The unofficial super custom manual

Did anyone ever do this for super customs?

Open source.

Would have
Overview
Maintanance list
top 20 common problem solutions



If not I am going to start one.. just a pdf.

Anyone can take it, edit it, and update the version.

No (c) issues if use own photos, diagrams and writing.

Ifixit started doing vehicles which is great, but no supercustom / hiace.

I got a right to be able to repair my van easily with repair information and it is frustrating that even Toyota themselves in some countries say they cannot provide service/repair manuals, and yet are the first to issue takedown notices on information that has been uploaded that they claim (c) to - where they have juristriction anyway. Toyota is way better than brands like VW that use anything in their power to make user servicing/repairing as difficult for the user as possible/ designing for planned obsolescence ; however, things are getting worse with technology being able to stop access to repairs. New Laws incoming... but until then...



I went ahead and started it - anyone is welcome to copy and paste this and fill in the gaps as they like and paste it to the next thread.

Once it is reasonable in text form with enough info to start, i will add photos, format it with tables and turn it into a very useful pdf and upload it ... that people can still continue to add to / update.

I will keep working on it when i get more time. I dont have any manuals at all to get any figures from - it is ok to reference figures from the original manual without any (c) problems, so if anyone can fill any of these from the original japanese manual that would be great - put a note that it came from the original manual if possible. You cant(c) recommended tyre pressures etc!



Version 1  (Update Version Number With Each Edit)
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Users Manual: Toyota Hiace Super Custom
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Open Source - The Contributors make no claim for the accuracy of the data nor accept any liability for their use. Use your own text, images  and diagrams. You can add other open source non text, images  and diagrams. though  Do not use text, images or diagrams.


Your Vehicle Details

Year
Eg 1994
Model
Rego
Engine
Chassis No. / Vin
Colour code



1 - About the Super Custom

The Super Custom is a van that was sold in Japan based on a the 4th (Known as H100) generation Toyota Hiace (August 1989- August 2004). It shares many but not all it’s parts. It is kind of a luxury Hiace and can have cool features like 4wd, moon roof, electric curtains, a built in tea maker /refrigerator. They can offer features not available in vans even available today like diff locking 4wd and their use of reliable Toyota Engines like the 1kz has kept them popular.

Super Custom Versions
-KZH106W-MFPQT
-KZH106W-MRMGT
-KZH106W-MRPGT
-Living Saloon
-Living Saloon EX
-Super GL

The Super Custom was also called:
Toyota Commuter
Toyota RegiusAce
Toyota HiClass
Jinbei Haise (China)


If your supercustom has a 1kz engine (most common), it shares the same engine (But probably not same ECU) as:

Land Cruiser Prado KZJ90, KZJ95, KZJ120L, KZJ120R[1]
Hilux Surf KZN130, KZN185



2 - Getting Started

Driving a Super Custom - general tips
Driving a Diesel - general tips



3 - Instruments and gears
Instrument Panel - image of layout
Overdrive Button - What it does
Gears - How they work
Door Controls - Overview (central locking?)
Sub Steering Wheel Controls - How to adjust height
Windscreen Wiper Controls - Overview



4 - Fuse Boxes
Location and layouts  - images

5 - Simple Problem Solutions

Wheel Changing  - Overview

Roof Racks
Tow Bars
Jump Starting



6 - Engine Compartment

Brake Fluid Reservoir
Air Filter
Engine oil Dipstick
Oil Fill Cap
Dipstick for Automatic transmission Fluid
Power steering fill cap.
Battery
Reservoir  and fill cap for radiator
Fill Cap Front windscreen washer
Fill Cap rear windscreen washer



7 - Driving Tips
Parking
Roll over Stability
Off road  - 4wd fixed and selection models



8 - Off road (4wd fixed and selection models)

Changing gears
Steering
Traction
Stability
Steep Hills
Sand
Mud
Recovery



9 - Servicing

Oil and Oil Filter - 10 000km or 5000km less is best
Replace fuel fliter - 20 000km or less
Air filter
Check and clean / replace
Fuel Tank Drain
Brake pads
Brake Fluid
Lubricate shaft joints
Drain and refill cooling system
Replace Auto Transmission Fluid
Change Air Filter
Replace front and rear differential oil
Replace Transfer oil case oil
Replace Engine Timing Belt

How Tos:
Changing engine oil
Changing Air Filter
Replacing Fanbelts
Replacing Crankshaft Pulley
Changing cabin lights



10- Technical Specifications

Overview

Year /Model
Engine
Power (Max)
Torque (Max)
Valve Clearances
Compression Pressure
Timming
Engine Oil
Capacity
Oil Grade
Oil Classification
Oil Change Frequency
Oil Fiter Type
Oil Temperature
Head Torque
Engine Air Intake
Filter Type
Frequency

Cooling

Electrical
Alternator Belt/ water belt Tensions

Battery
Starting Current
CCA

Glow Plugs

Fuses
See fuse box section

Transmission

Auto
Fluid
Capacity 
Frequency
comments

Transmission - Manual

Fuel

Fuel Filter location
Replacement frequency
Excess water in fuel  indicator on dash location
Fuel tank Capacity
Engine compartment under passenger seat


Suspension and Brakes

Brakes
Type
Replacement time / thicknesses
Fluid replacement frequency


Brake pads Part nos


Aircon
Air con belt tension
Aircon belt part no


Tyres
Size
Normal
Laden
Lowest permissible (eg on sand)

Dimensions


Overall length
Full width
Total height
Wheel Base
Tread
Vehicle Weight
Gross vehicle weight
Min Turning radius
Fuel Tank Capacity
Real Fuel consumption stats



11- Fault Diagnosis

Diagnosing  a Supercustom can be problematic as the vehicles are imported outside of Toyota Network Dealerships. Workshop Manual Can be difficult to obtain. Being Japanese - the original manuals are in Japanese if you can even get hold of one. Toyota themselves in other countries outside of Japan even claim they have no access to them. This Open Source Manual is part of your  “right to repair’. Apple was recently fine $9 million in Australia and new laws are incoming regarding people having access to the information that they need to repair things they own, including vehicles.

Be careful ($) who you choose to try and resolve problems if it is not yourself, you really need someone that knows the 1kz engine , for example a toyota 4wd specialist. 

The good news is the 1kz engine is also used in Toyota Landcruiser Prados and Toyota Surfs so this is why these kinds of mechanics are ideal. The supercustom is also know as/ is almost the same as a Toyota RegiusAce. 1kz engines are well know as reliable engines capable of 500 000km +  when maintained.


Links to workshop manuals online:


Start Faults

Will Not start

-Run out of fuel
-Battery flat
-Battery Dead
-Solenoid
-Start Motor
-Glow Plugs
-Fuel Pump Fault
-Electrical Fuses

Starts with difficulty

-Glow plugs failed

Produces Excess smoke

Warning Lights

See warning light section earlier

Do not drive with  failed fan belt, engine will overheat warp and need replacing. Repair. Very expensive.









Running Faults


Idles Rough

-EGR?
-Fuel injector pump setting incorrect?




Engine Cuts out while idling/ driving

-Air leak in fuel system  - cheapest options first. 

Try replacing the  2 fuel hoses into Fuel filter/Primer pump (Probably perished /old)
Replace clips with hose clips that you can do up to ensure no air can get sucked into the fuel through gaps. Also replace Primer pump/fuel filter housing and water sensor (these ra quite old now and may leak slightly) incase there are any leaks here too. You can find them from 4wd specialists for toyota prados and surfs - not expansive.

-Fuel Pump Problems. 

This is expensive go down this route last.Run some diesel fuel cleaner that gets rid of algae / contaminants (probably with detergents). This is not the same as straightforward injector cleaner as you want something that might help cleanteh filters in the fuel pump and it doesnt get very warm here.


-Fuel Injector pump settings

-ECU fail

Some user report resolving problems by getting capacitors replaced (may as well do them all - about 17) and bad tracks on motherboards repaired/ reflowed.

-ERG?



Engine noises

-Fanbelt rattle

Crankshaft pulley/harmonic balancer?

-Timing belt?
-Worn engine mounts (no idea…)


Thermal Faults

Engine overheating

Failed Radiator
Water loss
Exteme conditions (very hot/ high load up very steep inclines (go very slowly!?)

Noises

Belt Squeals


Diagnosis port - Location, reading codes without code reader  and code meanings.







12 - Common problems as these vehicles age and ideas to keep them reliable/ fix them economically

Some of these vehicles are Classic 25 + years old now and still going strong; however, age will mean some parts break or  wear out despite the awesome Japanese engineering system of “constant improvement”.

ECU - buy a spare from wreckers that perfectly matches to yours? - they are becoming more and more rare.
Fuel Pumps
Rear Handle snap

Clean out 25 years of tar

Clean fuel tank
Don’t run out of fuel, you may be sucking in 20 years of tank dirt into filters.




Common Parts and part numbers to search for


Air Filter

Fuel Filter



13 - Pimping Your Wagon

Spotlights

Cleaning/ Polishing

Decal removal nightmare

Original Mag wheel restoration.

Leisure Battery

Bed Platform

Camper conversions

Hey Bagface, how is this coming along? Is there a first draft available somewhere?

Hey Bagface any updates?