TOYOTA LAND CRUISER 1998 Factory Repair Manual

CodeMaterial
nameHeat*
resistant
temperature
limit °C (°F)Resistance to
alcohol or gasolineNotes
AASAcrylonitrile
Acrylic Styrene80
(176)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease.)Avoid gasoline and
organic or aromatic
solvents.
ABSAcrylonitrile
Butadiene Styrene80
(176)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease.)Avoid gasoline and
organic or aromatic
solvents.
AESAcrylonitrile
Ethylene Styrene80
(176)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease.)Avoid gasoline and
organic or aromatic
solvents.
ASAAcrylonitrile
Styrene
Acrylate80
(176)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease.)Avoid gasoline and
organic or aromatic
solvents.
CABCellulose
Acetate80
(176)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease.)Avoid gasoline and
organic or aromatic
solvents.
EPDMEthylene
Propylene100
(212)Alcohol is harmless.
Gasoline is harmless if applied only
for short time in small amounts.Most solvents are
harmless but avoid
dipping in gasoline,
solvents, etc.
FRPFiber
Reinforced
Plastics180
(356)Alcohol and gasoline are
harmless.Avoid alkali.
EVAEthylene
Acetate70
(158)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease).Avoid gasoline and
organic oraromatic
solvents.
PAPolyamide
(Nylon)80
(176)Alcohol and gasoline are
harmless.Avoid battery acid.
PBTPolybutylene
Terephthalate160
(320)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PC
Polycarbonate120
(248)Avoid gasoline, brake
fluid, wax, wax removers
and organic solvents.
Avoid alkali. Alcohol is harmless.
HANDLING PRECAUTIONS
1. The repair procedure for plastic body parts must conform with the type of plastic material.
2. Plastic body parts are identified by the codes in the following chart.
3. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding,
painting etc.), consideration must given to the property of the plastic.
*Temperatures higher than those listed here may result in material deformation during repair.
PLASTIC BODY PARTSPP-2

CodeMaterial
nameHeat*
resistant
temperature
limit °C (°F)Resistance to
alcohol or gasolineNotes
PEPolyethylene80
(176)Alcohol and gasoline are harmless.Most solvents are
harmless.
PETPolyethylene
Terephthalate75
(167)Alcohol and gasoline are
harmless.Avoid dipping in water.
PMMAPolymethyl
Methacrylate80
(176)Alcohol is harmless if applied only
for short time in small amounts.Avoid dipping or immersing
in alcohol, gasoline, sol-
vents, etc.
POMPolyoxymethylene
(Polyacetal)100
(212)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PP
Polypropylene80
(176)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PPOModified
Polyphenylene
Oxide100
(212)Alcohol is harmless.Gasoline is harmless if
applied only for quick wiping
to remove grease.
PS Polystyrene60
(140)Alcohol and gasoline are harm-
less if applied only for short time
in small amounts.Avoid dipping or immersing
in alcohol, gasoline, sol-
vents, etc.
PUR Polyurethane80
(176)Alcohol is harmless if applied only for
very short time in small amounts
(e.g., quick wiping to remove
grease).Avoid dipping or immersing
in alcohol, gasoline, sol-
vents, etc.
PVCPolyvinylchloride
(Vinyl)80
(176)Alcohol and gasoline are harmless if ap-
plied only for short time in small amounts
(e.g., quick wiping to remove grease).Avoid dipping or immersing
in alcohol, gasoline, sol-
vents, etc.
SANStyrene
Acrylonitrile80
(176)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease).Avoid dipping or immers-
ing in alcohol, gasoline,
solvents etc.
TPOThermoplastic
Olefine80
(176)Alcohol is harmless.
Gasoline is harmless if applied only
for short time in small amounts.Most solvents are harm-
less but avoid dipping in
gasoline, solvents,
etc.
TPUThermoplastic
Polyurethane80
(176)Alcohol is harmless if applied only
for short time in small amounts
(e.g., quick wiping to remove
grease).Avoid dipping or immersing
in alcohol, gasoline, sol-
vents, etc.
TSOPTOYOTA
Super
Olefine Polymer80
(176)Alcohol and gasoline are
harmless.Most solvents are
harmless.
UPUnsaturated
Polyester11 0
(233)Alcohol and gasoline are
harmless.Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.
PLASTIC BODY PARTSPP-3

HANDLING PRECAUTIONS ON RELATED COMPONENTS
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
The TOYOTA LAND CRUISER is equipped with an SRS (Supplemental Restraint System), such as the driver
airbag and front passenger airbag and seat belt pretensioners. Failure to carry out service operations in the
correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing, pos-
sibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system,
it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of
parts, inspection or replacement), be sure to read the following items carefully, then follow the correct proce-
dure described in this manual.

Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic
trouble codes become the most important source of information when troubleshooting.
When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes
before disconnecting the battery.

Work must be started after 90 seconds from the time the ignition switch is turned to the ºLOCKº position
and the negative (-) terminal cable is disconnected from the battery.
(The supplemental restraint system is equipped with a back-up power source so that if work is started
within 90 seconds of disconnecting the negative (-) terminal cable from the battery, the SRS may
deploy.)
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by the
audio memory system.
Then when work is finished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory system, never use a back-up power supply from outside
the vehicle.

Even in cases of a minor collision where the SRS does not deploy, the passenger's airbag assembly,
the steering wheel pad and seat belt pretensioners should be inspected.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs.

Never disassemble and repair the airbag sensor assembly, steering wheel pad in order to reuse it.

If the airbag sensor assembly, steering wheel pad have been dropped, or if there are cracks, dents or
other defects in the case, bracket or connector, replace them with new ones.

Do not expose the airbag sensor assembly, steering wheel pad directly to hot air or flames.

Use a volt/ohmmeter with high impedance (10 k
/V minimum) for troubleshooting of the electrical cir-
cuit.

Information labels are attached to the periphery of the SRS components. Follow the instructions on the
notices.

After work on the supplemental restraint system is completed, check the SRS warning light.

Before repairing the body, remove the SRS parts if, during repair, shocks are likely to be applied to the
sensors due to vibrations of the body or direct tapping with tools or other parts.

Do not expose the SRS parts directly to hot air or flames.
NOTICE:
1) The maximum ambient temperature tolerance is 120
°C (248°F) for the front airbag sensor, 105°C
(221
°F) for the center airbag sensor assembly and 93°C (200°F) for the steering wheel pad, and
front passenger airbag assembly. If it is possible that the ambient temperature may reach or ex-
ceed the temperature limit, remove the sensors and the steering wheel pad from the vehicle or
protect them with a hot insulation material before staring work.
2) Prior to welding, remove adjacent SRS parts form the vehicle or protect them with fire-proof cov-
ers.

If the vehicle is damaged, visually inspect for damage to the steering wheel pad using the inspection
procedures described in section RS of the repair manual for the relevant model year.
INTRODUCTIONIN-6

STEERING WHEEL PAD (with Airbag)

When removing the steering wheel pad or handling a new steering wheel pad, it should be placed
with the pad top surface facing up.
In this case, the twin-lock type connector lock lever should be in the locked state and care should be
taken to place it so the connector will not be damaged. In addition do not store a steering wheel pad
on top of another one. Storing the pad with its metallic surface up may lead to a serious accident if
the airbag inflates for some reason.

Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is
very dangerous.)

Grease should not be applied to the steering wheel pad and-the pad should not be cleaned with de-
tergents of any kind.

Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), without
high humidity and away from electrical noise.

When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the
steering column near the combination switch connector before starting work.

When disposing of a vehicle or the steering wheel pad alone, the airbag should be deployed using
an SST before disposal.
Carry out the operation in a safe place away from electrical noise.
FRONT PASSENGER AIRBAG ASSEMBLY

Always store a removed or new front passenger airbag assembly with the airbag deployment direc-
tion facing up. Storing the airbag assembly with the airbag deployment direction facing down could
cause a serious accident if the airbag inflates.

Never measure the resistance of the airbag squib.
(This may cause the airbag deploy, which is very dangerous.)

Grease should not be applied to the front passenger airbag assembly and the airbag door should not
be cleaned with detergents of any kind.

Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without
high humidity and away from electrical noise.

When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed
on the glove compartment finish plate at the left side of the glove compartment before starting work.

When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an
SST before disposal.
Perform the operation in a safe place away from electrical noise.
SEAT BELT PRETENSIONER

Before doing any operation which will apply a strong shock to the vehicle, or before removing the
seat belt pretensioner, be sure to apply the sensor shock.

Never disassemble the seat belt pretensioner.

Do not subject the seat belt pretensioner to shocks or bring magnets close to it.

Do not expose the seat belt pretensioner to high temperature or fire.

Do not drop the seat belt pretensioner. Never use a seat belt pretensioner which has been dropped.

Never install the seat belt pretensioner in another vehicle.

Store removed seat belt pretensioners on a flat, stable surface.

After frontal collision, always check whether the seat belt pretensioners have been activated.

When disposing of a vehicle or the pretensioner by itself, always activate the pretensioner before
disposal.

The seat belt pretensioner is hot when activated, so let it cool down fully before you dispose of it.
Never apply water to the seat belt pretensioner.
INTRODUCTIONIN-7

Component to be alignedSection of repair manual for
relevant model
Front WheelsSuspension and Axle (SA) section
Rear WheelsSuspension and Axle (SA) section
Plopeller ShaftPropeller Shaft (PR) section
AIRBAG SENSOR ASSEMBLY

Never reuse the airbag sensor assembly involved in a collision when the SRS has deployed.

The connectors to the airbag sensor assembly should be connected or disconnected with the sensor
mounted on the floor. If the connectors are connected or disconnected while the airbag sensor as-
sembly is not mounted to the floor, it could cause undesired ignition of the supplemental restraint sys-
tem.

Work must be started after 90 seconds from the time the ignition switch is turned to the ºLOCKº posi-
tion and the negative (-) terminal cable is disconnected from the battery, even if only loosening the
set bolts of the airbag sensor assembly.
WIRE HARNESS AND CONNECTOR

The SRS wire harness is integrated with the cowl wire harness assembly and floor wire harness as-
sembly. The wires for the SRS wire harness are encased in a yellow corrugated tube. All the connec-
tors for the system are also a standard yellow color. If the SRS wire harness becomes disconnected
or the connector becomes broken due to an accident, etc., repair or replace it as shown on page.
2. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in section BR of the repair manual for the relevant model year when handling brake sys-
tem parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC
system.
3. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions
given in the repair manual for the relevant model during alignment and section Dl of this manual.
4. COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to the body panels. Strictly ob-
serve the following precautions to prevent damaging these components and the body panels during
handling.

Before repairing the body panels, remove their components or apply protective covers over the com-
ponents.

Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body
to ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
INTRODUCTIONIN-8

Lift-Up Type Swing Type: High Strength Sheet Steel
HIGH-STRENGTH STEEL (HSS) PARTS
Generally, High-Strength Steel (HSS) is that which has an intensity value of at 35 kgf/mm2 (343 MPa), and
distinguished from mild steel.
The handling of HSS is the same as for mild steel, but the following should be observed.
1. Panel Hammering: Because HSS is thinner than mild steel, care should be taken to avoid warping dur-
ing hammering operations.
2. Removing Spot Welds: Because HSS is tougher than mild steel, damage will occur more easily to a
regular drill. Therefore, an HSS Spot Cutter is recommended.
Also, use a high-torque drill at low speed, and supply grinding oil to the drill use.
3. Panel welding: Panel welding procedures for HSS are exactly the same as for mild steel. Plug welding
should be done with MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than
specified.
BODY PANEL CONSTRUCTIONCN-4

mm in.
150
2505.91
9.84
QUARTER PANEL (CUT)
Replacement Parts
QUARTER PANEL
HOW TO USE THIS MANUAL
Each repair method description provided in Section RE of this manual comprises two pages, divided into 2
blocks (REMOVAL AND INSTALLATION) and includes illustrations to facilitate body repair.
BODY PANEL REPLACEMENT
RE-28
REMOVALCut and Join Location
Cut and Join Location
150 mm
250 mm
[Cut and Join Location]
Cut and Join
Location
(Cut Location for
Supply Parts)
[Cut and Join Locations]
1. Cut and join the parts at the locations as shown
above.
REPLACEMENT PARTS AND METHOD
(CUT)
Replacement method
(ASSY) Assembly replacement. . . . . . .
(CUT) Major cutting (less than 1/2 of parks used). . . . . . . .
(CUT-H) Half cutting (about 1/2 of parks used). . . . . .
(CUT-P) Partial cutting (most of parts used). . . . . .
PARTS LOCATION
REMOVAL DIAGRAM
Describes in detail removal of the damaged parts involving repair by cutting.
REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
INTRODUCTIONIN-2

mmin,
50.20RE-29 BODY PANEL REPLACEMENT
INSTALLATIONButt Weld
Butt Weld
Foamed Material
Application Areas
Body Sealer
Butt Weld
Body Sealer
about 5 mm
2. Temporarily install the new parts and check the
fit of the rear door, back door, tail gate and rear
combination light.
3. After installing the new parts, apply foamed ma-
terials. 1. Before temporarily installing the new parts,
apply body sealer to the wheel arch.
HINT:
1) Apply body sealer about 5 mm (0.20 in.) from
the flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4 mm (0.12 -
0.16 in.) in diameter.
3) For other sealing points, refer to section AR.
INSTALLATION DIAGRAM
Describes in detail installation of the new parts involving repair by welding and/or cutting, but exclud-
ing painting.
INSTALLATION GUIDE
Provides additional information to more efficiently help you perform the installation.
SYMBOLS
See page IN-4.
ILLUSTRATION of WELD POINTS
Weld method and panel position symbols.
See page IN-5.
INTRODUCTIONIN-3

Parts Name
Code
Radiator Grille
ABS
Front Bumper Cover
TSOP
Fog Light
PC/PP
Front Turn Signal Light
PMMA/PC/AAS
Side Turn Signal Light
SAN/AAS
Cowl Top Ventirator Louver
TSOP
Outer Rear View Mirror
ABS
Outside Moulding (Fender, Front & Rear Door, Quarter)
TSOP
Outside Handle (Front & Rear Door)
PC
Rocker Panel Moulding
TSOP
Side Door Step Plate Cover (Front, Rear)
PP
Quarter Ventirator Louver
PPO/PA
Rear Combination Light
PMMA/PP/AAS
Rear Light
PMMA/PP
Back Door Outside Moulding
TSOP
License Plate Light
PC
License Plate Light Cover
AAS
Back Door Outside Handle
POM
Rear Bumper Cover
TSOP
Reflex Refrector
PMMA/ABS
Rear Fog Light
PC/PP
Outer Under Rear View Mirror
PC/PBT
Roof Moulding
PVC
LOCATION OF PLASTIC BODY PARTS
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPP-4

Cutting toolNote
Aluminum-Rivet
Steel-Rivet
T-Rivet with
f6.4 mm
f6.4 mmf6.5 mm f4.8 mmf5 mm f4 mmf4 mm Rivet sizeBlade size
Drill blade
Cutting can be done with drill blade or
rivet cutter for an aluminum-rivet with
f4.8 mm.

When a rivet cutter is used for an
aluminum-rivet (except f4.8 mm), a
steel-rivet, or a Trivet with f6.4 mm, it
is possible that the drill will spin abnor-
mally damaging the rivet hole and
breaking the rivet cutter.
Waterproof special-Rivet
with
f4.0 mmDrill blade with f4.0 mm
Aluminum-Rivet
with
f4.8 mm
Waterproof-Rivet
with
f4.8 mm or f6.0 mmRivet Cutter (P/N 09060-60350)
When a ordinary cutter is used for a
waterproof-rivet with f4.8 mm or f6.0
mm, the rivet can not be cut as it spins
with the cutter. Aluminum-RivetSteel-RivetWaterproof-RivetT-Rivet
External Appearance
Inner Outer After installation Before installation
Outer
Inner After installation Before installation
Inner
Outer After installationBefore installation
Waterproof Seal
Outer Inner After installationBefore installation
Mandrel
Charac-
teristics

Small nonwaterproof
rivet

No magnetic
adherence
Small nonwaterproof
rivet

Magnetic adherence
Small waterproof
rivet

Waterproof seal
Large waterproof rivet

Mandrel sticks out
after installation fX mm
Rivet Size FlangeMandrel
RIVET REMOVAL AND INSTALLATION
PARTS NAME AND VARIETY OF RIVET
RIVET REMOVAL
1. SELECTION OF CUTTING TOOL
INTRODUCTIONIN-15