*STICKY* General Servicing Info

[TonyN]

General servicing info for quick reference.

If you see anything you think should be included on this page, PM me the link to the item, or just type it in a reply on this thread and I'll add it to the post. I'll delete replys once they are in the main post to keep things tidy.
Feel free to point out any errors, wecan get them sorted out and try to cut down on some of the conflicting info.

Nothing to complicated or technical, just the stuff the 'average Joe' (or Joanna ;-) ) should be able to check and sort out, and we won't lose the info as it gets old as is dropped from the server.

Cheers.
Tony

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DRIVE TRAIN

Standard rear diffs GL5, SAE 90 for above 18 deg C or 80W or 80W-90 for below 18 deg C. 2.2 Liters

LSD rear diffs just use specific LSD gear oil.

Front diffs without ADD (not Surfs) are same as rear diffs above. 1.6 Liters

Front diffs with ADD (all 2nd gen Surfs) are GL5 SAE 75W-90. 1.86 Liters

Planetary T/case (Automatic and most manual Surfs) needs GL4 or 5 SAE 75W-90 1.1 Liters

Reduction gear T/case (MK1 Surfs, and manual 4Runners) as above but 1.6 liters.



Manual Gearbox......3.0L Multipurpose Gear oil API GL-4 or GL-5, SAE 75W-90

Automatic Gearbox......Up to 4.5L Dexron II ATF fluid.



Wheel bearings....Lithium base wheel bearing grease NLGI No.2

Propshafts....
Spiders and slide yokes..Lithium base chassis grease NLGI No.2

Double cardan joint......Molydbenum-disulfide lithium base chassis grease NLGI No.2




Ball joints......Molydbenum-disulfide lithium base chassis grease NLGI No.1 or No.2



Front drive shaft drive bushings....

Molydbenum-disulfide lithium base chassis grease NLGI No.2

End float 0.075mmm and 0.69mm with a maximum of 1.0mm.
There are two washer thicknesses, one is 1.8mmm and the other 2.25mm. If more than 1.0mm end float and using a 1.8mm thick washer, change to the 2.25mm washer. If more than 1.0mm end float and using the 2.25mm thick washer, bushes are worn and need replacing.

Part Numbers. 90560-27010, 1.8mm. 90560-27005, 2mm and 90560-27011, 2.25mm.

Thanks to Nev

Clutch fluid...SAE J1703 or FMVSS No.116 DOT 3

Anti Roll bar
Stabilizer Bush, part No Y48815-20200 ..£6.06ea
Stab. Bush Bracket, part No Y48823-35060 ..£7.64ea


BRAKES

Minimum pedal floor clearance when depressed...60mm
Pedal freeplay.....3-6mm
Parking brake adjustment.....13-19 clicks
Brake fluid...SAE J1703 or FMVSS No.116 DOT 3

LN130 (bought for 1990 truck)Genuine Toyota pads, Part No.04465-YZZAF (Fit Hilux 8/88-current, LC70 1/90-current.

KZN185 (bought for 1996 truck) Genuine Toyota pads, Part No. 04465 35280 by Rob

STEERING

Wheel free play....>30mm
Power Steering fluid..... ATF fluid Dextron-II.

TYRES

265/70 R15 110S....
Front 29psi, rear 29psi Loaded or unloaded
215 R15 100S....
Front 28psi, rear 33psi Loaded or unloaded



ENGINE

3VZ-E
Engine oil.........4.2L (4.5 inc filter)

1KZ-T
Engine oil.........7L (8L inc filter)

A102 Oil Filter Toyota Part No. T90915-30002 (By Mart)

2L-T
Engine oil.........5.8L (6.8 inc filter)

Oil Grade.
Petrol.....
API SG or SH multigrade, or ILSAC multigrade.
Recommended viscosity....
Diesel.....
API CD or better

Filter Cross Referance Numbers Thanks to MattF

Oil Filters (all diesels)....
Toyota 90915-30002
Fram PH5123
Fiaam FT5429
Tecnocar RD1216
Unipart GFE328
Mahle OC275
Purflux LS895
Mann WP928/80

Fuel Filters (all diesels)....
Toyota
Unipart GFE5316
Mann WK828
Mahle KC83
Fram P4922
Fiaam FP5091

Air Filters...

2.4TD...
Mahle LX606
Mann C20189
Fram CA3688
Fiaam FL6806

3.0TD (2nd Gen KZN130)...
TBA

3.0TD (3rd Gen KZN185)...
Toyota 17801-67030

V-Belts Thanks to Tony Goodwin

3.0TD 3rd Gen KZN185....
Fan/Alt belt 90916-02385 x2
aircon belt 90916-02397




Fault Codes

To get the basic diagnostic codes, find the grey box marked Diagnostics, and join connections TE1 and E1 together. Then turn the ignition on and count the flashes of the check light.
2 figure codes have a small gap between flashes, longer gaps between individual codes, continuous flashes means all clear.

Pull the ECD fuse for 10 sec or so to clear old codes.

Diagnostic fault codes for the 2LTE diesel engine.

1 - Normal
2 - Turbo boost pressure sensor
4 - Coolant temperature sensor
5 - Correction resistance (Pump)
6 - Pump speed sensor (Pump)
7 - Throttle position sensor
8 - Intake air temperature sensor
9 - Vehicle speed sensor
10 - Starter switch
11 - Switch sign (Vehicle not in P or N or A/C on)
12 - Timer control valve (Pump)
13 - Crank position sensor

1KZ/TE codes....



Vacuum pump rotors......Toyota Part 29331-56070 and cost £13.15 +VAT each.
'89-'91 cars use four and the '91-'94 cars with the later type of alternator use three. thanks to Elvie

RPM sensor o-ring...
http://www.hiluxsurf.co.uk/showpost....56&postcount=6

Starter Motor.....

Contacts
Allthe parts can be obtained from Toyota.
http://www.afm15.dial.pipex.com/sur...eplacements.pdf
All the starter bits are listed here;

Plunger, Magnet Switch (Solenoid) Part No. 28235-17030- £14.92
Fits 2LTE, 3L..LN13# IKZTE, 2L#, KZN130, LN108,112,85..4FC

Starter Kit, Motor Terminal (The bit the plunger hits and connects the starter motor) Part No. 28226-54220 £9.39
Fits 2LTE, 3L..LN13# IKZTE, 2L#, KZN130, LN108,112,85..4FC

Starter Kit, Battery Terminal (The other bit the plunger hits) Part No. 28226-54320 £5.78
Fits 2LTE, 3L..LN13# IKZTE, 2L#, KZN130, LN108,112,85..4FC
thanks to Fieldsy


Cooling........

1KZ/TE 71*C thermostat 90916-03121

Coolant...

3VZ-E.....10L (9.8 with Auto)
2L-T......9.1L
1KZ-T.....10L

Type......Ethylene-glycol antifeeze/anticorrosive

Thermostat (91' 2.4)..... 88 degree (Toyota part no 16340 54010) thanks to JimL
Cap (91' 2.4)..... 0.9 bar (Toyotoa part no 16401 63010) thanks to JimL

2LT/E Electric fan temp sender......
Toyota part number T83420-20020 thanks to Kitesurf Phil

Filling cooling system........

With all the heaters on, fill it via the hose that does a 180 deg bend into the heater control valve with a watering can, fill till coolant comes out rad, put cap on, keep filling till coolant comes out of heater control valve and pop pipe back on.

Take it for a run and check it at the rad cap when cold or next morning and it shouldn't need much more water.


Cylinder Head............


2.4 2LT/E... thanks to Koi
1st stage 58ft/lb 78nm
2nd stage 90 degree turn
3rd stage 90 degree turn.

Undoing Crank Pulley bolt.....

http://www.hiluxsurf.co.uk/showpost....8&postcount=19



2L/T Vacuum hoses......



Rear window..........

Relays are avalable from
Omron Electronic Components Europe
Sub-Miniature Automotive PCB Relay
G8SN-1C7-CUK 12DC (320oms) spdt motor,resistive.

Or from Maplins
JM67X 12V/12A Min relay Thanks to Tom Lilley

Rear Wiper Blade........

Screw on type, Genuine Toyota, pt no 85220-22461 (350mm)
__________________

[Rob]

Air filter 17801-67030
Oil filter 90915-30002
Fan/Alt belt 90916-02385
aircon belt 90916-02397

More for 3rd gen:

Fuel filter 23303-64010
Dash bulb - Heater controls (each, you need 2) 90076-04003
Front A/R bar drop link bush (each, you need 2 of these per side) 90948-01003
Brake shoe Kit 04495-35230

[Gizmo]

Starter Motor

Plunger and two contacts (prices as of 2004)


Parts Issued..... Description........ Price
T28226-54220.....Starter Kit...........£9.39
T28226-54320.....Starter Kit...........£5.78
T28235-17030.....Plunger, Switch....£14.92

[TonyN]

There is a Ozzie manual from Max Ellery that covers the 2 L/T. Only the EFI differences are not on it.

I guess you can get a manual from Toyota, but I've not made inquires yet.

[scottrods]

There is a Ozzie manual from Max Ellery that covers the 2 L/T. Only the EFI differences are not on it.

I guess you can get a manual from Toyota, but I've not made inquires yet.

Anyone got the service schedule for a 97 Surf 3.0 Turbo diesel with intercooler?

[sonicsi]

There is a Ozzie manual from Max Ellery that covers the 2 L/T. Only the EFI differences are not on it.

I guess you can get a manual from Toyota, but I've not made inquires yet.

Bin there and they are not interested in offering any help to people with imports so Toyota GB is a “none starter”.

[TonyN]

Bin there and they are not interested in offering any help to people with imports so Toyota GB is a “none starter”.

You much have a w**ker dealer then! Our local main dealer is really helpful, I get no end stuff from them.

[bundubasher]

I've got my '94 4Runner Owners Manual in front of me. Now I have the incorrect dipstick in my motor so I change my oil strictly by the book. It says:

1KZ-T with filter 7.1L
1KZ-T without filter 6.4L

This is a big difference to the:

1KZ-T Engine oil.........7L (8L inc filter)

in the above sticky.

Can anybody help clarify this for me?

[osker]

Hi,

What's the best way to raise the rear of a surf onto axle stands - I'm thinking ... jack under rear diff and lower onto stands ... just want to check?

When is it best to jack up the chasis and does it matter which bit you raise?

Thanks,
Keith

[Woodzie]

Hi,

What's the best way to raise the rear of a surf onto axle stands - I'm thinking ... jack under rear diff and lower onto stands ... just want to check?

When is it best to jack up the chasis and does it matter which bit you raise?

Thanks,
Keith

There arethree good places for a trolly jack
Front under the wishbones then axel stand the main cross member/ center of the main cross member (if you can get your axel stands either side).
Rear under the diff then axel stand under the Halfshaft casing as close to the wheels as poss.
Give the grease nipples plenty of grease on the props
Most of the chasis is too high for a standard trolly jack

[osker]

Cheers Woodsie - I'll hopefully sort it tomorrow. Just need to get hold of some grease! I'm looking out for your next salisbury trip!

Keith

[sledge]

thought id have a go at a write up on cv boot replacement




CV boot replacement


1) loosen wheel nuts, jack up truck and place the side your working on an axel stand.
Remove wheel

2) Remove dome centre . Undo the 12mm bolt that secures the shaft. Loosen the 6 12mm nuts, holding the hub on.
Unscrew to the end of the bolt( do not take them right off). Use a hammer to tap around the edge of the hub until the 6 cone washers become loose. Remove the 6 nuts, washers and cone washers.


3) Use a flat bladed screwdriver to pry off the hub (might be stubborn and need to be hit with a hammer)

4) Remove the circlip, that holds the shaft in, and the big washer that's behind it.


5) Undo the 6x17mm nuts holding the shaft to the engine . I found the best way to do this was to put a spanner on the nut below, and undo the one above (you may need a breaker bar for this). When you get to the last one, put the spanner on the back of the bolt

6) Once you have all 6 nuts removed, you will need to align the lower wishbone parallel to the ground using a jack.
Pull the shafts outer casing, until it is free from the bolts . You may need to use a screwdriver to leaver it off.
Once off, turn the steering all the way to the right. Line up the outer casing to the mounting plate so they can slot between each other.


7) Remove shaft. Once out, you will need to remove the outer casing. And remove the circlip that holds the rollers in place. Once off clean up shaft and any other areas that have grease on them.



8) Install cv boot(s), making sure you pack them with grease.

9) Reverse these steps

or another alternitive http://toyotasurf.asn.au/techsite/cvjoints.htm

[frosty]

Just a big thanks to Sledge cracking guide! replaced both boots yesterday using your guide and advice worked perfectly! so thanks for taking the time to put it on here!! the only problem i had was pulling the drive shaft free I had to loosen the torsion bar a little to give the that extra couple of mm clearance! cheers again!

[TriniSURF]

Hello, i just put 2.8 quarts of bel ray oil in my rear diff. 140 body.
Is that the correct body?

[TriniSURF]

It is a 1992 surf.