHAFT f...

Page 623: ...he winch roller bracket with four bolts and two nuts Torque the bolts Torque 700 kg cm 51 ft Ib 69 N m 17 INSTA LL WINCH MOTOR al Align the grooves of the motor and input shaft and assemble through th...

Page 624: ...ll the front bumper and license plate bracket with the 16 bolts Torque See page WI 42 d Check the clearance between the rear base member and member support Standard clearance Zero If necessary adjust...

Page 625: ...N s e e Ch andec i clearance between the nd d0 Z b m mb necessary select the f Torque the rear b member spacer number Torque 380 k Me member to winch g cm 27 ft lb 37 N m Its INSTALL TWO WIRE HARNESS...

Page 626: ...WI 62 LenlNn mm 10 20in WINCH Electric Winch 5 FILL WINCH WITH AUTOMATIC TRANSMISSION FLUID Oil grade ATF Type F capacity 2 0 titen 2 1 US qu 1 8 Imp qts 6 INSTALL CHAIN WIRE 5ee page WI 41...

Page 627: ...BrU 1 I J spriflg b Commutator j 7 j In 7 6I...

Page 628: ...ve the three bo lts and then remove the winch motor with No 2 magnet switch assembly DISASSEMBLY OF NO 2 MAGNET SWITCH ASSEMBLY See page WI 63 1 REMOVE MAGNET SWITCH COVER a Remove the connector cover...

Page 629: ...63 1 REMOVe COMMUTATOR COVER a Remove the two screws and cover b Remove the a ring 2 REMOVE BRUSHES a Using a screwdriver remove the positive brush from the brush holder b Remove the two screws and p...

Page 630: ...s no continuity between any segment replace the armature Commutator 1 INSPECT COMMUTATOR FOR DIRTY OR BURNT SURFACE If the surface is dirty or burnt clean with sandpaper NO 4 0 or a lathe 2 INSPECT CO...

Page 631: ...ield coil 2 INSPECT TH AT FIELD COIL IS NOT GROUNDED Using an ohmmeter check for continuity between the field coil brush lead and field frame If there is continuity repair or replace the yoke sub asse...

Page 632: ...BEARING Turn each bearing by hand while applying inward force If the bearing sticks or resists replace it 2 IF NECESSARY REPLACE BEAR ING a Using a 10 mm socket wrench and SST remove the bearing from...

Page 633: ...lead wire terminal and magnet switch body If there is no continuity replace the magnet switch c Using an ohmmeter check for continuity between the main terminals with the plunger pushed in_ d Using a...

Page 634: ...er than the standard replace the thrust washer Thrust washer standard thickness 1 6 mm 0 063 h c Remove the commutator end frame and thrust washer 3 INSTALL O RING THRUST WASHER AND COM MUTATOR END FR...

Page 635: ...se hole b Install the base on the winch motor with two bolts 2 INSTA LL BRACKET AND STOPPER TO NO 2 MAGNET SWITCH a Install the bracket rld stopper to the magnet switches with screws b Connect the bas...

Page 636: ...er INSTALLATION OF WINCH MOTOR WITH NO 2 MAGNET SWITCH ASSEMBLY INSTALL WINCH MOTOR a Align the grooves of the motor and input shah and assemble through the a ring b Install and torque the three bolts...

Page 637: ...n System _ __ _ __ Performance Test SYSTEM COMPONENTS _ __ _ _ COMPRESSOR CONDENSER RECEIVER FRONT COOLING UNIT Evaporator Thermistor EXPANSION VALVE Ale SWITCH 60 Series TEMP CONTROL RESISTOR 70 Seri...

Page 638: ...torque Torque specification for O ring fittings Fining silt I Torque 0 31 in Tube I 135kg m 110It lb 13N m 0 50 in Tube 225kg cm 1161t lb 22N m 0 62 in Tube 325kg m 124 It lb 32N m No cooling or TROU...

Page 639: ...Thermistor faulty O1eckthermistor AC 31 AfCamplifierfaulty Check amplifier AC 35 Condenser clogged AC 28 Drive belt slipping Check or replace drive belt AC 27 Compressor faulty Checkeompressor AC 24 I...

Page 640: ...er set at cool NOTE The gauge indications may vary slightly due to ambient temperature conditions_ 1 NORMALLY FUNCTIONING RE FRIGERATION SYSTEM Gauge reading Low pressure side 1 5 2 0 kg cml 21 28 psi...

Page 641: ...AIR CONDITIONING SYSTEM Troubleshooting 3 INSUFFICIENT REFRIGERANT Condition Insufficient cooling Probable eause Diagnosis Remedy Gas leakage at some place Insufficient refrigerant in 1 Check with le...

Page 642: ...ser cooling nwHiei nl Diagnosis EXa S iverefrigtrantin eyele_refripe Tlntover Condenser cooling insufficient_condenser fin elogogedor lan motorlaulty 1 Clean condenser 2 ChKklanmotor ope tion 13 1f 1...

Page 643: ...entvlC1Jum purgi 9of nlW frilltr nt 21 Cheekeompreuoroil to 11 ifdiny or in wffiei nt 3 Vacuumpurgellnd c h rgenewrefrigeranl 8 REFR IGERANT DOES NOT CI RCULATE Condition Does not cool Cools from time...

Page 644: ...eslcie PrenuretoolOwtthigh prenureside Manifold gauge set Ohmmeter 9 INSUFFICIENT COMPRESSION Condition Doet not cool Probable use r Diagnolis Compreniondefective I V IVIIUkingOrbroken s dingPlrtl i p...

Page 645: ...AIR CONDITIONING SYSTEM Air Conditioning System Circuit AC 9 AIR CONDITIONING SYSTEM CIRCUIT FJ 60 Series Single Ale...

Page 646: ...AC 10 AIR CONDITIONING SYSTEM Air Conditioning System Circuit FJ 70 Series AIR CONDITIONING SYSTEM CIRCUIT Cont d Ill e e 01 Ii l o...

Page 647: ...AIR CONDITIONING SYSTEM Air Conditioning System Circuit AC AIR CONDITIONING SYSTEM CIRCUIT Cant d BJ HJ 60 Series Single A C...

Page 648: ...AC 12 AIR CONDITIONING SYSTEM Air Conditioning System Circuit AIR CONDITIONING SYSTEM CIRCUIT Cont d BJ HJ 70 Series i d ui dt i i e I i I oiJ llil j f Ill e e r hl __ 0 I o...

Page 649: ...AIR CONDITIONING SYSTEM Air Conditioning System Circuit AC 13 AIR CONDITIONING SYSTEM CIRCUIT Cont d I ij 0 II li m I 0 11 1111 0 0 mJ 0 iiI I 0 lIE 0 0 m em 0 13 0 0 m 0 m 1E i 0 ail...

Page 650: ...14 AIR CONDITIONING SYSTEM Air Conditioning System Circuit AIR CONDITIONING SYSTEM CIRCUIT Cant d HJ 60 Series Dual A C i il in i I Im 1 I 0 I l le If 0 1 IiI 1 I 1 0 m Illll I 0 0 0 m 0 I G 0 0 1 0 m...

Page 651: ...33 73F Drive belt tension New belt 125 25 Ib Used bel t sa 20 Ib NOTE New belt refer5 to a new belt which has never been Used belt refers to a belt which has been used on a running engine for 5 minut...

Page 652: ...MINUTES 3 CHECK AMOUNT OF REFRIGERANT Observe the sight glass on the receiver I Amount olrlfrige lnt In UHieient None too much or UHicient Empty or nearly Impty Proper ortoomJch Too much Proper Remed...

Page 653: ...system has been ex posed to the atmosphere it must be evacuated Aher installation of a component the system should be eviKuated for approximately 15 minutes A com ponent in service that has been open...

Page 654: ...EAKS NOTE After evacuating the system check for leaks a Install the refrigerant can tap valve as described in step 2 Ib Open the high pressure valve to charge the system with refrigerantvapor c When t...

Page 655: ...vapor state When the refrigerant container is placed rightside up re frigerantwill enter the system as a vapor Put the refrigerant container in a pan of warm water maximum temperatu re 40 C 140 F to k...

Page 656: ...nd containers of A 12 allow the remaining refrigerant to escape by slowly removing the charge line c Turn ofi the engine d Using a shop rag quickly remove both hoses from the compressorselVice valves...

Page 657: ...the psychrometerat the air inlet After measuring the temperatures of the Wt and dry bulb thermometers at the evaporator air inlet relative humidity can be obtained Example Supposing dry and wet bulb...

Page 658: ...AC 22 System Cem 70 SYSTEM COMPP NENTS AIR CONDITIONING SYSTEM...

Page 659: ...M System Components d CONDITIONING SVSTE ONENTS Cont AIR COMP SYSTEM AC 23 Liquid Condenw Line Tube Front Cooling Unit GrOmmel LiQuid Line M Aear Cooling Unit...

Page 660: ...ESSOR a High pressure gauge reading is not low and low pres sure gauge reading is not higher than normal b Metallic sound c Leakage from shaft seal If defects are found repair the com pre5sor 4 CHECK...

Page 661: ...3F Engine Series Compressor 36 Engine Series AIR CONDITIONING SYSTEM Compressor AC 25 ComprnsorMO Inli ll Br kel...

Page 662: ...LE FROM BATTERY 3 DISCONNECT CLUTCH LEAD WIRE FROM WIRING HARNESS 4 DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM See page AC 16 5 DISCONNECT TWO FLEXIBLE HOSES FROM COMPRESSOR SERVICE VALVES cap th...

Page 663: ...1 9 25 0 75 0 98 Canada Using a belt tension gauge check the drive belt tension Belt tension gauge Nippondenso BTG 20 95506 00020 or Borroughs No BT 33 73F Drive belt tension New belt 125 25 Ib Used...

Page 664: ...NECT TWO LIQUID LINE TUBES FROM RECEIVER NOTE Cap the open fittings immediately to keep mois ture out of the system S REMOVE RECEIVER 70 Series only 7 REMOVE CONDENSER Remove the fou r bolts INSTALLAT...

Page 665: ...DER NOTE Do not remove the caps until ready for con ne tion 2 CONNECT TWO LIQUID TUBES TO RECEIVER Torque 135 kg cm 10 ft Ib 13 N m 3 I F RECEIVER WAS REPLACED ADD COMPRESSOR OIL TO COMPRESSOR Add 20...

Page 666: ...immediately to keep mois ture out of the system 5 REMOVE GROMMETS FROM INLET AND OUTlET FITTINGS 6 REMOVE FOLLOWING COMPONENTS a Glovebox b Duct c Instrument panel brace 7 0 series only 7 DISCONNECT...

Page 667: ...aporator 2 CHECK FITTINGS FOR CRACKS OR SCRATCHES Repair as necessary Thermistor INSPECTION OF THERMISTOR CHECK THERMISTOR OPERAT ION la Place the thermistor in cold water While varying the temperatur...

Page 668: ...INSTALL COOLING UNIT Install the cooling unit with the two nuts four screW5 and one bolt CAUTION Be careful not to pinch the wire harness while installing the cooling unit 3 INSTALL BRACE 70 Series on...

Page 669: ...g cml 185 213 psi 1 275 1 471 kPa 4 CHECK EXPANSION VALVE If t he expansion valve is faulty the low pressure reading will drop to 0 kg cml 0 psi 0 kPal otherwise it is OK NOTE When the low pressure dr...

Page 670: ...he resistor 5 CONNECT TEMP CONTROL RESISTOR CONNECTOR 6 INSTALL CENTER CLUSTER PANEL 7 CONNECT NEGATIVE CABLE TO BATTERY REFRIGERANT LINES ON VEHICLE INSPECTION 1 INSPECT HOSES AND TUBES FOR LEAKAGE U...

Page 671: ...e the glove box Ex Dual AlCI b Disconnect the lead wires of the AlC harness c Using an ohmmeter check the continuity between the two terminals of the pressure switch The ohmmeter must indicate zero oh...

Page 672: ...Series Dual A C REMOVAL OF COOLING UNIT 1 REMOVE SUCTION HOSE AND LIQUID HOSE REMOVE COVER Remove seven screws 3 REMOVE REAR COOLING UNIT FROM CAR BODY Remove three bolts DISASSEMBLY OF REAR COOLING U...

Page 673: ...tting of the evaporator d Remove the pressure switch if necessary 5 CHECK THERMISTOR AND EXPANSION VALVE IN SAME ORDER AS FRONT COOLING UNIT AND EXPANSION VALVE INSTALLATION OF REAR COOLING UNIT INSTA...

Page 674: ...CLUTCH RELAY CONTINUITY a Check that there is continuity between terminals 1 and 3 b Check that there is no continUity between terminals 2and4 If continuity is not as specified replace the relay 5 IN...

Page 675: ...relay 9 HJ 60 Series AfT Australia only INSPECT AlC CUT RELAY TEMPERATURE NOTE Inspect the AlC cut relay temperature the same way as the clutch relay 10 INSPECT REAR COOLER RELAY CONTINUITY a Check th...

Page 676: ...air comes out of pipe c Disconnect the battery d Blow into pipe and check that air comes out of filter not out of pipe If a problem is found replace the VSV 3 CHECK FOR SHORT CIRCUIT Using an ohmmeter...

Page 677: ...CLUTCH MANUAL TRANSMISSION AUTOMATIC TRANSMISSION TRANSFER PROPELLER SHAFT FRONT AXLE AND SUSPENSION REAR AXLE AND SUSPENSION BRAKE SYSTEM STEERING BODY WINCH LUBRICANT P A 2 A 3 A 5 A 7 A A 10 A 14...

Page 678: ...glinger wnr FlywhHlruflOO Torque Specifications Part tightened M nercylind r Body Clutch tine union Clevisloeknul M SI cylirlder Clutch boon Clutchbooner Bracket BrlCket Body ReluHcylinder ttbolt Rlle...

Page 679: ...orkl0hubsleeve clearaoce 5ynchronizer ring to gear ciearance 3rd 4thandSth Limit 5ynchronizer ring to g ear distance 111 gear Limit 2nd gear Limit InpUlshafl snap ringlhickness 43 984 mm 47 91 mm 50 1...

Page 680: ...r 5th locking balllnd spring Sv ight Crew plug for reverse restrict pin shilt ndlllectlevef shalt Shiftltverhousing It shilt Clutch houling It Transminion use CIStcover x Transmission ease Aev rselhih...

Page 681: ...m Less than 0 7 seconds Lenthanl 2seconds 14 20psi 34 40psi 235 275 kPa 85 94psi 588 647 kPa 53 61 psi 363 422 kPa 54 78psi 158 193 psi 1 089 1 334 kPa 199 242 psi 1 373 1 667 kPa Between boot end fac...

Page 682: ...8 TorquecQ lverter x Drive plate 290 21 28 Valve body 100 Oil pan 61in lb Oil pan drain plug 280 Cooler pipe union nut 25 Testing plug 6Sin lb 7 4 Neutral stan switeh Ibolt 130 13 Neutral start switch...

Page 683: ...M ATM STD Limit MTM ATM Limit 17 STD New bearing Reusedbnring 40 009 mm 40 009 mm 0 03 mm 0 Q19 0 068mm 0 081 mm 0 10 0 25mm 0 15 0 30mm 0 25 mm 0 30 mm 1 0mm 2 30 2 35 mm 2 60 2 6Smm 0 27S 0 625mm 0...

Page 684: ...r c w x P W rt k Qff cover With liqu d seller Other Transf r indie tor switch Sl ftdometerdrivengearlockplltebolt Di phntgmcylinde body x Transferfrontclie Oi phr lmcylindercover x Oiaphragm cylindtr...

Page 685: ...ss Torque Specifications Propeller shift le Differenti 1 Propellershl f l le Tr nsfer SERVICE SPECIFICATIONS _ Propeller Shaft Limit 0 8 mm Less th n 0 05 mm CoI 2 00 mm B 2 03 mm 811 2 06 mm Uneolore...

Page 686: ...16 3 6 51 353 2 6 37 255 3 75 53 368 wl Third seal 10RI5 6PRLT 2 1 30 206 3 2 146 314 2 36 245 3 50 343 7 00 16 6PRLT 1 8 126 1771 2 4 34 235 2 2 31 216 28 140 2751 8J70l R V 7 50 1S 6PRlT 26 177 2 0...

Page 687: ...ion pre sure kiVcm1 psi kP 0 1 NormllrQtd Rough road S ndyroad nllion Model TiresiZl Abov lI0km h Abo e SOkm h Abov 15km h 68mph 31 mph 9mph Rnr Fronl Front Re r Others 2 1 2 8 1 75 2 8 I 1 05 2 45 se...

Page 688: ...TD 112mm 0 04 0 08 in 1 lmm D 04 0 04 in I I 2mm 0 04 0 08 in 1 lmm 0 04 t 0 04 in 1 4 2mm 0 16 t 0 08 in 1 4 lmm 0 16 t 0 04 in 32 00 30 00 21 00 Leu Ih n 3 0 mm m 0 118in 3 3ftl 0 047 in Discwhll ll...

Page 689: ...arm It Housing 96 BelringClp Housing 97 71 96 Knucklespindll Housing 475 34 Front ule hub bearing lock nUl 800 58 78 DilCbrlkee liper Steeringknueklt 900 as SpringU bolt Al llhousing 1 250 123 Rllrspr...

Page 690: ...bearing 4 6 kg cm 3 5 5 2 irl lb 0 4 0 6 N m Drive pi ion to ring gear backlash Pinion gear to side gear backlash Rirlg gear runoot Limit Comp ionfla gerunout Rirlg gear installation temperature Side...

Page 691: ...ential earrier Differentialearrier x AIllehousing Differenti l LHeatt It RH case LSD SpringU bolt It AIlllhouling Front pring braeket It Hanger pin Rearspring shacklex l ufspring Rear hock bsorber x A...

Page 692: ...brake D iKI Rear brake Parkiogbrake Except 75 series Booster push rod 10 piston clearance Blade Rotation play Shoeliningthid ness Drum inside diameter Padthid ness Discthid ness DiserufIOut Drum insid...

Page 693: ...linder x Bac k ingplate Front brake tube clamp Front disc x Frontaxle hub Front disc brake cylinder x Steering knuckle Orum brake bading plate x Rear axle housing Parkingbrake bellcrankbrid et x Badin...

Page 694: ...087 0 7094 io 0 197 0 203 mm 0 495 0 505 mm 0 795 0 805 mm 1 395 1 405mm 1 795 1 805 mm 0 0078 0 0080io 0 0195 0 0199io 0 0313 0 0317 in 0 0549 0 0553 in 0 0707 0 0711 in 0 05 mm 0 D020 in or IHI 1 95...

Page 695: ...988 1 4 990 mm 0 5901 0 5902 in 50mm 1 97in 1 85 in 2 8kg cm 2 4 in lb 0 3 N mj or Il s 0 03 mm Maximum 0 06 mm 0 0012 in 0 0024 in 1 97 in 1 85in 0 0610 In 0 0551 in Flow contrOl valve spring length...

Page 696: ...ector shaft end cover x Gear housing 1 150 83 113 Sector shaft adjusting screw lock nut 50 33 Gear housing x Frame 1 240 90 Inlermediateshaft x Worm shaft 360 26 35 Joint protector bolt 65 56in b A Pi...

Page 697: ...TIONS Steering A 21 Torque Specifications Cont d StH ringlinkage Pan tiotltentd kg m ft Ib Cont dl R I V rod clamp bolt 450 33 44 R I yrod t Pitmantrm 25 67 91 St ringdamper x R l yrod 750 Steeringdlm...

Page 698: ...32 Sell outer support x Seatbllck w oSeillreciining 325 24 32 Se 1 OUler support x SealctJshion w oSeiureclining 325 32 Sell inner support x SeJlcushion 325 24 32 Seattr ck x Seal cushion 200 20 Se t...

Page 699: ...lock Sellcushion 380 Seat nnersllpport 11 Sutback 380 27 Seal lnnerSllpport 11 SeatCU hion 380 27 Rear parlll l SUI 70 73 75VserieJI Seat frame 11 Body 160 15 75PHritsl Seatf me 11 Body 19 60 62 serie...

Page 700: ...38 3 mm 1 508 in STD 38 000 38 025 mm 1 4961 1 4970 in 38 3 mm Clutch lever to lock plate cle8r nce 0 5 1 5mm 1 508 in 0 020 0 059 in Torque Specifications Pantigntened Lock plate drum P T O Bearing...

Page 701: ...8661 0 8674il l 22 3 mm 0 878 in STD 14 000 14 027 mm 0 5512 0 5522 in limit 14 2mm 0 559 in STD 75 000 75 046 mm 2 9528 2 9546 in 75 5 mm 2 972 in STD 85 2 85 3 mm 3 354 3 358 in 86 0 mm 3 386 in ST...

Page 702: ...ity USq1s Imp Qu 3 5 3 7 3 1 9 5 2 3 15 0 15 9 13 2 5 0 5 3 2 2 2 3 1 9 2 1 2 2 lB 3 0 3 2 2 6 2 5 2 2 630 21 301 SIOcc 27 401 800 27 101 390 13 201 0 5 0 5 0 0 3 0 3 0 3 I 2 0 2 1 1 8 CllSSification...

Page 703: ...B STANDARD BOLT TORQUE SPECIFICATIONS p STANDARD BOLT TORQUE SPECIFICATIONS 8 2...

Page 704: ...IFICATIONS HOW TO DETERMINE BOLT STRENGTH Mark Huagon Boil 4 _ I I Srudbolt hndNO 5 1 Nomlfk 4 6 I f 7 7T Nom k Hexagon 11 91 boil r w wuhe hexagonbol Htxagol l protruding 5T Hex gon flange boil w wuh...

Page 705: ...a Djlmeter Pitd mm kg em kg cm 48 in lb 60 52 in lb 1 2 30 1 25 260 2 290 28 1 25 0 5 39 53 50 15 50 83 1 5 1 150 83 1 25 1 25 3JO 32 1 25 59 1 5 930 61 1 5 1 400 131 80 78 inAb 1 25 19 21 21 6T 1 25...

Page 706: ...c SST AND SSM Pog SST SPECIAL SERVICE TOOLS C 2 SSM SPECI AL SERVICE MATERIALS C 7...

Page 707: ...21010 IG 111__1 H I 09216 oo020 IBelt T ionGaugll I 09211i 0003O T_ C bI 1 I I I I OUli OQ101 1 0 I 1 1 s TooIS 1 I IcrtJ 1_ a 0931l1 20010 I I I C IC GloOde Tooa I 09301 55a22 ICIU ChGuodITOOI 1 1 I...

Page 708: ...9313 10021 t II PIU9 S 09315 00D21 8elriro lRemover Repllc Q ee ctJ l 09311 60010 Tronl fe a ng R pl e 1 0931HOO20 P He s ngR mO f 0932i 20011 u f ing 093J8 OO021 CompanionFtong olclingTool m 09332 25...

Page 709: ...9517 36010 t I I I O9SlHOO11 I e 09550 10012 BAepl or Sell I i 09554 30011 R I 09556 30010 I I I 119602 1 1010 I I I I pill 09I0s 60016 c I I I I I 1 0960 60021I SI Uto Be n llCup mo i I I I I 0 W_ I...

Page 710: ...Illustration Part No 01111 12012 ITi RocIEnd P_1 12 22011 a 9 _12 _12 OIIIz t5CIU P t _ w IHOQ10 Adiullin9 _W I 0II11 JDD20 lIuring ting Sc ww_ W _ 09111 I0Il10 AdjuItw g L NuI W _ b IHDDIO nno e e lD...

Page 711: ...it or or g u Part Name Illustration Part No 1l I 0I1OWOII10 S Re DI7OI ZlDI1 l SPV s tI 711 ODD10 OD l17 J l7Dll 737 011010 Dl15I lICIll 2 h t t OnU DDD12 a I I I If7Q l11D2D IOiI S Rt plR 1 I I I Dl7...

Page 712: ...00070 Dupontpa le No 4817 WealherstripPrimer BO Adh ion Promolor Union Carbide Corporation WealherstripAdhesive 366ET Cemedine IMPON SEALANT E LDU PONT DE NEMDURSI Butyl TapeSel 0B850 0065 Su lPacking...

Page 713: ...ELECTRICAL WIRING DIAGRAMS D...

Page 714: ...Radio and Tape Player Charging Rear Air Conditioner 1 g 2 5 Cigarette li flter Rear Fog Lighu 5 5 Rear Window Oefogger Combination Meter 2 7 3 1 6 4 Rear Wiper and Wa her 4 Seat Belt Warning 3 Startin...

Page 715: ...LAND CRUISER Heavy Duty ELECTRICAL WIRING DIAGRAM 1985 Produ tion Vehicles Page 1 to Page 8 I I I j C T l 8 r l I t 1...

Page 716: ...2 LAND CRUI SER Heavy Duty Cont d l r I i I I r I I I r _ if I1 1 _ _ I r IL I e z _lg L r l H n I I U j...

Page 717: ...LAND CRUISER H vy utyJ Cont d i I I1 j 1 f I1 i I j _ f I r 1 h 1 i m j L i 1 I f1 l 1 1 i li Jli e I i IGJ Ir 1 f I l I I I 1 1...

Page 718: ...4 LAND CRUISER Heavy Duty di m _ 0 r r l 1 l I __ I Il L Lg lG l l _ _ I I S _ I 1...

Page 719: ...LAND CRUISER IHeavy DutyIICont dl r I s s I I I I 2 _ _ r H l Jl i i i 0 f L _ _ _ _ f J...

Page 720: ...6 LAND CRUISER Heavy Outy Cont dl jJ J I...

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