engine TOYOTA LAND CRUISER 2004 J100 Service Manual

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2004 L/C100 from Aug ’03 Prod. (OM60A04U)
Always slow down in gusty cross-
winds. Because of its profile and
higher center of gravity, your ve-
hicle is more sensitive to side
winds than an ordinary passenger
car. Slowing down will allow you
to have better control.
When driving offroad or in rugged
terrain, do not drive at excessive
speeds, jump, make sharp turns,
strike objects, etc. This may cause
loss of control or vehicle rollover
causing death or serious injury.
You are also risking expensive dam-
age to your vehicle’s suspension
and chassis.
Do not drive horizontally across
steep slopes. Driving straight up
or straight down is preferred. Your
vehicle (or any similar offroad ve-
hicle) can tip over sideways much
more easily than forward or back-
ward.
Breakin period
Drive gently and avoid high speeds.
Your vehicle does not need an elaborate
break−in. But following a few simple tips
for the first 1600 km (1000 miles) can add
to the future economy and long life of
your vehicle:
Avoid full −throttle acceleration when
starting and driving.
Avoid racing the engine.
Try to avoid hard stops during the first
300 km (200 miles).
Do not drive for a long time at any
single speed, either fast or slow.
Do not tow a trailer during the first 800
km (500 miles).
Fuel
FUEL TYPE
Your new vehicle must use only un-
leaded gasoline.
To help prevent gas station mix −ups, your
Toyota has a smaller fuel tank opening.
The special nozzle on pumps with un-
leaded fuel will fit it, but the larger stan-
dard nozzle on pumps with leaded gas will
not.
At a minimum, the gasoline you use
should meet the specifications of ASTM
D4814 in the U.S.A. and CGSB 3.5 −M93
in Canada.
NOTICE
Do not use leaded gasoline. Use of
leaded gasoline will cause the three
way catalytic converter to lose its ef-
fectiveness, the emission control sys-
tem to function improperly, and dam-
age to the engine. Also, this can in-
crease maintenance costs.

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2004 L/C100 from Aug ’03 Prod. (OM60A04U)
OCTANE RATING
Select Octane Rating 87 (Research Oc-
tane Number 91) or higher. For im-
proved vehicle performance, the use of
premium unleaded gasoline with an Oc-
tane Rating of 91 (Research Octane
Number 96) or higher is recommended.
Use of unleaded gasoline with an octane
rating or research octane number lower
than stated above will cause persistent
heavy knocking. If it is severe, this will
lead to engine damage.
If your engine knocks...
If you detect heavy knocking even when
using the recommended fuel, or if you
hear steady knocking while holding a
steady speed on level roads, consult your
Toyota dealer.
However, occasionally, you may notice
light knocking for a short time while accel-
erating or driving up hills. This is normal
and there is no need for concern.
GASOLINE CONTAINING DETERGENT
ADDITIVES
Toyota recommends the use of gasoline
that contains detergent additives to
avoid buildup of engine deposits.
However, all gasoline sold in the U.S.
contains detergent additives to keep clean
and/or clean intake systems.
QUALITY GASOLINE
Automotive manufacturers in the U.S.,
Europe and Japan have developed a
specification for quality fuel named
WorldWide Fuel Charter (WWFC) that
is expected to be applied world wide.
The WWFC consists of four categories
that depend on required emission lev-
els. In the U.S., category 3 has been
adopted. The WWFC improves air quali-
ty by providing for better emissions in
vehicle fleets, and customer satisfaction
through better vehicle performance.
CLEANER BURNING GASOLINE
Cleaner burning gasoline, including re-
formulated gasoline that contains oxy-
genates such as ethanol or MTBE is
available in many areas.Toyota recommends the use of cleaner
burning gasoline and appropriately blended
reformulated gasoline. These types of gas-
oline provide excellent vehicle perfor-
mance, reduce vehicle emissions, and im-
prove air quality.
OXYGENATES IN GASOLINE
Toyota allows the use of oxygenate
blended gasoline where the oxygenate
content is up to 10% ethanol or 15%
MTBE. If you use gasohol in your Toyota,
be sure that it has an octane rating no low-
er than 87.
Toyota does not recommend the use of
gasoline containing methanol.
GASOLINE CONTAINING MMT
Some gasoline contain an octane en-
hancing additive called MMT (Methylcy-
clopentadienyl Manganese Tricarbonyl).
Toyota does not recommend the use of
gasoline that contains MMT. If fuel con-
taining MMT is used, your emission con-
trol system may be adversely affected.
The Malfunction Indicator Lamp on the in-
strument cluster may come on. If this hap-
pens, contact your Toyota dealer for ser-
vice.

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2004 L/C100 from Aug ’03 Prod. (OM60A04U)
GASOLINE QUALITY
In a very few cases, you may experience
driveability problems caused by the partic-
ular gasoline that you are using. If you
continue to have unacceptable driveability,
try changing gasoline brands. If that does
not rectify your problem, then consult your
Toyota dealer.
NOTICE
Do not use gasohol other than
stated above. It will cause fuel sys-
tem damage or vehicle performance
problems.
 If drive ability problems are occur
(poor hot starting, vaporizing, en-
gine knock, etc.), discontinue the
use.
 Take care not to spill gasohol dur-
ing refueling. Gasohol may cause
paint damage.
FUEL TANK CAPACITY
96 L (25.4 gal., 21.1 Imp. gal.)
Fuel pump shut off system
The fuel pump shut off system stops sup-
plying fuel to the engine when the engine
stalls or an airbag inflates upon collision.
To restart the engine after the fuel pump
shut off system activates, turn the ignition
switch to “ACC” or “LOCK” once and start
it.
CAUTION
Inspect the ground under the vehicle
before restarting the engine. If you
find that liquid has leaked onto the
ground, it is the fuel system has
been damaged and it is in need of
repair. In this case, do not restart the
engine.
Operation in foreign countries
If you plan to drive your Toyota in
another country...
First, comply with the vehicle registration
laws.
Second, confirm the availability of the
correct fuel (unleaded and minimum oc-
tane number).

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2004 L/C100 from Aug ’03 Prod. (OM60A04U)
Threeway catalytic converter
The threeway catalytic converter is the
emission control devices installed in
the exhaust system.
Its purpose is to reduce pollutants in the
exhaust gas.
CAUTION
Keep people and combustible
materials away from the exhaust
pipe while the engine is running.
The exhaust gas is very hot.
Do not idle or park your vehicle
over anything that might burn
easily such as grass, leaves, pa-
per or rags.
NOTICE
A large amount of unburned gases
flowing into the threeway catalytic
converter may cause it to overheat
and create a fire hazard. To prevent
this and other damage, observe the
following precautions:
Use only unleaded gasoline.
 Do not drive with an extremely low
fuel level; running out of fuel could
cause the engine to misfire, creat-
ing an excessive load on the three
way catalytic converter.
 Do not allow the engine to run at
idle speed for more than 20 min-
utes.
Avoid racing the engine.
 Do not pushstart or pullstart your
vehicle.
 Do not turn off the ignition while
the vehicle is moving.
 Keep your engine in good running
order. Malfunctions in the engine
electrical system, electric ignition
system or fuel system could cause
an extremely high threeway cata-
lytic converter temperature.
 If the engine becomes difficult to
start or stalls frequently, take your
vehicle in for a checkup as soon
as possible. Remember, your Toyota
dealer knows your vehicle and its
threeway catalytic converter sys-
tem best.

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2004 L/C100 from Aug ’03 Prod. (OM60A04U)
To ensure that the threeway cata-
lytic converter and the entire emis-
sion control system operate proper-
ly, your vehicle must receive the
periodic inspections required by the
Toyota Maintenance Schedule. For
scheduled maintenance information,
refer to the “Scheduled Maintenance
Guide” or “Owner ’s Manual Supple-
ment”.
Engine exhaust cautions
CAUTION
Avoid inhaling the engine ex-
haust. It contains carbon monox-
ide, which is a colorless and
odorless gas. It can cause un-
consciousness or even death.
Make sure the exhaust system
has no holes or loose connec-
tions. The system should be
checked from time to time. If you
hit something, or notice a
change in the sound of the ex-
haust, have the system checked
immediately.
Do not run the engine in a ga-
rage or enclosed area except for
the time needed to drive the ve-
hicle in or out. The exhaust
gases cannot escape, making
this a particularly dangerous sit-
uation.
Do not remain for a long time in
a parked vehicle with the engine
running. If it is unavoidable,
however, do so only in an un-
confined area and adjust the
heating or cooling system to
force outside air into the vehicle.

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Keep the back door and quarter
windows closed while driving. An
open or unsealed back door and
quarter windows may cause ex-
haust gases to be drawn into the
vehicle.
To allow proper operation of
your vehicle’s ventilation system,
keep the inlet grilles in front of
the windshield clear of snow,
leaves, or other obstructions.
If you smell exhaust fumes in
the vehicle, drive with the win-
dows open and the back door
closed. Have the cause immedi-
ately located and corrected.
FUNCTIONS OF ENGINE OIL
Engine oil has the primary functions of
lubricating and cooling the inside of the
engine, and plays a major role in main-
taining the engine in proper working order.
ENGINE OIL CONSUMPTION
It is normal that an engine should con-
sume some engine oil during normal
engine operation. The causes of oil
consumption in a normal engine are as
follows.
Oil is used to lubricate pistons, piston
rings and cylinders. A thin film of oil
is left on the cylinder wall when a pis-
ton moves downwards in the cylinder.
High negative pressure generated when
the vehicle is decelerating sucks some
of this oil into the combustion chamber.
This oil as well as some part of the oil
film left on the cylinder wall is burned
by the high temperature combustion
gases during the combustion process.
Oil is also used to lubricate the stems
of the intake valves. Some of this oil
is sucked into the combustion chamber
together with the intake air and is
burned along with the fuel. High tem-
perature exhaust gases also burn the
oil used to lubricate the exhaust valve
stems.
The amount of engine oil consumed de-
pends on the viscosity of the oil, the
quality of the oil and the conditions the
vehicle is driven under.
More oil is consumed by high −speed driv-
ing and frequent acceleration and decel-
eration.
A new engine consumes more oil, since
its pistons, piston rings and cylinder walls
have not become conditioned.
Oil consumption: Max. 1.0 L per 1000
km (1.1 qt./600 miles, 0.9 Imp.qt/600
miles)
When judging the amount of oil con-
sumption, note that the oil may become
diluted and make it difficult to judge
the true level accurately.
Facts about engine oil
consumption

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As an example, if a vehicle is used for
repeated short trips, and consumes a nor-
mal amount of oil, the dipstick may not
show any drop in the oil level at all, even
after 1000 km (600 miles) or more. This
is because the oil is gradually becoming
diluted with fuel or moisture, making it
appear that the oil level has not changed.
The diluting ingredients evaporate out
when the vehicle is then driven at high
speeds, as on an expressway, making it
appear that oil is excessively consumed
after driving at high speeds.
IMPORTANCE OF ENGINE OIL LEVEL
CHECK
One of the most important points in prop-
er vehicle maintenance is to keep the en-
gine oil at the optimum level so that oil
function will not be impaired. Therefore, it
is essential that the oil level be checked
regularly. Toyota recommends that the oil
level be checked every time you refuel
the vehicle.
NOTICE
Failure to check the oil level regularly
could lead to serious engine trouble
due to insufficient oil.
For detailed information on oil level check,
see “Checking the engine oil level” on
page 294.
Your engine is fitted with iridiumtipped
spark plugs.
NOTICE
Use only iridiumtipped spark plugs
and do not adjust gaps for your en-
gine performance and smooth drivabil-
ity.
Iridiumtipped spark plugs

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Brake system
BRAKE SYSTEM
This brake system has two independent
hydraulic circuits. If either circuit should
fail, the other will still work. However, the
pedal will be harder to press, and your
stopping distance will increase. Also, the
brake system warning light may come on.
CAUTION
Do not drive your vehicle with only a
single brake system. Have your
brakes fixed immediately.
BRAKE BOOSTER
The brake booster uses brake fluid pres-
surized by the pump to power−assist the
brakes. If the brake booster fails during
driving, the brake system warning light
comes on and buzzer sound continuously.
In this case, the brakes may not work
properly. If they do not work well, depress
the brake pedal firmly. If the brake system
warning light comes on, immediately stop
your vehicle and contact your Toyota deal-
er. The brake system warning light may stay
on for about 60 seconds after the ignition
key is turned to “ON” position. It is nor-
mal if the light turns off after a while.
Depressing the brake pedal repeatedly
may turn on the brake system warning
light and buzzer. It is normal if the light
turns off and the buzzer stops sounding
after a few seconds.
You may hear a small sound in the engine
compartment after the engine is started or
the brake pedal is depressed repeatedly.
This is a pump pulsating sound of the
brake system, and it is not a malfunction.
CAUTION
Do not pump the brake pedal if the
engine stalls. Each push on the
pedal uses up your brake fluid
pressure reserve.
Even if the power assist is com-
pletely lost, the brakes will still
work. But you will have to push the
pedal hard, much harder than nor-
mal. And your braking distance will
increase.
ANTILOCK BRAKE SYSTEM
(with “ABS” warning light)
The antilock brake system is designed
to automatically help prevent lockup of
the wheels during a sudden braking or
braking on slippery road surfaces. This
assists in providing stab
ility and steer-
ing performance of the vehicle under
these circumstances.
Effective way to press the ABS brake
pedal: When the anti −lock brake system
function is in action, you may feel the
brake pedal pulsating and hear a noise.
In this situation, to let the anti −lock
brake system work for you, just hold the
brake pedal down more firmly. Do not
pump the brake in a panic stop. This
will result in reduced braking perfor-
mance.
The anti −lock brake system becomes op-
erative after the vehicle has accelerated
to a speed in excess of approximately 10
km/h (6 mph). It stops operating when the
vehicle decelerates to a speed below
approximately 5 km/h (3 mph).

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2004 L/C100 from Aug ’03 Prod. (OM60A04U)
Depressing the brake pedal on slippery
road surfaces such as on a manhole cov-
er, a steel plate at a construction site,
joints in a bridge, etc. on a rainy day
tends to activate the anti−lock brake sys-
tem.
You may hear a click or motor sound in
the engine compartment for a few seconds
when the engine is started or just after
the vehicle begins to move. This means
that the anti −lock brake system is in the
self check mode, and does not indicate a
malfunction.
When the antilock brake system is ac-
tivated, the following conditions may
occur. They do not indicate a malfunc-
tion of the system:
You may hear the anti −lock brake sys-
tem operating and feel the brake pedal
pulsating and the vibrations of the body
and steering wheel. You may also hear
the motor sound in the engine compart-
ment even after the vehicle is stopped.
At the end of the anti −lock brake sys-
tem activation, the brake pedal may
move a little forward.
CAUTION
Do not overestimate the antilock
brake system: Although the antilock
brake system assists in providing ve-
hicle control, it is still important to
drive with all due care and maintain
a moderate speed and safe distance
from the vehicle in front of you, be-
cause there are limits to the vehicle
stability and effectiveness of steering
wheel operation even with the anti
lock brake system on.
If tire grip performance exceeds its
capability, or if hydroplaning occurs
during high speed driving in the rain,
the antilock brake system does not
provide vehicle control.
Antilock brake system is not de-
signed to shorten the stopping dis-
tance: Always drive at a moderate
speed and maintain a safe distance
from the vehicle in front of you.
Compared with vehicles without an
antilock brake system, your vehicle
may require a longer stopping dis-
tance in the following cases:
Driving on rough, gravel or snow
covered roads.
Driving with tire chains installed.
Driving over the steps such as the
joints on the road.
Driving on roads where the road
surface is pitted or has other differ-
ences in surface height.
Install all 4 tires of specified size at
appropriate pressure: The antilock
brake system detects vehicle speeds
using the speed sensors for respec-
tive wheels’ turning speeds. The use
of tires other than specified may fail
to detect the accurate turning speed,
resulting in a longer stopping dis-
tance.

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DRUMINDISC TYPE PARKING BRAKE
SYSTEM
Your vehicle has a drum−in −disc type
parking brake system. This type of brake
system n eeds bedding −down of the brake
shoes periodically or whenever the parking
brake shoes and/or drums are replaced.
Have your Toyota dealer perform the bed-
ding− down.
BRAKE ASSIST SYSTEM
When you slam the brakes on, the
brake assist system judges as an emer-
gency stop and provides more powerful
braking for a driver who cannot hold
down the brake pedal firmly.
When you slam the brakes on, more pow-
erful braking will be applied. At this time,
you may hear a sound in the engine
compartment and feel the vibrations of the
brake pedal. This does not indicate a mal-
function.
The brake assist system becomes opera-
tive after the vehicle has accelerated to
a speed in excess of approximately 10
km/h (6 mph). It stops operating when the
vehicle decelerates to a speed below
approximately 5 km/h (3 mph). The brake assist system may not work for
about 60 seconds after the engine is
started.
For an explanation of this system’s warn-
ing light, see “Service reminder indicators
and warning buzzers” on page 126.
Brake pad wear limit indicators
The brake pad wear limit indicators on
your disc brakes give a warning noise
when the brake pads are worn to where
replacement is required.
If you hear a squealing or scraping noise
while driving, have the brake pads
checked and replaced by your Toyota
dealer as soon as possible. Expensive ro-
tor damage can result if the pads are not
replaced when necessary.