maintenance procedures 60 series

8/4/2019 Maintenance Procedures 60 Series

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F O "" R " E 'W " O ' R D '.1 ~ , I " . . . , . . . . . . .This manual describes the maintenance procedures for the 1'986TOly'O'TA lLANO CRUISER models sold in the United Statesand Canada.Detailed reparr procedures ar e contained in the foUowingmanuals:

"81 2F Engine Emission Control Rep,a'ir Manual(Pub, No, 36 ,Q,43 IE): 2 ' F IEngi'ne Hepair M:anu ,a l 1 ( ' I P u b ' i ' No " 3610 ,4E ' )B S erie s Englin,e' Hepa ir M a nu all (,Pu b, IN o i"3 604 7'E )2'H, '12H-T Enqine Hapair Man iua l l (Pub. No, RMI01 '2E)L an d C ru is er Heavv Duty Cha ss is an d Bodv Rep,a'ir iManua:1(Pub. No. 36262EJ


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I I

, - - 9 - -- ,8 - - ' 6 - - ~ T O " : ' rvo__ T A : : - ' : - A : - : I N I ' T ' E " N - - A : - ' N - , C - , E"" 1/,1 .. . I . _ ' . . ' ' . . ' , ' . _ - . . - . . . , ' , - _ 1 . -. ,- ' :. . - - _., I I" . . _ " . .. " "" ~ ," I" I . _ '_ . '. 1 . . . . " I . .

P R : - " - '- " ' " " C " " . . . .- E o . U R - " E S - , M . A : ' : , : : N > U A : : : : - _ . ~ ' ' . " . ' " . . . . . . I ' . ' . . . . ' . " . . . : . . ' . . . . . ' . ' _ . . ' . . . . _ ~ . . . . . . I ..... .. ' .. ' , .' ...' I 'NT'R'ODUCTI!ON

LAND CRU ISER (ZF EN 'G INE)LAND CRUISER (3B,,2H ENGINE)AP:PENDIX.

e '1 9B ,6 'T OY 'O lA , MO 'T OIR C O IR POR A,T IO NA JI rig hts reserved, This book may not bed- d lad ,. hi repro ucec or eoprec I In W' 0 e Dr In part;w'ithou t the' wtitten p erm is si0n of TovotaMlotor Corporatl 0n.

...


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, . ,I N T R O O ' U C " - ' T I O ' "N. . ' " ' I . " . . ' . . ' , ' '[ ' , . ' , ' . , I ' , ' , ' ' ' ' ' , : . ~ ' . , 1_ '_ !GEN ER A.L P RE CA U'T lO N ,S ~ , ~ ~ ~ ~ I ' , ~ I ~ ~ i

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PR,ECA,UT IONS FOR VE'HICLES EQUIIPP':E,DW I,TH A CA'TAIL,YTIC C!ONVE!RTER ,t ~ ,t I t, I i .. 1--3GEN "ER"'A"L I R " E P ' A " I R I I N S ~ ' T - RU 'C"'T -IO ""N 'S" l' .....= -1 r , " , = _1 ~ -" _. I . ! ~ _ " ~ 1 - . " 1 '< . . . . I . ~ , ' . . . . . . ' ' .< '.. - '. I i I . 1 . . I . . 1 ~A ,BBREV IAT ION IS USED liN T IH IS MANUAL It i tit 1:5


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,I W R ' O " : N " G ' ", I .. . ~.. . ' ! " ': '" ,

'I N O O 2 2

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I,I

IN0023

1. K.n!ow ' the, importance of p er io di c m a ln te na ne e.(a) E.verv service item in the periodic maintenance listm u st Ibe-:perfo rrned_ ._ _. .... _.(b) Fa:I1jng to, item ca n cause the, enqine to run poorlyand increase ex h,8USt em iss ions,

, 2 i i Listen to the customers comments Cllreful ly,, ,A i lw a y s det er rn ln e exactly wha t the customer complaint is "i' f anv, an d v erif y' 'it before proceedi ng 'with repa i rs.

,3 1 Detef'mi'ne iif you have an s'n,g,ine: or emission syste,m pro-blem,(a) E,ngine problems are' usuallv not: caused 'by the ernis-

sian control systems.(b) Wlhe,n troubleshootinq, always check the enqlne and

the iqnition 'System first,

4., Check hose and wilring connections first,The, most frequent cause o f problems i s ,s i rnp lv a bad con-nection in w i r i n q or v a c u u m h,o S 8 ' S , .Always. make sure thatconnections are secure and correct,

5. Observe 'the follow'iing precautions to avoid dam'8 , g e ' to theparts ~, . I .(,a ) To disconnect vacuum' hoses." P I U U on the' end, not them idd le of the hose ,

To pull apart etectrlcal connectors, pull on the' con-nector- itself, not the wires,I B ' , " B ca ' r o e : fu l l not to drop electrical component s..such 8 = ' 5 :' . ' ", ' ," , '. I. ',' '.' ~ ..... I I ; ; ; i ' . ' . ' '. iii U ,"" '. II'I:, , I : ' , ' ". ' , .,sensors or relays. If they air! dropped on a hard floor,they should be replaced and not reused.W - 'he-'n'steam cleanlnq an e ' : n g c - ~ n - ' e " protect the distriI :,_ ' , .. ". . __.. ,'" I . . '. . ,. _ .. " . .... ,,;;,'. 1-butor, coil. air fIter r carburetor intake, air pump andV'C'V frorn water.

(e} Never use an impact wrench to remove or install!thermo switches or thermo sensors.

(b)(c)

(f ) When checkinq continuity at the wire connector,insert the tester probe careful I I Y ' to prevent terminalsfrom bending.(g l When usinq a vacuum qauqe, never force t.he hoseonto e li connector that is to o ~arge.. Us ' a ' a s te p- dow nadapter instead ..Once the' hose ha s 'been st retch ed, it

m ay leak.


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' ..3EX,amp,I Ie 6., T e l l O hoses be fo re d is connec tina them:

(a) When discormectinq vacuum h oses, u se' tags to identi-fy how ' they should be reconnected,{b) After completino a Job, double check that the V(J:C-u u m ho ses a re propsrlv connected, A , la bel under thehood shows the proper layout.

IIN0024

PRECA,UTI,ON'S FOR V' IE ,HICLES E'QUIPPED WITHI ACATAILYTIC C:O'INV',E,RTEIRW'A,RNING,: Il f large amounts D 'f unburned ga lso~ ine flo'w intothe' catalytic converter t it may ' overheat and cr'eaite a fire hazard,To pr levent tillis, obser ve 'the fo l l : l o 'w ing precaution s and ex'p' la, inthem to your customer.

21 Avol,dl prolonued iidl,ingliAvoid running the en'g,~neat fast idle speed 'for more than10 minutes and an idle speed for more than 20 minutes,

31 A : v o ,id s pa r k [ump test,f( a l) Spark ju m p o nlv when absotutelv necessarv. 'Performth is test as rapidly as poss ib le ,(b ) Whit,e testinq, never race 'the engine"

4. ,Av'oi'd,prolonged e n l Q 1 i n e compression measurement .E,ngi'ne compression tests must be mads as rapidly asP, 0 . , .ssib IQ_ ,-.~4_1 __ v~

5.. Do not run engine whe,n fuel tank is nearlv empty.This m ay cause the enqine to misfire ano create an extraload on the catalytic converter"

6" Av,oid coasting with ignition turned off and prolongedb,rakiinl'g.

7,, , 001 no t dispose of used cata l 'y t ic converter nea r parts, con-taminatad w'ith gas IDI~ne 'or oi l .


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1..4 IN I TR .O DU 'C 'T IO N I ,_ 'General Repal ir lnstructionsG iE INERAL R.EPAIR INSTRIUCTIONiS1. IUse fend,er s-eat end fh,or cover's to keep the v eh ic le c le a na nd IprB'v,ent damaqe ,

3. B,ef'ore pe,rfor'ming e' lec tr~cal l lor f:uel work, diseonnect then,eglat iv 'e ( -. - .) battery ca b I a t

4,. Ch,eck . 'h os e a nd wir ' : ing connectors to make sure that they'are secure and correct,

5 .. Alwa'ys replace ' g a : s l k e t s and ' a '- rin g s with new ' ones,6 ~, A I 'w ays use seater ,on gaslkets ' to, pravent leaks~7 ~. Carsfu II Iy observe' a~~specifications for bo l t torques I

, A l w I 1 Y S use a torque wrench,8 , 1 Use of Speciail Servj,ce! Tools (SST.) m ay be; required,

,d:ependi,ng on the nature of the repair .. Be sure to use theSST 'where 'sipec:iified~ and fO~'low th e proper 'wo'rk procedIUlre!~

'9 ., Care must be taken whe!n ja c kiin gl 'U p and sUPPolrting the'~V "eh ~ I C - ' I e ' " B'e' ' 5 ' , u r : l e " to " I i i f t l en d I 5 - :up p O ' I ' r t ' I t' : he " v ' , e - ' h ~ I C ' . Ie 9 t t h e_ __ ,-._ ,! .- . , , _ - _ ' _ " . 1 1 _ _ 'u __: 1 " _ , ,- - " _ - '- ' _ 'I ' , , " '" , - .- , , '_ , ' 'UI, -,proper ~Olcartons.(a) Ilf the vehicle ls to be jacked UiP only at the front orrear end, be sure to block the whee ls in order toensur e s af et v.(b) Always U9 e ' a hvd ra u ~c ho ist or j ack stand, It isex trsrnelv danqerous to , work on a vehicle supported

onlv by' a jack. even for a small job that: csn befinished quickly.


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Ale Air ConditionerA/T Automatic TransmissionEG R Exhaust G,as HecirculationEX Exhaust [manifold, va l ve )IiN [I ntake (rn a ntfo td, v a lv e]MIT' Manual TransrnlsslonPCV Posilt~ve Crankcase Ventilation:SST Special Service Too l i S ,T 1 M TransrnissionV ~ ' C . , . V ,: V : ' : C '~ : . ' rn C . 0 n t r io .'. V ' , a l i v eauu ~ . ~_.__w I 'Withwlo 'Without


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2,-1

LA,NO 'CRUISER(2F ENGINE :FJ SERI:ES ONLYFOR USA)

P a g , eM A 'I N TE ,N AN ICE SCH 'EDU L E .. I I I . I . ~ ~~~~,~~ 2- 2

.

:2 - 4 "- ,

G ' - ~ ' E N ' E R " A ' " LN ' " 'O . , T E S . ,. 1 ' . . ~ . I _11 . E 'e--- serv ice item in 'the oerlodic maintenance l lst mus t bev _ .ry ... ..____ ._ _ ~ __. _ .' _. _ _u . _ . _

- gr fo rm - s 'd, ~ I' " . .. .. ~ . :., . Failure to, do evan one item can cause the enalne to runpoor l y a nd l increase exhaust ern iss!ons,


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i

2 - , 2 LA,ND CRUI,SER (2F ENGINEJ ,Maintenance Schedule

MAIN _ENIANCE SCHEDULEM '8 intenance operations: A . . . .,

A ' -~ ~

C he ck an d/o r a dju st if necessarvRepl lac :e , cha:nge or lubricateInspect and correct or replaceif n e eessa ry

- ORMAL CONDITION SCHEDIULE_.Service interval I Mla intenanc.e ' services b e y o n d 60~OO'O miles, ( ,96" ,000 km,) should be performed at the, same(Odometer readingl or months, intervals shown each maintenance schedule. See page.whichever " . '1Sy.stem l comes first) M iiles 1,000 1 ! 0 15 I 20 30 40 4 5, 50 6 ,0 (item No.)I. \ Krn )( 1 000 1 ! 6 i 24 32 48 ,64 72. 80 96. IMaintenance items ,. : .... .."_ IMlonths 1 2 18 24 I 36 ,48 54 160 72 .; .

I

.ENGI INE Valve c learance A A A A 12~7 (itaim 1 }_Dr: ive bslts'" I 1 24 (i te,ml 1 )"I Engine' oil and ell filter R R IR R I R R Clem 3' )-5"_

I Eng;ine coolant'" I I R 2~5 (item 4)Exh,81ust . and [mountings 1 I

I ripes ~ 2-6 I!tem 9).. -FUIEL . Idlile speed a.nd fast idlle speed~5~ I A I 2R7 a (item 1,1 1 2 ,)I . ;'. I IAi~rfi tter R R 2-6 (item 8, }Fue l ~ines and con nections ~ I I, I ,2-6 {Item 6}IF'uel i flller cap gasket I R , 2= 6 {item 5 ,): 1

II .I IGNI IT ION Spa!rk plugs. '* R R 2-4 (item ,2 )I , _BRA K E .'S Brake l inilngls and drums, il 1 I I I I 2'~10' (I i te rn 1 ! 6}

I ,I'. L Brake ,pads and discs 1 I I II I 2-10 (ltem 17)_I . lBrake m n e pipes. a n d hoses 1 1 'I I 2,~10 (ilte.m 1 5 1 ).

II

ICHASSIS Steerinq I' k I I II I I 2~'112 ,(itelm 1 9)lln:age,_. I' B , a n joints a n d dust covers I -I I II I I 2 ~ '1 12 {item 1 9).. IM . an ua l t .. transfer, diffarential an d I I 2-B (iteml 13)ransn"nS.SIQln~, I I I I ~steerinq glear box oiJc3l , 2,-9 (item 14)I. IFront whee l beariing. ' g , rease I R R 2 : " 1 0 (item 1 ,8 ). ;I St:eering knuckle a n d chass is gl lre lase~4J R R R R 2 - " 3 (iitem 2 0 ) 1i ,I _

_I

-. , . _I Propel ler shaft greas.e~4) R R R R 2='13 (item .20',~I ..

I-Bolts a n d nuts on chassis a n d b o d y I ~ I I 2 -1 3 (il l lem 21 )I._ -

M aintenance service indicated by a n a ste ris k (*) is required under the term 'S of the Emission 'Control .systems Wlarran.ty~ Se eOwner's G U i ide 1 0 r com pl et.e warrantv lnforrnation,N O ' T E r ( 1 } 1 After 60,000 miles (96,000 krnl or 72 months" inspect e'very 10,000 miles ( l6;OOO km) or 12 months ,(2) A.fter 60,~OOOmiles (96 ,OOO krn) o r 7 '2 m o nth s, re pla ce every 30;000 miles ( : 48~OOOkrn] or 36 months .( 3 . ) 1 Inspsct the steeri ng ge,ar box ani y for 0il Isekaqe.(4) If th e veh~Ch3; ha s belen immerssd in water f it sho u Id be re-preased wlth ~n 24 hou rs.(5) Adjustment at 15,000 miles (24,000 krn] or 18 months only.


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LAND ICR'U ' I ,SE,R (2F ENGINIE)~ Maintenance Schedule 2..3Follow the severe condition schedu le if vehic,le is operated malnlv under one or more of: the follow'ing severe conditions:

T 'o w ~ng,a trailer, u sin g a c am pe r or car to p c a rrie r. Ope-rating on dusty, rouqh, muddy or salt spread roads, A ,epe'at short trips less than 5 m iles 1 (8 krn) and outside temperatures remain below f reez.tng~ E xtansive id i!ing such B I S , police taxi or door-to-door de l iverv use . .

Ser00e interval~Odomete.1(' re.,ading or months,

~--~~~~~~--~~---r--~~~==~-'~~~~--~~~~--~=-~~System w h i c n e " / t H " comes fiJ's:t) M iiles x 1.000 .5 1 ' , 5 , 10 .~6 20 2 2 . 5 25 30,

~2 16 24 32 as 40 I 48I II -1 9 11 2 1B ,2 4 21 30 38A . A

M a i ~t a na n ce s er vi ce s beyond, 6 0 ,OOQ m il es ~.96j'OOO I km ) s ho . u l d be.pe.r l 'o.rm~d 8:t the s am s intervals shown in eaclh maintenance schedule , See page

Utero No..50 152,5 55 60SO ,8:4 88 '9 '6..60 6, 3 68 12

A6 42 45 4 8 - i .5 4

i:AN G I INEV a lv e clea r iiine e

II1

rua,

I. !D r l l V ' 8 ' belts' 1 i 2=4 (~tem'1~I~------------~~~--~~====~~~==F=~==~--~--+---r-_'---+--~~+=~~~~~~~~+-----------_'Engillie oil and oil filter R R I R R R R R R R R 1 R I~ 26 Ot-enl 3}

I 1 2-6 ~ite'm 9)A I ? - - 7 . , . 8 ,~~tem~~. 1 2 f ,

"

R ,R 2=6 ~hem 7,8)

R ,2 - 16 ~tem 5)I.IGN IT l iON Spark p~ugs.:. A 2~4 ( . item 2)

21,3 (item 21}

r 2-'1 0 ~~te;m 1 : 5 )2~10 (litem 17)

;BRAK ES Bra ke [ i l f 1 l ings ,S I nd drum:s.B ra I ke p ad s a nd discs,Brake Iine pipes and hoses, 2 .- 1 a . O tem .~5)

-ICHASSI 5 Steeri f]9 !.ink a i g e Ba III jei tits a nd dust COVEns

212 (item '19}2~12 Utem 19.~

IlRR

R IR IRR ' R R

M 8 i l r l U a I tri3lnsm lsslon ..tra M i s f e r . . d j ' f f e - r e rn t ta Ia I ' ld st,eering gea if bo x oil C J I, IR

2> 9 ~,item 1 1 3 )2-9 '~itelm14.~R

I front wheel beeri n ' 9 1 grease, -Steeriing k nu ck le a nd c ha ss is g re ..a se C4 f 1 1 : R. R ' 2>13 ( item 20)IR R

:Mainte'nance service indicated by an asterisk (*), is required under the terms of the Emission Control Systrsms Warranty_ SeeOwns r's Gu ide for corn p lete warranty ,;nform ation,N'OTE:(1) After 6,0',000 miles ( ,96 , ,000 krn] or 72 months, inspect every 10,000 miles. (16; .000 krn) OIF 12 menths.(2) After 6.0,,000m ll es ('9 ,6 1; .000 km) or 7'2 months, replace e V 6 1 r y 3,0,000 miles (4 8,0 '0 0 k m) or 36months.{3} Inspeet the steerinq gear box only for oil leekaqe,('4 } I f th e vehicle has b ee n imme rs ed in water, ~tshould be re-qreassd within .2'4hours.(5} Appllcable when 'Operating mainly on dusty roads, Ilf not" follow the normal condition schedule,( ,6 ) Adjustm,ent ,at 15,000 m il es (, 24 " .0 00 krn) o r 1a months 'only.


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2: 1 1- . . . .CORR'ECT

I

MAOO:3!5,*ippondenso. I . , _ L"'i ~ ~ - : : :: : J : c.- . . . .

E COOOJ 'E C O O O 4 EOQ002

Loc k , _ " "_ "~Bolt

Locik~~Bolt

Adjust] nglBolt

wJo Power Steering

..,

W : ' R - : O ' N G -" . ' .. . " ,_ " - ...~.: ' . C 0 "1 A > , : R ' . : ': 'E C - 'T' - ' 1 . 1 - , . . 'MA0200

!GOOQ4

M,AINTENAN'CE OPER,ATIONS.EN"GI IN IECold Eln,gine Operations1. I,N,SPECT DR I'VE :BE L ,TS

(a ) V isu ellv check the drive belt fo-r cracks, oi l iness orwear, Check that the belt does not touch the bottomof the pulley gir,oove.

II f necessarv j replace the' drive belt.(b) IU :s ii ng a beilit ten sio n g ,a ug e" check the drive belt ten-

iI.ston- ..Belt tension g,auge:

N ippondensoBorrouqhsDrive belt tension:Used belt

B T ' ' G - - , - - ~ ' O : I ( - 9 ' - : . . : ' 5 " , - 0 -, 6 . - 0 .- ' ' 0 : 0 . , 2 . . . . .0...,..... L. ,' _.,' _._ ' [':No ~ BT , -3 3 - , '7 '3 IFAir eon.OthersAilr con,Others

80 + - 20' IblOO :+ 20 Ib125, + 25 Ib ,145 ~ 251b

INew belt~ If necessary, ad]ust the dr iva belt t ,en sion~C,AiU 'T ' IO ,N:1t, Do not Ipry on the die-cast bo,d'y' of the air pump.2., If the vehicle is equipped 'with power steering, the

belt tension of the; aill'pump and alternator is a d , j u , : s t e d iby' tur'ning the adjusting bolt.

NOT'E: "New belt" refers to a belt which has been used less

than 5 minutes on a runninq engine'. "Used belt" refers to a belt which has been used on arunninq en,gline for- 5 minutes or more,'. A fter rap lacing th 9' drive be It, check, that: it f i'ts p roper t vin the, ribbed ' Q l r , o , o v e s , especia I ly ' in the places difficu 'it tosee

2. R'EIPLAC:E, SPARK PlU'GS(a) Disconnect the spark p:lugl wires at the boot, DO, INOT

pu lion the wires, R:emove the' spark pluqs,

Gap:g""". '0 " 8 : ' rnrn 1 ( 0 .. O ' ' 3 : ' - ' , - in.]. - : . , . : . : " I , .: :. ~. : - . : , _ tReCO!mmlended spark pluqs:

N !O W14E"XR,-UN ' G K ' " - S : P R ' _ - 4 - - E 'V ' .,.:_ I ..... . .. I, .~. ' {


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LA N D CRU ISER (2F ENIGINE) ~ Ma . i n t enanoo ' Operations 25_ . : '

I_ _MAJ ): ;m 2 i

MA0203 LUOOO5

;.: ..... ~'~.'.; .:v,~ . ","" '-..' ...I l. U0 00 6 l .U OOO r

GA.SO l JNE . i E : , N G I I N : E-1, i ! If., II 1i!1 iW -4 Q 2O fW '~4 Q .10W.,50/r I ~~, "1 OW"SO .~~}lIl=40 MDW150

~'F=2Q 0 .20 .~ 60 80 '100~C ~29 = 18 -:'i .4, 1S 27 ~a~MP iBR.A 'nJ IR~ RI I ,NG ,E AJNT IC: : iP ' J i, . ' rEO E !!E :FO 'RENEXT i ou CI1 IANG 'E

3 ~ REPLA.CE EN 'G I NE OI 'L , A : ND O'IL FitTER.(a ) IR em o ve the oH drain p~ iug and drain the oil into a

C10n ta l ine r,

[b] Usiing SS'Tt remove; the ' 0 1 1 filter ,(locateo on right sideof e;ngi ne b l o ck) .SST 09'228~44011fe) lnspect and clean the oil filter installation sur fa ce . .(d) Apply clean engine oHI to ' the igask.et 0 1 ' the new oi l

filter.

(e ) L ig'htlly screw in the oil fIter to wh ere you f e 1 e ' I resis-tanee.(f ) Then, u s i n ' Q I SST,. tighten the oil filter a n extra ,3/4

turn.

I(g) Clean and install the oil drain plug with a new gas.k .et~(h) Fill the ,en'gine with new oll, Use AIPI grade S:F or

SF/C'C, multigrade viscosjtv and fuel-efficient oil,Engl'ine 0 il capa,ci i ty (Dra in and refi I I' w i th o'iI f : . i lter chan,ge) : :

7,.,8 liters (8.2 U,S qts, 6,~9 lmp, qts]

I 4~ REPLACE ENO'IINE CO IOLAN ' T, (a) D rain the coolant from the radiator and enqine draincocks, (E1ngine drain ls at left rear of engine block.l

(b) Close the drain cocks.(c) F ii i I svstern with coolant,Coolant capacity (wI heater lor ailrconditioner] ~16, , "5 l i ters ( "7 'J 4 , US , qts l 4 ~ . .5 trnp, qts)Use a g.ood i brand of ethv le ne-q lv co l ba se coolant, mixedaccord ing to the' manufactu rer's instructions.

Drain Cock


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cO. . .

MIA0118

FJ60r==- '- - -=- .b.~~.=d

r = - = - " _ - ,i,_.:-:-:_-=--,

MAO.233

5 1 1 'R IEPLA:CE G A S,K E,T IN FUEL FILLE:R C.AP(a ) R 'e'mo ve' the 'four screws and locking plate..PuH outthe old glask,et~{b) I:nstall the new glas!ket b'Y' hand, iln sta l ~ the lock ingplate with four screws"

6 . IN ,SP,ECT FUEL L ,I~~N ES,A . 'N,D ' CO 'NNECT IO iNS ,' V i sua l l v 'inspect the fuel l ines fo r c ra cks, leakaqe looseconnections, deformation or tank band looseness,

7~, INSPECT A~R f'l LTE,'R(a) Visually check that the element is not excesslvelvdirty, damaged or oily ..NO i 'TE , : Oil iness, m ay indicate a stu ck, PCV ' valve,1 f necessary. replace the element,(b) Clean the element with compressed air.Clean by blowing fro.:m the inside first then the' outside,

8~ R,EP,L "ACE A : R F'I L TERHep lace the u sed a ir cleaner element with a newone,

9 . ~ ,N ,SPECT , EX ,'H ,A U'S T P I'P IES AN I D , MO iUNT I : NGSV 'j su 8 1 111y ~nspect the p ipes, ha nqsrs, a nd connection s fo rsevere corrosion. l eaks or damaqs .


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C:,AUTI ,ON, :1. NE:VE'R allow t : h , e tachometer terminal to touch

groun,d as it : could result in damage to the ign,iterand/or i ,gnit io 'n, coil,2 . A s s o m e tachometers w i 1 1 ' 1damage the 'ignition,f werecommend checklnq the compatlbllitv of y'our unit

b " efore usin" 9 ' : '' " r " _ ,I , ,I!( I C ) . Set th e idle speed bv turninq the ' ID LE SP EED AD~

.....__~======-.......,......== M _ A O _ ' 2 _ _ , 1 I l ,J U IST ~NG SeR E'W'i

IN EXiEX , I~N

liN EXIE,X IN I

I!

IN EX'",I" : ~ . .. 'I -EX IN

MA0210

ldle Speed, , '- 'A d ju stin g S cr ew

Hot Elngine Operations10~ ADJUIS,T ' V ' A , LVE CILEARANCE

(s) W'arm up the enqlna to normal operating temperature,{b) 'Stop the engine! and remove the, via~vecover,

A,d l , jus t the valve clearance,. 1 Start the enqine, IUS 'S a feeler gauge to measure between th e valvestern and rocker arm Loosen the lock nut and turnthe ad ju stin q s cre w to set th e proper clearance.Hold the adiustinq screw n position an d tightenthe lock nut,

'. Hechack the clearance. The fee ler gauge shou li dmo ve with a v e ' r - y ' sll iglht d , r a l , g ~ ,Valve clearance: Intake 0.20 mm 1(0.008 in.)I Ex hi8UI st . O~,35mm (0,.01,4 in.)(d) R,ei:nsta U the, valve cover,(e) R,e j' nsta II the, a ir c lea ner .

11' ' " A.DJU'ST I ;D 'lE S ,P E,E D', ( : a l ' ) Preparation

.' Air cleaner installed Choke va~V'efuU y o pen'.' Accessories switched off'. ,A ,III vacuum lines connected (' i i . .e. . All, EG R systems,etc.)I . Transmission 'In N1E'U'TR,A,L position

Engine' idling at n o rma l operatinq temperature(b) Connect a tachometer to the e'n,gine.Connect the tachometer positive (+,) terminal to the'ignition coil negative (-) terminal,

Idlle speed: 6,50 'rpmN'O!'TE,: Leave the tachometer connected for further ad-J ustrnents,


16/40

MAQt2:1i2

Ma~n:D 1a p h r a i 'g r n Sub Diaphraqm ,IM.A ' (D4 io :

MAO: ! i,MA0 2 1 5

Fast ld le Adlustlnq Screw '. MA0!211 I

12. , A , 'DJUST FA ST IID LE S , P E , E I D '(a) Stop the engine and fu Hy ' pu IIout th e choke knob,

(b) Disconnect the hose from the distributor main dia-phraqm and plug the hose end, This will cut thevacuum advancer.

' ( : C ' ) ' Discon nect the hoses from ports o f the 'VCV forE :V ',A P a nd EGR v a lv e, a nd' plu g the h o se e nd s.This wiU shut off the E 'VAP ' purqe and EG R svstsms,

(d) Fullv open the choke valve,-(e} Start the engine.( f : ) Set the fast id le soeed by turninq the fast id Ie adjust-.lng, s e : f , e w ' . .Fast ~dllespeed: '1,,800 rpmI ( g . , . Check that the len'gine retu rns to idle speed when the

choke button is pushed in aliiI the' w,ay , .(h) Reconnect the ho se 's t o the proper locations .


17/40

29.- .., . .

MAna , 53 IMA02~6

.:::.::-:-" ~. : : : ' ?.. :.~

MA 005 3 ;MA0211 r

D rai n P ~'u 'g D ra in PI ug(for MIT) {for Transfer)

D rain Plug

-I

TRANSMIISSII,ON1,3,. CHECK OI IL LEV'E'L IN' TRANSMISSION,TRANSF'ER A N D D IFF'E REN T,IA L

Re 'mOV8 1 the filler plug and feel Inside the hole with v o u rfinger. 'Check that the o,LIcome's to within 5 mm ( 1 0 , . 2 0 in.)o f the bottolm edge, of the hole, If the level ~s low a dd oi luntil it begins to run out: of the filler hole,Transmission and t ra n sfe r o ill l]-O il gra[de: A PII G L -,4 o r GL -5. Vlsccsitv; SAE 9'0,Diff[ere:ntial Q,il _,

Oil grade: AP' I GIL-5 hv po id gea r ollViscosity: Above ~18'C (0 F) ,S,AE'90B elo w ,~'18 c ( '0 ' 0 I F ) SA E ,80W'-90or S O W '

14. REP'LAC:E, TRA , I NSM ISS ION . F T,RA NS,FER A NDDIFIFERENI'T'IA,L [OIL(a) Hemove the drain plug, and drain the oil,(b). Reinstail th e drain plug,.(c) Add ne'w' o~~unti I it begins to' run out of the fillerhole.Transmission and transfer' oil -Capa,c~ty; - .'

T ransrn issionTransfer

Di'ffe[rent:ia~oil ......Capacity:Front 3 .0 lite rs(3~2USQ l 1 S , 2.6 lmp, qts)2~5liters(2'.6 US qts, 2.2 lrnp, qts)R e ' , a , r


18/40

2- ' 1 1 0 -..

. I

1 MA O O 5 1 M AOO58

MA022 ,2

B R " A " K '~ E ' S '. ,'. . . ' '. I " . I~ , ,1 . ._"'1 '5 ~ I l lN S iP EC T BRA ,K E L I N E PlplES AND HO'SES

NO'TE ,: ~nspect in a lwell I ighted area. II nspect the entirec irc um f erenc e and length of th e brake hoses u sing a mirroras required. Turn the 'front wheels fullv rigiht or left beforeinspectinq the front brake,(a ) Check all b ra ke I in es a nd! ho ses for:

D am a g,e - C o rro s io n'. Wea r - Leaks Deformation CracksCheck. a~1I clampsleaksqe.

(c ) C heck that the ho se s a nd lin es are c lea r o f sha rp edqes,movinq parts an d the exhaust system.(d!) Check that the' lines instalted in grommets passthrouqh the center of the qromrnets.

Bend's(b)

Twiststo r tiqht ness and connections for.[' r ',' i _ : _ I ' . _ . - - ' - ' : . : . [ . ' . . -\;j' e s . . . ~

16.. INSPEC'T R 'E AR , B ,R AK !E L.IN,INGS A N ,D ' D RU ,M ;S ,( a ' ) 1 Check th e lin in qs fo r w ear ..'M inl tlmUlm Ijning thickness: 1.5mm ( 0 1 1 1 0 , 5 9 in.)!(b,') Check the brake drums for scorinq or wear,M ia l x~mum drum i n l s i d l e , diarneter: 2:97 mm (,1,',..69 in.](c) Clean the brake parts w ith a, damp cloth,NOTE: Do not use compressed air to clean the brakeparts,

17~ INSPECT FR ON 'T B ,:RA IK IE P AD S A,NO D' I ,SCS(a' l l Check the, thickness o f the disc brake pads and Ch'9Ckf or irreq u la r wear,,M;,in' i 'mum pad thickness: " , , 0 mm (O~03['9n.)(b) Check the disc for wear or runout,Mi 'n i :mum disc thickness: '19 .0 mm ' (0,.,748 ln.]M1aximum disc runout: Q ' i , l i S [ mm ,(OJ,0059 1 in.')

CH'ASSI,S'18,~ ,R EP,A CK F,RO N 'T W 'HE E,L , BE,A,RII ,NGS

(a) Chanqe th e front wh eel b earin q grease" Hernove the hubs and inner and outer bearings.C lsan in solvent an d inspect the bearinqs for

darnaqe, Pack the bearings and axle hubs w ith lithium basemultipurpose grease"

Grease g r [ a l d [ e : Lithium basemultipurpose ' g r e a : s e(NL ,G ' I No. 2 l


19/40

, LA ,N ID CRUIIS,i:IR, (2 I F' ENGINE) ,_ M,aintenance Operat ions

MAJ0223

MIA0:223

MA022,5

(b] lnstatl the hubs. and adjust the' 'wheel' bearinq preload, U :sing SST', tiglh'ten the' adjusti:ng nut and turn the,

hub right and ~eft tW 'O I or three times.5 S 'T " 0 - : 1 9 ' 6 " : : 0 ' - 7 , - , 6 - ' 0 ' - : 0 ' - ' 2 " ' 1 0 : " ,.~_ j ' . " ' . , " ' . : ' : _ . " . . ' . ITorque: 6 00 krg"clm (43 'ft-!Ilb, 59 N ,m )

.' Loosen the' adjusting' nut until it ca n Ibeturned b, yhand .

' Reti'ghten the adjusting nut.Torque: 40 ~ 70 kg..ern (35 .-.or 60 iin.,-'Ilb,4~O"- 6.8 Nm)

Insure that the hub turns smoothlv and there is noplav in th e b ea rin q,

.' IUsing a sprinq tension 'glauge" check for correct pre-load,Front wheel, bearing friction prelload (at startinq point):0.4 - 3i,3 kg (0.9 ~ 7~,3 l ib" ,4,......32 N)~ the preload is . incorrect, loosen or tJghten the nut to cor-rect the preload,

(e),[d]

Insta!l the lock washer and lock nut.,t.ock the, adjusting nut by bendinq one of the ockwasher teeth inward,


20/40

2-12

MA0:223

MA0225

.......LFreeplav~-~.'T

M A O O O O

IMA04113 ,

(el' U sin q S ST " tighten the lo ck nut.SS ,T 09 '6 07- 6 0 '0 20 !Torq ue: 800 kg-ern (58 ft-lb, 78 N -m](f) ! L o ck the lo ck nu t by bendinq one o f the lock washe r

teeth outward,

i \ Hecheck the preload at the hub bolt.g ,:Front 'whee!1 bear ' ing friction preload ( at : s ta r ti n g point):0 :.4 ~ 3 ~,3 'kg (O~ ,9 - -7~3 lb, 4 .... . .2 N )

19~ I 'IN SP 'IEC T'STE ,ER IN G L IN K A,G E", G EA ,R BO 'X ,S T'E E'R IN G W 'H EE ,L FR,EEPLAV,~ 'BAILl JOINTS A N DDUST CO'VERI(a) Check that the steering i i J \ , . h e e ~ fraeplav is :Ma,ximum: ,4'0mm (, 1~57 ln.)

With th e vehicle stopped and whee ls pointed straighta hea d ro 'c lk the s t 1 e 1 e r i i n g wheel ge'nt~y back a nd forth" - h II h t o ;'W I t_ ' , II: , I g : ' rr -I nqer p ressu re,II f c orre ct, a dlju st o r repa ir ~,(,b ) C heck the steer~ng l inka'Qle for l ooseness o r damage ,

'Check that: Tie rod e nd s, re la y rod ends...shimmy dampe r endpitman arm do not have excessive play,.' Dust seals are not darnaqed,

(c) Check the steerinq gea lr bo x fo -r ,o ~:1eaks.(d) I nspect the ba tII fa ints fo r excessive looseness.(e) :1 nspect the dust cover for damage,


21/40

20~ LUB,E S,TEIER~NG KNUCKL,E, ' C , H A , S , S , I S ANDPRO'PELL,E 'R SH,AF 'T(a)' Remov ,e ' the screw p lug from each stee'ring knucklean d rep ac k with II ubrieant.Steering knuckle 'grea:se . . .. . ..

M1olyibden1um, disulfide lithium base chassis greasie(N'LG!I NI ,o . 2)

(b) Reins taHI the' two screw pluqs.[c) Lubricate chassis components, referrinq to the' lubri-cation chart. Before pumping ~n 'gre,ase" wipe off anymud and dust on the, grease fittinq,Grea:se: grad;,e:

S,teering I~ik ends ~,Molybd,enum disulphids I~ilfhiu'mbase chassis g'r'ease( , 'N ' L G : ~II N '~0 " 2 ' ' ' ) ' 1. ..... ,,"'_ I I ' '.... . " ."_.

Propeller shaft --Lithium bas-echassis g r 1 e a s e (N LGI N io l 2)1(d) Check the steerinq Ilinkage dust seals for damaqe,

IM IA0116MA023 : 2 ;

: 2". , T IG 'lH i' TE ,N BOLT,S AND NU'TS O"N CHASSIS ,ANDBO ,DYT j 'l gh te n the fol lowing parts: Fro!nt seats rnourrtinq bolts,Torque: 375 kg~c:m(27 ft-Ib, 37 N~m') Front and rear leaf sprinc IU- ,bo l t mount inq nutsTorque: 1,250 kg-em (90 ft-lb, 12:3Nm)

2 3 3 3

2 ' 1

Lu b rtc atl nq P o si tio n s:Steering1~ 81ide Yoke2 '. R :e~ ay Rod EndPropeller Shaft,J.~ Sp ider4 . , S-Hd eY o ke

'I, I

I

-,.--.", ,I

4


22/40

LAND CRU-SER(38,2H ENGINE: 8,HJI SERIESON- V FOR CANADA)

PageIM I AI 'N T :E N AN ,'C E S ,C ,H ED UIL E ,'~ ~ ,~ ,t " " .. ~ ~ ,~ .. ~ ~I 3~2,MIAINTENANCE OPEIRATI'ONS . 'i ~ ~ " ,~ i . ... '" '. 3..4

G E - N ' I I E R ' A ' L N " O .T ' E S - ~ . ' :, 1 -- =. ' . ', ,, . " ." - - - = - . 'W IEvery servlce item in the period ic maintenance tist must be

performed, Failure to do even one item cain cause the engine to runpoorlv and increase exhaust emissions,


23/40

3..IMAINT'ENAINCE SCIHE'O:UILEI M a in te na ln ce o p er a tio n s: C heek and/o r adju st if necessary;

Repl,ac,~'" c han ge' o r lu bricate;'I nspect and co rrect or rsp lacsif necessary

A '_.R --

NORMIAl CQ'ND,ITION SC'HEDULEI .III

--- --Service interval .1 M aintenance . beyond ,96;000 krn should.. services" I(Oldomete ' " r r-ea:dlng or months, b e performed at the same interva Is shown In

System whichever 'first) e a c h maintenance schedule. See paigecomes I , ; I j . - .. (item N l o . ) '\ ._ - I ---. lK m X 1 1 - 0 , 0 0 1 6 24 3 2 48' 6 ,4 72 ,80 '9 6. . . 1I Maintenance items Mlonths 12 1 1 8 ,24 36 48 54 160 72 I-.: '_'- -E.NGINE Valve clearance , A A I A A 38 (ilitlem 1 B ),I II Drive ' belts ~ R I R 3- , 4 (~ite"m1 ,r2),.- _Eng1ine oil l a n d oil filter R ( , 1 ) 35 (item 5 6)~::. :. iI : :.1 ._ . I

-- ,Eng'~n'e 'coolant's' R 36 (item 7)I ~- : ,Ii :Vacuum "~hoses [~ R 345 (item 3 4 }ump 01 _ < -. " -I_ , l ,

Exhaust .. 8 1 f 1 1 d mountings I I[ I I 3=7 (item 12)ipes IFUEL I d l l , e spe-ed r 5 , ) A A 39 (itern 17).' -, - -

I A ir fil te r \ II H I[ I R : 3-6 [itern 8 9)I _ J..: '- .. -! iFue l filter R IR 3 , -7 {item, t 4 .)I I, !Fuel feed 'tilte r II ,~ 3,~7 f 1 3 ;}I

plump I - ,It:em- - - _Injection pump glovernor dia ph lia 'g m oi l~ R R R R 3-8 (litem 1 5). ; ._ !FueJI lines and cion necti o n s I I 37 (ltern 1 1 ")- '

IrIFuel filler cap gasket R I 3 = 6 (item ., 0' )IBRA,KES Brake [ l inings a n d drums I il I I 3~11 (item 2 . 3 ) 'I =I ...Bra.ke pads a n d discs I [ ~ I II 3 , ~ 1 2 (item 24)--Brake line pipes a n d hoses I I I [I I 3,-1 '1 (wtem 22)_CHASSIS S:te,er:~n9 1 I~nk.a,ge ~ I ![ I 3 14 (item , 26 )

IJ~ I j

- --Bali joints a n d dust covers I I I I I 3-14 ~ite',ml 26 )I ":.Tr a ins rn is s io n f transfer, dilfferenti tilI and steerwng I 39 (item 1 8)I I I i _ - - 'gea r bo x O U t3l i I 3 - 1 1 0 ( i tG 'm 19)' .~ --Front wheel bearinq A I R 3-"'i 2 r .25)rease 1 , rternI

I i--Steerinq knuckle an d chassis 9rease'" R R ' A R 3-14 (itern 27)II Propeller shaft g r , e a , s e ( 4 ) R : R R R 3-14 (iteml 27)I II , I

i I -Bolts a n d h ,. Sind body I II I i 3 = 1 6 r 28)nuts on c assrs . I~temN 'OT IE :r( 1 ) Haplace every 6,0 00 k.m or 6 months, but replace oil fi~ter eVlery 12,000 krn or 1 2 months,(2') After 96,000 km or 72 months, replace every 48,000 km or 36 months,, ( 3 - ) rnsp ec t th e stls,sring gear box only for o n le ak ag e . .(4 ) I f th e v ,eh icle has , been irnmersed in wate r, ~tshou Id be ra-qreased with in 2 4 hou rs .(5) Adjust onlv 81t the first 24.000 krh or 18 months an d 48,000 km or 36 months .


24/40

LAND CR,UISER (.3iB,2H E.NGINE) '_, Ma' in t ,enance ScheduleFollow the severe condition schedule if vehicle is operated mainlv under one or more of' the followlnq severe conditions:

.' Towinq a trailer, usingl a camper or car tOPI carrier, Operating 'On dusty, r o uQ lh , mudd .y or salt spread roads. Hepeat snort trips l es s than 5 miles ( ' .8 krnl and ou ts id e temperatures remain b elow f re ez l ng . E x tensive ld Iling such as police, taxi or door-to-door delivery use..

,Service lntervel, (O ~ o m . e .t9. r e. a di n 9 o r . ,m , o n t l h s. "rhrchever cernes f i rs t )

M a n n t e . l i 1 , a n e e! s e r v i ces . b e yond 96.000 krn shou_lIdbepe rio,rl l"rilB"diat the ssrns ~rrterva 1 ; 5 , show!iI iin sa c ,n ,mali nte nance schldu'l e.System ~ ~n ~n an ce i ~~ s . \, ~K _, m_ :X~lr='~=,.=O~=8_.'1_2_+1_1_:6_~2_4~3='2=~3_6='~~~~~~~_6_ 4~7_2~_8 _0~=8=4~8 _8=~~9_ 6~

~ Months ,6'9 1.;2 18 2.4 27 48 54 6'0 63 6:!6 7.2E N G I N E

See pa.ge(item IN o.]

3-8 ,tiitem 16)I o rive be. Its, I: R 3-4 (~tamt,2:~

E n g . ne 0 ' 1 ' 1 and 0 1 1 1 1 f~ter R~1:~R

3-5 (item 5~6)3= 6 ( ite m ] ')

Vacuu m pump 0 i~hose'sExhauc ;t pipes an d m o o - - * - , ,. _.0;1 . 1 " " . . . . 0;1 "" ,_, _ _ un dngs

,FUEL3-7 (item , 2)3 9 O t e ' m , ~7}3,~'6 Utem 8 , . 9 )3,- '1 litem ~4],3-7 (utem 13) ,3~8 ![jrtem 1 5l3~7 (~t.em 11~3~,6 [itern 1iO)

(4}.1L R

Inje'ct~on pem P QIO\l 'Brn0 r d iaph fam oi[1 R R

I BRAKES I Brake l in ingSSlnd drumsBrake' pads ,8 nd discs

R

RJ . - ~ 1 ~item 23~3- ~:2 [item 2:4~

B r a l ka H ne r .: ipes , a . n o i " i h 'os : I ! ' > ,. . . '1 1 " " . ~ . . . . . 'Y ,~ ~8.wlCHASS IS S1ee r in 'g I inkage

: B a~ j o i nts a n d du st: coversI I

R

R-R RfA 'R

1 "r an s mi s .s~on . ua nsfe r, di ffe re.n tl 8 .1 a ndsteering ge~r boxoi~'5)

F e R .

.3-~4 ( item 26~3~14 ~t 6 ' 1 T n 26,~310 (ltem 20)3~,0 ~iftem 2 .. H

Front wh~el bsaring '9 rease R00 II I. Ft RJ

R A R ,( I IR[)In

I I8 0 . . 1 ' ' ' ' ' ' ' and nUII"e on c',h'assis a - , . - . I ; b _.d..I . i I I!.I _ . _ ~ _ ~ ! I Q _ - " un!i..4 ,0. V

NOTE:(1.) Heplace ,every 3", .000 km or 3 months" but replace 0 ' 1 1 filter B , v B l r y 6;000 krn or 6 months,('2') After 96,000 krn or 72 months, replace eV'Bry 48,,000 krn or 36 , months,(3) Applicable when operatlnq mai nilly [ondusty roads. If n ot, f ollo w ' the normal condltion s ch ed ule . .,(4) Heplace e'V'ery-48,000 km or 3[6 months, inspect evn'Y 6,000 krn or 6 , months.{5) II nspect the stee'ring gear box onlv ' for oi l leakaqe,(6) I'f the. vehicle has been immersed ln water" !r t sh ou ld b e rs- gre ased within 24 hours,('7} Adjust only at the first 24,000 kim or '18 months and 48",000 krn or 3 6 1 months.

312 (item 25)


25/40

L ,A ,N O IC ,R UISE R (38, '2H EN'GINE) ~ M;a in tenance Operations

'W IRONG

II

I!I

MAO035

, N:ippondensoI Borroughs

Lack Bo~'t

B orro u q hs,... s

3B Engine

M A ', : , ' , " ' ,, N " , ' , ' . ', E ! N " " : ' -A - - - ' N - ' C - E - ' 0 " ' . ' p - ~ , R , ; A"T ' I - 0 ', ' " ." ', N -" > : . : S . . 1 I . I __ ~ '. '." . ' , "_ _ I . "... . . . . .ENG' I !N IECold Engine Operations1. ~N,S'PECT DRIIVE B , E , L TS

(a) Visuallv check the drive belts for cracks, oiliness owear, Cheek that: the belt does not touch the bottomof the pu IIa 'y qroove,

If necesserv, replace the drive belt,(b) Uslnq a belt te nsio n 'ga u g:9 ',check the drive belt ten.'sron ,B,e'~ttension gauge':Nippondenso BTGi-:2'O(95506 ..00,0'20)

Borroughs N O i . 8'T-33-73F'N lOT'E ; W hen checkinq the tension, b e , 'S ur e t he g a l u ' g e ' ith b I ' ~n t ne ne t protrusions,D'r i ve' be~t tension: A~rCon,!( Used belt) Others

8 0 ' + 2 : 0 : I b ' :.....= I ..10'0 20 IbIf necessarv, adjust the drive belt tension.

2~, R ,EPL ,A CE DRIVE BIE'L,TS(a) Remove the old belts,(b) Insta I a new belt andl adjust it: tO I the specified ten-

,.SI'on ..(c) Usin'g a belt tension gauge" check the drive belt ten~srorr,Belt tenslo n g l B ' u g i 1 9 ' :N : ippondenso

BorroughsDl!ri ive bel t tension:(New belt)NOTE : '. 1 W'hen checking the, tension, be sure the ga:ulg:B is . on thebeIt , p rotru sions, "New belt refers to a belt wh'ich has been use,d l e s s

than 5 minutes on a running enqine, "Used bs I t" .e fers t0 a belt -,h ~-h h 'S b.on sed 0 ' - - a:1 '8 '. ' r: .., i ' . , ~ . . , ~ .c W lea _ ' ~ ' ~ i _ U~l.;oli.


26/40

I 2HI E l ng in e!

MAMOO

DI IESEL e:NGINE-.- I T T I I ..I 1 1W,40 lOW. ~OW~iO ),, , "IF

-- ~,[1/IN-4iI ) , 1eW~50 ")I 1'lOW~3a !, I I -I -I 'Sw:; ._3i) I III

J : . . . _It 30J ,I I rrI %0 -I I-~ I I- ,9F-20 0 20 40 60 : B i D '100tJ ;C~ 2~ 9 -,1,8 -7 > 4 ~8 2 . 1 ' 36r E M P - i S R ' _ A ruft~ iF lA .NGiE, ANT,I I : ; ! PA TED [BEFORE ! INDnr ,0" (:i1"!ArfG e

MA0 4 1 2 '

3B Engine

SST

'.

MA0 4 l 0 J

4 1 REP'L,ACE V,ACUIUMI - PUMP OIL H'O'SES(a ) Rem o ,v e ' th e o ld o il ho ses,(b) Install new oll hoses,After' replacinq, start the enqine and check for oil leaks,NOTE,; Check for oil leaks in the next step, after ,engi'neo il a nd 0i Ifi l ter re p Iacement.

I!

5. , REPLA, ICE E N G I N E 'OI IL(a] , W'it.h the' engine warm, remove the oil drain pluq anddrain th,eoit

(b) C lea n and 'install th e oil drain ,p l iugwith the gas,ket~(c) F'il I1 the engine 'with new .o i l . A,P'I grade c e , , . CD orbetter ..Engine oil cap\8c:i 'ty ( ' lOrain and refill without oil filterchanqe):3 8 eng!lilne 5.8 ~it,ers1(6.1 U ,S qts, 5 1 1 lrnp, qtsl

2H e'lngiine 9.1 liters ( 9 , 1 , 6 US qts, 8,.0 1 1 m 1 P . qtsl

6 I! RE,PLACE ENGINE OIL AND on. FILTER(a ) With the elngine' warm" remove the oil drain pliuig an ddrain the oil,(b] 'Using :S,5'T'",remove the o il filter [located on the right

side of e'ng,ine block),SST 38, E J ' n g i n e 09:228,-,440112 H engine 09 12 28 -6 0'0 " 0 1

(c ) :1 nsta ll a n e w , a , ~ 1 11Iter. ~nspect and clean the oil filter installation su rface. ' Put a :ight coat of enqine oil on the glasket .


27/40

i

L i'glh til 'y 'screw in the fi Iter tOI where you fee II resist-ance,I II~'-, -.,h ", SST i h h '" I f - '" ' I I 3'-/. ' T " en USIng ' : : , , : : - 1 I t~g:rten n e oil trlter an extra '

turn.

(d) C lean a nd install the oil drain p ' lug 'with ,B new qasket(e) IF l~ the engi:ne with new oil. A PI gir.ade c e ' l CD o

better,Engine 'oil eapacltv (Drain an d 'r'efiU w~th oil filter ctl1ange)!38 engine 6.7 liters ( 7 ., 1 1 I U S qts, 5,~'9m p. qts)2H engine 1O~, '1i i ; t e r s , I( 1 l' . , 3 , US qts, '9 ~4 Imp, qts)

7~ REP'L ,ACE EN,G~NE COO'LA,N'T(a) Drain the coolant from radiator and enqlne draicocks , (En g i ne d r, ain ls at II eft. rear of engi ne b lock.](b) C lose the drain cocks.(c) F i 'I ,1 system with coolant,Coolant capacity (wI heater):,38 enlgi:ne 13~,B~iters, (:14~6US qts, 1 2 M 1 lmp, qts]

Drain Cock 2H eng,ine 15,. ,4, ' l i te.rs ' 1 6 1 , , 3 US, qts, '13~6mp, qts)Drain Cock.

MAO07 ' 5

~~

8, ! IN S PE CT ' A I'R F I'L 'T E R(a) Visually check that the air cleaner element Is not ex

csssivelv dirty" darnaqed or oily ..!I f necessary. rep lace the air cleaner element,(b) Clean the, element with compressed air.First blow from inside throuqhlv, Then 'blow' off the ouside of the element.R,E:P,L ,ACE AI IR Fill TE,IR~ - - ---Rep~ac,ethe u sed a ir cleaner element 'with a new one ,

10i 'REPL,ACE GASKE ' l ' IN FU'E,L FILLER CAP,(a ) Rem ove the fou r screw s a ndl Io ck 'i n9 plate, Pullout

the, old gasket ..(b ) ~Ista l l the new qaske t by hand .. Install the lockin

plate 'with four screws .


28/40

BJ 70. Sa r le sMAOO57 ,MA02. 4 5

F ug- F e , ' I ~ , d , . - P :- rn p F ~ II i t l " ~ -C~ U,' __ IL~r

11. IN SP 'IE ,C 'T FUIE,L ,L ~N ES A N ID C ON N EC TIO N :S( 'a) Visual Iy inspect the, fu el lines fo r cracks, l eakaqe

loose connections or deformations.

(b) Visually inspect the fuel tank vapor vent s vs te rn ho se sand' connections for looseness, sharp bends or damage.

( C ' ) I Vlsuallv inspect the fuel tank 'for deformation, cracksfuel l eakage or tank band looseness,'(d) Visuallv inspect the filler neck for darnaqe or fuel

le a ka 9 ' 9 , . ,

1 ,2 ., IN S P'E C T IE"X,IHAU',ST PIP'E,S , AND MIOUNT I INGSV,~, _~1'-' i n s c ct th ,- -,,-:",' , = ' - ' hat '"-,e r s ' and C " , : _ ' O ' , : n _ nectio n _- 5 , - for,'HiU3 ~ Y w , ,~p, ec ., , . 'e p Ilpes, '; nQ_ '~ Ii',sever, ! corrosion, leaks or darnaqe ,

13 t, : IN SPECT FUEL FEED PU,MP' FIL TEiR(a) Hemovs the 'inlet union bolt from the feed purno.(b) Rem,Qve the filter from the union bolt,(c) Clean the filter and check the damaqe ,"d) I nsta I iI th e fiIter 'to the, un ion bo lt,(e) lnstall the union bolt tOI the feed pump with ,8 new'

ga'skat.

1 -4 ". R E ,P L ACE IFUE,L FI L TEIR(a) 'Usingl SST, remove the fuel fIter (located on theintake man ito l id).SST 09228,34010(b) [I nstal I a n!8W fuel filter,

Put a light coat of 'fuel: on th e qasket, Hand tighten ONLY~ 00' NOT ' use a wrench to

tigihten th e flter,


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3..

IMlAOO62 i

1 3 B '. : ' , ' .Front

I IN EX U\1 EX I~ EX

2H 1, ,

MA0252

(c) After insta IIinq, bleed alr from fuel filter by operatinqthe prirning pump, Turn the priming! pump knob , counterclockwise to

' f r , e ' e it. 'L o o sen the f ue l filter bleeder pl lugl and operate thepriming pump plunger until no air bubbles comaout: of the p ~uQ~

1( ' d ) A fter b [Iee d ing a ir I c- he c k to r fu ell I e a k s .,

' . L o c ik the prim ing pump plu nger a nd then tightenth e fu e I fIter b,leeder !p luq,

115. I J [NS IP 'ECT I [NJECT I 'ON PlUMP' GO 'VER INORDIA IPHR,AGM DI[L( :a ' ) ' A am o v e the screw : P ~ I U ' gfrom th e g o ve rn o r hous inq,(b) Supplv the diaphragm with 2 - 4 drops of the properdiaphragm euR eco rnm ended d i ap hraqm 0i I[

N ID Part No, 995500-0'140'BO, S,'C 'H P art. N o. 0 L-, ,3 '6V'1

Hot Engin1e Operations'16~ A,DJIUST VALVE CLEARAiNCE

(a , ) ' Warm u p the engine to norma l operatinq temperature.(b) Stop the eng ine an d remove the v.ave cover,(c) Ad] ust the valve clearance,

Start the enqine,.' Use 'feeler ig,augeto measure between the valve stern

and ro ck er arm . Loosen the' lock nut and turn th ea dju s. tin g s crew to set th e proper c learance , Holdthe adjustinq screw in oosition and tiqhten the locknut,

H echeck the clearance. The feeler g .a u g e s ho u l dmove with a very sliqht drag,.Valve clearance: Intake 0.20 mm (01008 in.)Exh,Bust O,~3 ,6mm (0 ..01.4 int)(d) Re insta U the va l ve cover.

,-,,


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,3 B E,ngli:ne 2 H E ng 'in e

,I

Fu ll ~Throttl eAdjust ' ~W 1 ! , g Screw Fu I~IThr ottle~ Adjusting Screw

MA040U

3 B E ng ine 2 H E ng ine'

Sto.p P I Ia 'to e', . . . . _ . IAdJ'ust'inn Screw .. . , . _ _ . , . _ : : : t . . . . . . ' . . . '. . ' S " " . P ' ~ . " -.: . .,~~t(]P ~Iate'? A dlustl S ' . J u S 1 J n g :'Cf,9W. , . - '.. . . . . . .... . ..

.

F i ll e r Plug for ' T IM I

........Filler P~ulgfor Tr ansfar

M,M053MA0256

MAm)53M.AiCt2'11

' 1 ' 7 1 ' AIDJUST IDLE SPEEDfa) ~nitial conditions:

Air cleaner installed Eng'ine coolant normal operatinq temperature Accessorles switched off T ran sm issio n in neutral

[b] Check that the venturi lever touches the, futlthrottleadjustinq screw when the accelerator pedal is , de-pressed a n the w ' a y~

I ( C ) Check that the venturi lever touches the stop plataadju stlnq sc rew ' when th e accelerator pedal is released,If not, adjust the accelerator linkaqe.

l td) II nstall a tachometer to' the enqine,(e) Start the engine.(f) Check the enqine ldle speed.I :dle speed: , 3B , , e n l g : i : n e 65;0 rpm2H enlgj1n,e ( 'MiT ) , 650 rpm(AIT) 750 rpmlf not specified, adjust by turning the stop plate adjustinqs,cre'w . .

T!R,ANS,M,ISSION"IBt 'CHE,C,K OIL 'L 'E V'E L, II 'N MAINIUAL T 'RANSM' IS ,S I : 'O 'N"

T RA ,N ISFE :R ,A N ID IDIFFEIR,ENTIALRem'OV8 1 the ftller p' lug and fee,i inside the' hole with y o u rf ing~-rr~Check that the oil COlm:9S to within 5 mm (0;,20 ln.)of the bottom edge o f the hole, If the leve!1 i-slow" add oilunti I 'it b e, g'ins to ru n ou t of th e fi II ler ho,le.


31/40

LANID ,C1RUISER (38,2M !ENGINE) ~ Maintenance Operations

Add j'f hot

Drain P ' ~ u g(for MifT) iDra~nPlug(for T ra ns fer) " .

MAOO6 J ,

1 ' 9 ' 1 CHECK :FlU ID L I EVEL , IN AUTOM.AT'ICTRANSMISSIONNIOTE . : The vehic le m ust ha ve been driven so that theengi 'ne and: transmission a re at normal operat inq ternperature, (fluid tem perature: 70 - 80 :oC or 15,8 -= 176 0 F(a ) Park the veh tete o n a !ie V' e~ :surface"(b) W ith. the en'gine id I inq, shift the sel iect ,o r into each

glea ' t f rom the lip" range to the Ii L" ranqe and returnto the "P' range again.(cl PuII out the transmission dipstick and 'w ~pe it c lean(d) Push it back fu I I 'y into the fi ller tube,(e ) Pull it out a nd c he ck that th e 'flu j'd le ve l 'is in the HrDTranqe,If ' 1 1 o W I add flu id.Flu i ,d type.: A TF D EX RiO 'N @; nC,AUT'IION:: Do not overfill.

201 t, R.IEPLACE, MANUAL TRAN,SMISSIONI, TRA ,NSFERAND DIF FEREN'TIAL 01 L,[a} R em ove the drain pllu 'Q an d drain th e oil .(b) R:einsta ti l the drain pluq ,(c) Add new 0n unti I it blegl~nsto run out of this fi llehole,Transmiss ion and t l ran 's fer O ill ~o u gr' ,ade: A , P i l G L -4 or G l-5

V i it S ' A ' E ' seSCOSl.y :,' ",Capacity: TransmissionTransfer

4 ' M 9 Iiters(5.2, US qts, 4.3 lmp, qts)(M / T ,) 2 ,. ,2 lit ers ,(2.3 U I , S qts, 1~.9Irnp, qts](AIT) 2~1 Iitelrs(2~2US qts 1~8rnp, qts]

Differ,el",_tlia~: oil -Oi g.ra,de:V iscosJ l ty ' : '

A IP ' I G L - 5, h ypo id gelar oilA.bo've -18,0.C ('0F) SAE 90Be, : l ow -1S 'oC (0 F) SA ,E 8 0W . .9 0 1 o rSOW

Capacity =Front.Haar

3.0 : l li te r s ( 3 ,~ ,2US qts, 2.6 I:m p. qts]2 ..5 liters t2.6 USqts, 2,.2 Imp, qts]

,21. RE,PLACE A,UTOMATIC ' TRAN ISM ISS , ION FILUl iD(a') Remove' the draln p'!UQI an d drain th e tluid.(b} Reinsta II the drain pil lug secure Iy.Torque: 280 kg-ern (.20 ft-tb ..27' N~;m)


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l L A NO CR'UISER. (38,2H 'E N GfN E } - M a 'intena nce Operations

OK]f hot

MA0166

M A O O & : 5

(c) Pour ,A'T,F through the f il ler tube,FI "d~ A T F 0- r E X " '- R " 'O N @ n1 m : i : ': ,I, > ~,'""',,, ,(d) W 'ith the engine ~,ding, shift the selector into eachgear from the ~~" ranqe to t 1 h e : JI L " ranqe and return

tOI the /I P" range aqa in ,(e ) With the enqine iddingls check the fluid l ev e LAdd fluid up to the JlCOOl"" ' leve l on the dipstick,(f) Check the fluid leve l with the no rm a l flu id t.em -perature' ( '7 0 - , B O a C or 158, ~ 1 7 , 6 @ F) and add a snecessa tv,CAIUT ON: Do not overfUI,Drain and refill capa,city:5 . ,0 l iters ( . 5 , , 3 US qts, 4 .4 Imp, qts)Drv filiI capacity:'15.0 liters (116.9 US qts, 13,.2 Imp , qts)

BRAIKES22. IN,S,PECT BRAKE L,INE P I I P E , S AND HOSIES

N O i'TE~ , I nspect in a 'w ell ' l I iqhted area, Inspect the entirecircumference and length of the brake hoses usIng a mirrora s requ ired, Turn the, 'front w heels f'u Uy riqht or leftbefore' inspecting! the front brake,(a) Check all brake l ines and hoses for:

.' Corrosion.' Leaks D am a qe Wear'. Deformation C ra cks

[b] Check all clamps for tightness and connections forl sakaqe.

(c) Check that the hoses and lines are clear of 'Sharpedges,. rnovinq parts and, the exhaust system

(d) Check that the lines installed in grommets passthrough the center of the qrornmets,

Bends Twists

2 :3 ~ , I N 'S ,PEC T IRE.AR BR,AKE LI'NliNGS AND DR.UMS,(a ) 'C heck the Iininqs for ' w ' e a r - ,Min'ilmum lining thickness: ' 1 ~ 1 5mm ( O ~ I O I 5 1 9 in,l(b) Check, the brake drums for scorinq or wear ..Max im um drum inside d iameter : 297 m m ('11 .6 '9 in.,)(c) Clean the brake parts, with a damp cloth.N OT iE: D o not u se compressed air to clean the brakeparts ..


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3..12 LAND CRUIISER (~,B,,.,H ENIG I INE ) I~ ' Main tenance , Operations

MAD.2 ' J 8 I

MA0'222

MA02 '2' J ',

24 . ~N SPEiC T FRON T ' BR ,A IK E P ,A DS A N D D I 'se,S(a) 'Check the thickness of the disc brake pads and check

for lrrequ la r wear,Mirnimum pad thlckness. '1],tOmrn (0,,039 in.)[b) Check the disc for wear or runout,Mi :n imum ' disc th ickness: 1 '9 1,. 0mim (0. ,748 in.],Maximu'm' disc runout: IO~15 mm (010059 in.]

CIHASSIS25. RE ,PA CK FRO 'N T' 'WHEEIL BEA, IR INGS,

I(a) Chanqe the front wheel bearinq g lrease . . Remove the hubs and inner a'nd outer bearlnqs.Clean 'in solvent and 1ispect the bearinqs ford am a qe ..'. Pack the bearings and ax , e' hubs with lithium basemu ltipu rpose , g rease . .

Glr,ease 'gr'ade:' Lithium base multipurpose g r e ' a l s l e(N - G N 2-\" L , ' . '.'10. 'I

(b] . I nstall the h ubs, and adjust th e 'whee~bearinq preload. Us'inlg SS'T, tighten the adjust nut and turn the hubright and left two or three' times,

S,ST 09607 '~6010 '2 '0Torque:' 600 kg-ern (43 ft-lb, ,5 9 Nm)

Loosen this adjusting nut until 'it ca n be turned bvhand,

Retiqhten the adlustinq nut,Torque: 40 ~ 70 k.g-,cm(35 - 60 in-lb. 4 1 0 - 6.8 ,NI~ lml )

'. Insure that the hub turns srnoothlv and there 'is noplav : in t he b ea rin q,


34/40

LAND CRUISER (3i8,2:H ENGIN:E) - M1aintenance Operations

M1A0225

U:s~nga spring tension glBuge, check to r correct pre-load,Front wheel bearj ,ng ' fr ii ,c t, ii o ,n preload (at:startilng poinit):0 '1 4 - 3 , .3 k g (: O~9- 7 1 3 I r b [ , , 4 _ , 3 : 2 [ N 'Ilf the,preload is incorrect, loosen or tighten the nut to cor-rect 'the preload.

I'I[

I

(c)[ lnstall the, lock. washer and I O C i k nut.(d)' Lock the adiustinq nut bv bendinq one of the lockwasher teeth 'inward ..

(e) Usjng SST', tighten the lock nut,.SS,T'109 16,07-6,OO:20Torque: :8[00 kq-cm (,58ft..b, 78 N1m l )(1] l.ock the lock nut by bend ing one of the lock washerteeth outward,

(gl) Recheck the preload at the hub bolt.F o n t , " , " , h - : -C \ e l b e a 'ing-'riction p"reload (at s t a r t i n q point):o ,W .,. _ _ ._r ._ _ _II! ... ". _.. . ." , .O~[4__3 ~ .3kg ( '-0.9 1 . . . . . . . 7~3lb , 4 _, 3 2[ N )

I,


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,3..14 L~ND CRUIS:E,R (.3 8, : 2"H EN G IN E,) - Maint,enance Operations

,27~ LUBE STEERING KNUCK[L,'E,~CHASSIS ANDP'ROPELLER S,HAF 'T(a ) [Remove the screw phJQ : 'from each steerinq knuckleand repack with hJbrilcant~S te eri n g k nu c kle g r r e a s a - M o l yb de nu lm d i su Ip h i delithium base chassls 'grea,S8 (N LG i l [N o , ~2 )(b) iReinstall the two screw plugs..(c) [Lubricate chassis components, bv referring to' the

lubrication chart" Before purnpinq in grease, wipe off~~~~~~~~~~~~~~M_M_22_9~1 any ~ u d a n d dust on t h e g r e a s e f i t t ~ n g .

Grease grade:Steering link ends . .. .. .M olybd :e lnu ,m diisullphlide lithium base chas si s g rea sefNLGI No,. 2)Prope~lershaft .......Lithium base chas si s grease (N:LGI' No.2)(d) Check the steering linkage dust seals 'for damage . .

MAt)fl13

26 ~ I I N S 1 P E C T S,TIEE:RINIG L,INKAGE, G iEA R 'B 'O 'X .,BALL JOIN'T AND DUST COVER(a l ) Check the steering linkage for looseness o r darnaqa.

Check that: Tie rod ends, relay rod ends, center arm, shimmvdamper and d rag li nk do not have excessive play~

Dust seals ar e not damaged"(b 1 Check the steeri ng qear box for oil teaks ,(c) ~nspect the bal [I[oint for excessive looseness.(,d) lnspect the dust cover for damage,


36/40

IL A N ID C R'U IS IE R (38,2H E NGIIN E .) ~ M a iinte 'na nce Operations 3 ...1 15 ''-.'

3 3 3

,I 'I I I"I

2

IIII I

Lu bricatlon Positions:Stee'r'~ng1. Slide Yoke2. Ael ,8Y Rod End

2 3 3

Propelter Shaft3 S '"d. " 1 " / _ .. . . ..p ,~ er4~ . s ~ide Yoke

42 11

- : - 1

L bri . p .. 'ur ncation ,OSltions,:Steering1. Sl ide 'Yoke2~ Rlei ay' R ad EndPropeller Shaft3. Sp:ider4 ., Slide, Yoke

MAU2 6 2


37/40

3-16 LAND CRUISER ('38,2H IENrG IIN I ,E ,) - Ma i ntena .n rce Operations

MA011 '6MJi. - - - II . .. . . 023. ,2

28. ' T I IGHTEN ,BOLTS AN'D N IUTS ' O N I C'HA,SSIS ANDBODY'Tighten the foUowing parts:.' Front seats mourrtinq bolts'Torque: BJ70 4 00lkg-c m (2:9 ft-lb, 3 9 !N~m),HJ60 375 kq-cm (27 ft-Ib" 37' Nm)'.' Front and rear leaf sprinq U-bolt rnountinq nutsTo rque : 1,25,0 kg..em (90 ft Ib, 12,3 N ' -m )


38/40

, A . .'

AP'PEN' O'IIX . . 1 . ; . < . , _P ' a g e

O E,N ER A,L , M AI,N 'T 'E ,IN AN CE ~ I ~I ~ I I ~ ' ~ i i t ,i i' A 2


39/40

A-2 A ..PPE INDIX _ , G enera! IMaintenlan,ceG EN ER,AL M,AIN 'TE,N A :N CE (b) Check the nleadHglht a im .

8. WARINl l iN IG iL I 'G :HTS A ND BUZZERSThese are the m aintenance a nd lnspections i tems'which are considered to b e th ,e o w n er's responsibil-itv, Thev can be performed by the owner or theycan have them done a t a service shOIP" T'hese i tems .include those which should be cheeked on a dailvb . th h'" h "' d ..SIS, tnose w _ JCI~I lin most c.ases,,_o not require(speclal] tools and those which are considered tob, e reasonable fo r the owner to perform,I tem s and procedures 'for g,en'era~ maintenance area s fotlo ' --,,~-_ , __ WS,

Check that all war-n'inlg Iights and buzzersfu net ion proper Iy '.9 1 H!ORN

Check that it is workinq,10,. W1IN D S,H IE LD G L "A SS

C heck for scratches, pits or abrasions.1'. W'I INDSHIELD W i I P E R , AN!D WASH E.R.

(a) Check operation of the wipers andwasher.(b) Check that the wipers do not streak.

QUTSI,DE VEH' , IC!LE1.. T~RES

(a) Check the pressure with a gauge. If nec-essary 1adjust,(b) Check fo r cuts, damage or excessiv e w ea r ~

1 1 . 2 . . W I ,N D S ~ H I EL,D' DEFROSTERCheck that air comes out from the defrosteroutlet when operating the heater or alrconditioner.. WIHEEL N'UTS

When checking the tires, check the nuts. forlooseness or for m issing nuts. ~f necessary,tighten them,13. iREAR VIEW MIRROR

Check that it is mounted securely.31 T I RE ROTAT'ION

It is recommended that tires be rotatedevery 7t500 m il es '('1 2;0 00 krn).

1 4 ' 1 SU'!N VI 'SOR,SCheck that thev mo v e freelv a nd a re mounted!secu rely.

4. W'INDSHIELD WIP,ER BLADESCheck for wear or' cracks w'hs 'never theydo not wipe c le an .. If necessary, replace,

1 51 , S ' T 'E E R . I I N I G 'W H E , E LCheck that it ha s specified freeplav. Be alertfo r c ha ng es in steerlng condition, such as hardsteering, excessive freeplav o r strange noise.

5~ FILU'ID LE ,AKS l(a) Check underneath 'for leakinq fuel, o n ,wa te r o r other f Il u id~fb ) If v o u smeU ga so iline fume's o r noticeanv leak, have the cause found andcorrected,

16! SEATS(a ) C heck that a I I f ro n t seat con tro Is.su ch a 's

seat adjusters, seatback reel iner, etc. op-erate srnoothlv ..(b) Check that a ll latches l ock securelv in

an-y position.(c ) Check that the l ocks hold securely ina nv latc hed posit io n~(d) Check that the head restraints move upand down smoothly and that the locks

ho~d securely i'n amy latched position,(e) Fo r toldinq-down rear seat backs, checkthat the latches lock securely.

16~ :D'O'ORS A I ND E,NGIN!E H!DOD(a ') Check that alii doors inc ludl n91the backdoor operate smoothly, and that alllatches lock securely.(b) Check that the enqins hood secondarylatch secures the hood from openinqwhen the prirnarv latch is released.

INS , I IDE V1EiHICLE7;. LI:GiHTS

(a) Check that the headl l ights, stop I m g n ts ,te i'i9ihs turn signa I Iights;.. a nd otherJ i ,ghts a re a I ~ wo rki ng .

17. SE,AT BEll TS(,a ) Check that the seat belt bu ck lesj retrac-tors and anchors operate properly and

srnoothlv.


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A PP'EN 'O IX .......Ge'nera,!1 M,a in tenance A3''"" , :",'(b) Cheek that belt 'we,bbing Is not cut,frayed worn Of demaqed , :27~ B'RAKE ANID CLU'TCH FLUID L~E'V'E,LS(a) Check that the brake ftuld l eve l is nea rthe upper level !Ine on the ses-throuqh18,., A CC :EL ,EIRA 'TO A PED AL'Check the pedal for smooth operation and un-even pedal effort or catch i 'ng!.

.,reserve I, r .,(b) Check that the clutch flu id l eve~ is up tothe, top of the narrow neck of the see-throuqh reservoir.19:~ CL,UTCH PiEDA,l

(a) Check the pedal for smooth operation.(b) Check the clutch booster functlon.

28~ ENG'INE ,DRJVE BELT ,SCheck aII drive belts for' fray"ing, cracks" wearor oiliness,2 0 " 'B 'R "A '" K E P ' I E , D A : L. Ii I t J ," .", ," . . 1 _ ' . : . , 1 I

(a) Check the pedal for smooth operation.(b] Check, the brake booster fu notion.

29. ENGI,INE, ,OIL L,EVELCheck the, leve~ o n the dipstick with the en-gin,e turned off"21. BR ,A K,ES ,

At a , safe place, check that: the brakes do no tpull to, one side when applied,:3;0. POWER, STEERING FLUilD LEVE!L

Check the level on the dipstick.The level should be in the lj'HOTl1 or nCO'LDpranqe dependlnq on the Huid temperature.,2. 'P,ARKING BRAKE

(a", Check that the lever has the' propertrevel,(b)' 0 n a ' S a f e i: nc ~ n e t check that vehic le 'i sheld securelv with on ly the' parkinqb rak e ap 'P " lie..d," , " " r= . . I",": ! I I !

31 1 E,XH,A IUST SY,STEMVisuallv inpsect for cracks, holes or loose : S U I P -ports,~f any cnang,e in the sound of the exhaust orsmall of the exhaust fum es is noticed, haveth e' c au se located and corrected.UND:ER: I HOQ ,D

23~ WINiD,SHIELD' 'W A SH EIR F 'L ,U 10Check that there j's sufficient flu id in thetank ..

24. ENGilNE COOLANT' LEVElLCheck that the coolant level is between the"F U L,'LI'I and UL 'OW ' iI ' l in es o n the see-through

~r ese r vo ill r ~25~ R,A,DIATO,R A'NO HO,SIES

(a) Cheek that the front: of the radiator isclean and not blocked with leaves, dirtor buqs,(b .) C heck th e hoses. fo r cracks, k inks " rot . Olrl o ose connections,

26. BA'TTERY ELE.'C'T 'ROL VTE LEVELCheck that the eleetrolvte l eve~1of a i I batteryC;OI~ 1 - is bet veen th e ' - - - e-- a d l ower ~Ioel!Oi:1 S t< _'~I,WT:irrt: i1 ~~_I_-: u p 'p f _ n '_ . , ~ _ ~ , ~ v -:1nss on th e case, lf level W S lo w a nd d i s tm liedwater only.

maintenance procedures 60 series

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