drive belt tensioner TOYOTA LAND CRUISER 1998 Factory Repair Manual

CH0086
Correct Wrong
AC1HP-03
B00808
A
B
- AIR CONDITIONINGDRIVE BELT
AC-15
2740 Author
: Date
:
2004 LAND CRUISER (RM1071U)
DRIVE BELT
ON-VEHICLE INSPECTION
1. INSPECT DRIVE BELT'S INSTALLATION CONDITION
Check that drive belt fits properly in the ribbed grooves.
2. INSPECT DRIVE BELT TENSION
Check that the tension is within A range on the auto tensioner
scale.
If the tension is not within the A range on the scale, replace the
belt with a new one.
HINT:
When replacing the drive belt with a new one, the belt's tension
should be within the B range on the belt tensioner scale.

AC1HQ-03
EM6656
AC-16
- AIR CONDITIONINGDRIVE BELT
2741 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REMOVAL
REMOVE DRIVE BELT
Loosen the drive belt tension by turning the drive belt tensioner
counterclockwise, and remove the drive belt.

BO21G-03
H05264
Claw
H05265
: 4 Clips
- BODYSEAT BELT PRETENSIONER
BO-141
2715 Author
: Date
:
2004 LAND CRUISER (RM1071U)
SEAT BELT PRETENSIONER
REMOVAL
NOTICE:

If the wiring connector of the seat belt pretensioner
is disconnected with the ignition switch at ON or ACC,
diagnostic trouble codes will be recorded.

Never use seat belt pretensioner from another ve-
hicle. When replacing seat belt pretensioner, replace
it with a new one.
1. REMOVE FRONT DOOR SCUFF PLATE
2. REMOVE FRONT DOOR OPENING TRIM
3. REMOVE REAR DOOR SCUFF PLATE
4. REMOVE REAR DOOR OPENING TRIM
5. REMOVE CENTER PILLAR LOWER GARNISH
(a) Using a screwdriver, remove the center pillar garnish cov-
er.
HINT:
Tape the screwdriver tip before use.
(b) Using a screwdriver, remove the center pillar lower gar-
nish as shown in the illustration.
HINT:
Tape the screwdriver tip before use.
6. REMOVE FRONT SEAT OUTER BELT SHOULDER AN-
CHOR
7. REMOVE FRONT SEAT OUTER BELT FLOOR AN-
CHOR
8. REMOVE RETRACTOR OF FRONT SEAT OUTER
BELT
CAUTION:
Never disassemble the retractor of front seat outer belt.
NOTICE:
When removing the retractor of front seat outer belt, take
care not to pull the seat belt pretensioner wire harness.

BO1KZ-04
BO0632
BO0633
15°
45°
- BODYSEAT BELT
BO-139
2713 Author
: Date
:
2004 LAND CRUISER (RM1071U)
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. Except manual type:
RUNNING TEST (IN SAFE AREA)
(a) Fasten the front seat belts.
(b) Drive the car at 10 mph (16 km/h) and slam on the brakes.
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.
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.
HINT:
Before removing the pretensioner connector, be sure to read
the precautionary notice in the RS section.
(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 over 45 degrees
of tilt.
If a problem is found, replace the assembly.
3. Except driver's seat belt (ELR/ALR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
HINT:
Before removing the pretensioner connector, be sure to read
the precautionary notice in the RS section.
(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.

Z00030
B00807
B00808
B
A
AC2024
CORRECT WRONG
- CHARGINGCHARGING SYSTEM
CH-3
1838 Author
: Date
:
2004 LAND CRUISER (RM1071U)
5. INSPECT DRIVE BELT
HINT:
A belt tensioner is used, so checking the belt tension is not nec-
essary.
(a) Visually check the drive belt for excessive wear, frayed
cords etc.
If necessary, replace the drive belt.
HINT:

Cracks on the rib side of a drive belt are considered ac-
ceptable. If the drive belt has chunks missing from the
ribs, it should be replaced.

The drive belt tension can be released by turning the belt
tensioner counterclockwise. The pulley bolt for the belt
tensioner has a left-hand thread.
(b) Check the belt tensioner operation.

Check that the belt tensioner moves downward
when the drive belt is pressed down at the points in-
dicated in the illustration with approx. 98 N (10 kgf,
22.0 lbf) of force.

Check the alignment of the belt tensioner pulley to
make sure the drive belt has not slipped off the
pulley.
If necessary, replace the belt tensioner.

Check that the arrow mark on the belt tensioner falls
within area A of the scale.
If it is outside area A, replace the drive belt.
HINT:

When a new belt is installed, it should lie within area B. If
not, the drive belt is not correct.

After installing a belt, check that it fits properly in the
ribbed grooves.

Check by hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.
6. REMOVE ENGINE UNDER COVER NO.1
7. VISUALLY CHECK GENERATOR WIRING AND LIS-
TEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.

CH06N-05
B16653
B00809
CH-16
- CHARGINGGENERATOR
1851 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSTALLATION
1. INSTALL GENERATOR
(a) Install the generator with the bolt and 2 nuts.
Torque:
Bolt: 39 N´m (400 kgf´cm, 29 ft´lbf)
Nut 10 mm: 39 N´m (400 kgf´cm, 29 ft´lbf)
Nut 8 mm: 15.5 N´m (158 kgf´cm, 11 ft´lbf)
(b) Connect the generator connector.
(c) Connect the generator wire with the nut.
Torque: 9.8 N´m (100 kgf´cm, 87 in.´lbf)
(d) Install the terminal cap.
(e) Install the wire clamp to the cord clip on the generator.
2. INSTALL PS VANE PUMP PULLEY
(See page SR-47)
3. INSTALL RADIATOR ASSEMBLY
(See page CO-19)
4. INSTALL GENERATOR DRIVE BELT
Install the belt by turning the belt tensioner counterclockwise.
HINT:
The pulley bolt for the belt tensioner has a left - hand thread.
5. FULL ENGINE COOLANT
6. START ENGINE AND CHECK FOR LEAKS
7. RECHECK ENGINE COOLANT LEVEL
8. PERFORM ON-VEHICLE INSPECTION
(See page CH-2)
9. INSTALL ENGINE UNDER COVER NO.1

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.

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

B04470
RH No.3 Timing Belt Cover
LH No.3 Timing Belt CoverNo.2 Timing Belt Cover
Camshaft Position
Sensor Connector
Engine Wire
Oil Cooler Pipe
Timing Belt
Fan Bracket Drive Belt Timing Pulley
Timing Belt Tensioner Dust Boot
N´m (kgf´cm, ft´lbf) : Specified torqueCover Plate
7.5 (80, 66 in.´lbf)
16 (160, 12)
39 (400,29)
245 (2,500, 181)
32 (330, 24)
16 (160, 12)
7.5 (80, 66 in.´lbf)
Water Bypass
Hose
CO-4
- COOLINGWATER PUMP
1765 Author
: Date
:
2004 LAND CRUISER (RM1071U)

B04471
Generator Wire
Generator Connector
Wire Clamp
Generator
Crankshaft PulleyDrive Belt Tensioner
No.1 Timing Belt Cover
Timing Belt
Timing Belt Guide
(Crankshaft Angle Sensor Plate)No.2 Idler Pulley
Timing Belt Cover SpacerGasket
N´m (kgf´cm, ft´lbf) : Specified torque

Non-reusable partWater Inlet Housing
Assembly
Water Pump
O-Ring

Gasket
O-Ring
39 (400, 29)
34.5 (350, 25)
18 (185, 13)
21 (215, 15)
- COOLINGWATER PUMP
CO-5
1766 Author
: Date
:
2004 LAND CRUISER (RM1071U)