Toyota Land Cruiser FJ40, FJ43, FJ45, FJ55 1975–1980 Repair Manual Set (P/N 98126)

The engine volume supplies the internal engine work referenced by the chassis/body book. Together, they provide engine and vehicle-system procedures without treating the chassis manual as an engine-overhaul guide.

Internal engine repair is limited to the 2F gasoline engine. The B Engine Repair Manual, Pub. No. 98260, and H Engine Repair Manual, Pub. No. 98112, are separate publications and are not included. U.S. emission-control service is assigned to the separate Emission Control Repair Manual, Pub. No. 98117.

Text Search, Bookmarks and Wiring Detail

Search and circuit detail: OCR text search in the engine PDF has recognition errors, and several pages need rotation. The chassis/body PDF has no text search. Both have chapter bookmarks. Starter and charging circuit labels are readable; small chassis wiring codes require zooming.

ZIP download containing two printable PDFs, 622 pages total, including the engine volume’s four opening pages and five memo pages, plus five opening pages and the back cover in the chassis/body volume.

2F Overhaul, Driveline Repair and Body Electrical Work

The following selected repair topics give a cross-section of the contents. Other subjects include heat-control-valve inspection and trailer-socket-switch testing.

• 2F engine service: Tune-up, cylinder-head overhaul, timing-gear and camshaft work, and cylinder-block disassembly, inspection, machining-related repair, and reassembly.

• Engine support systems: Oil-pump overhaul, lubrication and cooling circuits, water-pump and fluid-coupling service, radiator and thermostat testing, fuel-pump repair, and carburetor adjustment.

• Starting, ignition and charging: Starter overhaul and performance testing, distributor repair, alternator service, and regulator inspection and adjustment.

• Driveline and axles: Clutch hydraulics and clutch-unit repair, manual-transmission and transfer-case overhaul, propeller-shaft service, axle repairs, differential setup, and free-wheel hubs.

• Steering and brakes: Steering-gear repair and wheel alignment, master-cylinder and booster overhaul, vacuum-pump service, and front drum, front disc, rear, and parking brakes.

• Body and body electrical: Model-specific panel and glass procedures, lighting and switch tests, wipers, combination meters and gauges, heaters, and wiring diagrams.

• PTO winch: Power take-off and winch disassembly, component inspection, reassembly, and worm-bearing adjustment, supported by cutaway views.

The overhaul work is suited to mechanics and experienced owners who can use a press, dial gauges, electrical test equipment, and the specified Toyota SSTs.

2F Tune-Up and Internal Engine Repair

Tune-up detail: Oil and coolant checks, drive-belt and air-cleaner service, and battery, spark-plug, and high-tension-cord inspection are covered. Separate procedures address valve clearance, compression, initial and fast-idle settings, and the throttle positioner.

Internal repair: Step-by-step cylinder-head procedures cover valves, springs, rocker arms, and manifolds. Timing-system work extends to valve lifters; the block chapter covers pistons and rings, connecting rods, crankshaft and bearings, cylinder boring, camshaft-bearing replacement, input-shaft bearing service, and crankshaft rear oil-seal installation.

Fuel, Cooling and Engine Electrical Systems

Fuel and cooling: Carburetor circuit drawings distinguish U.S. and non-U.S. layouts, with teardown, inspection, assembly, and linkage adjustment procedures. Lubricating System Circuit and Cooling System Circuit drawings show the oil and coolant paths alongside the pump-service material.

The carburetor chapter warns against cleaning jets or orifices with wire or a drill because the calibrated openings can be enlarged and fuel consumption increased.

Electrical variants: Starting System Circuits and Charging System Circuits support bench and on-vehicle checks. Ignition procedures distinguish U.S. vacuum-retard and non-U.S. vacuum-advance distributors; charging repair separates conventional, heavy-duty, and vacuum-pump alternators, with regulator inspection and adjustment.

Transmission, Transfer and Axle Setup

Transmission and transfer: The H41/H42 four-speed and J30 three-speed chapters include gear, synchronizer, bearing, and shift-fork checks. Transfer procedures distinguish direct and vacuum-operated front-drive controls. These variant-specific sections help match inspection and assembly procedures to the unit being repaired.

Axles: Semi-floating and full-floating rear assemblies have separate procedures. Differential repair includes pinion positioning, bearing preload, backlash, and tooth-contact inspection; front-axle work covers steering-knuckle centering and Birfield-joint service.

Steering, Brake and Body Variants

Brake chapters separate single and tandem master cylinders, including U.S./Canada versions, and standard and tandem boosters. Steering coverage includes the main and intermediate shafts, steering-gear housing, linkage, and front-wheel alignment checks.

Frame dimensions are presented in four model-specific series groups. Body procedures distinguish FJ55 hood, front and rear doors, windshield, tailgate, and roof-headlining work from FJ40 hood, door, and back-door service.

Body Electrical Tests and Wiring Applicability

The electrical chapters cover fuse blocks, ignition and starter switches, lighting, turn and hazard circuits, wipers, combination meters, gauges, front-drive vacuum controls, and heaters. FJ55 tailgate coverage includes the power-window circuit, safety switch, regulator motor, and mechanical lock adjustments.

Six multi-page wiring diagrams cover FJ40/FJ43/FJ45, FJ55, HJ45, and BJ40/BJ43 outside the U.S. and Canada, plus 1975-model FJ40 and FJ55LG for the U.S. and Canada. Wire-color codes, connection grids, and broken-line optional circuits support tracing the applicable vehicle configuration.

The North American diagrams are specifically labeled 1975 Model and should not be treated as wiring updates for the entire listed year range.

Toyota Tools, Reference Tables and Repair Cautions

Numbered disassembled views use operation-sequence markers and detail references. Toyota SST listings identify tools such as the 09213-60015 crankshaft pulley and gear puller, 09530-35010 differential drive-pinion adjusting gauge, and 09634-60012 steering-knuckle centering gauge.

Reference tables supply standard and component-specific torques, approved lubricants, fluid capacities, wear limits, clearances, backlash and preload data, and electrical test values.

Front-axle cautions address mismatched shims and incorrect inner-race/cage orientation, which can upset preload or joint movement; disc-brake warnings cover separating caliper halves or prying pistons into their bores, where sealing surfaces can be damaged.

Major engine, transmission, axle, and brake work involves heavy assemblies and safety-critical systems. Secure the vehicle on stands rather than a jack alone, support removed assemblies with rated equipment, and isolate the battery before electrical service.

Examples of Timing-Gear and Differential Backlash Data

The 2F timing-gear inspection specifies standard backlash of 0.05–0.13 mm, with a 0.2 mm limit.

Differential adjustment specifies 0.15–0.20 mm backlash between the ring gear and drive pinion.