Toyota Land Cruiser HJ45 Diesel 1975–1979 Repair Manual Set (P/N 98112E)

The engine volume provides internal engine and diesel fuel-system repair procedures, while the companion volume handles Land Cruiser drivetrain, chassis, body, and electrical service.

Coverage limits: Dyna repair coverage is confined to the H-engine volume. The FJ- and BJ-series material belongs to the chassis and body volume; their engine repair manuals are separate publications.

PDF Files, Bookmarks, and Diagram Detail

Search and diagram access: Neither PDF supports text search. Both have embedded chapter bookmarks, and small wiring-diagram labels require zooming for comfortable reading.

The ZIP download contains two printable English PDFs totaling 643 pages, including 11 cover and preliminary pages already included in the individual publication counts.

H-Engine Overhaul and Land Cruiser Workshop Coverage

These selected contents outline the major repair areas rather than reproduce the complete contents. Other topics include battery inspection and roof-headlining removal and installation.

• Engine repair: Tune-up checks, compression testing, internal disassembly, cylinder-liner service, component measurement, reassembly, and checks after engine installation.

• Diesel fuel system: Bosch A-type injection-pump overhaul, feed-pump testing, nozzle inspection, automatic-timer testing, and pneumatic and mechanical governor adjustment.

• Drivetrain: Clutch hydraulics and clutch-unit repair, H41/H42 and J30 manual transmissions, transfer-case overhaul, propeller shafts, and transfer-mounted parking brakes.

• Axles and steering: Semi-floating and full-floating rear axles, differential setup, Birfield joints, free-wheel hubs, steering gear, linkage, and wheel alignment.

• Brakes and winch: Drum and disc brake service, brake-booster adjustment, vacuum-pump repair, brake bleeding, and front winch/PTO overhaul.

• Body and electrical: Frame dimensions, doors and glass, tailgate mechanisms, heaters, wipers, gauges, front-drive vacuum control, component tests, and regional wiring diagrams.

The depth of the overhaul, calibration, and inspection material makes this set best suited to experienced technicians and rebuilders with the measuring tools and workshop equipment these jobs require.

Engine Inspection and Rebuild Decisions

The overhaul chapter follows the cylinder head, combustion chambers, valve train, pistons, connecting rods, crankshaft, camshaft, timing gears, cylinder block, liners, flywheel, oil seals, and related bearings through disassembly, measurement, repair decisions, and assembly.

Standard dimensions, wear limits, and oversize/undersize tables help a rebuilder assess whether components can be reused, require machining, or need replacement. Cylinder-liner work includes size selection, installation allowance, protrusion checks, and boring and honing to suit the piston.

Separate sections cover the oil pump and filter, intake and exhaust manifolds with their venturi arrangements, water pump, thermostat, radiator, and fan-drive components.

Injection-Pump Calibration and Governor Differences

The fuel-system material documents plunger and delivery-valve inspection, camshaft and tappet checks, control-rack movement, prestroke and injection-interval adjustment, delivery-volume calibration, and final installation timing.

The HJ pneumatic MN governor receives airtightness and spring-setting procedures. The HU mechanical RU governor has separate speed-control, damper-spring, and slip-torque adjustments. These application-specific sections distinguish the settings and test arrangements used for the two governor types.

Toyota identifies dedicated fixtures and tools, including injection-pump tool set 09260-46011 and cylinder-liner remover/replacer 09218-46010. Pump calibration requires the specified test-bench equipment.

Incorrect installation of the RU governor-gear retainer ring can allow it to disengage, reducing speed control and permitting engine overrun. The nozzle-cleaning instructions also warn against touching lapped surfaces with bare fingers because this can cause corrosion.

Drivetrain, Axle, and Chassis Adjustments

The chassis volume supplies step-by-step procedures for transmission and transfer-case disassembly and assembly. Supporting inspections cover synchronizers, shaft clearances, bearings, and selective snap rings or thrust washers.

Differential procedures extend to bearing preload, ring-and-pinion backlash, and tooth-contact checks. Front-axle material adds drive-shaft alignment and steering-knuckle preload; clutch and brake sections include release adjustment, booster pushrod adjustment, and hydraulic bleeding.

Component-specific torque tables, lubricant specifications, fits, clearances, and special-service-tool listings support these procedures.

Electrical Tests, Body Service, and Drawings

Engine electrical coverage includes starter inspection, separate HU/HJ alternator procedures, generator-regulator tests, glow-system checks, and over-injection-magnet adjustment.

Body electrical sections provide switch-terminal checks and tests for gauges, wipers, heaters, tailgate power-window components, and front-drive vacuum control. Body procedures distinguish the door, glass, hood, and tailgate arrangements illustrated for the different Land Cruiser configurations.

Drawings include the H41/H42 transmission-and-transfer cutaway, Bosch A injection-pump construction views, MN governor linkage and sections, RU governor timing and characteristic charts, and HU/HJ engine electrical connection diagrams.

Regional wiring sheets cover Land Cruiser applications, including HJ45 and North American FJ40/FJ55 variants. The engine PDF also contains a Dyna wiring diagram labeled RU20-30, BU20-30, JU20, and HU30; those diagram labels do not extend the H-engine repair coverage to other engines.

High-pressure diesel fuel, brake systems, supported driveline assemblies, and rotating pump-test equipment present serious hazards. Use the manuals' safety notes, the specified test equipment, and appropriate lifting and support practices during repair work.

Nozzle-Pressure and Liner-Protrusion Examples

For the H-engine nozzle inspection, the manual specifies opening pressures of 115–125 kg/cm² for new nozzles and 105–125 kg/cm² for reused nozzles. The separate ranges distinguish the acceptance criteria used during nozzle testing.

The cylinder-block inspection section specifies liner protrusion of 0.03–0.12 mm above the block surface, with accompanying measurement illustrations and liner-selection information.