Description

Toyota FJ40 Service Manual – 184 Pages of Factory Specs

You’ve got a Toyota FJ40 Service Manual in front of you that’s been through more shop floors than most techs have seen paychecks. 184 pages, factory-issued, printed when the FJ40 was still rolling off the line. The document you’re looking at covers the Bandeirante models – TB25L and OJ32L – from chassis TB 10001 to 17461, built between January 1962 and August 1968. That’s the real deal. No aftermarket rehash, no clueless editor guessing at bolt sizes.

184 Pages of Factory Specs

Page 2 lays out the index. Thirteen groups cover everything from general description (Grupo 1) to special service tools (Grupo 13). The manual is dense – no wasted space, no filler photos of smiling technicians. Each group gets its own section, and the torque values are printed alongside the procedure. Need the flywheel bolt spec? It’s in Grupo 3 (Embreagem). Want the final drive ratio? Page 3 gives you 5.120 for the axles. The technical specifications table on page 3 lists vehicle weight, wheelbase (2,285 mm – 90 inches), and engine output: 94 HP at 2,800 rpm from the Mercedes OM314 diesel.

Any shop that works on FJ40s knows the value of having the factory numbers in front of you. Aftermarket manuals transcribe these specs wrong more often than I’ve seen a tech skip a torque sequence. This one is photocopied from the original Toyota printing – you can see the edge of the page numbers. You’re getting what the dealer workshop had.

Does This Manual Cover the Mercedes Diesel Swap?

Those early FJ40s came with a Mercedes-Benz OM314 diesel, not the Toyota B or 2F gas engines. Grupo 2 is entirely dedicated to that engine – 3,780 cc, 4-cylinder, 17:1 compression, 94 HP. The manual shows the injection pump timing marks, the cylinder head bolt sequence, and the oil filter specs. If you’re trying to keep a Bandeirante running or restore one, this is the only source you need for the OM314 data. No generic gasoline manual will cut it.

Torque values? Page 3 lists the reduction gear ratios, but the specific bolt torques are scattered throughout the groups. For example, Grupos 5 and 7 cover the rear and front axles – semi-floating rear, diamond-type front. You’ll find the wheel bearing preload specs there. The manual uses metric units, but you can convert to foot-pounds (1 Nm ≈ 0.7376 ft-lb). I recommend converting before you start – don’t math in the middle of a job.

Torque Values and Tolerances: Page 3 Data

The technical specifications table on page 3 is your cheat sheet. Wheelbase 2,285 mm (90 inches), track 1,360 mm front, 1,356 rear. Tire size 5.5J x 16 (6-lug). Brakes? Hydraulic, two cylinders per wheel – Grupo 9 gives the bleeding procedure. Suspension is leaf springs: 6 leaves front, 8 leaves rear, 1,310 x 69.8 x 6.35 mm each. Capacities: coolant 14.5 liters, fuel tank 60 liters, air filter oil bath 1 liter. All numbers you need for a proper fluid fill.

When I see a DIYer trying to set valve lash on an OM314 without these numbers, I cringe. The manual specifies the gap – it’s in Grupo 2. Don’t guess. Guessing gets you bent pushrods and a tow bill.

Why OEM Documentation Beats Aftermarket

I’ve seen third-party manuals that tell you to torque head bolts to 90 ft-lb on engines that need 120. Or they skip the torque-to-angle steps entirely. This Toyota manual is the original engineering release. The wiring diagram in Grupo 11 (Sistema elétrico) shows the 12-volt 135 amp battery and the 3HP starter motor – correct for the 1960s models. Aftermarket sources often use generic schematics that mix up wire colors. You can trust the factory print because it was drawn by the people who designed the harness.

Another example: the SST (Special Service Tools) list in Grupo 13. Toyota specifically called out tools like the clutch alignment fixture and the rear axle bearing puller. If you’re rebuilding, you’ll need to know which puller works. The manual shows the tool numbers. You can cross-reference them with the Automotive Industry Overview on Toyota’s owner site, but the manual itself has everything.

Who Should Use This Manual?

DIY mechanics who own an FJ40 Bandeirante and need to rebuild the OM314 diesel from the ground up – you’re the primary audience. Home garage enthusiasts who want to restore a 1960s Toyota four-wheel drive will find the chassis specs and suspension details essential. Beginners should be cautious – this manual assumes you know how to use a micrometer and a torque wrench. If you’ve never pulled a cylinder head, read through Grupo 2 first and make sure you understand the bolt sequence. It’s step-by-step but not hand-holding.

Professional mechanics will appreciate the accuracy. I keep a copy of this in the shop for any vintage Toyota jobs that roll in. The brake adjustment specs in Grupo 9 are spot-on, and the electrical system troubleshooting logic in Grupo 11 saves hours of chasing shorts.

FAQ

Does this manual cover the gasoline engine?

No. This manual is for the Mercedes OM314 diesel only.

Is the manual written in English?

The text is in Portuguese (original Toyota do Brasil manual). However, the diagrams, torque tables, and part numbers are universal. If you can read a torque spec in Nm and follow an illustrated sequence, language is not a barrier. Many of our customers use it with a translation app for the text, but the technical data is clear.

Can I use it for a 1975 FJ40?

Only if your 1975 has the OM314 engine and early chassis dimensions. The manual covers TB25L/OJ32L chassis from 1962 to 1968. Later models switched to Toyota’s own diesel and gasoline engines. For a 1975 FJ40 with a Toyota engine, you need a different manual.

Are torque values in foot-pounds or Newton-meters?

The manual lists torque in kilogram-force meters (mkgf). You can convert: 1 mkgf = 7.233 ft-lb = 9.807 Nm. Page 3 shows the engine torque maximum at 26 mkgf (188 ft-lb). I always convert before starting.

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If you own an FJ40 Bandeirante and you’re tired of guessing torque values or chasing non-existent parts diagrams, stop wasting billable hours. Access the Factory Manual now and get the real numbers onto your workbench.