Toyota Chassis and Body workshop and repair manual
Toyota Land Cruiser - Chassis and Body factory workshop and repair manual Covers FJ40,FJ43, FJ45, FJ60, BJ40, BJ 42, BJ43, BJ45, BJ46, BJ60 series and HJ47 and HJ60 series
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File size 120 Mb Bookmarketed with 851 pages
1980 publication . Does not cover the engine. Covers Clutch, transmission (4 speed H41 and H42 and 3 speed J30),transfer case,propeller shaft, front and rear axles,steering,brakes,winch,frame,body and electrical.
- Safety first
- Wear safety glasses and gloves; work in a well-ventilated area; don’t work on a hot engine; keep loose clothing/jewelry away from moving parts.
- If you must raise the vehicle, use a proper jack and jack stands on level ground — never rely only on a jack.
- Quick overview of approach
- Read the engine codes (diagnostic step) to know why the check engine light (CEL) is on.
- Do a basic visual/quick test inspection and simple fixes (gas cap, loose hoses, fuses).
- Use the multimeter and live data (if available) to test sensors/components the code points to.
- Replace only parts that fail diagnostics; common parts causing CELs are gas cap, O2 sensor, MAF, coils/plugs, EVAP components, catalytic converter.
- Tools you need (basic tools first — full descriptions and how to use each)
- OBD-II code reader / scanner (required for most Toyota models 1996+)
- Description: a handheld device that plugs into the car’s data link connector (DLC) and reads stored trouble codes and sometimes live sensor data.
- How to use: locate DLC (usually under dash by steering column), plug in the reader, turn key to ON (engine off) or start if instructed, follow on-screen prompts to read codes. Write down codes exactly (e.g., P0135). Use the device’s “live data” if available to watch sensor values while engine runs.
- Why required: tells you why CEL lit; prevents unnecessary part replacement.
- OBD-I diagnostic method (for older Toyotas pre-1996)
- Description: older Toyotas don’t use OBD-II; they flash the CEL in patterns or require a jumper to the diagnostic port to pull codes.
- How to use: locate the diagnostic connector or ECU; either turn key to specific position or short the two diagnostic terminals (follow model-specific procedure) and count blink sequences (e.g., flash, pause, flash = code). Look up Toyota OBD-I blink code chart for your model/year.
- Why required: older cars don’t have an OBD-II port; reading blinks is the way to get codes.
- Digital multimeter (DMM) (required)
- Description: measures voltage, current, resistance, and continuity.
- How to use: set to voltage to check battery (DCV, 20V range), touch red probe to positive battery terminal and black to negative; resting battery ~12.6V, engine running 13.5–14.5V (charging). Use ohms setting to check continuity/resistance of sensors or wires. Use diode/continuity mode to check fuses and wires.
- Why required: confirm sensor signals, check power/ground, verify components before replacing.
- Basic hand tool set (required)
- Description: set containing ratchet, metric sockets (8–19 mm), extensions, combination wrenches, screwdrivers (Phillips and flat), pliers, and adjustable wrench.
- How to use: use sockets/ratchet to remove battery terminals, sensor nuts, airbox bolts, spark plug wires/coils. Screwdrivers for clamps and panels. Pliers for clamps and hose clips.
- Why required: basic removal/installation of components.
- Flashlight or work light (required)
- Description: bright handheld light or headlamp.
- How to use: illuminate hard-to-see engine areas.
- Why required: so you can see connectors, codes on stickers, sensors.
- Safety jack and jack stands (optional but often needed)
- Description: hydraulic jack plus stands to safely support the car when lifted.
- How to use: raise car with jack at recommended lift points, place jack stands under solid frame points, slowly lower onto stands. Never get under car supported only by a jack.
- Why required: needed to access undercar parts like O2 sensors, catalytic converter.
- Spark plug socket and gap tool (if checking/replacing plugs)
- Description: deep 5/8" or 13/16" socket with rubber insert and a feeler gauge or gap tool.
- How to use: remove coil or plug wire, use socket on extension to remove plug, check/adjust gap, torque to spec when installing.
- Why required: misfires often set CELs; checking plugs/coils is common.
- O2 sensor socket (recommended if replacing O2 sensor)
- Description: special socket with a slot to clear the wire harness.
- How to use: fits over sensor, use breaker bar/ratchet to remove/install sensor.
- Why required: easier removal of oxygen sensors, often seized.
- Mass airflow (MAF) sensor cleaner (if applicable) and clean cloths
- Description: aerosol cleaner formulated for MAF sensors.
- How to use: remove MAF, spray cleaner onto sensing wires/element, don’t touch element, let dry, reinstall.
- Why required: dirty MAF causes rich/lean codes and CEL; cleaning often fixes it.
- Torque wrench (recommended for critical bolts)
- Description: tool to tighten nuts/bolts to specified torque.
- How to use: set desired torque and tighten until it clicks.
- Why required: some sensors/plugs require proper torque to seal and avoid damage.
- Optional specialized tools (explain why/when)
- Fuel pressure gauge: measures fuel system pressure; needed when diagnosing fuel delivery-related codes.
- Vacuum/smoke leak tester: introduces smoke into intake/evap system to find vacuum leaks; useful when codes suggest EVAP or vacuum leak.
- Fuel injector cleaner/tester or oscilloscope: used for deeper fuel/spark diagnosis; not required for beginners.
- Battery charger/maintainer: keeps battery charged during long diagnostics or when clearing codes.
- Where to find the diagnostic port and basic steps to read codes
- OBD-II (1996+)
- Find DLC under dash/near steering column; 16-pin trapezoid connector.
- Plug in scanner, turn ignition to ON, follow prompts, read and record codes and freeze frame if displayed.
- Search the code (e.g., “P0420 Toyota”) for likely causes; use Toyota-specific forums/repair manual for exact troubleshooting steps.
- OBD-I (older Toyotas)
- Locate two-wire diagnostic connector (often near firewall or passenger side kick panel).
- Turn key to ON and short terminals per service manual; count flashes and note code sequence; refer to Toyota OBD-I code chart for meanings.
- If unsure, consult model-specific manual or online resources for blink-code procedure.
- Basic visual checks to do before replacing parts
- Gas cap: check for cracks, tightness; loose/damaged gas cap often triggers EVAP codes. How to do: tighten cap until it clicks; if old, replace with correct OEM or OEM-equivalent cap.
- Vacuum hoses: look for cracked, disconnected, or loose hoses on intake and EVAP system; fix by reconnecting or replacing hoses.
- Air filter / MAF: inspect filter for heavy dirt; remove and clean MAF per instructions if dirty.
- Wiring and connectors: inspect harnesses near sensors for corrosion, broken wires, or unplugged connectors.
- Fuses and relays: visually inspect fuse box and swap/test suspected relays or fuses with multimeter continuity.
- Using the multimeter for basic tests (how-to)
- Battery voltage at rest: set DMM to 20V DC, probe positive then negative battery posts; expect ~12.4–12.7V (fully charged).
- Charging voltage with engine running: same setting, start engine, read ~13.5–14.5V if alternator charging properly.
- Checking sensor power/ground: backprobe connector (or test harness end with connector unplugged) to verify 12V power or 5V sensor reference on appropriate pins (consult wiring diagram).
- Checking O2 sensor (narrowband): backprobe signal wire with engine warmed; voltage should fluctuate ~0.1–0.9V (switching) if functioning.
- Continuity/resistance: use ohms to check wiring continuity and resistance per service specs.
- Interpreting common codes and likely parts (what might need replacement and why)
- P0440 / P0455 / P0446 (EVAP purge/large leak, purge valve)
- Why: leak in EVAP system or failed purge valve; loose gas cap common.
- What to do/replace: tighten/replace gas cap first; inspect hoses; replace purge valve if stuck/leaking. Replacement required if diagnostics show valve stuck or leaks confirmed.
- P0130–P0167 (O2 sensor circuit)
- Why: failing O2 sensor, heater circuit fault, wiring corrosion.
- What to do/replace: test O2 sensor with multimeter; replace sensor if out of spec. Use O2 sensor socket and anti-seize on threads.
- P0171 / P0172 (Fuel trim lean/rich)
- Why: vacuum leak, MAF sensor dirty/failing, fuel pressure problems, leaking injector.
- What to do/replace: clean/inspect MAF, check for vacuum leaks (spray or smoke test), check fuel pressure; replace MAF if cleaning fails; replace vacuum hoses if damaged.
- P0300–P0304 (random/misfire specific cylinder)
- Why: bad spark plug, ignition coil, fuel injector, vacuum leak, compression problem.
- What to do/replace: inspect coils, swap coil to another cylinder to see if misfire moves, check plugs and gap; replace faulty coil/plug/injector as indicated.
- P0420 (Catalyst system efficiency below threshold)
- Why: failing catalytic converter, or upstream sensor (O2) bad, exhaust leak.
- What to do/replace: confirm O2 sensors and exhaust leaks first; catalytic converter replacement only if converter is confirmed degraded — expensive, so verify with diagnostics.
- Cam/crank position sensor codes
- Why: sensor failure or wiring; causes poor running or no-start.
- What to do/replace: test sensor with DMM/oscilloscope; replace sensor if out of spec.
- MAF sensor codes (P0100–P0104)
- Why: dirty or failed MAF.
- What to do/replace: clean MAF first; replace if cleaning doesn’t restore correct readings.
- Thermostat/coolant temp sensor (P0115–P0119)
- Why: bad coolant temp sensor or open circuit; affects fuel mixture and can set CEL.
- What to do/replace: test sensor resistance/voltage vs temperature; replace sensor if out of spec.
- When replacement is required and how to decide
- Replace only after confirming failure with codes + simple tests (multimeter/live data/swap tests).
- Start with cheapest/easiest fixes: tighten/replace gas cap, clean MAF, fix vacuum hoses, replace spark plugs/coils if worn.
- For expensive parts (catalytic converter), confirm upstream sensors and wiring are good first; avoid replacing catalyst just because of a P0420 without further testing.
- How to clear codes and verify repair
- Use the OBD-II scanner’s “clear codes” function after repair, then test drive to see if CEL returns.
- Don’t clear codes before diagnosing — you’ll lose the stored data that points to the failure.
- If CEL returns, read codes again and continue diagnostics.
- Quick beginner-friendly troubleshooting checklist (in order)
- Use OBD-II scanner to read codes (or OBD-I blink read if older car).
- Tighten/replace gas cap if EVAP code.
- Visually inspect hoses, connectors, and air filter; clean MAF if dirty.
- Check battery voltage and charging system with DMM.
- Test/inspect spark plugs and ignition coils for misfire codes.
- Test O2 sensor signals and replace if out of range.
- If vacuum/EVAP suspected, use smoke test or soapy water to find leaks (optional tool) and replace faulty hoses/valves.
- Replace only parts that fail the tests.
- Typical replacement parts and rough notes on cost/effort
- Gas cap: cheap, easy (under ).
- Air filter: cheap, easy.
- MAF sensor: moderate cost (–0 depending on vehicle), cleaning may fix it.
- O2 sensor: moderate cost (–0), requires O2 socket and sometimes lifting car.
- Spark plugs: low cost, easy with spark plug socket.
- Ignition coil: moderate cost, simple swap.
- EVAP purge valve: moderate, easy access often.
- Catalytic converter: expensive, labor involved; confirm before replacing.
- Cam/crank sensors: moderate, sometimes labor-intensive depending on location.
- Final concise advice
- Always read the code first — don’t guess.
- Use the multimeter and swap tests to confirm before buying parts.
- Start with the easiest/cheapest fixes (gas cap, cleaning MAF, plugging hoses).
- When in doubt on complex items (catalytic converter, engine-internal issues), consider a professional to avoid unnecessary replacement.
- Safety reminder
- Disconnect battery negative when working on electrical connectors for extended swaps or when instructed by repair manual.
- Support vehicle properly when working underneath.
No more questions — follow this checklist and use the tools above to read codes and confirm component failures before replacing parts. rteeqp73
Beware frame rust on used cars Used cars can have hidden frame rust.
Toyota Camry Full Rear Body Repair And Repaint | Timelapse
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Toyota Land Cruiser - Chassis and Body factory workshop and repair manual Covers FJ40,FJ43, FJ45, FJ60, BJ40, BJ 42, BJ43, BJ45, BJ46, BJ60 series and HJ47 and HJ60 series Download on PDF