light TOYOTA LAND CRUISER 1996 J80 Service Manual

BO37N−01
BO2455
Cotton
TapePanel
Cover
−
BODY FRONT DOOR
BO−9
1996 LAND CRUISER (RM451U)
DISASSEMBLY
HINT:
Tape a screwdriver tip before using to pry parts.
1. REMOVE DOOR INSIDE HANDLE BEZEL
2. REMOVE ARMREST
3. REMOVE ARMREST PANEL BASE UPPER
4. REMOVE COURTESY LIGHT
5. REMOVE LOWER FRAME BRACKET GARNISH
6. REMOVE DOOR TRIM
(a) Remove the 3 screws from the door trim.
(b) Using a screwdriver, remove the clip and remove the trim
by pulling all of the trim up.
(c) Remove the 11 screws and armrest base from the door
trim.
(d) Remove the inner weatherstrip from the door trim.
(e) Remove the 8 screws and door pocket from the door trim.
7. REMOVE DOOR BELT MOULDING
Pry out the clip from the edge of the panel, and remove the
moulding .
8. REMOVE DOOR WEATHERSTRIP
NOTICE:
Do not pull strongly on the weatherstrip as it may tear.
9. REMOVE DOOR INSIDE HANDLE
10. REMOVE DOOR LOCK CONTROL RELAY
11. REMOVE SERVICE HOLE COVER
NOTICE:
Do not block the trim clip sealing with the tape.
12. REMOVE OUTSIDE REAR VIEW MIRROR
13. REMOVE DOOR GLASS RUN
14. REMOVE REAR LOWER FRAME
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BO37S−01
−
BODY REAR DOOR
BO−15
1996 LAND CRUISER (RM451U)
DISASSEMBLY
HINT:
Tape a screwdriver tip before using to pry parts.
1. REMOVE DOOR INSIDE HANDLE BEZEL
2. REMOVE DOOR SPEAKER COVER
3. REMOVE ASH TRAY
4. REMOVE ARMREST BASE UPPER
5. REMOVE ARMREST
6. REMOVE DOOR TRIM
(a) Remove the courtesy light.
(b) Remove the 3 screws from the door trim.
(c) Using a screwdriver, remove the clips and remove the trim
by pulling all of the trim up.
(d) Remove the inner weatherstrip from the door trim.
(e) Remove the 11 screws and the armrest base from the door trim.
7. REMOVE DOOR BELT MOULDING
Pry out the clip from the edge of the panel, and remove the
moulding.
8. REMOVE DOOR WEATHERSTRIP
NOTICE:
Do not pull strongly on the weatherstrip as it may tear.
9. REMOVE DOOR INSIDE HANDLE
10. REMOVE SERVICE HOLE COVER
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BO2455
Panel
Cotton Tape Cover
BO−22
−
BODY BACK DOOR
1996 LAND CRUISER (RM451U)
(b) Remove the service hole cover.
(c) Remove the door lock control.
(d) Remove the door lock.
(e) Remove the license plate light cover.
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BO37X−01
−
BODY BACK DOOR
BO−23
1996 LAND CRUISER (RM451U)
ADJUSTMENT
1. ADJUST UPPER BACK DOOR
(a) Adjust the door in forward/rearward and left/right direc-
tions.
Adjust the door by loosening the door side hinge bolts.
(b) Adjust the door in left/right and vertical directions. Adjust the door by loosening the body side hinge bolts.
(c) Adjust the door lock striker. (1) Check that the door fit and door lock linkage are ad-
justed correctly.
(2) Adjust the striker position by slightly loosening the striker mounting screws, and hitting the striker with
a hammer. Tighten the striker mounting screw
again.
2. ADJUST LOWER BACK DOOR
(a) Adjust the door in forward/rearward and left/right direc- tions.
Adjust the door by loosening the door side hinge bolts.
(b) Adjust the door in left/right and vertical directions. Adjust the door by loosening the body side hinge bolts.
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BO−24
−
BODY BACK DOOR
1996 LAND CRUISER (RM451U)
(c) Adjust the door lock striker.
(1) Check that the door fit and door lock linkages areadjusted correctly.
(2) Adjust the striker position by slightly loosening the striker mounting screws, and hitting the striker with
a hammer.
(3) Tighten the striker mounting screws again.
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BO38J−01
BO6675
−
BODY SIDE PROTECTION MOULDING
BO−43
1996 LAND CRUISER (RM451U)
INSTALLATION
HINT:
Precautions for storing moulding materials:
Store in cool place, avoiding direct sunlight, high temper-
ature and dust.
The moulding is of polyvinyl chloride, so do not allow it to
come in contact with thinner or other solvent, open flame,
or boiling water.
The storage time for the moulding and adhesive are lim-
ited to about 9 months.
1. CLEAN MOULDING MOUNTING SURFACE
Wipe off stains with cleaner.
2. HEAT BODY MOUNTING SURFACE
Using a heat light, heat the body mounting surface to 30 −50 ° C
(86−122 °F).
NOTICE:
When the moulding is installed, the temperature of the
mounting surface should be 20 °C (68 ° F) or higher.
3. HEAT MOULDING
(a) Using a heat light, heat the moulding to 30 −60 °C
(86−140 °F).
NOTICE:
Do not heat the moulding excessively.
(b) The temperature should not be higher than 80 °C (176
° F).
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BO38Q−01
BO−46
−
BODY WINDSHIELD
1996 LAND CRUISER (RM451U)
REMOVAL
1. REMOVE HOOD
2. REMOVE WIPER ARMS
3. REMOVE COWL LOUVER
4. REMOVE INNER REAR VIEW MIRROR
5. REMOVE PERSONAL LIGHT ASSEMBLY
6. REMOVE PERSONAL LIGHT COVER
7. REMOVE SUN VISORS AND HOLDERS
8. REMOVE ASSIST GRIPS
9. REMOVE FRONT PILLAR GARNISHES
10. LOOSEN ROOF HEADLINING
11. REMOVE WINDSHIELD GLASS
(a) From the outside of the vehicle , cut off the weatherstrip.
NOTICE:
Do not damage the body and the glass.
(b) Push piano wire through between the body and glass from the interior.
(c) Tie both wire ends to the wooden blocks or equivalent.
NOTICE:
When separating, take care not to damage the paint or inte-
rior ornaments.
To prevent scratching the safety pad when removing the
windshield, place a plastic sheet between the piano wire
and safety pad.
(d) Cut the adhesive by pulling the piano wire around it.
(e) Remove the glass.
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−
BODY WINDSHIELD
BO−49
1996 LAND CRUISER (RM451U)
(b) Clean off the sealer oozing out from the masking tape with
a clean rag saturated in cleaner.
6. INSPECT FOR LEAKS AND REPAIR
(a) Do a leak test.
(b) Seal any leaks with auto glass sealer.
Part No. 08833−00030 or equivalent
7. INSTALL ROOF HEADLINING
8. INSTALL FRONT PILLAR GARNISHES
9. INSTALL ASSIST GRIPS
10. INSTALL SUN VISORS AND HOLDERS
11. INSTALL PERSONAL LIGHT COVER
12. INSTALL PERSONAL LIGHT ASSEMBLY
13. INSTALL INNER REAR VIEW MIRROR
14. INSTALL COWL LOUVER
15. INSTALL WIPER ARMS Torque: 20 N·m(205 kgf·cm, 15 ft·lbf)
16. INSTALL HOOD Torque: 18 N·m(185 kgf·cm, 13 ft·lbf)
17. ADJUST HOOD (See page BO−6)
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BO−64
−
BODY SLIDING ROOF
1996 LAND CRUISER (RM451U)
11. REMOVE FRONT SEAT OUTER BELT SHOULDER AN-
CHOR
12. REMOVE CENTER PILLAR UPPER GARNISH
13. REMOVE FRONT SHOULDER BELT ANCHOR AD-
JUSTER
14. REMOVE NO. 1 REAR SEAT OUTER BELT SHOUL- DER ANCHOR
15. w/ No. 2 Rear Seat REMOVE NO. 2 REAR SEAT OUTER BELT SHOUL-
DER ANCHOR
16. REMOVE QUARTER AND REAR PILLAR GARNISH
17. REMOVE ASSIST GRIPS
18. REMOVE FRONT PILLAR GARNISH
19. REMOVE SUN VISORS AND HOLDERS
20. REMOVE INNER REAR VIEW MIRROR
21. REMOVE PERSONAL LIGHT ASSEMBLY AND PER- SONAL LIGHT COVER
22. REMOVE NO. 1 AND NO. 2 ROOM LIGHT
23. REMOVE BACK DOOR OPENING TRIM
24. REMOVE SLIDING ROOF OPENING MOULDING
25. REMOVE CONTROL SWITCH
(a) Remove the screw.
(b) Using a screwdriver, remove the switch cover.
(c) Remove the 2 screws and switch body, then disconnect the connector.
(d) Remove the 2 screws and bracket.
26. REMOVE ROOF HEADLINING
(a) Using the clip remover, remove the 7 clips.
(b) Remove the roof headlining.
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BO0632
BO39M−01
BO0633
15°
45°
N10070
Full Belt Length
minus 200 mm
(7.87 in.)
−
BODY SEAT BELT
BO−93
1996 LAND CRUISER (RM451U)
SEAT BELT
INSPECTION
CAUTION:
Replace the seat belt assembly (outer belt, inner belt, bolts,
nuts or sill −bar) if it has been used in a severe impact. The
entire assembly should be replaced even if damage is not
obvious.
1. All seat belts: RUNNING TEST (IN SAFE AREA)
(a) Fasten the front seat belts.
(b) Drive the car at 10 mph (16 km/h) and make a very hard stop.
Check that the belt locks and cannot be extended at this
time.
HINT:
Conduct this test in a safe area. If the belt does not lock, remove
the belt mechanism assembly and conduct the following static
check. Also, whenever installing a new belt assembly, verify the
proper operation before installation.
2. Driver ’s seat belt (ELR): STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Tilt the retractor slowly.
(d) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out at over 45 degrees
of tilt.
If a problem is found, replace the assembly.
3. Except driver’s seat belt (ALR/ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Pull out the whole belt and measure the length of the whole belt.
Then retract the belt slightly and pull it out again.
(d) Make sure that the belt cannot be extended further.
If a problem is found, replace the assembly.
(e) Retract the whole belt, then pull it out to the full length mi-
nus 200 mm (7.87 in.).
(f) Tilt the retractor slowly.
(g) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out at over 45 degrees
of tilt.
If a problem is found, replace the assembly.
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