Toyota Land Cruiser 2H/12H-T 1980–1985 Repair Manual Set (P/N RM012E)

For HJ60 work, the volumes pair diesel-engine diagnosis and overhaul with the applicable chassis and body procedures.

Coverage limits: HJ61 and HJ75 coverage is limited to the engine volume. The chassis/body volume does not provide chassis or body procedures for those series. Separate 2F and B-series engine repair manuals are not included.

PDF Search, Circuit Detail, and File Contents

Text access and wiring detail: Manual content is not searchable in either PDF, and neither file has embedded PDF bookmarks. Small circuit labels, particularly on the foldout wiring diagrams, require magnification.

The ZIP download contains two printable English-language PDFs totaling 1,189 pages. The counts include three front-matter pages in each volume and the chassis/body volume’s 25-page wiring-diagram appendix.

Diesel Overhaul, Drivetrain Repair, and Electrical Diagnosis

This is a selection of covered work, rather than a complete contents list. Further topics include seat-belt warning checks and antenna service.

• Engine mechanical: Diesel troubleshooting, compression testing, turbocharger inspection, and step-by-step cylinder-head, timing-gear, camshaft, and cylinder-block repair procedures.

• Fuel system: Injection-nozzle testing and overhaul, feed-pump and automatic-timer repair, plus injection-pump disassembly, reassembly, bench testing, and calibration.

• Drivetrain and axles: Clutch adjustment and hydraulic bleeding, manual-transmission and transfer teardown, propeller-shaft service, differential repair, and suspension inspection.

• Steering and brakes: Manual and power-steering service, hydraulic brake diagnosis, booster and vacuum-pump repair, and drum, disc, and parking-brake procedures.

• Front winches: Power-takeoff service, mechanical and electric winch repair, and winch-motor electrical testing.

• Body and electrical systems: Body-hardware adjustment, glass and headliner work, diesel starting and charging diagnosis, vehicle circuit diagrams, and electrical-component checks.

These manuals suit experienced technicians equipped for component overhaul; injection-pump repair requires considerable skill and a dedicated test bench.

Diesel Diagnosis and Internal Engine Repair

Symptom charts address cranking and starting faults, rough idle, sudden stopping, low power, smoke, abnormal noise, and shutdown problems. Their check-and-remedy references help connect a complaint to the relevant mechanical, fuel, or electrical test before repair work is selected.

Cylinder-head work includes valves, guides, seats, rocker shafts, pushrods, manifolds, and the different 2H/12H-T layouts. Timing-system coverage adds automatic-timer drive components, timing marks, gear-backlash inspection, and front oil-seal replacement.

Cylinder-block procedures cover pistons and rings, connecting rods, crankshaft, main and rod bearings, camshaft bearings, cylinder inspection and boring data, and rear oil-seal service.

Injection-Pump Variants and Bench Calibration

The fuel chapter distinguishes the 2H manual-transmission governor, 2H automatic-transmission governor, and 12H-T boost-compensated arrangement. Separate nozzle sections cover opening-pressure, leakage, and spray-pattern tests.

Bench-test material includes injection volume and timing, governor adjustment, high-altitude compensator data, idle-up controls, sealing, and precision-component inspection. Governor characteristic diagrams show how the documented adjustments affect pump behavior.

Cooling and Lubrication Repair

Cooling coverage includes water-pump overhaul, thermostat testing, and radiator and cap checks. Lubrication sections address oil-pressure diagnosis, oil-pump repair, oil-cooler and relief-valve work, plus the 12H-T piston-cooling oil nozzles and check valves.

Diesel Starting, Preheating, and Charging

Electrical charts distinguish the 2H super-glow and fixed-delay arrangements from the 12H-T intake-heater/timer system. Turbocharger diagnosis includes mechanical checks and indicator- and warning-light fault tracing.

Starting and charging procedures cover the starter and relay, EDIC-equipped and non-EDIC 2H systems, the overinjection magnet, and alternators with and without IC regulators. Separate material addresses 12- and 24-volt charge-light relays and the HJ60/HJ61 ignition main relay.

Transmissions, Transfer Cases, and Axles

The chassis volume covers clutch master and release cylinders, H41/H42 four-speed and J30 three-speed transmission teardown, and transfer-case bearings, gears, seals, clearances, and preload. Propeller-shaft procedures distinguish standard and double-Cardan designs.

Front-axle work includes steering knuckles, axle shafts, the differential, free-wheel hubs, suspension, shock absorbers, and wheel alignment. Rear-axle sections distinguish semi-floating and full-floating designs and conventional versus limited-slip differentials. Transmission-and-transfer and axle cutaways support assembly identification.

Steering and Brake Systems

Steering coverage includes intermediate shafts, tilt and standard columns, linkage, and separate steering-gear procedures for the 40- and 60-series families. Power-steering material adds fluid-pressure testing and pump and gear-housing repair.

Brake sections cover the master cylinder, booster, vacuum pump, front drum and disc brakes, rear brakes, and parking brakes. The proportioning-and-bypass valve and load-sensing proportioning valve have their own inspection and service material.

Front Winch Repair

Mechanical and electric winch sections cover brakes, gears, and power-takeoff components. Motor inspection extends to the armature, commutator, brushes, thermo-switch, and magnetic switches.

Body Hardware and Vehicle Electrics

Body procedures cover 60-series hood, doors, lift gate, swing-out doors, instrument panel, roof headlining, and glass, with separate 40-series hood and door procedures. Frame-dimension drawings provide body and chassis reference measurements.

Electrical material includes connector handling, switch and relay locations, fuse and fusible-link layouts, lighting, turn/hazard circuits, wipers and washers, headlight cleaners, combination-meter and warning systems, rear defogger, and radio. Heater service covers the blower, controls, air-inlet unit, and heater assembly.

The wiring appendix contains general-destination diagrams for 1981 production vehicles and separate USA/Canada diagrams.

Workshop References and Component Precautions

Factory references include torque tables, inspection limits, clearances, shim selections, bearing-preload and gear-backlash data, alignment specifications, lubricant and capacity information, electrical test values, and SST/SSM indexes.

Toyota SST references include the 09241-76022 injection-pump stand set, 09992-00023 cylinder-compression check gauge set, 09992-00240 turbocharger pressure gauge, and 09634-60013 steering-knuckle centering gauge.

Injection-pump precautions address the precision sliding surfaces of plungers and delivery valves and the need to retain component order. Manual-steering cautions explain how separating the recirculating-ball nut or running it against the worm ends can damage the assembly.

Major work involves pressurized diesel test equipment, brake hydraulics, heavy drivetrain and winch assemblies, and a securely supported vehicle. Follow the manuals’ isolation, cleanliness, pressure-control, and support precautions before teardown.

Nozzle Pressure and Turbocharger Clearance Examples

For reused injection nozzles, the opening-pressure specifications are 105–125 kg/cm² for the 2H and 180–210 kg/cm² for the 12H-T. The nozzle chapters pair these ranges with leakage and spray-pattern tests.

The 12H-T turbocharger inspection specifies impeller-wheel axial play of 0.13 mm or less, with an assembly-replacement criterion when the limit is exceeded.