Toyota Land Cruiser FJ40, FJ43, FJ45 & FJ55 1962–1974 Repair Manual Set (P/N 98087)

Together, the volumes support work that crosses engine and vehicle systems, including engine removal, clutch inspection, and transmission refitting.

Emission-control service requires a separate manual, as directed in the engine publication.

PDF Bookmarks, Wiring Detail, and Page Count

Search and diagram access: Both PDFs have embedded bookmarks, but their technical text is not searchable. The engine PDF includes section and page bookmarks; the chassis PDF has chapter bookmarks. Small labels in the chassis vehicle wiring diagrams require zooming.

The ZIP contains two printable PDFs totaling 532 pages. This includes six engine cover, introductory, and publication pages; three chassis introductory pages; and five unnumbered chassis wiring-diagram sheets.

Engine Overhaul, Drivetrain Repair, and Body Electrics

The following selected repair topics show the scope of the publications. Other included subjects range from exhaust-pipe replacement to air-cleaner service.

• Engine overhaul: Step-by-step procedures for engine removal, cylinder-head repair, block inspection, and crankshaft, piston, valve-train, and timing-gear work.

• Transmission and transfer: Three- and four-speed transmission overhaul, two-range transfer repair, and mechanical and vacuum-operated front-drive controls.

• Axles and differentials: Ball-joint and Birfield front-axle designs, with pinion-depth, bearing-preload, backlash, and tooth-contact checks.

• Brake systems: Hydraulic drum brakes, the driveline parking brake, remote vacuum boosters, and later booster/tandem-master-cylinder assemblies.

• PTO front winch: Power take-off, drive-shaft, worm-gear, and drum-mechanism disassembly, inspection, and assembly procedures.

• Frame and body: Frame inspection and repair, wagon and hardtop service procedures, and canvas-top and pickup body components.

• Electrical diagnosis: Starter and charging-system tests, distributor checks, instrument testing, wiper repair, and configuration-specific wiring diagrams.

These manuals are written for service personnel and mechanics who understand component construction and operation; internal overhaul work calls for measuring equipment and the specified service tools.

Engine, Fuel, and Cooling Systems

Beyond routine tune-up, the engine sections document valve-guide replacement, cylinder boring and honing, camshaft-bearing replacement, and flywheel/bellhousing alignment checks. The special-tool listings identify Camshaft Bearing Remover & Replacer 09215-60010.

Carburetor differences: Separate sections cover earlier Land Cruiser FJ and gasoline-truck FA carburetors, followed by the common two-barrel design introduced at Engine No. F-294920. The “Cross Section View of Carburetor” supports the operating descriptions and adjustment procedures.

Lubrication: Oil-pump inspection and repair accompany oil-pressure-regulator service. Oil-filter coverage distinguishes the earlier replaceable-element arrangement from the screw-on type introduced at Engine No. 273211.

Mechanical fuel-pump inspection, manifold heat-control valve checks, and radiator, thermostat, and water-pump service are also included.

Clutch, Axles, Steering, and Brakes

Clutch coverage includes hydraulic master- and slave-cylinder repair, bleeding, and pressure-plate/release-lever adjustment. Transmission sections distinguish column- and floor-shift arrangements. The vacuum front-drive chapter covers control valves, diaphragm operation, and leak checks.

Axle setup: Semi-floating rear-axle coverage includes shaft endplay and bearing replacement. Front steering-knuckle setup uses Steering Knuckle Centering Gauge 09634-60012 for centering, shim selection, and bearing preload. The centering instructions address premature axle-bushing wear caused by misalignment.

Steering-gear repair covers worm-and-sector-roller components and the separate FJ55 linkage arrangement. Leaf-spring, shackle, and shock-absorber service accompany alignment checks and toe-in adjustment; an FJ55 rear-stabilizer component view is included.

Booster diagnosis: Vacuum/pressure tests and operational checks distinguish the earlier remote booster from the later assembly. The “Tandem Master Cylinder & Brake Booster Section View” supports the later unit’s separate overhaul procedures.

Follow the manual’s precautions when handling loaded clutch springs, lifting drivetrain assemblies, or servicing brake hydraulics.

Frame, Body, and Electrical Diagnosis

Model-specific frame dimension diagrams accompany frame alignment and repair procedures. Body sections distinguish door alignment, glass and weatherstrip replacement, removable hardtop panels, seat mechanisms, and pickup body component views.

Wagon rear window: The “Tail Gate Regulator Wiring Diagram” accompanies motor, control-switch, safety-switch, and circuit-breaker fault diagnosis.

Separate vehicle wiring diagrams identify FJ40(L), FJ55(L)V, FJ55LG, and Australian FJ55V configurations. Harness-routing and clamp illustrations distinguish left- and right-hand-drive bodies.

Instrument testing covers gauges and sending units. Wiper-motor overhaul and heater-blower, heater-core, and rear-seat-heater service extend the electrical and accessory coverage.

Engine electrics: Starter overhaul includes armature, field-coil, magnetic-switch, and no-load tests. Alternator output tests, regulator circuit checks, and distributor advance testing accompany the “Wiring Diagram of Engine Electrical System.” The alternator precautions explain how reversed battery polarity can damage the rectifiers.

Troubleshooting charts connect hard starting, gear noise, brake drag, and inoperative wipers with probable causes and repair checks. Reference sections include component-specific torque tables, journal-specific standard and undersize bearing dimensions, wear limits, lubricants, capacities, and electrical test specifications.

Selected Ignition Gaps and Differential Backlash

For the F engine’s contact-breaker ignition, the tune-up section lists a distributor point gap of 0.4–0.5 mm (0.016–0.020 in.) and a spark-plug gap of 0.7–0.8 mm (0.028–0.031 in.) alongside the related inspection and adjustment instructions.

The rear-differential setup section specifies ring-and-pinion backlash of 0.15–0.20 mm (0.006–0.008 in.), with bearing-preload adjustment and tooth-contact illustrations.