2009 Toyota FJ Cruiser Service & Repair Manual

Last Modified: 8-27-2020 6.10:8.0.50 Doc ID: RM000000UYV05MX Model Year Start: 2009 Model: FJ Cruiser Prod Date Range: [08/2008 - ] Title: INTRODUCTION: HOW TO USE THIS MANUAL: GENERAL INFORMATION; 2009 MY FJ Cruiser [08/2008 - ] GENERAL INFORMATION 1. GENERAL DESCRIPTION (a) This manual is written in accordance with SAE J2008. (1) Diagnosis (2) Removing / Installing, Replacing, Disassembling / Reassembling, Checking and Adjusting (3) Final Inspection (b) The following procedures are omitted from this manual. However, these procedures must be performed. (1) Use a jack or lift to perform operations. (2) Clean all removed parts. (3) Perform a visual check. 2. INDEX (a) An alphabetical INDEX section is provided at the end of the manual as a reference to help you find the item to be repaired. 3. PREPARATION (a) Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure. Be sure to use SST and SSM when they are required and follow the working procedures properly. A list of SST and SSM is in the "Preparation" section of this manual. 4. REPAIR PROCEDURES (a) A component illustration is placed under the title where necessary. (b) Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. The following illustration is an example. (c) Torque specifications, grease application areas and non-reusable parts are emphasized in the procedures. HINT: There are cases where such information can only be explained by using an illustration. In these cases, torque, oil and other information are described in the illustration.

(d) Only items with key points are described in the text. What to do and other details are explained using illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. Illustration What to do and where to do it Task heading What work will be performed Explanation text How to perform the task Information such as specifications and warnings, which are written in boldface text (e) Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be different from the actual vehicle. (f) Procedures are presented in a step-by-step format. 5. SERVICE SPECIFICATIONS (a) SPECIFICATIONS are presented in boldface text throughout the manual. The specifications are also found in the "Service Specifications" section for reference. 6. TERM DEFINITIONS CAUTION Possibility of injury to you or other people. NOTICE Possibility of damage to components being repaired. HINT Provides additional information to help you perform repairs. 7. INTERNATIONAL SYSTEM OF UNITS (a) The units used in this manual comply with the International System of Units (SI UNIT) standard. Units from the metric system and the English system are also provided. Example: Torque: 30 N·m {310 kgf·cm, 22ft·lbf}

Last Modified: 8-27-2020 6.10:8.0.50 Doc ID: RM000000UYW06GX Model Year Start: 2009 Model: FJ Cruiser Prod Date Range: [08/2008 - ] Title: INTRODUCTION: IDENTIFICATION INFORMATION: VEHICLE IDENTIFICATION AND SERIAL NUMBERS; 2009 MY FJ Cruiser [08/2008 - ] VEHICLE IDENTIFICATION AND SERIAL NUMBERS 1. VEHICLE IDENTIFICATION NUMBER (a) The vehicle identification number is stamped on the vehicle body and on the certification label, as shown in the illustration. (1) Vehicle Identification Number (2) Certification Label 2. ENGINE SERIAL NUMBER AND TRANSMISSION SERIAL NUMBER (a) The engine serial number is stamped on the cylinder block of the engine and the transmission serial number is stamped on the housing as shown in the illustration. (1) Engine Serial Number (2) Transmission Serial Number

Last Modified: 8-27-2020 6.10:8.0.50 Doc ID: RM0000018UO014X Model Year Start: 2009 Model: FJ Cruiser Prod Date Range: [08/2008 - ] Title: INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION; 2009 MY FJ Cruiser [08/2008 - ] PRECAUTION 1. BASIC REPAIR HINT (a) HINTS ON OPERATIONS 1 Attire Always wear a clean uniform. A hat and safety shoes must be worn. 2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. 3 Safe operation When working with 2 or more persons, be sure to check safety for one another. When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. When jacking up the vehicle, be sure to support the specified location with a safety stand. When lifting up the vehicle, use appropriate safety equipment. 4 Preparation of tools and measuring gauge Before starting the operation, prepare a tool stand, SST, gauge, oil and parts for replacement. 5 Removal and installation, disassembly and assembly operations Diagnose with a thorough understanding of proper procedures and of the reported problem.

Before removing parts, check the general condition of the assembly and for deformation and damage. When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to ensure reassembly of components to their original positions. Temporarily mark hoses and their fittings if needed. Clean and wash the removed parts if necessary and assemble them after a thorough check. 6 Removed parts Place removed parts in a separate box to avoid mixing them up with new parts or contaminating new parts. For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this manual. Retain the removed parts for customer inspection, if requested. (b) JACKING UP AND SUPPORTING VEHICLE (1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. (c) PRECOATED PARTS (1) Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory. (2) If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive. (3) When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part. (4) Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden. (d) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks. (e) BOLTS, NUTS AND SCREWS (1) Carefully follow all the specifications for tightening torques. Always use a torque wrench. (f) FUSES (1) When inspecting a fuse, check that the wire of the fuse is not broken. (2) When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating.

ILLUSTRATION SYMBOL PART NAME ABBREVIATION FUSE FUSE MEDIUM CURRENT FUSE M-FUSE HIGH CURRENT FUSE H-FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB (g) CLIPS (1) The removal and installation methods of typical clips used for vehicle body parts are shown in the table below. HINT: If clips are damaged during a procedure, always replace the damaged clip with a new clip. SHAPE (EXAMPLE) ILLUSTRATION PROCEDURES 1. Remove the clips with a clip remover or pliers.

SHAPE (EXAMPLE) ILLUSTRATION PROCEDURES 1. Remove the clips with a clip remover or screwdriver. 1. Remove the clips with a wide scraper to prevent panel damage. 1. Remove the clips by pushing the center pin through and prying out the shell. 1. Remove the clips by unscrewing the center pin and prying out the shell. 1. Remove the clips by prying out the pin and then prying out the shell. (h) CLAWS (1) The removal and installation methods of typical claws used for vehicle body parts are shown in the table below. HINT: If claws are damaged during a procedure, always replace the damaged claws with new caps or covers.

SHAPE (EXAMPLE) ILLUSTRATION PROCEDURES 1. Using a screwdriver, detach the claws and remove the cap or covers. 1. Using a screwdriver, detach the claws and remove the cap or covers. 1. Using a screwdriver, detach the claws and remove the cap or covers. (i) HINGE, GUIDE, CLAMP AND PIN ETC. (1) The removal and installation methods of typical hinge, guide, clamp and pin used for vehicle body parts are shown in the table below. HINT: If clamps are damaged during a procedure, always replace the cap or cover that has damaged clamps with a new one. SHAPE (EXAMPLE) REMOVAL/INSTALLATION

SHAPE (EXAMPLE) REMOVAL/INSTALLATION (j) REMOVAL AND INSTALLATION OF VACUUM HOSES (1) To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage. (2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected. (3) After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout. (4) When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, it may leak air. Use a step-down adapter if necessary. (k) TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL

(1) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench. Formula: T' = L2 / (L1 + L2) * T T' Reading of torque wrench {N*m (kgf*cm, ft.*lbf)} T Torque {N*m (kgf*cm, ft.*lbf)} L1 Length of SST or extension tool {cm (in.)} L2 Length of torque wrench {cm (in.)} NOTICE: If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged. 2. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND FRONT SEAT OUTER BELT ASSEMBLY WITH PRETENSIONER The FJ CRUISER is equipped with a Supplemental Restraint System (SRS). CAUTION: Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made when servicing the SRS, it is possible that the SRS may fail to operate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following section carefully. (a) GENERAL NOTICE (1) As malfunctions of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery. (2) Work must be started at least 90 seconds after the ignition switch is turned OFF and after the cable is disconnected from the negative (-) battery terminal. (The SRS is equipped with a backup power source. If work is started within 90 seconds after turning the ignition switch OFF and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy. When the cable is disconnected from the negative (-) battery terminal, clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before. CAUTION: Never use a backup power source (battery or other) to avoid erasing system memory. The backup power source may inadvertently power the SRS and cause it to deploy. (3) Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and seat belt pretensioner should be inspected

You're Reading a Preview

2009 Toyota FJ Cruiser Service & Repair Manual

Description

Reviews

Q&A

Recently Viewed