TOYOTA LAND CRUISER 1998 Factory Repair Manual

CH06I-04
B00809
B16653
- CHARGINGGENERATOR
CH-7
1842 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REMOVAL
1. DRAIN ENGINE COOLANT
(See page CO-2)
2. REMOVE GENERATOR DRIVE BELT
Loosen the belt tension by turning the belt tensioner counter-
clockwise, and remove the drive belt.
HINT:
The pulley bolt for the belt tensioner has a left - hand thread.
3. REMOVE ENGINE UNDER COVER NO.1
4. REMOVE RADIATOR ASSEMBLY
(See page CO-17)
5. REMOVE PS VANE PUMP PULLEY
(See page SR-40)
6. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the rubber cap and nut, and disconnect the gen-
erator wire.
(c) Disconnect the generator wire clamp from the cord clip on
the generator.
(d) Remove the bolt, 2 nuts and generator.

CH0M5-01
B16375
B16387
Socket Wrench
SST
B16386
SST
B12270
SST
B12272
SST
- CHARGINGGENERATOR
CH-1 1
1846 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REPLACEMENT
1. REPLACE FRONT BEARING
(a) Remove the 4 screws, bearing retainer and bearing.
(b) Using SST and a hammer, tap out the bearing.
SST 09950- 60010 (09951- 00250), 09950- 70010
(09951-07100)
(c) Using SST and a press, press in a new bearing.
SST 09950- 60010 (09951- 00470), 09950- 70010
(09951-07100)
(d) Install the bearing retainer with the 4 screws.
Torque: 2.6 N´m (27 kgf´cm, 23 in.´lbf)
2. REPLACE REAR BEARING
(a) Using SST, remove the bearing cover (outside) and bear-
ing.
SST 09820-00021
NOTICE:
Be careful not to damage the fan.
(b) Using SST and a press, press in a new bearing.
SST 09820-00031

B12273
SST
CH-12
- CHARGINGGENERATOR
1847 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(c) Using SST, push in the bearing cover (outside).
SST 09285-76010

ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
SSM Special Service Materials
w/ with
w/o without
5. ECU (ELECTRONIC CONTROL UNIT)
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
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 each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all
equipped with memory function, it is not possible to make a record of the memory contents. So when the
operation is finished, it will be necessary to explain this fact to the customer, and request the customer to
adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80°C (176°F).
NOTICE: If it is possible the ambient temperature may reach 80° (176°F) or more, remove the ECUs
from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
INTRODUCTIONIN-9

Applicable models:
FOREWORD
This repair manual has been prepared to provide essential infor-
mation on body panel repair methods (including cutting and
welding operations, but excluding painting) for the TOYOTA
LAND CRUISER.
UZJ100, FZJ10_ series
HDJ10_, HZJ105 series
This manual consists of body repair methods, exploded dia-
grams and illustrations of the body components and other infor-
mation relating to body panel replacement such as handling pre-
cautions, etc. However, it should be noted that the front fenders
of the TOYOTA model is bolted on and require no welding.
When repairing, don't cut and join areas that are not shown in
this manual. Only work on the specified contents to maintain
body strength.
Body construction will sometimes differ depending on specifica-
tions and country of destination. Therefore, please keep in mind
that the information contained herein is based on vehicles for
general destinations.
For the repair procedures and specifications other than collision-
damaged body components of the TOYOTA LAND CRUISER
refer to the repair manuals.
If you require the above manuals, please contact your TOYOTA
Dealer.
All information contained in this manual is the most up-to-date
at the time of publication. However, specifications and proce-
dures are subject to change without prior notice.
TOYOTA MOTOR CORPORATION

GENERAL REPAIR INSTRUCTIONS
Work PrecautionsSAFETY
1. Before performing repair work, check
for fuel leaks. If a leak is found, be sure
to close the opening totally.
2. If it is necessary to use a frame in the
area of the fuel tank, first remove the
tank and plug the fuel line. SAFETY
Never stand in direct line
with the chain when using
a puller on the body or
frame, and be sure to at-
tach a safety cable.VEHICLE PROTECTION
When welding, protect the
painted surfaces, windows,
seats and carpet with heat-
resistant, fire-proof covers.
Glass Cover
Safety Cable
Seat Cover
WRONG
SAFETY WORK CLOTHES
HAND TOOLS
Keeping your hand tools in
neat order improve your
work efficiency. In addition to the usual mechanic's wear, cap and safety shoes,
the appropriate gloves, head protector, glasses, ear plugs, face
protector, dust-prevention mask, etc. should be worn as the
situation demands.
Dust-
Prevention
MaskWelder's
Glasses
Ear
Plugs
Face
Protector
Body
Tools
Stand
Head
Protector Eye
Protector
Welder's
Gloves Safety
Shoes
INTRODUCTIONIN-10

Proper and Efficient Work Procedures
REMOVAL
NUMBER OF SPOT WELDS AND PANEL POSITIONS
The number of spot welds and the panel positions to
be removed are shown for your reference.
HINT: See Symbolsº on page IN-4, 5.
PRE-REMOV AL MEASURING
Before removal or cutting opera-
tions, take measurements in ac-
cordance with the dimension dia-
gram. Always use a puller to
straighten a damaged body or
frame.
REMOVAL OF ADJACENT COMPONENTS
When removing adjacent components, apply
protective tape to the surrounding body and
your tools to prevent damage.
HINT: See Handling Precautions on
Related Componentsº on page IN-6.
PRECAUTIONS FOR DRILLING OR
CUTTING
Check behind any area to be drilled or
cut to insure that there are no hoses,
wires, etc., that may be damaged.
HINT: See Handling Precautions on
Related Componentsº on page IN-6.
CUTTING AREA
Always cut in a straight
line and avoid reinforced area.
Cutting Okay
Corners
Reinforcement
WRONG
INTRODUCTIONIN-11

Thickness of
welded portionSize of plug hole
1.0 (0.04) under 5 (0.20)
f over
1.0 (0.04) - 1.5 (0.06)6.5 (0.26)
f over
1.5 (0.06) over8 (0.31)
f over Parts Name Parts Number
Spot Sealer08839 - 00070
REFERENCE:
mm (in.)
PREPARATION FOR INSTALLATION
SPOT WELD POINTSAPPLICATION OF WELD-THROUGH PRIMER
(SPOT SEALER)
Remove the paint from
the portion of the new
parts and body to be
welded, and apply
weld-through primer.
HINT: See ºANTIRUST
TREATMENTº' on page
AR-2.
When welding panels with a
combined thickness of over
3 mm (0.12 in.), use a MIG
(Metal Inert Gas) welder for
plug welding.
HINT: Spot welding will not
provide sufficient durability
for panels over 3 mm (0.12
in.) thick.
Less Than
3 mm
*The above SSM
or equivalent
Air Saw
20 - 30 mm
Puncher
Overlap
ROUGH CUTTING OF
JOINTS
For joint areas, rough
cut the new parts,
leaving 20 - 30 mm
(0.79 - 1.18 in.)
overlap.MAKING HOLES FOR PLUG WELDING
For areas where a spot welder cannot be
used, use a puncher or drill to make holes
for plug welding. SAFETY PRECAUTIONS FOR
ELECTRICAL COMPONENTS.
When welding there is a danger
that electrical components will
be damaged by the electrical
current flowing through the body.
Before starting work disconnect
the negative terminal of the bat-
tery and ground the welder near
the welding location of the
body.
INTRODUCTIONIN-12

INSTALLATION
PRE-WELDING MEASUREMENTS
Always take measurements before
installing underbody or engine com-
ponents to insure correct assembly.
After installation, confirm proper
fit.WELDING PRECAUTIONS
1. The number of welding
spots should be as follows.
Spot weld: 1.3 x No. of
manufacturer's spots.
Plug weld: More than No. of
manufacturer's plugs.POST WELDING REFINISHING
1. Always check the welded
spots to insure they are
secure.
2. When smoothing out the
weld spots with a disc grind-
er, be careful not to grind off
too much as this would
weaken the weld.
WRONG
WRONG
OKAY
2. Plug welding should be done
with a MIG (Metal Inert Gas)
welder. Do not gas weld or
braze panes at areas other
than specified.
Safety Glass
Body
Measurement
Diagrams
SPOT WELDING PRECAUTIONS
1. The shape of the welding tip
point has an effect on the
strength of the weld.
2. Always insure that the seams
and welding tip are free of
paint. SPOT WELD LOCATIONS
Try to avoid welding over
previous spots.New Spot
Locations
Old
Spot
Locations
Tip Cutter
INTRODUCTIONIN-13

Parts NameParts Number
Pastar UC (Oil Base)08836-00155
Pastar UW (Water Base)08836-001 15
Pastar Gun (For thick application)08836-00091 Parts NameParts Number
Rustop W (Aerosol)08860-00200
Rustop W (1
Milky White)08860-00210
Rustop W (18
Milky White)08860-00230
Rustop B (1
Black)08860-00220
Rustop B (18
Black)08860-00240 Parts NameParts Number
Body Sealer, White (Cartridge Type)08839-00020
Body Sealer, White (Tube Type)08839-00030
Body Sealer, Black (Cartridge Type)08839-00040
ANTI-RUST TREATMENT
When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the re-
quirements of your country.
HINT: For further details, see the description given in Section AR of this manual.
BODY SEALER
Apply body sealer to the
required areas.ANTI-RUST AGENT (WAX)
Apply anti-rust agent to following
sections.

Inside of the hems of the doors
and hood.

Around the hinges of the doors
and hood.

Inside of the welded parts with
boxed cross-section.
Tube Type
Cartridge Type
*The above SSM or equivalent
*The above SSM or equivalent
UNDERCOAT
Apply undercoat to the underbody and
wheel housings.
*The above SSM or equivalent
Spray Gun
Undercoating
(Water base) Undercoating
(Oil base)
INTRODUCTIONIN-14