Toyota 1996 LAND CRUISER User Manual Download Page 81

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AC2RB

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AIR CONDITIONING

RECEIVER

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1366

Author:

Date:

1996 LAND CRUISER (RM451U)

RECEIVER

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VEHICLE INSPECTION

INSPECT FITTINGS FOR LEAKAGE

Using a gas leak detector, check for leakage.
If there is leakage, check the tightening toque at the joints.

Brought to you by BirfMark

Brought to you by BirfMark
Version 1.00 - 12/21/2010

Summary of Contents for 1996 LAND CRUISER

Page 1: ...given that pertains to all repair operations contained in that section Read these precautions before starting any repair task 3 TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to h...

Page 2: ...and the text below it provides detailed informa tion Important specifications and warnings always stand out in bold type 6 REFERENCES References have been kept to a minimum However when they are requ...

Page 3: ...and the text below it provides detailed informa tion Important specifications and warnings always stand out in bold type 6 REFERENCES References have been kept to a minimum However when they are requ...

Page 4: ...CATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and the certification label as shown in the illustration A Vehicle Identification Number Plate B C...

Page 5: ...scrape them with a file or oth er abrasive objects 5 Install the cable ends to the battery terminals after loosening the nut and tighten the nut after installa tion Do not use a hammer to tap the cabl...

Page 6: ...erve all specifications for bolt tightening torques Always use a torque wrench i Use of special service tools SST and special service ma terials SSM may be required depending on the nature of the repa...

Page 7: ...rigid racks It is extremely dangerous to do any work on a vehicle raised on a jack alone even for a small job that can be finished quickly l Observe the following precautions to avoid damage to the f...

Page 8: ...oval of vacuum hose 1 When disconnecting vacuum hoses use tags to identify how they should be reconnected to 2 After completing a job double check that the vacu um hoses are properly connected A label...

Page 9: ...fety stand JACK POSITION SCREW TYPE JACK POSITION Front Front Under front differential IN 8 INTRODUCTION REPAIR INSTRUCTIONS 1996 LAND CRUISER RM451U VEHICLE LIFT AND SUPPORT LOCATIONS o Brought to yo...

Page 10: ...t system are difficult to confirm so the diag nostic trouble codes become the most important source of information when troubleshooting When troubleshooting the supplemental restraint system always in...

Page 11: ...nts or other de fects in the case bracket or connector replace them with new ones 8 Do not directly expose the airbag sensor assembly steering wheel pad or front passenger airbag as sembly to hot air...

Page 12: ...which is very dangerous 3 Grease should not be applied to the steering wheel pad and the pad should not be cleaned with deter gents of any kind 4 Store the steering wheel pad where the ambient tempera...

Page 13: ...se should not be applied to the front passen ger airbag assembly and the airbag door should not be cleaned with detergents of any kind 4 Store the airbag assembly where the ambient tem perature remain...

Page 14: ...sired ignition of the supplemen tal restraint system g WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the cowl wire har ness assembly and floor wire harness assembly The wires for...

Page 15: ...erential Lock Switch CD Flat Sed Truck IN0309 Wheel Lift Type Truck with Dollies FREE Applied lip II Range II H II Position OFF Normal Driving ii Towing with Rope L Released lIN II Range II N I Positi...

Page 16: ...nstall the antenna as far as possible away from the ECU and sensors of the vehicle s electronic system 2 Install the antenna feeder at least 20 cm 7 87 in away from the ECU and sensors of the ve hicle...

Page 17: ...s so that even if the power source is reconnected the audio system will not produce any sound un less the ID number selected by the customer is input again Ac cordingly when performing repairs on vehi...

Page 18: ...shooting procedure and how to make use of it are described on the following pages System Page 1 Engine DI 1 2 Automatic Transmission DI 129 3 Anti Lock Brake System DI 188 4 Supplemental Restraint Sys...

Page 19: ...rouble code chart or the problem symptoms table 4 5 6 Check and repair the affected system or part in accordance with the instructions in Step 6 7 After completing repairs confirm that the problem has...

Page 20: ...ing A C operation Shifting from N to D Other Data Problem Constant Sometimes times per day month Inspector s Name CUSTOMER PROBLEM ANALYSIS CHECK INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEM...

Page 21: ...function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly By using these check functions the problem areas can be narrowed down quickly and tro...

Page 22: ...initial diagnostic trouble code check it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past Therefore check the wire harness and con nectors See pa...

Page 23: ...ething important in the repair operation and make a wrong guess somewhere which will only lead to a standstill For example for a problem which only occurs when the en gine is cold or for a problem whi...

Page 24: ...etc and check to see if the mal function occurs ON HINT If a vehicle is subject to water leakage the leaked water may contaminate the ECU When testing a vehicle with a water leak age problem special...

Page 25: ...the type of instrument or other factors If a malfunction code is displayed during the DTC check mode check the circuit for the code listed in the table below For details of each code turn to the page...

Page 26: ...and starter relay 1 ECM power source circuit 2 Fuel pump control circuit 3 ECM 1 Starter signal circuit 2 Fuel pump control circuit 1 Fuel pump control circuit DI 147 DI 151 IN 29 PROBLEM SYMPTOMS TA...

Page 27: ...ck vibrates due to knocking If engine knocking occurs ignition timing is retarded to suppress it DTC No DTC Detection Condition Trouble Area P0325 No knock sensor 1 signal to ECM with engine speed 1 2...

Page 28: ...ition Switch LOCK OFF Ignition Switch START LOCK Ignition Switch ON Ignition Switch ACC START ON ACC D D Indicates the place to check the voltage or resistance D Indicates the connector position to ch...

Page 29: ...ow whenever these instructions appear OPEN CIRCUIT This could be due to a disconnected wire harness faulty con tact in the connector a connector terminal pulled out etc HINT S It is rarely the case th...

Page 30: ...NT Measure the resistance while lightly shaking the wire harness vertically and horizontally 4 RESISTANCE CHECK SHORT CIRCUIT CHECK a Disconnect the connectors on both ends b Measure the resistance be...

Page 31: ...heck the continuity 1 Disconnect connectors A and C and measure the resistance between them In the case of Fig 2 Between terminal 1 of connector A and terminal 1 of connector C No continuity open Betw...

Page 32: ...Between Terminal 1 of connector B and Body Ground 0V Between Terminal 1 of connector C and Body Ground Then it is found out that there is an open circuit in the wire har ness between terminal 1 of B a...

Page 33: ...ground Continuity short Therefore it is found out that there is a short circuit between terminal 1 of connector B2 and terminal 1 of connector C 8 CHECK AND REPLACE ECU First check the ECU ground circ...

Page 34: ...on Transaxle ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom D...

Page 35: ...Diesel Injection Control EDU Electronic Driving Unit EFI Electronic Fuel Injection E G Engine EGR VM Exhaust Gas Recirculation Vacuum Modulator ELR Emergency Locking Retractor ENG Engine ESA Electron...

Page 36: ...ion Block J C Junction Connector KD Kick Down LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left Hand LHD Left Hand Drive L H W Length Height Width LLC Long...

Page 37: ...ment RFS Rigid Front Suspension RH Right Hand RHD Right Hand Drive RLY Relay ROM Read Only Memory Rr Rear RR Rear Engine Rear Wheel Drive RRS Rigid Rear Suspension RWD Rear Wheel Drive SDN Sedan SEN S...

Page 38: ...tion TMMK TOYOTA Motor Manufacturing Kentucky Inc TRAC Traction Control System TURBO Turbocharge U D Underdrive U S Undersize VCV Vacuum Control Valve VENT Ventilator VIN Vehicle Identification Number...

Page 39: ...Check Connector 2 Total Diagnosis Comunication Link TDCL 3 OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode ECL Engine Control Level ECM Engine Control...

Page 40: ...or O2S OBD On Board Diagnostic On Board Diagnostic System OBD OC Oxidation Catalytic Converter Oxidation Catalyst Convert OC CCo OP Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction...

Page 41: ...Way Catalytic Converter Three Way Catalytic TWC Manifold Converter CCRO TWC OC Three Way Oxidation Catalytic Converter CCR CCo VAF Volume Air Flow Air Flow Meter VR Voltage Regulator Voltage Regulato...

Page 42: ...IT TO NAKED FLAME 5 BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT 6 DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrige...

Page 43: ...t se quence could cause the SRS to unexpectedly deployed during servicing possibly leading to a serious accident Further if a mistake is made in servicing the SRS it is possible the SRS may fail to op...

Page 44: ...ay 7 Blower speed control switch 8 A C switch 9 A C amplifier 10 Thermistor 11 Wire harness AC 5 AC 33 AC 33 AC 61 AC 64 AC 69 AC 69 AC 74 AC 60 Compressor operates intermitently 1 Refrigerant volume...

Page 45: ...r 2 ECM 3 Wire harness AC 74 No warm air comes out 1 Engine coolant volume 2 A C control assembly 3 Water valve 4 Heater radiator AC 69 AC 49 AC 46 A C indicator does not light up when mode lever at D...

Page 46: ...ediately after air conditioning is turned off refrigerant in sight glass stays clear Too much 1 Discharge refrigerant 2 Evacuate air and charge proper amount of purified refrigerant 6 When air conditi...

Page 47: ...orifice and blocks circulation of refriger ant 1 Replace condenser 2 Remove moisture in cycle through repeatedly evacuating air 3 Charge proper amount of new refrigerant 3 Insufficient cooling Sympto...

Page 48: ...n refrigeration system Probable cause Diagnosis Remedy S Vacuum indicated on low pres sure side very low pressure indi cated on high pressure side S Frost or dew seen on piping be fore and after conde...

Page 49: ...Insufficient cooling of condenser S Excessive refrigerant in cycle refrigerant over charged S Condenser cooling condenser fins clogged or cooling fan faulty 1 Clean condenser 2 Check cooling fan with...

Page 50: ...side Trouble in expansion valve S Excessive refrigerant in low pressure piping S Expansion valve opened too wide Check expansion valve Replace if defective 9 Defective compression compressor Symptom s...

Page 51: ...hen compressor is OFF approximately 392 588 KPa 4 6 kgf cm2 57 35 psi b Bring the gas leak detector close to the drain hose before performing the test HINT S After the blower motor is stopped leave th...

Page 52: ...E AIR FROM REFRIGERATION SYSTEM a Connect the vacuum pump adapter to the vacuum pump b Connect the center hose of the manifold gauge set to the vacuum pump adapter c Open both the high and low hand va...

Page 53: ...set c Open the valve of charging cylinder d Press the valve core on the side of manifold gauge and expel the air inside of the center hose 2 INSPECT REFRIGERATION SYSTEM FOR LEAKS a Open the high pres...

Page 54: ...TEM AT 1 1996 LAND CRUISER RM451U AUTOMATIC TRANSMISSION SYSTEM PRECAUTION If the vehicle is equipped with a mobile communication system refer to the precautions in the IN section Brought to you by Bi...

Page 55: ...d valve when the system is being charged with liquid refrig erant a Open the high pressure hand valve fully b Charge specified amount of refrigerant then close the high pressure hand valve HINT A full...

Page 56: ...AC2QB 01 Z04523 AC 14 AIR CONDITIONING AIR CONDITIONING SYSTEM 1996 LAND CRUISER RM451U POSITIONING Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 57: ...ion gauge check the drive belt tension Belt tension gauge DENSO BTG 20 95506 00020 or Borroughs No BT 33 73F Drive belt tension New belt 100 150 lbf Used belt 60 100 lbf HINT S New belt refers to a be...

Page 58: ...LAND CRUISER RM451U REMOVAL 1 LOOSEN IDLE PULLEY LOCK NUT Torque 39 N m 400 kgf cm 29 ft lbf 2 REMOVE COMPRESSOR DRIVE BELT Loosen the adjusting bolt and remove the drive belt Brought to you by BirfM...

Page 59: ...R CONDITIONING DRIVE BELT AC 17 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page AC 16 Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 60: ...not connect the wrong hoses 2 CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES Tighten the nuts by hand 3 CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET 4 REMOVE CAPS FROM SERVICE VALVES ON RE FRIGER...

Page 61: ...2 DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE HINT Slide the sleeve of the quick disconnect adapter upward to un lock the adapter and remove it from the service valve...

Page 62: ...ISER RM451U REFRIGERANT LINE ON VEHICLE INSPECTION 1 INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2 INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector check for leakage of refrigerant...

Page 63: ...ion Hose 10 100 7 N m kgf cm ft lbf Specified torque z Non reusable part 5 4 55 48 in lbf 10 100 7 14 140 10 10 100 7 10 100 7 10 100 7 AIR CONDITIONING REFRIGERANT LINE AC 21 1996 LAND CRUISER RM451U...

Page 64: ...ose 10 100 7 Condenser x Liquid tube 10 100 7 Reciever x Liquid tube 5 4 55 48 in lbf Pressure switch x Liquid tube 10 100 7 Cooling unit x Liquid tube 10 100 7 Expansion valve x Evaporator 5 4 55 48...

Page 65: ...NIT COMPONENTS v Packing Engine Coolant Temp Cut Relay NC Amphfier J Thermistor Lower Unit Case Non reusable part JI b y Upper Unit Case c Packing Expansion Valve Gromet o Drain Hose paCking A V Blowe...

Page 66: ...E AND LIQUID TUBE FROM COOLING UNIT FITTING Remove the 2 bolts and both tubes Torque 10 N m 100 kgf cm 7 ft lbf NOTICE Cap the open fittings immediately to keep moisture or dirt out of the system HINT...

Page 67: ...lower unit cases 6 REMOVE EVAPORATOR FROM LOWER UNIT CASE HINT If the evaporator was replaced add compressor oil to the com pressor Add 40 cc 1 4 fl oz Compressor oil ND OIL 8 or equivalent 7 REMOVE...

Page 68: ...26 AIR CONDITIONING COOLING UNIT 1996 LAND CRUISER RM451U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 25 Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 69: ...CONDITIONING COOLING UNIT AC 27 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page AC 24 Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 70: ...e claws of the hose clip with pliers and slide the clip along the hose to a place where it does not clamp the hose to the pipe b Disconnect the water hoses HINT S Push the water hose onto the heater r...

Page 71: ...R CONDITIONING HEATER UNIT AC 29 1356 Author Date 1996 LAND CRUISER RM451U b Remove the 2 nuts and a screw then remove heater unit Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12...

Page 72: ...30 AIR CONDITIONING HEATER UNIT 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page AC 28 Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 73: ...UNIT REMOVAL 1 REMOVE INSTRUMENT PANEL AND REINFORCE MENT See page BO 76 2 REMOVE COOLING UNIT See page AC 24 3 REMOVE BLOWER UNIT a Disconnect the connectors b Remove the bolt and 2 nuts then remove...

Page 74: ...32 AIR CONDITIONING BLOWER UNIT 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page AC 31 Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 75: ...eakage replace the compressor assembly 7 REMOVE MANIFOLD GAUGE SET See page AC 19 8 MAKE THESE VISUAL CHECKS a Leakage of grease from the clutch bearing b Signs of oil on the pressure plate or rotor R...

Page 76: ...Compressor Compressor Bracket O Ring O Ring 37 375 27 N m kgf cm ft lbf Specified torque z Non reusable part 10 100 7 25 250 18 37 375 27 10 100 7 AC 34 AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH...

Page 77: ...he open fittings immediately to keep the moisture or dirt out of the system 6 REMOVE ENGINE UNDER COVER 7 REMOVE DRIVE BELT See page AC 16 8 REMOVE COMPRESSOR a Disconnect the connector b Remove the 4...

Page 78: ...OVE ROTOR a Using SST remove the snap ring SST 07114 84020 NOTICE The snap ring should be installed so that its beveled side faces up b Using a plastic hammer tap the rotor off the shaft NOTICE Be car...

Page 79: ...COMPRESSOR AND MAGNETIC CLUTCH AC 37 1996 LAND CRUISER RM451U b Using SST remove the snap ring SST 07114 84020 NOTICE The snap ring should be installed so that its beveled side faces up c Remove the s...

Page 80: ...F REFRIGERANT Specified amount 850 50 g 29 98 1 76 oz Using a gas leak detector check for leakage of refrigerant If there is leakage check the tightening torque at the joints 8 INSPECT A C OPERATION R...

Page 81: ...LAND CRUISER RM451U RECEIVER ON VEHICLE INSPECTION INSPECT FITTINGS FOR LEAKAGE Using a gas leak detector check for leakage If there is leakage check the tightening toque at the joints Brought to you...

Page 82: ...ID TUBES FROM RECEIVER Remove the 2 bolts and both tubes Torque 5 4 N m 55 kgf cm 48 in lbf NOTICE Cap the open fittings immediately to keep moisture or dirt out of the system HINT At the time of inst...

Page 83: ...IR CONDITIONING RECEIVER AC 41 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page AC 40 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 1...

Page 84: ...R BLOCKAGE OR DAMAGE If the fins are clogged wash them with water and dry with compressed air NOTICE Be careful not to damage the fins If the fins are bent straighten them with a screwdriver or pliers...

Page 85: ...e b Center brace 3 DISCONNECT DISCHARGE HOSE AND LIQUID TUBE Torque 10 N m 100 kgf cm 7 ft lbf NOTICE Cap the open fittings immediately to keep moisture or dirt out of the system HINT At the time of i...

Page 86: ...C 44 AIR CONDITIONING CONDENSER 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page AC 43 Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 87: ...e page AC 26 2 CHECK EVAPORATOR FINS FOR BLOCKAGE If the fins are clogged clean them with compressed air NOTICE Never use water to clean the evaporator 3 CHECK FITTINGS FOR CRACKS OR SCRATCHES Repair...

Page 88: ...ION 1 REMOVE HEATER UNIT See page AC 28 2 REMOVE HEATER RADIATOR a Remove the screws and plates b Pull the heater radiator out 3 INSPECT FINS FOR BLOCKAGE If the fins are clogged clean them with compr...

Page 89: ...500 rpm for at least 5 minutes b Then check that the high pressure reading is 1 37 1 57 MPa 14 16 kgf cm2 199 228 psi 4 CHECK EXPANSION VALVE If the expansion valve is faulty the low pressure reading...

Page 90: ...DIATOR PIPE AND WATER VALVE a Grip the claws of the hose clip with pliers and slide the clip along the hose to a place where it does not clamp the hose to the pipe b Disconnect the water hoses HINT AT...

Page 91: ...ROL CABLE a Set the vehicle in these conditions S Ignition switch on S Blower speed control switch on S Temperature control switch to COOL position b Set the water valve to COOL position install the c...

Page 92: ...50 AIR CONDITIONING WATER VALVE 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page AC 48 Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 93: ...E 2 REMOVE BLOWER MOTOR a Disconnect the link from the lower cover b Remove the 2 screws then remove the lower cover while pushing the locking protrsion as shown c Disconnect the connector from the bl...

Page 94: ...T BLOWER MOTOR OPERATION Connect the positive lead from the battery to terminal 2 and the negative lead to terminal 1 then check that the motor op eration is smooth If operation is not as specified re...

Page 95: ...NDITIONING FRONT BLOWER MOTOR AC 53 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page AC 51 Brought to you by BirfMark Brought to you by BirfMark Version 1...

Page 96: ...OVE BLOWER MOTOR a Disconnect the connectors from the blower motor and rear heater relay b Remove the bolt and rear heater relay c Remove the 2 screws and side cover d Remove the bolt and 7 screws the...

Page 97: ...LOWER MOTOR OPERATION Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 then check that the motor op erations smoothly If operation is not as specified repla...

Page 98: ...AIR CONDITIONING REAR BLOWER MOTOR 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page AC 54 Brought to you by BirfMark Brought to you by BirfMark Version 1...

Page 99: ...EMOVE BLOWER RESISTOR Disconnect the connector and remove the 2 screws and blower resistor 3 INSPECT BLOWER RESISTOR RESISTANCE Measure resistance between terminals 1 and 4 Standard resistance 1 8 2 2...

Page 100: ...EMOVE BLOWER RESISTOR a Disconnect the connector b Remove the 2 screws and blower resistor 3 INSPECT REAR BLOWER RESISTOR CONTINUITY Condition Tester connection Specified condition Constant A1 B1 A2 A...

Page 101: ...HICLE INSPECTION 1 REMOVE GLOVE COMPARTMENT PARTS See page BO 76 2 INSPECT THERMISTOR RESISTANCE Measure the resistance between terminals Standard resistance 1 500 at 25 C 77 F If resistance is not as...

Page 102: ...1 REMOVE THERMISTOR 2 INSPECT THERMISTOR RESISTANCE a Place the thermistor in cold water while varying tempera ture of the water measure resistance at the connector and at the same time measure temper...

Page 103: ...CONNECTOR FROM PRESSURE SWITCH 3 RUN ENGINE AT APPROX 1 500 RPM 4 INSPECT PRESSURE SWITCH OPERATION a Connect the positive lead from the ohmmeter to termi nal 2 and the negative lead to terminal 1 b...

Page 104: ...mount 850 50 g 29 98 1 76 oz 2 REMOVE PRESSURE SWITCH a Disconnect the connector b Remove the pressure switch from the liquid tube Torque 10 N m 100 kgf cm 7 ft lbf HINT At the time of installation lu...

Page 105: ...CONDITIONING PRESSURE SWITCH AC 63 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page AC 62 Brought to you by BirfMark Brought to you by BirfMark Version 1...

Page 106: ...AIN RELAY INSPECTION INSPECT HEATER MAIN RELAY CONTINUITY Condition Tester connection Specified condition Constant 1 3 2 4 Continuity Apply B between terminals 3 and 5 4 5 Continuity If continuity is...

Page 107: ...EATER RELAY INSPECTION INSPECT REAR HEATER RELAY CONTINUITY Condition Tester connection Specified condition Constant 2 6 1 3 Continuity Apply B between terminals 2 and 6 1 4 Continuity If continuity i...

Page 108: ...CLUTCH RELAY INSPECTION INSPECT MAGNETIC CLUTCH RELAY CONTINUITY Condition Tester connection Specified condition Constant 1 3 Continuity Apply B between terminals 1 and 3 2 4 Continuity If continuity...

Page 109: ...r Date 1996 LAND CRUISER RM451U ENGINE COOLANT TEMPERATURE ECT CUT RELAY INSPECTION INSPECT SWITCH CONTINUITY Check the continuity betweeen terminals of the switch as shown in the chart below If conti...

Page 110: ...RUISER RM451U AIR CONDITIONING CONTROL ASSEMBLY REMOVAL 1 REMOVE INSTRUMENT CLUSTER FINISH CENTER PANEL WITH A C CONTROL ASSEMBLY 2 REMOVE A C CONTROL ASSEMBLY Remove the 3 screws and A C control asse...

Page 111: ...e lead to terminal A 8 b With the air inlet control button pushed in check that the FRESH or RECIRC indicator light lights up c Next push in the button again and check that the indica tor light goes o...

Page 112: ...dicator light lights up c Then connect the positive lead from the battery to ter minal A 13 and check that the indicator dims If operation is not as specified replace the A C control assem bly 4 Blowe...

Page 113: ...Continuity If continuity is not as specified replace the A C control assem bly 7 INSPECT MODE CONTROL SWITCH CONTINUITY Switch position Tester connection Specified condition FACE A14 B16 Continuity B...

Page 114: ...A C control assem bly 10 INSPECT TEMPERATURE CONTROL SWITCH RESIS TANCE a Measure resistance between terminals B 1 and B 2 Standard resistance Approx 3 0 k b Check that the resistance between terminal...

Page 115: ...ONING AIR CONDITIONING CONTROL ASSEMBLY AC 73 1996 LAND CRUISER RM451U INSTALLATION Installation is the revese order of removal See page AC 68 Brought to you by BirfMark Brought to you by BirfMark Ver...

Page 116: ...F No voltage 5 Ground Start engine Approx 10 to 14 v 5 Ground Stop engine No voltage If circuit is as specified try replacing the amplifier with a new one If the circuit is not as specified inspect th...

Page 117: ...1996 LAND CRUISER RM451U REMOVAL 1 REMOVE GLOVE COMPARTMENT DOOR See page BO 76 2 REMOVE A C AMPLIFIER a Disconnect the connector from the amplifier b Remove the screw and the amplifier Brought to yo...

Page 118: ...CONDITIONING AIR CONDITIONING AMPLIFIER 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page AC 75 Brought to you by BirfMark Brought to you by BirfMark Versi...

Page 119: ...he battery to terminal 5 and the negative lead to terminal 1 b Push each of the rear heater switch knob in and check that their indicators lights up If operation is not as specified replace the switch...

Page 120: ...rect Clutch C2 Forward Clutch C1 2nd Brake B2 1st Reverse Brake B3 Rear Planetary Carrier Rear Planetary Ring Gear Output Shaft Front Rear Planetary Sun Gear No 2 One Way Clutch F2 No 1 One Way Clutch...

Page 121: ...lip and speedometer driven gear from the speedometer driven gear sleeve 2 REMOVE SPEEDOMETER DRIVEN GEAR OIL SEAL Using SST remove the oil seal SST 09921 00010 3 REINSTALL SPEEDOMETER DRIVEN GEAR OIL...

Page 122: ...UTOMATIC TRANSMISSION SPEEDOMETER DRIVEN GEAR 788 Author Date 1996 LAND CRUISER RM451U f Tighten the serrated collar with pliers Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 2...

Page 123: ...ove the bolt and No 2 vehicle speed sensor b Remove the O ring from the No 2 vehicle speed sensor 3 REINSTALL NO 2 VEHICLE SPEED SENSOR a Coat a new O ring with ATF and install it to the No 2 ve hicle...

Page 124: ...the nut b Remove the bolt and park neutral position switch 4 REINSTALL PARK NEUTRAL POSITION SWITCH a Install the park neutral position switch and bolt b Install a new lock plate and the nut Torque 6...

Page 125: ...after removing all the old FIPG on the contacting surface of the oil pan and transmission case apply new FIPG to the oil pan See page AT 1 FIPG Part No 08826 00090 THREE BOND 1281 or equivalent 3 WHEN...

Page 126: ...ere with the oil pan 6 DISCONNECT CONNECTOR FROM EACH SOLENOID VALVE 7 REMOVE VALVE BODY a Remove the 17 bolts Torque 10 N m 100 kgf cm 7 ft lbf Bolt length Bolt A 23 mm 0 91 in Bolt B 32 mm 1 26 in b...

Page 127: ...e 1996 LAND CRUISER RM451U 8 REINSTALL VALVE BODY ASSEMBLY To install follow the removal procedure in reverse HINT After installation fill ATF and check the fluid level See page DI 131 Brought to you...

Page 128: ...3 REMOVE SPRING FROM PARKING LOCK PAWL SHAFT 4 REMOVE PARKING LOCK PAWL AND SHAFT 5 REINSTALL PARKING LOCK PAWL AND SHAFT 6 REINSTALL SPRING 7 REINSTALL PARKING LOCK PAWL BRACKET HINT S Push the lock...

Page 129: ...e AT 7 3 REMOVE THROTTLE CABLE Remove the retaining bolt and pull out the throttle cable 4 REINSTALL THROTTLE CABLE a To install follow the removal procedure in reverse HINT If throttle cable is new s...

Page 130: ...ight Switch Shift Lock Solenoid Key Interlock Solenoid Shift Lock Control Switch Battery Stop Light MAIN FL FL ALT FL AM1 STOP ACC IG ECU IG CIG IG ACC STP P1 P2 P E KLS SLS SLS AT 12 AUTOMATIC TRANSM...

Page 131: ...ect the ECU connector 2 INSPECT SHIFT LOCK SOLENOID a Disconnect the solenoid connector b Using an ohmmeter measure the resistance between ter minals Standard resistance 20 28 If the resistance is not...

Page 132: ...as specified replace the solenoid 4 INSPECT SHIFT LOCK CONTROL SWITCH Inspect that there is continuity between each terminal Shift position Tester condition to terminal number Specified value P posit...

Page 133: ...r Grille Oil Cooler AUTOMATIC TRANSMISSION AIR COOLED OIL COOLER AT 15 799 Author Date 1996 LAND CRUISER RM451U AIR COOLED OIL COOLER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark V...

Page 134: ...screws b Using a screwdriver disconnect the clip HINT Tape a screwdriver tip before use c Remove the radiator grille 2 REMOVE OIL COOLER a Loosen the 2 clips and disconnect the 2 hoses b Remove the 8...

Page 135: ...OOLER AT 17 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page AT 16 HINT After installation check fluid level See page DI 131 Brought to you by BirfMark Br...

Page 136: ...e Plug z O Ring Engine Under Cover Stabilizer Bar Crossmember with Transfer Under Cover z Non reusable Part z z Gasket z AT 18 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION UNIT 802 Author Date 1996 L...

Page 137: ...e Rear Mounting Plug for Hydraulic Test Oil Cooler Pipe Transfer Shift Control Link Transfer Shift Lever Cushion x 6 x 6 Clip Transfer Shift Lever Knob AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION UN...

Page 138: ...disconnect the cable from the bracket b Disconnect the throttle cable from the linkage 4 REMOVE UPPER SIDE STARTER MOUNTING BOLT Torque 39 N m 400 kgf cm 29 ft lbf 5 REMOVE TRANSMISSION SELECT LEVER...

Page 139: ...Remove the 4 screws and console e Remove the 4 screws and transfer shift lever boot f Remove the 3 bolts and console box g Disconnect the 3 connectors h Remove the 6 screws and transmission shift leve...

Page 140: ...re sensor S Center differential lock indicator switch S L4 position switch S Neutral position switch 7 DISCONNECT BLEEDER HOSE FROM TRANSFER 8 REMOVE FRONT AND REAR PROPELLER SHAFT See page PR 3 9 REM...

Page 141: ...ove the 6 bolts Torque 55 N m 550 kgf cm 40 ft lbf HINT At the time of installation first install gray colored bolt and then 5 other bolts 14 REMOVE FRONT EXHAUST PIPE ASSEMBLY a Remove the 2 nuts bol...

Page 142: ...EMBER a Support the transmission with a transmission jack b Remove the 8 bolts and 2 nuts and then remove the crossmember Torque Bolt 61 N m 620 kgf cm 45 ft lbf Nut 74 N m 750 kgf cm 54 ft lbf 17 REM...

Page 143: ...the installed surface of the transmission housing Correct distance More than 15 7 mm 0 618 in 2 INSTALL TRANSMISSION Installation is in the reverse order of removal See page AT 20 HINT S After instal...

Page 144: ...river airbag and front passenger airbag Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing possibly leading to a serious acciden...

Page 145: ...Harness BE 14 BE 14 Only one light comes ON 1 Headlight Bulb 2 HEAD LH Fuse No 2 R B 3 HEAD RH Fuse No 2 R B 4 Wire Harness Lo Beam does not light up 1 Headlight Bulb 2 Headlight Control Relay No 2 R...

Page 146: ...asher No 1 R B 3 Wire Harness BE 19 Turn signal does not light up in one direction 1 Turn Signal Switch 2 Wire Harness BE 19 Only one bulb does not light up for hazard turn 1 Bulb 2 Wire Harness Turn...

Page 147: ...3 Wiper Relay 4 Wire Harness BE 27 BE 27 BE 27 Wipers do not operate in INT 1 Wiper Switch 2 Wiper Motor 3 Wiper Relay 4 Wire Harness BE 27 BE 27 BE 27 Washer does not operate 1 Washer Hose or Nozzle...

Page 148: ...ight does not light up 1 Bulb 2 Wire Harness WARNING LIGHTS COMBINATION METER Symptom Suspect Area See page Warning lights do not lights up Except discharge SRS and door open 1 GAUGE Fuse I P F B 2 Me...

Page 149: ...t indicator lights do not light up L 2 D 1 Bulb 2 Shift Position Indicator Wiring Circuit 3 Park Neutral Position Switch 4 Light Control Rheostat 5 Wire Harness BE 34 AT 6 BE 34 Shift indicator lights...

Page 150: ...L SYSTEM Symptom Suspect Area See page Power door lock control system does not operate ALL 1 POWER Fuse I P F B 2 Power Main Relay No 1 R B 3 Wire Harness Power door lock control system does not opera...

Page 151: ...e Power mirror system does not operate 1 CIG Fuse I P J B 2 Mirror Control Switch 3 Mirror Motor 4 Wire Harness BE 69 BE 69 Power mirror operate abnormally 1 Mirror Control Switch 2 Mirror Motor 3 Wir...

Page 152: ...BE1LU 01 BODY ELECTRICAL POWER SOURCE BE 9 1147 Author Date 1996 LAND CRUISER RM451U POWER SOURCE LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 153: ...ICAL IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH 1148 Author Date 1996 LAND CRUISER RM451U IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH LOCATION Brought to you by BirfMark Brought to you by BirfMar...

Page 154: ...START 2 3 4 6 9 10 Continuity If continuity is not as specified replace the switch 2 INSPECT SWITCH CONTINUITY Condition Tester connection Specified condition SW OFF Key removed No continuity SW ON Ke...

Page 155: ...E 12 BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM 1150 Author Date 1996 LAND CRUISER RM451U HEADLIGHT AND TAILLIGHT SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 156: ...BE1LY 01 BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM BE 13 1996 LAND CRUISER RM451U COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 157: ...ontinuity Low beam A3 A9 Continuity High beam A9 A12 Continuity If continuity is not as specified replace the switch 3 INSPECT HEADLIGHT CONTROL RELAY CONTINU ITY Condition Tester connection Specified...

Page 158: ...d to terminal 5 and check that the test bulb goes out If operation is not as specified replace the relay 6 INSPECT TAILLIGHT CIRCUIT a Connect the positive leads from the battery to termi nals 1 and 6...

Page 159: ...n a level place S The driver gets into the driver s seat and puts the vehicle in a state ready for driving with a full tank S Bounce the vehicle several times b Adjust headlight in vertical alignment...

Page 160: ...t headlight in vertical alignment 1 Using adjusting screw A adjust the headlight aim to within the specifications HINT The beam angle will change about 0 11 with one mark 2 Make sure the gauge bubble...

Page 161: ...Y ELECTRICAL TURN SIGNAL AND HAZARD WARNING SYSTEM 1156 Author Date 1996 LAND CRUISER RM451U TURN SIGNAL AND HAZARD WARNING SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Versio...

Page 162: ...TURN SIGNAL FLASHER OPERATION a Connect the positive lead from the battery to terminal 2 and the negative lead to terminal 3 b Connect the 2 turn signal light bulbs parallel to each other to terminal...

Page 163: ...1M3 01 BE 20 BODY ELECTRICAL INTERIOR LIGHT SYSTEM 1158 Author Date 1996 LAND CRUISER RM451U INTERIOR LIGHT SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 201...

Page 164: ...nd the switch body with the switch OFF switch pin pushed in closed door If operation is not as specified replace the switch 3 INSPECT FRONT PERSONAL LIGHT CONTINUITY Switch position Tester connection...

Page 165: ...E1M5 01 BE 22 BODY ELECTRICAL BACK UP LIGHT SYSTEM 1160 Author Date 1996 LAND CRUISER RM451U BACK UP LIGHT SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 166: ...ELECTRICAL BACK UP LIGHT SYSTEM BE 23 1996 LAND CRUISER RM451U INSPECTION INSPECT PARK NEUTRAL POSITION SWITCH CONTINUITY See page AT 6 Brought to you by BirfMark Brought to you by BirfMark Version 1...

Page 167: ...BE1M7 01 BE 24 BODY ELECTRICAL STOP LIGHT SYSTEM 1162 Author Date 1996 LAND CRUISER RM451U STOP LIGHT SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 168: ...ON INSPECT STOP LIGHT SWITCH CONTINUITY Switch position Tester connection Specified condition SW pin free 1 2 Continuity SW pin pushed in No continuity If continuity is not as specified replace the sw...

Page 169: ...9 01 BE 26 BODY ELECTRICAL WIPER AND WASHER SYSTEM 1164 Author Date 1996 LAND CRUISER RM451U WIPER AND WASHER SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2...

Page 170: ...per INT B10 B16 Continuity Wiper ON B1 B16 Continuity Washer ON B1 B2 B16 Continuity If continuity is not as specified replace the switch 3 INSPECT INTERMITTENT WIPER OPERATION a Turn the wiper switch...

Page 171: ...ed replace the switch 5 INSPECT REAR WIPER RELAY CONTINUITY a Check that there is no continuity between terminals 1 and 3 b Check that there is continuity between terminals 2 and 3 If continuity is no...

Page 172: ...ed INSPECT FRONT WIPER MOTOR OPERATION Connect the positive lead from the battery to terminal 3 and negative lead to terminal 1 and check that the motor oper ates at low speed If operation is not as s...

Page 173: ...MOTOR OPERATION a Operate the motor at low speed and stop the motor opera tion anywhere except at the stop position by disconnect ing positive lead from terminal 3 b Connect terminal 3 and 4 c Connect...

Page 174: ...BE1MB 01 BODY ELECTRICAL COMBINATION METER BE 31 1169 Author Date 1996 LAND CRUISER RM451U COMBINATION METER LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 175: ...BE1MC 01 BE 32 BODY ELECTRICAL COMBINATION METER 1996 LAND CRUISER RM451U CIRCUIT Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 176: ...BODY ELECTRICAL COMBINATION METER BE 33 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 177: ...nnect the positive lead from tester to terminal 3 and the negative lead to terminal 2 c Revolve shaft d Check that there is voltage changer from approx 0 V to 11 V or more between terminals 3 and 2 HI...

Page 178: ...gauge needle indicates EMPTY c Connect terminals 4 and 5 on the wire harness side con nector through a 3 4 W test bulb d Turn the ignition switch ON and check that the bulb lights up and the receiver...

Page 179: ...0 0 591 Approx 3 0 E Approx 200 0 7 874 Approx 110 0 If resistance value is not as specified replace the sender gauge 9 INSPECT FUEL LEVEL WARNING LIGHT a Disconnect the connector from the sender gaug...

Page 180: ...receiver gauge needle moves to the hot side If operation is as specified replace the sender gauge Then re check the system If operation is not as specified measure the receiver gauge re sistance 12 I...

Page 181: ...l through a test LED c Check that the bulb does not light when the engine is stopped d Check that the LED flashes when the engine is running The number of flashed should vary with engine speed If oper...

Page 182: ...en terminal and the switch body with the switch ON switch pin re leased opened door b Check that there is no continuity between terminal and the switch body with the switch OFF switch pin pushed in cl...

Page 183: ...LOSE No continuity 5 Ground Ignition switch position ON Battery positive voltage 5 Ground Ignition switch position LOCK or ACC No voltage 9 Ground Constant Battery positive voltage If circuit is as sp...

Page 184: ...ter If the warning light does not light up inspect bulb or wire har ness 27 INSPECT LIGHT CONTROL RHEOSTAT a Connect terminals 1 and 3 through a 3 4 W test bulb b Connect the positive lead from the ba...

Page 185: ...BE1ME 01 BE 42 BODY ELECTRICAL DEFOGGER SYSTEM 1180 Author Date 1996 LAND CRUISER RM451U DEFOGGER SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 186: ...aners with abrasive ingredients When measuring voltage wind a piece of tin foil around the top of the negative probe and press the foil against the wire with your finger as shown a Turn the ignition s...

Page 187: ...ases to about 12 V as the meter probe is moved to the other end 4 IF NECESSARY REPAIR DEFOGGER WIRE a Clean the broken wire tips with a grease wax and silicone remover b Place the masking tape along b...

Page 188: ...BODY ELECTRICAL POWER WINDOW CONTROL SYSTEM BE 45 1183 Author Date 1996 LAND CRUISER RM451U POWER WINDOW CONTROL SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12...

Page 189: ...on Specified condition UP 1 2 5 7 8 12 Continuity OFF 1 2 5 12 Continuity DOWN 1 2 12 5 7 8 Continuity Front Passenger s Switch Window lock Switch position Tester connection Specified condition UP 7 8...

Page 190: ...llumina tions go out If operation is not as specified replace the master switch 3 Using an ammeter INSPECT ONE TOUCH POWER WINDOW SYSTEM a Disconnect the connector from the master switch b Connect the...

Page 191: ...switch 5 INSPECT POWER WINDOW SWITCH CONTINUITY Switch position Tester connection Specified condition UP 1 5 3 4 Continuity OFF 1 2 3 4 Continuity DOWN 1 2 4 5 Continuity If continuity is not as speci...

Page 192: ...9 INSPECT PASSENGER S DOOR PTC OPERATION a Disconnect the connector from the power window switch b Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 4 on the...

Page 193: ...terclockwise b Reverse the polarity and check that the motor turns clockwise If operation is not as specified replace the motor 12 INSPECT RIGHT SIDE PTC OPERATION 13 INSPECT POWER MAIN RELAY CONTINUI...

Page 194: ...DY ELECTRICAL POWER DOOR LOCK CONTROL SYSTEM BE 51 1189 Author Date 1996 LAND CRUISER RM451U POWER DOOR LOCK CONTROL SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 195: ...INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switch position Tester connection Specified condition LOCK 1 3 Continuity OFF No continuity UNLOCK 2 3 Continuity If continuity is not as specified r...

Page 196: ...e leads from terminals d After approximately 60 seconds connect the positive lead from the battery to terminal 4 and the negative lead to terminal 2 and check that the door lock moves to LOCK position...

Page 197: ...d Driver s door courtesy switch position OFF Door closed No continuity 2 Ground Driver s door courtesy switch position ON Door opened Continuity 5 Ground Passenger s door lock switch position OFF Door...

Page 198: ...nger s door courtesy switch position ON Door opened Continuity 16 Ground Constant Continuity 1 Ground Ignition switch position LOCK or ACC No voltage 1 Ground Ignition switch position ON Battery posit...

Page 199: ...voltmeter to termi nal 15 and the negative lead to terminal 16 c Close the door with ignition switch truned to LOCK or ACC check that the meter needle indicates battery posi tive voltage d Open the d...

Page 200: ...BE1MK 01 BODY ELECTRICAL SLIDING ROOF SYSTEM BE 57 1195 Author Date 1996 LAND CRUISER RM451U SLIDING ROOF SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 201: ...tion Specified condition No 1 limit switch OFF SW pin released No continuity No 1 limit switch ON SW pin pushed in 1 5 Continuity No 2 limit switch OFF SW pin released No continuity No 2 limit switch...

Page 202: ...nuity between terminals A2 and B2 b Check that there is continuity between terminals A3 and B3 c Check that there is continuity between terminals A6 and B1 If continuity is not as specified replace th...

Page 203: ...d above Continuity 9 Ground No 2 limit switch position OFF Sliding roof closed No continuity 9 Ground No 2 limit switch position ON Sliding roof open Continuity 11 Ground Constant Continuity 6 Ground...

Page 204: ...01 BODY ELECTRICAL POWER SEAT CONTROL SYSTEM BE 61 1199 Author Date 1996 LAND CRUISER RM451U POWER SEAT CONTROL SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21...

Page 205: ...uity DOWN 4 12 10 11 Continuity Rear vertical switch Switch position Tester connection Specified condition UP 2 10 6 7 Continuity OFF 2 6 7 Continuity DOWN 2 7 6 10 Continuity Reclining switch Switch...

Page 206: ...ified condition FORWARD 4 10 7 9 Continuity OFF 4 7 9 Continuity BACKWARD 4 9 7 10 Continuity If continuity is not as specified replace the switch 3 INSPECT SLIDE MOTOR OPERATION a Connect the positiv...

Page 207: ...and the negative lead from the battery to the front vertical motor connector illus trated terminals and move the front edge of seat cushion to the highest position b Continue to apply voltage and che...

Page 208: ...OP ERATION a Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 and check that the motor turns clockwise b Reverse the polarity and check that the motor turns...

Page 209: ...the seat wire harness side connector and recline the seat back to the most forward position b Continue to apply voltage and check that there is a circuit breaker operation noise within 4 to 40 second...

Page 210: ...umbar support motor connector and move the lumbar support to front end position b Continue to apply voltage and check that there is a circuit breaker operation noise within 4 to 60 seconds c Reverse t...

Page 211: ...BE 68 BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM 1206 Author Date 1996 LAND CRUISER RM451U POWER MIRROR CONTROL SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12...

Page 212: ...side INSPECT MIRROR SWITCH CONTINUITY Switch position Tester connection Specified condition OFF No continuity UP 1 6 3 4 Continuity DOWN 1 3 4 6 Continuity LEFT 1 2 3 4 Continuity RIGHT 1 3 2 4 Contin...

Page 213: ...n through AM can be received in very clearly Not only does FM stereo have the smallest service area but it also picks up static and other types of interference noise easily 3 RECEPTION PROBLEMS Beside...

Page 214: ...obstruction This is called fade out 4 COMPACT DISC PLAYER Compact Disc hereafter called CD Players use a laser beam pick up to read the digital signals recorded on the CD and re produce analog signals...

Page 215: ...eaning MAINTENANCE If the disc gets dirty clean the disc by wiping the surface from the center to outside in the radial directions with a soft cloth NOTICE Do not use a conventional record cleaner or...

Page 216: ...but AM FM not operating 3 Either speaker does not work 4 Either AM or FM does not work 5 Reception poor Volume faint 5 Few preset tuning bands 5 Sound quality poor 6 Cannot set station select button 7...

Page 217: ...BE 74 BODY ELECTRICAL AUDIO SYSTEM 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 218: ...BODY ELECTRICAL AUDIO SYSTEM BE 75 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 219: ...BE 76 BODY ELECTRICAL AUDIO SYSTEM 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 220: ...BODY ELECTRICAL AUDIO SYSTEM BE 77 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 221: ...See page BE 70 BE 78 BODY ELECTRICAL AUDIO SYSTEM 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 222: ...BODY ELECTRICAL AUDIO SYSTEM BE 79 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 223: ...BE 80 BODY ELECTRICAL AUDIO SYSTEM 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 224: ...BODY ELECTRICAL AUDIO SYSTEM BE 81 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 225: ...BE 82 BODY ELECTRICAL AUDIO SYSTEM 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 226: ...See page BE 70 BODY ELECTRICAL AUDIO SYSTEM BE 83 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 227: ...See page BE 70 BE 84 BODY ELECTRICAL AUDIO SYSTEM 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 228: ...BODY ELECTRICAL AUDIO SYSTEM BE 85 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 229: ...BE 86 BODY ELECTRICAL AUDIO SYSTEM 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 230: ...BODY ELECTRICAL AUDIO SYSTEM BE 87 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 231: ...BE 88 BODY ELECTRICAL AUDIO SYSTEM 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 232: ...BODY ELECTRICAL AUDIO SYSTEM BE 89 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 233: ...BE 90 BODY ELECTRICAL AUDIO SYSTEM 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 234: ...BODY ELECTRICAL AUDIO SYSTEM BE 91 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 235: ...BE 92 BODY ELECTRICAL AUDIO SYSTEM 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 236: ...BE1MQ 01 BODY ELECTRICAL AUDIO SYSTEM BE 93 1996 LAND CRUISER RM451U LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 237: ...inuity DOWN Button Position Pushed in 3 4 Continuity Illumination circuit 1 6 Continuity If continuity is not as specified replace the switch 2 INSPECT ANTENNA MOTOR OPERATION a Connect the positive l...

Page 238: ...e 1996 LAND CRUISER RM451U CLOCK TROUBLESHOOTING HINT Troubleshoot the lock according to the table below Clock will not operate 1 Clock loses or gains time 2 1 5 seconds day Brought to you by BirfMark...

Page 239: ...BE 96 BODY ELECTRICAL CLOCK 1234 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 240: ...D CRUISER RM451U CLIP REPLACEMENT The removal and installation methods of typical clips used in body parts are shown in the table below HINT If the clip is damaged during the operation always replace...

Page 241: ...ape Example Removal Installation Removal Installation Removal Installation BO 2 BODY CLIP 1236 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 1...

Page 242: ...assenger airbag Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing possibly leading to a serious accident Before servicing in cl...

Page 243: ...s are necessary for normal function ing of the SRS airbag so make sure that they are correctly installed When replacing the bumper always inspect the side rail extensions If they are deformed or crack...

Page 244: ...BO37I 01 BODY REAR BUMPER BO 5 1239 Author Date 1996 LAND CRUISER RM451U REAR BUMPER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 245: ...WARD AND LEFT RIGHT DIRECTIONS Adjust the hood by loosening the hood side hinge bolts Torque 18 N m 185 kgf cm 13 ft lbf 2 ADJUST FRONT EDGE OF HOOD IN VERTICAL DIRECTIONS a Loosen the lock nut b Adju...

Page 246: ...ith pressurized gas S If the damper stay is to be replaced drill a 2 0 3 0 mm 0 079 0 118 in hole as shown in the illustration to completely release the high pressure gas before dis posing of it S Whe...

Page 247: ...BO37L 01 BO 8 BODY FRONT DOOR 1242 Author Date 1996 LAND CRUISER RM451U FRONT DOOR COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 248: ...the 11 screws and armrest base from the door trim d Remove the inner weatherstrip from the door trim e Remove the 8 screws and door pocket from the door trim 7 REMOVE DOOR BELT MOULDING Pry out the cl...

Page 249: ...gears of the window regulator NOTICE Do not apply grease to the spring 17 REMOVE LOCKING AND OPENING CONTROL LINK 18 REMOVE DOOR LOCK HINT At the time of reassembly apply adhesive to the 3 screws Par...

Page 250: ...M451U REPLACEMENT 1 REMOVE GLASS CHANNEL WITH SCREWDRIVER OR LIKE OBJECT 2 APPLY SOAPY WATER TO INSIDE OF WEATH ERSTRIP 3 INSTALL CHANNEL BY TAPPING IT WITH PLASTIC HAMMER Brought to you by BirfMark B...

Page 251: ...240 kgf cm 17 ft lbf 2 ADJUST DOOR IN LEFT RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust Torque 24 N m 240 kgf cm 17 ft lbf 3 ADJUST DOOR LOCK STRIKER a Check that the door...

Page 252: ...P 01 BODY FRONT DOOR BO 13 1996 LAND CRUISER RM451U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 9 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21...

Page 253: ...BO37Q 01 BO 14 BODY REAR DOOR 1248 Author Date 1996 LAND CRUISER RM451U REAR DOOR COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 254: ...trim c Using a screwdriver remove the clips and remove the trim by pulling all of the trim up d Remove the inner weatherstrip from the door trim e Remove the 11 screws and the armrest base from the do...

Page 255: ...E WINDOW REGULATOR Torque 5 0 N m 50 kgf cm 43 in lbf HINT At the time of reassembly apply MP grease to the sliding sur face and gears of the regulator NOTICE Do not apply grease to the spring 19 REMO...

Page 256: ...M451U REPLACEMENT 1 REMOVE GLASS CHANNEL WITH SCREWDRIVER OR LIKE OBJECT 2 APPLY SOAPY WATER TO INSIDE OF WEATH ERSTRIP 3 INSTALL CHANNEL BY TAPPING IT WITH PLASTIC HAMMER Brought to you by BirfMark B...

Page 257: ...ADJUST DOOR IN LEFT RIGHT AND VERTICAL DIRECTIONS Adjust the door by loosening the door side hinge bolts Torque 24 N m 240 kgf cm 17 ft lbf 3 ADJUST DOOR LOCK STRIKER a Check that the door fit and doo...

Page 258: ...U 01 BODY REAR DOOR BO 19 1996 LAND CRUISER RM451U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 15 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21...

Page 259: ...BO37V 01 BO 20 BODY BACK DOOR 1254 Author Date 1996 LAND CRUISER RM451U BACK DOOR COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 260: ...rstrip as it may tear d Remove the weatherstrip upper NOTICE Do not pull strongly off the weatherstrip as it may tear e Remove the door inside handle f Remove the door lock control g Remove the outsid...

Page 261: ...Y BACK DOOR 1996 LAND CRUISER RM451U b Remove the service hole cover c Remove the door lock control d Remove the door lock e Remove the license plate light cover Brought to you by BirfMark Brought to...

Page 262: ...k that the door fit and door lock linkage are ad justed correctly 2 Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a hammer Tighten the stri...

Page 263: ...door fit and door lock linkages are adjusted correctly 2 Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a hammer 3 Tighten the striker mount...

Page 264: ...Y 01 BODY BACK DOOR BO 25 1996 LAND CRUISER RM451U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 21 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21...

Page 265: ...illed with pressurized gas S If the damper stay is to be replaced drill a 2 0 3 0 mm 0 079 0 118 in hole in the aved shown in the il lustration to completely release the high pressure gas before dispo...

Page 266: ...BO380 01 BODY FRONT WIPER AND WASHER BO 27 1261 Author Date 1996 LAND CRUISER RM451U FRONT WIPER AND WASHER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 267: ...RM451U REMOVAL 1 REMOVE WIPER ARMS 2 REMOVE COWL LOUVER 3 REMOVE WIPER MOTOR AND WIPER LINK a Disconnect the connector then unfasten 4 bolts and wip er motor b Remove the wiper link Brought to you by...

Page 268: ...in B Approx 300 mm 11 8 in C Approx 250 mm 9 84 in D Approx 400 mm 15 7 in E Approx 410 mm 16 1 in F Approx 220 mm 8 66 in G Approx 60 mm 2 36 in b Check if the lower point where the washer fluid hit...

Page 269: ...lbf 3 INSTALL COWL LOUVER 4 INSTALL FRONT WIPER ARM a Install the wiper arms and operate the wipers once and turn the wiper switch OFF b Adjust the installation positions of the wiper arms to the posi...

Page 270: ...rim to pry it loose HINT Tape the screwdriver tip before use b Remove the back door trim 3 REMOVE WIPER ARM MOTOR AND REAR WIPER CONTROL RELAY a Open the cap b Remove the nut and wiper arm c Remove th...

Page 271: ...perating the washer check whether the point where the washer fluid hits the back door glass and the upsurge area are within the range indicated by the hatched line A Approx 120 mm 4 72 in B Approx 120...

Page 272: ...LL PULL HANDLE BEZEL 5 INSTALL PULL HANDLE 6 INSTALL REAR WIPER ARM a Install the wiper arm and operate the wipers once and turn the wiper switch OFF b Adjust the installation positions of the wiper a...

Page 273: ...BO48L 01 BO 34 BODY BODY OUTSIDE MOULDING 1268 Author Date 1996 LAND CRUISER RM451U BODY OUTSIDE MOULDING COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 274: ...the roof drip moulding from front ends SST 09806 30010 2 REMOVE FRONT DOOR BELT MOULDING See page BO 9 3 REMOVE REAR DOOR BELT MOULDING See page BO 15 4 REMOVE QUARTER BELT MOULDING Pry out the clips...

Page 275: ...ALL ROOF DRIP MOULDING Attach the upper edge of the moulding to the body flange Tap on the moulding by hand 2 INSTALL FRONT DOOR BELT MOULDING 3 INSTALL REAR DOOR BELT MOULDING 4 INSTALL QUARTER BELT...

Page 276: ...el Moulding Quarter Outside Moulding BODY WHEEL OPENING MOULDING BO 37 1271 Author Date 1996 LAND CRUISER RM451U WHEEL OPENING MOULDING COMPONENTS Brought to you by BirfMark Brought to you by BirfMark...

Page 277: ...wheel e Remove the front mudguard f Remove the front bumper extension g Remove the 4 nuts from engine room inside service hole h Remove the 2 screws i Remove the front wheel opening extension 2 REAR...

Page 278: ...CRUISER RM451U b Remove the quarter trim RH c Remove the quarter trim LH 4 REMOVE QUARTER OUTSIDE MOULDING a Remove the 2 nuts b Remove the screw c Using a screwdriver pry out the rearwheel moulding...

Page 279: ...l g Cool air intake duct h Air cleaner case assembly i Charcoal canister 2 INSTALL QUARTER OUTSIDE MOULDING Install the quarter outside moulding with the 2 bolts 3 INSTALL REAR WHEEL OPENING MOULDING...

Page 280: ...BO38H 01 BODY SIDE PROTECTION MOULDING BO 41 1275 Author Date 1996 LAND CRUISER RM451U SIDE PROTECTION MOULDING COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 281: ...scraper tip before use 2 REMOVE MOULDING AND ADHESIVE a Pull off the moulding by cutting the adhesive with a knife b Scrape off adhesive from the body with a cutter or sand paper NOTICE Remember that...

Page 282: ...moulding and adhesive are lim ited to about 9 months 1 CLEAN MOULDING MOUNTING SURFACE Wipe off stains with cleaner 2 HEAT BODY MOUNTING SURFACE Using a heat light heat the body mounting surface to 30...

Page 283: ...e sure that no dirt or dust can get onto the uncovered area 6 INSTALL MOULDING Push the moulding to the body as shown in the illustration NOTICE S Be sure that the body and moulding are heated to the...

Page 284: ...BO38P 01 BODY WINDSHIELD BO 45 1279 Author Date 1996 LAND CRUISER RM451U WINDSHIELD COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 285: ...e of the vehicle cut off the weatherstrip NOTICE Do not damage the body and the glass b Push piano wire through between the body and glass from the interior c Tie both wire ends to the wooden blocks o...

Page 286: ...more b Cut off the tip of the cartridge nozzle Fill the cartridge with adhesive c Apply adhesive to the weatherstrip on the glass edge re taining surface as shown in the illustaration ADHESIVE Sikafl...

Page 287: ...y tap from the outside with your open hand 4 APPLY ADHESIVE a Put masking tape around the weatherstrip to protect the paint and the glass b Cut off the tip of the cartridge nozzle Fill the cartridge w...

Page 288: ...lent 7 INSTALL ROOF HEADLINING 8 INSTALL FRONT PILLAR GARNISHES 9 INSTALL ASSIST GRIPS 10 INSTALL SUN VISORS AND HOLDERS 11 INSTALL PERSONAL LIGHT COVER 12 INSTALL PERSONAL LIGHT ASSEMBLY 13 INSTALL I...

Page 289: ...BO38S 01 BO 50 BODY QUARTER WINDOW GLASS 1284 Author Date 1996 LAND CRUISER RM451U QUARTER WINDOW GLASS COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 290: ...SH 7 REMOVE REAR PILLAR GARNISH 8 REMOVE ASSIST GRIPS 9 LOOSEN ROOF HEADLINING 10 REMOVE VENT LOUVER AND QUARTER BELT MOULDING a Remove the nut from the vent louver b Insert a screwdriver between the...

Page 291: ...outward from the interior part of the body flange c Pull the glass outwards and remove it with the weather strip 12 If using a new weatherstrip REMOVE QUARTER WINDOW GLASS a From outside of the vehic...

Page 292: ...EMOVE CENTER SASH Remove the screw and weatherstrip 2 REMOVE QUARTER WINDOW GLASS Pull up the sash and remove the 2 glasses 3 REMOVE QUARTER WINDOW GLASS RUN FROM SASH 4 REMOVE QUARTER WINDOW WEATHERS...

Page 293: ...ICE If the weatherstrip has hardened it may develop leaks HINT Use a new one if possible 2 INSTALL QUARTER WINDOW GLASS RUN 3 INSTALL QUARTER WINDOW GLASS Pull up on the sash and install 2 glasses 4 I...

Page 294: ...NT Begin installation in the middle of the lower part of the quarter window glass b Hold the glass in position on the body c From the inside pull on one cord at an angle so it pulls the lip over the f...

Page 295: ...RM451U 9 INSTALL REAR DOOR SCUFF PLATE 10 INSTALL REAR SEAT SIDE GARNISH 11 INSTALL QUARTER TRIM 12 INSTALL BACK DOOR SCUFF PLATE 13 w No 2 Rear Seat INSTALL NO 2 REAR SEAT Brought to you by BirfMark...

Page 296: ...BO38X 01 BODY BACK DOOR GLASS BO 57 1291 Author Date 1996 LAND CRUISER RM451U BACK DOOR GLASS COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 297: ...U REMOVAL 1 REMOVE WIPER ARM 2 REMOVE DEFOGGER CONNECTOR Disconnect the connector from the glass 3 REMOVE BACK DOOR GLASS HINT Remove the glass in the same manner as the windshield Brought to you by B...

Page 298: ...IP ON GLASS 3 INSTALL BACK DOOR GLASS 4 FIX IN GLASS 5 APPLY ADHESIVE Part No 08833 00030 or equivalent 6 CLEAN SEALER SURFACE 7 INSPECT FOR LEAKS AND REPAIR Part No 08833 00030 or equivalent 8 CONNEC...

Page 299: ...BO390 01 BO 60 BODY SLIDING ROOF 1294 Author Date 1996 LAND CRUISER RM451U SLIDING ROOF COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 300: ...BODY SLIDING ROOF BO 61 1295 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 301: ...BO 62 BODY SLIDING ROOF 1296 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 302: ...EMOVE BACK DOOR SCUFF PLATE 3 w No 2 Rear Seat REMOVE NO 2 REAR SEAT 4 REMOVE QUARTER TRIM RH 5 REMOVE QUARTER TRIM LH 6 REMOVE REAR SEAT SIDE GARNISH 7 REMOVE REAR DOOR SCUFF PLATE 8 REMOVE COWL SIDE...

Page 303: ...19 REMOVE SUN VISORS AND HOLDERS 20 REMOVE INNER REAR VIEW MIRROR 21 REMOVE PERSONAL LIGHT ASSEMBLY AND PER SONAL LIGHT COVER 22 REMOVE NO 1 AND NO 2 ROOM LIGHT 23 REMOVE BACK DOOR OPENING TRIM 24 REM...

Page 304: ...ver pry loose the 2 clips and remove the inner side garnish 29 REMOVE SLIDING ROOF GLASS a Remove the 6 nuts and shims HINT Make sure of the number of shims b Pull the glass upward to remove it 30 REM...

Page 305: ...am plate cover b Remove the large screw washers and shims c Turn the drive shaft by screwdriver to align the housing and gear point mark as shown d Install the cam plate cover with the screw e Install...

Page 306: ...CASING a Remove the screw and guide rail cover b Remove the screw c Pull out the cable guide casing 2 REMOVE SLIDING GUIDE RAIL a Make the drive cable to the front edge b Remove the 4 screws and both...

Page 307: ...difference in level between the sliding roof weatherstrip and roof panel Front End 0 9 3 9 mm 0 035 0 154 in Rear End 0 9 3 9 mm 0 035 0 154 in 2 If the sliding roof does not operate ADJUST SLIDING RO...

Page 308: ...ARD a Adjust by loosening the sliding roof installation nuts and move the sliding roof bracket forwards and backwards b When the front or rear alignment is not correct remove the glass and adjust the...

Page 309: ...CRUISER RM451U 5 ADJUST LEFT RIGHT CLEARANCE Adjust by loosening the sliding roof installation nuts and read just the sliding roof to the proper position Brought to you by BirfMark Brought to you by...

Page 310: ...01 BODY SLIDING ROOF BO 71 1996 LAND CRUISER RM451U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 67 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21...

Page 311: ...01 BO 72 BODY SLIDING ROOF 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See pageBO 63 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21...

Page 312: ...BO397 01 BODY INSTRUMENT PANEL BO 73 1307 Author Date 1996 LAND CRUISER RM451U INSTRUMENT PANEL COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 313: ...BO 74 BODY INSTRUMENT PANEL 1308 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 314: ...thor Date 1996 LAND CRUISER RM451U HINT Screw shapes and size are indicated in the table below The code A N correspond to those indicated on the previous page Brought to you by BirfMark Brought to you...

Page 315: ...OPENING COVER 6 REMOVE LOWER FINISH PANEL 7 REMOVE LOWER INSTRUMENT PANEL 8 REMOVE NO 2 HEATER TO REGISTER DUCT 9 LOOSEN DLC 3 AND FUSE BLOCK 10 REMOVE NO 2 CENTER CLUSTER FINISH PANEL 11 REMOVE STEE...

Page 316: ...PEAKER PANEL AND SPEAKER 19 REMOVE FRONT AND REAR CONSOLE BOX 20 DISCONNECT AIRBAG CONNECTOR a Remove the airbag connector from the airbag bracket NOTICE When handling the airbag connector take care n...

Page 317: ...BLY See page RS 22 a Remove the 4 bolts and 2 nuts and remove front passen ger airbag assembly b Pry up the 6 clips shown in the illustration and remove the airbag door CAUTION S Do not store the fron...

Page 318: ...BODY INSTRUMENT PANEL BO 79 1996 LAND CRUISER RM451U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 78 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12...

Page 319: ...BO 80 BODY INSTRUMENT PANEL 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page BO 76 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12...

Page 320: ...BO39C 01 BODY SIDE STEP BO 81 1315 Author Date 1996 LAND CRUISER RM451U SIDE STEP COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 321: ...01 BO 82 BODY FRONT SEAT Power Adjuster Type 1316 Author Date 1996 LAND CRUISER RM451U FRONT SEAT Power Adjuster Type COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 2...

Page 322: ...BODY FRONT SEAT Power Adjuster Type BO 83 1317 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 323: ...MOVE FRONT SEAT CUSHION a Remove the 4 bolts Torque 30 N m 300 kgf cm 22 ft lbf b Disconnect the connector then remove the front seat cushion 9 REMOVE SEAT CUSHION REAR PROTECTOR 10 REMOVE RECLINING A...

Page 324: ...nect the No 1 vertical seat link b Remove the 4 bolts vertical rod hold bracket RH and ver tical rod hold bracket LH Torque 20 N m 210 kgf cm 15 ft lbf c Using the 5 0 mm 0 20 in hexagon wrench remove...

Page 325: ...bf b Hold the No 1 vertical travel jack screw with a plier re move the nut and washer HINT At the time of reassembly apply adhesive to nut Part No 08833 00070 THREE BOND 1324 or equiva lent Torque 2 0...

Page 326: ...track inner reinforcement then separate the seat track RH and LH Torque 20 N m 210 kgf cm 15 ft lbf c Remove the reclining connecting rod 16 REMOVE SEAT WIRE 17 REMOVE RECLINING MOTOR 18 REMOVE RECLIN...

Page 327: ...BODY FRONT SEAT Power Adjuster Type 1996 LAND CRUISER RM451U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 84 Brought to you by BirfMark Brought to you by BirfMark Version 1...

Page 328: ...1 BODY FRONT SEAT Manual Adjuster Type BO 89 1323 Author Date 1996 LAND CRUISER RM451U FRONT SEAT Manual Adjuster Type COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12...

Page 329: ...BO39J 01 BO 90 BODY REAR NO 1 SEAT 1324 Author Date 1996 LAND CRUISER RM451U REAR NO 1 SEAT COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 330: ...BO39K 01 BODY REAR NO 2 SEAT BO 91 1325 Author Date 1996 LAND CRUISER RM451U REAR NO 2 SEAT COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 331: ...BO39L 01 BO 92 BODY SEAT BELT 1326 Author Date 1996 LAND CRUISER RM451U SEAT BELT COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 332: ...e that the belt locks when pulled out quickly b Remove the locking retractor assembly c Tilt the retractor slowly d Make sure that the belt can be pulled out at a tilt of 15 de grees or less and canno...

Page 333: ...e of the brake system and result in a driving hazard Replace the parts with parts of the same part number or equivalent S It is very important to keep parts and the area clean when repairing the brake...

Page 334: ...8 Booster push rod out of adjustment BR 33 BR 33 BR 9 BR 20 Brake drag 1 Brake pedal freeplay minimal 2 Parking brake lever travel out of adjustment 3 Parking brake wire sticking 4 Pad cracked or dis...

Page 335: ...ystem BR 21 BR 30 BR 21 BR 30 BR 21 BR 30 BR 21 BR 30 BR 21 BR 30 BR 20 BR 18 Noise from brake 1 Pad cracked or distorted 2 Installation bolt loosen 3 Disc scored 4 Pad support plate loosen 5 Sliding...

Page 336: ...CYLINDER HINT If the master cylinder has been disassembled or if the reservoir becomes empty bleed the air from the master cylinder a Disconnect the brake lines from the master cylinder b Slowly depre...

Page 337: ...plug until fluid starts to run out Then tighten the bleeder plug c Repeat this procedure until there are no more air bubbles in the fluid Bleeder plug tightening torque 11 N m 110 kgf cm 8 ft lbf 5 R...

Page 338: ...clearance A between the stop light switch and pedal Clearance 0 5 2 4 mm 0 020 0 094 in i Tighten the stop light switch lock nut j Connect the connector to the stop light switch k Check that the stop...

Page 339: ...t the brake system 4 CHECK PEDAL RESERVE DISTANCE S Release the parking brake S With the engine running depress the pedal and measure the pedal reserve distance as shown Pedal reserve distance a at 49...

Page 340: ...7 9 clicks If incorrect adjust the parking brake 2 IF NECESSARY ADJUST PARKING BRAKE HINT Before adjusting the parking brake make sure that the rear brake shoe clearance has been adjusted For shoe cl...

Page 341: ...BR1CH 01 BRAKE BRAKE MASTER CYLINDER BR 9 1996 LAND CRUISER RM451U BRAKE MASTER CYLINDER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 342: ...f immediately 3 DISCONNECT BRAKE LINES Using SST disconnect the 4 brake lines from the master cylin der and 3 way SST 09023 00100 Torque 15 N m 155 kgf cm 11 ft lbf 4 REMOVE MASTER CYLINDER a Remove t...

Page 343: ...OVE 2 PISTONS AND SPRINGS a Push in the piston with a screwdriver and remove the snap ring with snap ring pliers HINT Tape the screwdriver tip before use b Remove the No 1 piston and spring by hand pu...

Page 344: ...INSPECTION HINT Clean the disassembled parts with compressed air 1 INSPECT CYLINDER BORE FOR RUST OR SCORING 2 INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary clean or replace the cylinder Brought to...

Page 345: ...UISER RM451U REASSEMBLY Reassembly is in the reverse order of disassembly NOTICE Apply lithium soap base glycol grease to the rubber parts indicated by the arrows See page BR 9 Brought to you by BirfM...

Page 346: ...val See page BR 9 HINT Before installation adjust length of brake booster push rod See page BR 18 After installation fill brake reservoir with brake fluid bleed brake system See page BR 4 Check for le...

Page 347: ...n is normal 2 AIR TIGHTNESS CHECK a Start the engine and stop it after 1 or 2 minutes Depress the brake pedal several times slowly If the pedal goes down furthest the 1st time but gradually rises afte...

Page 348: ...BR1CO 01 BR 16 BRAKE BRAKE BOOSTER ASSEMBLY 1996 LAND CRUISER RM451U COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 349: ...tly operation is normal 2 AIR TIGHTNESS CHECK a Start the engine and stop it after 1 or 2 minutes Depress the brake pedal several times slowly If the pedal goes down furthest the 1st time but graduall...

Page 350: ...BR1CO 02 BR 18 BRAKE BRAKE BOOSTER ASSEMBLY 1996 LAND CRUISER RM451U COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 351: ...OVE MASTER CYLINDER See page BR 9 2 REMOVE THESE PARTS S Return spring S Clip and clevis pin S Clevis S Vacuum hose 3 REMOVE BRAKE BOOSTER a Remove the 4 booster installation nuts b Remove the booster...

Page 352: ...r cylinder b Set the SST on the gasket and lower the pin until its tip slightly touches the piston SST 09737 00010 c Turn the SST upside down and set it on the booster SST 09737 00010 d Measure the cl...

Page 353: ...BR1CR 01 BRAKE FRONT BRAKE PAD BR 21 1003 Author Date 1996 LAND CRUISER RM451U FRONT BRAKE PAD COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 354: ...and foreign particles cleaned off 4 CHECK DISC THICKNESS AND RUNOUT See page BR 27 5 INSTALL NEW PADS NOTICE When replacing worn pads the anti squeal shims must be replaced together with the pads a Dr...

Page 355: ...l the 2 pads HINT Apply disc brake grease to the caliper indicated by the arrows See page BR 33 NOTICE Do not allow oil or grease to get on the rubbing face 6 INSTALL ANTI RATTLE SPRING AND 2 PINS 7 I...

Page 356: ...BR1CT 01 BR 24 BRAKE FRONT BRAKE CALIPER 1006 Author Date 1996 LAND CRUISER RM451U FRONT BRAKE CALIPER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 357: ...le hose from the caliper Torque 30 N m 310 kgf cm 22 ft lbf b Use a container to catch the brake fluid as it drains out 2 REMOVE CALIPER Remove the 2 mounting bolts and caliper Torque 123 N m 1 250 kg...

Page 358: ...MOVE PISTONS FROM CYLINDER a Prepare the wooden plate to hold the pistons b Place the plate between the pistons and insert a pad at one side c Use compressed air to remove the pistons alternately from...

Page 359: ...ckness is less than the minimum repair or replace the disc 3 MEASURE DISC RUNOUT Using a dial indicator measure the disc runout at a position 10 mm 0 39 in from the outside edge Maximum disc runout 0...

Page 360: ...RM451U REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 26 NOTICE Apply lithium soap base glycol grease to the parts indicated by the arrows See page BR 33 Brought to you by B...

Page 361: ...TALLATION Installation is in the reverse order of removal See page BR 25 HINT After installation fill the brake reservoir with brake fluid bleed brake system see page BR 4 and check for leaks Brought...

Page 362: ...BR1CZ 02 BR 30 BRAKE REAR BRAKE PAD 1012 Author Date 1996 LAND CRUISER RM451U REAR BRAKE PAD COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 363: ...it so the hose is not stretched HINT Do not disconnect the flexible hose 4 REMOVE THESE PARTS a 2 brake pads b Anti squeal shim c 4 pad support plates d 2 pad wear indicator plates NOTICE The pad supp...

Page 364: ...a small amount of brake fluid from the reservoir b Press in piston with a hammer handle or an equivalent HINT Always change the pads on one wheel at a time as there is a possibility of the opposite p...

Page 365: ...BR1D1 01 BRAKE REAR BRAKE CALIPER BR 33 1015 Author Date 1996 LAND CRUISER RM451U REAR BRAKE CALIPER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 366: ...he flexible hose from the cali per Torque 30 N m 310 kgf cm 22 ft lbf b Use a container to catch the brake fluid as it drains out 2 REMOVE CALIPER Remove the 2 sliding pins and caliper Torque 88 N m 9...

Page 367: ...r b Use compressed air to remove the piston from the cylin der CAUTION Do not place your fingers in front of the piston when using compressed air 3 REMOVE PISTON SEAL Using a screwdriver remove the pi...

Page 368: ...C RUNOUT See page BR 27 Maximum disc runout 0 15 mm 0 0059 in If the runout is greater than the maximum adjust the disc runout or grind it on a On Car brake lathe 4 IF NECESSARY REPLACE DISC a Remove...

Page 369: ...RM451U REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 35 NOTICE Apply lithium soap base glycol grease to the parts indicated by the arrows See page BR 33 Brought to you by Bi...

Page 370: ...NSTALLATION Installation is in the reverse order of removal See page BR 34 HINT After installation fill brake reservoir with brake fluid bleed brake system See pageBR 4 and check for leaks Brought to...

Page 371: ...BR1D7 01 BRAKE PARKING BRAKE BR 39 1021 Author Date 1996 LAND CRUISER RM451U PARKING BRAKE COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 372: ...matchmarks on the disc and rear hub and remove the disc HINT If the disc cannot be removed easily turn the shoe adjuster until the wheel turns freely 4 REMOVE TENSION SPRING Using needle nose pliers...

Page 373: ...ECESSARY REMOVE AND DISASSEMBLE PARKING BRAKE BELLCRANK ASSEMBLY a Using a screwdriver remove the C washer b Remove the pin and disconnect the parking brake cable No 2 from the bellcrank c Remove the...

Page 374: ...in Replace the disc if the inside diameter is at the maximum value or more Replace the disc or grind it with a lathe if the disc is scored or is worn unevenly 4 INSPECT PARKING BRAKE LINING AND DISC...

Page 375: ...crewdriver remove the C washer b Remove the parking brake shoe lever and install the cor rect size shim c Using needle nose pliers install the parking brake shoe lever with a new C washer d Remeasure...

Page 376: ...ELLCRANK a Pull the bellcrank until all play in the interior linkage is tak en up b Screw in the bellcrank adjusting bolt to where it contacts on the dust seal c Loosen it one turn and lock it at that...

Page 377: ...2 seconds after adjusting the specified fluid pressure 4 IF NECESSARY ADJUST FLUID PRESSURE a Disconnect the No 2 shackle from the shackle bracket b Adjust the length of the No 2 shackle turning it L...

Page 378: ...will move down about 1 mm 0 039 in Even at this time the piston should not make contact with or move the load sensing spring b In this position check the rear brake pressure Front brake pressure kPa...

Page 379: ...SENSING PROPORTIONING AND BY PASS VALVE LSP BV BR 47 1996 LAND CRUISER RM451U LOAD SENSING PROPORTIONING AND BY PASS VALVE LSP BV COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Vers...

Page 380: ...Remove the nut and disconnect the shackle No 2 from the bracket c Remove the retainer 2 cushions and collar 2 REMOVE LSP BV ASSEMBLY a Using SST disconnect the 3 brake lines from the valve body SST 0...

Page 381: ...emove the clip and remove the spring from the valve 3 REMOVE SHACKLE NO 1 AND NO 2 a Remove the bolt and nut then remove the these parts S Load sensing spring S 2 plate washers b Loosen the 2 nuts and...

Page 382: ...ING AND BY PASS VALVE LSP BV 1996 LAND CRUISER RM451U INSPECTION INSPECT VALVE PISTON PIN AND LOAD SENSING SPRING CONTACT SURFACE FOR WEAR Wear limit 0 7 mm 0 028 in Brought to you by BirfMark Brought...

Page 383: ...LE NO 1 AND NO 2 TO LOAD SENS ING SPRING a Install the lock nut and shackle No 1 to the shackle No 2 b Torque the bolt and nut through the 2 plate washers Torque 18 N m 185 kgf cm 13 ft lbf 3 INSTALL...

Page 384: ...the shackle bracket with a retainer and nut Torque 13 N m 130 kgf cm 9 ft lbf e Install a new cotter pin 3 CONNECT BRAKE LINES Using SST connect the 3 brake lines SST 09751 36011 Torque 15 N m 155 kgf...

Page 385: ...he control relay 3 CONNECT ACTUATOR CHECKER SST TO ACTUA TOR a Connect the actuator checker SST to the actuator con trol relay and body side wire harness through the sub wire harness C SST and E SST a...

Page 386: ...es down g Push and hold in the SUB MOTOR switch for a few se conds and check that the pedal returns h Release the brake pedal i Push and hold in the SUB MOTOR switch for a few se conds j Depress the b...

Page 387: ...ess SST from the actuator control relay and body side wire har ness SST 09990 00150 09990 00200 09990 00210 8 CONNECT CONNECTORS a Connect the 2 connectors to the control relay b Connect the connector...

Page 388: ...BR1DJ 01 BR 56 BRAKE ABS ACTUATOR 1996 LAND CRUISER RM451U COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 389: ...Torque 15 N m 155 kgf cm 11 ft lbf 3 REMOVE ABS ACTUATOR ASSEMBLY a Disconnect the 2 connectors from the actuator b Remove the 4 bolts and actuator assembly Torque 19 N m 195 kgf cm 14 ft lbf 4 REMOVE...

Page 390: ...heck there is no continuity between terminals 2 and 5 c Connect the positive lead from the ohmmeter to terminal 5 and connect negative lead to terminal 4 d Check there is continuity between terminals...

Page 391: ...ATION Installation is in the reverse order of removal See page BR 57 HINT After installation fill the brake reservoir with brake fluid bleed brake system see page BR 4 and check for leaks Brought to y...

Page 392: ...BR1DM 02 BR 60 BRAKE FRONT SPEED SENSOR 1042 Author Date 1996 LAND CRUISER RM451U FRONT SPEED SENSOR COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 393: ...SOR a Remove the 8 clamp bolts holding the sensor harness from the axle housing b Remove the bolt and wire tie holding the sensor harness from the stabilizer bar c Remove the bolt and 2 clips holding...

Page 394: ...ce the sensor d Connect the speed sensor connector 2 INSPECT SENSOR INSTALLATION Check the sensor installation bolt is tightened properly and there is no clearance between the sensor and axle end If n...

Page 395: ...PEED SENSOR BR 63 1996 LAND CRUISER RM451U 4 CHECK THAT THERE IS NO FOREIGN OBJECT ON SENSOR 5 CHECK SPEED SENSOR SIGNAL See page DI 210 Brought to you by BirfMark Brought to you by BirfMark Version 1...

Page 396: ...LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page BR 61 HINT After installation check the speed sensor signal See page DI 190 Brought to you by BirfMark Brough...

Page 397: ...BR1DP 02 BRAKE REAR SPEED SENSOR BR 65 1047 Author Date 1996 LAND CRUISER RM451U REAR SPEED SENSOR COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 398: ...DISCONNECT SPEED SENSOR CONNECTOR a Disconnect the speed sensor connector b Remove the 3 clamp bolts and 2 clips holding the sensor wire harness from the suspension arm and frame 2 REMOVE SPEED SENSO...

Page 399: ...Connect the speed sensor connector 2 INSPECT SENSOR INSTALLATION Check the sensor installation bolt is tightened properly and there is no clearance between the sensor and axle end If not tighten the b...

Page 400: ...EAR SPEED SENSOR 1996 LAND CRUISER RM451U 4 CHECK THAT THERE IS NO FOREIGN OBJECT ON SENSOR 5 CHECK SPEED SENSOR SIGNAL See page DI 210 Brought to you by BirfMark Brought to you by BirfMark Version 1...

Page 401: ...LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page BR 66 HINT After installation check the speed sensor signal see page DI 190 Brought to you by BirfMark Brought...

Page 402: ...bles are connected to the correct terminals S Disconnect the battery cables when the battery is given a quick charge S Do not perform tests with a high voltage insulation resistance tester S Never dis...

Page 403: ...erminals of the battery Standard voltage At 20 C 68 F 12 7 12 9 V HINT S Before measuring the voltage turn the ignition switch OFF and turn off the electrical systems headlight blower motor rear defog...

Page 404: ...130 2 lbf Used belt 200 390 N 20 4 40 0 kgf 45 0 88 2 lbf If the belt tension is not as specified adjust it HINT S New belt refers to a belt which has been used less than 5 minutes on a running engine...

Page 405: ...er b Check the charging circuit as follows With the engine running from idle to 2 000 rpm check the reading on the ammeter and voltmeter Standard amperage 10 A or less Standard voltage at 25 C 77 F 14...

Page 406: ...eter Standard amperage 30 A or more If the ammeter reading is less than standard amperage repair the generator HINT If the battery is fully charged the indication will sometimes be less than standard...

Page 407: ...CH06H 05 CH 6 CHARGING GENERATOR 771 Author Date 1996 LAND CRUISER RM451U GENERATOR COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 408: ...CHARGING GENERATOR CH 7 772 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 409: ...nd adjusting bolt b Remove the 2 drive belts 4 REMOVE GENERATOR a Disconnect the generator connector b Remove the rubber cap and nut and disconnect the gen erator wire c Disconnect the generator wire...

Page 410: ...lator b Remove the 3 nuts bolt rectifier plate and rear end cover 2 REMOVE BRUSH HOLDER a Remove the brush holder cover from the brush holder b Remove the 2 screws and brush holder 3 REMOVE VOLTAGE RE...

Page 411: ...ubber insulators c Remove the seal plate 5 REMOVE PULLEY a Hold SST A with a torque wrench and tighten SST B clockwise to the specified torque SST 09820 63010 Torque 39 N m 400 kgf cm 29 ft lbf b Chec...

Page 412: ...ot loosen the pulley nut more than one half of a turn f Remove the generator from SST C g Turn SST B and remove SST A and B h Remove the pulley nut and pulley 6 REMOVE RECTIFIER END FRAME a Remove the...

Page 413: ...3 INSPECT SLIP RINGS a Check that the slip rings are not rough or scored If rough or scored replace the rotor b Using a vernier caliper measure the slip ring diameter Standard diameter 14 2 14 4 mm 0...

Page 414: ...terminal b Reverse the polarity of the tester probes and repeat step a c Check that one shows continuity and the other shows no continuity If continuity is not as specified replace the rectifier hold...

Page 415: ...09951 00260 09952 06010 c Using SST and a press press in a new bearing SST 09950 60010 09951 00500 d Install the bearing retainer with the 4 screws Torque 2 6 N m 27 kgf cm 23 in lbf 2 REPLACE REAR B...

Page 416: ...96 LAND CRUISER RM451U c Place the bearing cover inside on the rotor d Using SST and a press press in a new bearing SST 09820 00030 e Using SST push in the bearing cover outside SST 09285 76010 Brough...

Page 417: ...slowly press in the rectifier end frame c Install the 4 nuts Torque 4 5 N m 46 kgf cm 40 in lbf 4 INSTALL PULLEY a Install the pulley to the rotor shaft by tightening the pulley nut by hand b Hold SST...

Page 418: ...emove SST A and B 5 INSTALL RECTIFIER HOLDER a Place the seal plate on the rectifier end frame b Install the 4 rubber insulators on the lead wires c Install the rectifier holder with the 4 screws Torq...

Page 419: ...over on the brush holder 8 INSTALL REAR END COVER a Install the end cover together with the rectifier plate 1 Hand tighten the bolt first for positioning the plate 2 Tighten the 3 nuts and bolt Torque...

Page 420: ...e Connect the generator wire with the nut and rubber cap f Connect the generator wire clamp to the generator 2 INSTALL DRIVE BELTS a Install the drive belts b Adjust the drive belt with the adjusting...

Page 421: ...2 CHECK ENGINE COOLANT QUALITY a Remove the radiator cap CAUTION To avoid the danger of being burned do not remove the radiator cap while the engine and radiator are still hot as fluid and steam can...

Page 422: ...e glycol base coolant and mix it according to the manufacturer s direc tions S Using coolant which includes more than 50 ethyl ene glycol but not more than 70 is recom mended NOTICE Do not use an alco...

Page 423: ...CO111 01 COOLING WATER PUMP CO 3 698 Author Date 1996 LAND CRUISER RM451U WATER PUMP COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 424: ...the lock pivot and adjusting bolts of the genera tor and remove the drive belts c Disconnect the oil cooler hose from the clamp on the fan shroud d Remove the 2 bolts holding the fan shroud to the ra...

Page 425: ...age is found replace the water pump b Turn the pulley seat and check that the water pump bear ing moves smoothly and quietly If necessary replace the water pump 2 INSPECT FLUID COUPLING Check the flui...

Page 426: ...tion c Temporarily install the fan pulley mounting nuts d Install the fan shroud with the 2 bolts Torque 5 0 N m 50 kgf cm 43 in lbf e Connect the oil cooler hose to the clamp on the fan shroud f Inst...

Page 427: ...CO0IU 03 COOLING THERMOSTAT CO 7 702 Author Date 1996 LAND CRUISER RM451U THERMOSTAT COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 428: ...thermostat would have an adverse effect causing a lowering of cooling efficiency Do not remove the thermostat even if the engine tends to overheat 1 DRAIN ENGINE COOLANT 2 REMOVE WATER INLET AND THER...

Page 429: ...e opening temperature 80 84 C 176 183 F If the valve opening temperature is not as specified replace the thermostat c Check the valve lift Valve lift 10 mm 0 39 in or more at 95 C 203 F If the valve l...

Page 430: ...the water inlet housing and insert the thermostat in the water inlet housing HINT The jiggle valve may be set within 15 of either side of the pre scribed position 2 INSTALL WATER INLET Install the wat...

Page 431: ...DIATOR ON VEHICLE CLEANING NOTICE If using a high pressure type cleaner be careful not to deform the fins of the radiator core i e Main tain a distance between the cleaner nozzle and radiator core Bro...

Page 432: ...lief valve opening pressure Standard opening pressure 74 103 kPa 0 75 1 05 kgf cm2 10 7 14 9 psi Minimum opening pressure 59 kPa 0 6 kgf cm2 8 5 psi HINT Use the tester s maximum reading as the openin...

Page 433: ...CO0J0 03 COOLING RADIATOR CO 13 1996 LAND CRUISER RM451U COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 434: ...R INLET HOSE 6 DISCONNECT RADIATOR RESERVOIR HOSE 7 REMOVE RADIATOR a Stretch the belts and loosen the water pump pulley mounting nuts b Loosen the lock pivot and adjusting bolts of the genera tor and...

Page 435: ...OR CO 15 1996 LAND CRUISER RM451U 10 REMOVE RADIATOR a Remove the 2 bolts 2 nuts and radiator b Remove the 4 nuts and 2 radiator brackets Brought to you by BirfMark Brought to you by BirfMark Version...

Page 436: ...cm 43 in lbf d Connect the oil cooler hose to the clamp on the fan shroud e Install the drive belts with the adjusting bolt and pivot bolt f Stretch the belts tight and tighten the 4 water pump pulley...

Page 437: ...3 DTC Chart P DI 13 Matrix Chart of Problem Symptoms P DI 19 Circuit Inspection P DI 20 Adjustment Repair DTC Check P DI 13 Titles inside are titles of pages in in the bottom portion See the indicate...

Page 438: ...as Problem Occurred Problem Frequency Condition When Problem Occurs Weather Engine Operation Engine Temp Place Outdoor Temperature Constant Sometimes times per day month Once only Other Fine Cloudy Ra...

Page 439: ...ction is detected the applicable Diagnostic Trouble Codes DTC prescribed by SAE J2012 are recorded in the ECM memory See page DI 13 If the malfunction does not reoccur in 3 trips the MIL goes off but...

Page 440: ...300 P0306 or fuel trim malfunction DTC P0171 P0172 or other malfunc tion first malfunction only is detected S Because freeze frame data records the engine conditions fuel system calculator load engine...

Page 441: ...turned ON and the engine is not running HINT If the MIL does not light up troubleshoot the combination meter See page BE 2 2 When the engine started the MIL should go off If the lamp remains on the di...

Page 442: ...more S Throttle valve fully closed S Transmission in park or neutral position S Air conditioning switched OFF 2 Turn ignition switch OFF 3 Prepare the TOYOTA hand held tester 4 Connect the TOYOTA hand...

Page 443: ...68 F Returned to normal condition P0115 Engine coolant temp is fixed at 80 176 F Returned to normal condition P0120 VTA is fixed at 0 The following condition must be repeated at least 2 times consecut...

Page 444: ...fore use of this check is essential in engine troubleshooting 1 Is battery positive voltage 11 V or more when engine is stopped NO Charge or replace battery YES 2 Is engine cranked NO Proceed to page...

Page 445: ...eck the idle speed OK Idle speed 650 50 rpm NG Proceed to matrix chart of problem symptoms on page DI 19 OK 6 Check ignition timing PREPARATION a Warm up engine to normal operating temperature b Shift...

Page 446: ...6 CHECK Check for fuel pressure in the fuel return hose when it is pinched off HINT At this time you will hear a fuel flowing noise NG Proceed to page SF 6 and continue to trouble shoot OK 8 Check for...

Page 447: ...p 80 95 C 176 203 F SHORT FT 1 Short term Fuel Trim Bank 1 0 20 LONG FT 1 Long term Fuel Trim Bank 1 0 20 ENGINE SPD Engine Speed Idling 650 50 rpm VEHICLE SPD Vehicle Speed Vehicle Stopped 0 km h 0 m...

Page 448: ...operating ON CYL 1 CYL 6 Ratio of revolution variation for each cylinder when variation is large 0 IGNITION Ignition rate for all cylinders every 1 000 revolu tions 0 3 000 rpm EGRT GAS EGR Gas Temp...

Page 449: ...1 P0116 DI 34 Engine Coolant Temp Circuit Range Performance Problem Engine coolant temp sensor Cooling system 1 P0120 DI 35 Throttle Pedal Position Sensor Switch A Circuit Malfunction Open or short i...

Page 450: ...ess ECM 1 P0330 DI 59 Knock Sensor 2 Circuit Malfunction Open or short in knock sensor 2 circuit Knock sensor 2 looseness ECM 1 P0335 DI 62 Crankshaft Position Sensor A Circuit Malfunction Open or sho...

Page 451: ...osition switch circuit Closed throttle position switch ECM P1300 DI 97 Igniter Circuit Malfunction Open or short in IGF or IGT circuit from igniter to ECM Igniter ECM P1335 DI 102 Crankshaft Position...

Page 452: ...DI5OW 03 A15824 DI 16 DIAGNOSTICS ENGINE 1996 LAND CRUISER RM451U PARTS LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 453: ...lve fully closed 0 3 0 8 IG switch ON Throttle valve fully open 3 2 4 9 VG E5 2 E21 E5 16 G BR Idling N position A C switch OFF 1 1 1 5 THA E5 3 E2 E5 9 L Y BR B Idling Intake air temp 20 C 68 F 0 5 3...

Page 454: ...tain engine speed at 2 500 rpm for 2 mins after warming up Pulse generation OX2 E5 13 E1 E4 24 W BR B Maintain engine speed at 2 500 rpm for 2 mins after warming up Pulse generation HT1 E6 1 E03 E6 16...

Page 455: ...er signal circuit 2 Fuel pump control circuit DI 103 DI 115 Hot engine Difficult to start 1 Starter signal circuit 2 Fuel pressure control circuit 3 Fuel pump control circuit DI 103 DI 125 DI 115 High...

Page 456: ...of the air flow meter The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit with the power transistor controlled so that the potential of A and B remains eq...

Page 457: ...Main Relay Y R FL MAIN BR 1 Mass Air Flow Meter 2 2 2 2 2 2 1 1 1 F8 2 4 3 E7 E5 E5 VG MRLY 2 2 3 7 5 16 B E1 EB E21 EB1 EA2 DIAGNOSTICS ENGINE DI 21 1996 LAND CRUISER RM451U WIRING DIAGRAM Brought to...

Page 458: ...mass air flow rate on the OBD II scan tool or TOYOTA hand held tester RESULT Type I Type II Mass air flow rate gm sec Approx 0 gm sec 439 0 gm sec or more Type I Go to step 2 Type II Go to step 5 2 Ch...

Page 459: ...ltage between terminal VG of ECM and body ground while engine is idling OK Voltage 1 1 1 5 V P or N position and A C switch OFF OK Check and replace ECM See page IN 28 NG 4 Check for open and short in...

Page 460: ...geSF 65 CHECK Check continuity between terminal E21 of ECM and body ground OK Continuity 1 or less NG Check and replace ECM See page IN 28 OK 6 Check for open in harness and connector between mass air...

Page 461: ...hrottle position switch ON b Mass air flow meter output 2 2 V S Mass air flow meter Conditions a and b continue with engine speed 1500 rpm 2 trip detection logic a Mass air flow meter output 1 V b VTA...

Page 462: ...nsor are connected in series When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature the potential at terminal THA also changes...

Page 463: ...ure PREPARATION a Remove the fuse cover on the instrument panel b Connect the OBD II scan tool or TOYOTA hand held tester to DLC3 c Turn ignition switch ON and OBD II scan tool or TOYOTA hand held tes...

Page 464: ...connection at sensor If OK replace mass air flow meter NG 3 Check for open in harness or ECM PREPARATION a Remove instrument panel speaker No 1 panel See page SF 65 b Connect between terminals THA and...

Page 465: ...or TOYOTA hand held tester OK Temp value 40 C 40 F OK Replace mass air flow meter NG 5 Check for short in harness or ECM PREPARATION a Remove instrument panel speaker No 1 panel See page SF 65 b Disc...

Page 466: ...own on page DI 26 If the ECM detects the DTC P0115 it operates the fail safe function in which the engine coolant temp is assumed to be 80 C 176 F DTC No Detection Item Trouble Area P0115 Open or shor...

Page 467: ...er main switch ON CHECK Read temperature value on the OBD II scan tool or TOYOTA hand held tester OK Same as actual engine coolant temperature HINT S If there is open circuit OBD II scan tool or TOYOT...

Page 468: ...ure check for the ECM connector See page IN 28 c Turn ignition switch ON CHECK Read temperature value on the OBD II scan tool or TOYOTA hand held tester OK Temperature value 140 C 284 F or more OK Ope...

Page 469: ...No 1 panel See page SF 65 b Disconnect the E5 connector of ECM HINT Engine coolant temp sensor connector is disconnected c Turn ignition switch ON CHECK Read temperature value on the OBD II scan tool...

Page 470: ...temp sensor value 35 C 95 F or less 2 trip detection logic If THW 7 C 19 4 F 20 min or more after starting engine engine coolant temp sensor value is 35 C 95 F or less 2 trip detection logic INSPECTIO...

Page 471: ...mately 3 2 4 9 V when the throttle valve is fully opened The ECM judges the vehicle driving conditions from these signals input from termi nals VTA and IDL and uses them as one of the conditions for d...

Page 472: ...round may be open 1 Connect the OBD II scan tool or TOYOTA hand held tester and read the throttle valve opening percentage PREPARATION a Remove the fuse cover on the instrument panel b Connect the OBD...

Page 473: ...Disconnect the throttle position sensor connector b Turn ignition switch ON CHECK Measure voltage between terminal 1 of wire harness side con nector and body ground OK Voltage 4 5 5 5 V NG Go to step...

Page 474: ...for open and short in harness and connector between ECM and throttle position sensor VTA line See page IN 28 OK Check and replace ECM See page IN 28 5 Check voltage between terminals VCC and E2 of EC...

Page 475: ...le Area P0121 After the vehicle speed has been exceeded 30 km h 19 mph even once the output value of the throttle position sensor is out of the applicable range while the vehicle speed between 30 km h...

Page 476: ...ive force 0 V When the air fuel ratio is RICHER than the stoichiometric air fuel ratio the oxygen concentration in the ex haust gas in reduced and the oxygen sensor informs the ECM of the RICH conditi...

Page 477: ...Y R Y R EC 3 2 1 4 E1 E03 E1 7 DIAGNOSTICS ENGINE DI 41 1996 LAND CRUISER RM451U HINT After confirming DTC P0125 use the OBD II scan tool or TOYOTA hand held tester to confirm voltage output of heated...

Page 478: ...tage output of heated oxygen sensor bank 1 sensor 1 when engine is suddenly raced HINT Perform quick racing to 4 000 rpm 3 times using accelerator pedal OK Heated oxygen sensor bank 1 sensor 1 output...

Page 479: ...read using the OBD II scan tool or TOYOTA hand held tester WIRING DIAGRAM Refer to DTC P0125 Insufficient Coolant Temp for Closed Loop Fuel Control on page DI 35 for WIRING DIAGRAM CONFIRMATION DRIVI...

Page 480: ...anel b Connect the OBD II scan tool or TOYOTA hand held tester to the DLC3 c Warm up engine to normal operating temp CHECK Read the heated oxygen sensor bank 1 sensor 1 output voltage and short term f...

Page 481: ...the OBD II scan tool or TOYOTA hand held tester read the output voltage of the heated oxygen sensor bank 1 sensor 1 during idling OK Heated oxygen sensor bank 1 sensor 1 output voltage Alternates repe...

Page 482: ...xygen sensor s voltage output to change from rich to lean or from lean to rich is 1 sec or more during idling after the engine is warmed up 2 trip detection logic S Heated oxygen sensor bank 1 sensor...

Page 483: ...heater operates 2 trip detection logic HINT S Sensor 1 refers to the sensor closer to the engine body S Sensor 2 refers to the sensor farther away from the engine body WIRING DIAGRAM Refer to DTC P01...

Page 484: ...en sensor heater See page SF 64 NG Replace heated oxygen sensor OK Check and repair harness or connector between EFI main relay Marking EFI and heated oxygen sensor bank 1 sensor 1 2 and ECM See page...

Page 485: ...e engine is warmed up 2 trip detection logic S Heated oxygen sensor bank 1 sensor 2 HINT Sensor 2 refers to the sensor farther away from the engine body WIRING DIAGRAM Refer to DTC P0125 Insufficient...

Page 486: ...engine to normal operating temp CHECK Read voltage output of heated oxygen sensor bank 1 sensor 2 when engine suddenly raced HINT Perform quick racing to 4 000 rpm 3 min using accelerator pedal OK Hea...

Page 487: ...the MIL lights up DTC No DTC Detecting Condition Trouble Area P0171 When the air fuel ratio feedback is stable after engine warming up the fuel trim is considerably in error on the RICH side 2 trip de...

Page 488: ...im RESULT Pattern Heated oxygen sensor bank 1 sensor 1 output voltage Short term fuel trim 1 Lean condition Changes at 0 55 V or less Changes at about 20 2 Rich condition Changes at 0 4 V or more Chan...

Page 489: ...low meter and engine coolant temp sensor See page SF 40 SF 61 NG Repair or replace OK 6 Check for spark and ignition See page IG 1 NG Repair or replace OK Check and replace ECM See page IN 28 Brought...

Page 490: ...l cause catalyst overheating the MIL blinks when misfiring occurs DTC No DTC Detecting Condition Trouble Area P0300 Misfiring of random cylinders is detected during the any partic ular 200 or 1 000 re...

Page 491: ...4 No 5 No 6 FI6588 FI6538 A00064 10V Division GND 10V Division 100 m sec Division Idling GND Magnification 1 m sec Division Idling Injection duration DIAGNOSTICS ENGINE DI 55 1996 LAND CRUISER RM451U...

Page 492: ...eposit present Not wet with gasoline or oil 2 Electrode gap 0 8 mm 0 031 in PREPARATION a Install the spark plug to the high tension cord b Ground the spark plug c Disconnect injector connector CHECK...

Page 493: ...e between applicable terminal of ECM connec tor and body ground OK Voltage 9 14 V OK Go to step 4 NG 3 Check injector of misfiring cylinder See page SF 29 NG Replace injector OK Check for open and sho...

Page 494: ...EC 11 NG Repair EGR system OK 7 Check mass air flow meter and engine coolant temp sensor See page SF 40 SF 61 NG Repair or replace OK Check engine mechanical systems compression pressure See page EM...

Page 495: ...block vibrates due to knocking If engine knocking occurs ignition timing is retarded to suppress it DTC No DTC Detecting Condition Trouble Area P0325 No knock sensor 1 signal to ECM with engine speed...

Page 496: ...eaker No 1 panel See page SF 65 b Disconnect the E5 connector of ECM CHECK Measure resistance between terminal KNK1 KNK2 of ECM connector and body ground HINT S Connect terminal KNK1 to knock sensor 1...

Page 497: ...Reference INSPECTION USING OSCILLOSCOPE S With the engine racing 4 000 rpm measure between ter minals KNK1 KNK2 of ECM and body ground HINT The correct waveform is as shown S Spread the time on the ho...

Page 498: ...elec tromotive force in the pick up coil The NE signal sensor generates 24 signals for every engine revolution The ECM detects the standard crankshaft angle based on the G1 G2 signals detects the act...

Page 499: ...e Cold 185 275 Hot 240 325 Cold is from 10 C 14F to 50 C 122 F of engine coolant temperature sensor and Hot is from 50 C 122 F to 100 C 212 F Reference INSPECTION USING OSCILLOSCOPE During cranking or...

Page 500: ...NGINE 1996 LAND CRUISER RM451U 3 Check air gap See page IG 1 NG Replace distributor housing assembly OK Check and replace ECM See page IN 28 Brought to you by BirfMark Brought to you by BirfMark Versi...

Page 501: ...TC No DTC Detecting Condition Trouble Area P0340 No camshaft position sensor signal G signal to ECM with engine speed 550 rpm or more S Open or short in camshaft position sensor circuit S Camshaft pos...

Page 502: ...nector between ECM and camshaft position sensor See page IN 28 NG Repair or replace harness or connector OK 3 Check air gap See page IG 1 NG Replace distributor housing assembly OK Check and replace E...

Page 503: ...sensor signal NE 2 signal to ECM during cranking 2 trip detection logic S Open or short in crankshaft position sensor for NE2 signals S Crankshaft position sensor for NE2 signal S ECM No crankshaft po...

Page 504: ...rank shaft position sensor for NE2 signal See page IN 28 NG Repair or replace harness or connector OK 3 Inspect sensor installation and teeth of signal plate NG Tighten the sensor Replace signal plate...

Page 505: ...ding to the engine load If even one of the following conditions is fulfilled the VSV is turned ON by a signal from the ECM This results in atmospheric air acting on the EGR valve closing the EGR valve...

Page 506: ...place and turn the ignition switch OFF 6 Start the engine and do steps 3 and 4 again 7 Check the READINESS TESTS mode on the OBD II scan tool or TOYOTA hand held tester If COMPL is displayed and the M...

Page 507: ...n switch ON CHECK Read EGR gas temp on the TOYOTA hand held tester OK EGR gas temp 10 C 50 F or more HINT If there is and open circuit the TOYOTA hand held tester indicates 3 1 C 37 6 F OK Go to step...

Page 508: ...nsor connector is disconnected Before checking do a visual check and contact pressure check for the ECM connector See page IN 28 CHECK Read EGR gas temp on the TOYOTA hand held tester OK EGR gas temp...

Page 509: ...TOYOTA hand held tester CHECK Check operation of VSV when it is operated by the TOYOTA hand held tester OK EGR system is ON Air does not flow from pipe G to pipe E EGR system is OFF Air from pipe G i...

Page 510: ...C3 c Turn ignition switch ON and TOYOTA hand held tester main switch ON d Select the ACTIVE TEST mode on the TOYOTA hand held tester EGR system ON e Race the engine at 4 000 rpm for 3 mins CHECK Measu...

Page 511: ...sen sor connector OK Resistance 600 k or less HINT If there is open circuit ohmmeter indicates 720 k or more NG Check and replace EGR gas temp sensor See page SF 63 OK 2 Check for open in harness or E...

Page 512: ...e voltage between terminals of THG and E2 of ECM connector HINT EGR gas temp sensor connector is disconnected OK Voltage 4 5 5 5 V OK Open in harness between terminals E2 or THG Repair or replace harn...

Page 513: ...er No 1 panel See page SF 65 b Turn ignition switch ON CHECK Check VSV function 1 Connect between terminal EGR of ECM and body ground ON 2 Disconnect between terminal EGR of ECM and body ground OFF OK...

Page 514: ...Replace VSV for EGR OK Check for open in harness and connector be tween R B No 2 and ECM See page IN 28 7 Check EGR vacuum modulator See page EC 11 NG Repair or replace OK 8 Check EGR valve See page E...

Page 515: ...VSV connector for EGR d Race the engine at 4 000 rpm or 3 mins CHECK Measure the resistance of the EGR gas temp sensor while rac ing the engine at 4 000 rpm OK Resistance of EGR gas temp sensor after...

Page 516: ...lways open 2 trip detection logic Refer to DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected for the System Check Driving Pattern and Wiring Diagram INSPECTION PROCEDURE TOYOTA hand held...

Page 517: ...he TOYOTA hand held tester OK EGR gas temp 3 1 C 37 6 F OK Replace EGR gas temp sensor NG 3 Check for short in harness or ECM PREPARATION a Remove the instrument panel speaker No 1 panel See page SF 6...

Page 518: ...e IN 28 OBD II scan tool excluding TOYOTA hand held tester 1 Check resistance of EGR gas temp sensor See page DI 105 PREPARATION Disconnect EGR gas temp sensor connector CHECK Measure resistance betwe...

Page 519: ...eck the VSV for EGR See page DI 69 step 5 OK Check EGR valve See page EC 11 NG 4 Check operation of the VSV for EGR See page SF 60 NG Replace VSV for EGR OK 5 Check for short in harness and connector...

Page 520: ...and forth from rich to lean If the catalyst is functioning normally the waveform of the oxygen sensor after the catalyst switches back and forth between rich and lean much more slowly than the wavefo...

Page 521: ...GINE RACING PATTERN 1 Connect the OBDII scan tool or TOYOTA hand held tester to the DLC 3 2 Start and warm up the engine with all accessories switched OFF 3 Run the vehicle at 50 65 km h 31 40 mph for...

Page 522: ...nt DTC chart NO 2 Check heated oxygen sensor bank 1 sensor 1 See page SF 64 NG Repair or replace OK 3 Check heated oxygen sensor bank 1 sensor 2 See page SF 64 NG Repair or replace OK Replace front ex...

Page 523: ...is converted into a more precise rectan gular wavefrom by the waveform shaping circuit inside the combination meter it is then transmitted to the ECM The ECM determines the vehicle speed based on the...

Page 524: ...ltage between terminal SPD of ECM connector and body ground PREPARATION a Remove instrument panel speaker No 1 panel See page SF 65 b Disconnect cruise control ECU connector c Shift the shift lever to...

Page 525: ...When current flows to the coils due to signals from the ECM the rotor turns and moves the valve shaft forward or backward changing the clearance between the valve and the valve seat In this way the i...

Page 526: ...pen 20 V Division 10 msec Division ISC1 ISC2 ISC3 ISC4 20 V Division 10 msec Division IAC Valve Close A C Switch ON OFF FI6536 FI6537 DI 90 DIAGNOSTICS ENGINE 1996 LAND CRUISER RM451U WIRING DIAGRAM R...

Page 527: ...trument panel speaker No 1 panel See page SF 65 b Disconnect the E4 connector of ECM c Turn ignition switch ON CHECK Measure voltage between terminals ISC1 ISC2 ISC3 ISC4 of ECM connector and body gro...

Page 528: ...nals 4 S1 1 S2 6 S3 3 S4 in that order b Connect the positive lead from the battery to terminals 5 B1 and 2 B2 and the negative lead to terminals 3 S4 6 S3 1 S2 4 S1 in that order OK 1 The valve moves...

Page 529: ...Refer to DTC P0120 Throttle Pedal Position Sensor Switch A Circuit Malfunction on page DI 35 for WIR ING DIAGRAM INSPECTION PROCEDURE HINT If DTCs P0110 Intake Air Temp Circuit Malfunction P0115 Engi...

Page 530: ...h signal ON OK Confirm good connection at sensor If OK replace throttle position sensor NG 3 Check for open in harness or ECM PREPARATION a Remove instrument panel speaker No 1 panel See page SF 65 b...

Page 531: ...nd held tester OK CTP switch signal OFF OK Confirm good connection at sensor If OK replace throttle position sensor NG 5 Check for short in harness or ECM PREPARATION a Remove instrument panel speaker...

Page 532: ...on switch ON CHECK Measure voltage between terminals 1 and 2 of throttle position sensor connector OK Voltage 9 14 V OK Confirm good connection at sensor If OK replace throttle position sensor NG 2 Ch...

Page 533: ...ignition coil based on the engine rpm and ignition timing one revolution ago that is the time the Tr2 turns on When it reaches the ignition timing the ECM turns Tr1 off and outputs the IGT signal O Th...

Page 534: ...ness or connector OK 3 Disconnect igniter connector and check voltage between terminal IGF of ECM connector and body ground PREPARATION a Disconnect igniter connector b Remove instrument panel speaker...

Page 535: ...ECM connector and body ground PREPARATION Remove instrument panel speaker No 1 panel See page SF 65 CHECK Measure voltage between terminal IGT of ECM connector and body ground when engine is cranked O...

Page 536: ...0 1 V and less than 4 5 V OK Check and replace ECM See page IN 28 NG 7 Check voltage between terminal 3 of igniter connector and body ground PREPARATION Disconnect igniter connector CHECK Measure vol...

Page 537: ...NOSTICS ENGINE DI 101 1996 LAND CRUISER RM451U 9 Check ignition coil See page IG 1 NG Replace ignition coil OK Replace igniter Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21...

Page 538: ...ondition Trouble Area P1335 No crankshaft position sensor signal NE signal to ECM with engine speed 1 000 rpm or more S Open or short in crankshaft position sensor circuit for NE signal S Crankshaft p...

Page 539: ...mixture is therefore necessary in order to achieve good startability While the engine is being cranked the battery positive volt age is applied to terminal STA of the ECM The starter signal is mainly...

Page 540: ...tester to the DLC3 b Turn ignition switch ON and push TOYOTA hand held tester main switch ON CHECK Read STA signal on the TOYOTA hand held tester while starter operates OK Ignition Switch Position ON...

Page 541: ...rminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air fuel ratio adaptive control value memory etc DTC No DTC Detecting Condition Trouble Area P1600 Open in bac...

Page 542: ...CHECK Measure voltage between terminal BATT of ECM connector and body ground OK Voltage 9 14 V OK Check and replace ECM See page IN 28 NG 2 Check EFI fuse PREPARATION Remove EFI fuse from R B No 2 CHE...

Page 543: ...ondition Trouble Area P1605 Engine control computer malfunction for knock control S ECM WIRING DIAGRAM Refer to P0325 P0330 Knock Sensor 1 2 Circuit Malfunction on page DI 59 INSPECTION PROCEDURE 1 Ar...

Page 544: ...k neutral position switch goes off so the voltage of ECM terminal NSW becomes battery voltage the voltage of the ECM internal power source If the shift lever is moved from the N position to the D posi...

Page 545: ...4 NG Replace park neutral position switch OK 2 Check voltage between terminal NSW of ECM connector and body ground PREPARATION Remove instrument panel speaker No 1 panel See page SF 65 CHECK a Turn i...

Page 546: ...FL AM2 FL MAIN W R R B No 2 Y DI 110 DIAGNOSTICS ENGINE 1996 LAND CRUISER RM451U ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON battery positive voltage is applied...

Page 547: ...Proceed to next circuit inspection shown on matrix chart See page DI 19 NG 2 Check for open in harness and connector between terminal E1 of ECM connector and body ground See page IN 28 NG Repair or r...

Page 548: ...er finish panel b Remove instrument cluster finish center panel No 2 CHECK Check continuity between terminals OK Shift Position Terminal No to continuity Terminal No to continuity LOCK ACC 3 4 ON 2 3...

Page 549: ...rn ignition switch ON CHECK Measure voltage between terminal MREL of ECM and body ground OK Voltage 9 14 V NG Check and replace ECM OK 7 Check EFI fuse Marking EFI See page DI 105 NG Check for short i...

Page 550: ...etween terminal MREL of ECM connector and body ground See page IN 28 NG Repair or replace harness or connector OK Check for open and short in harness and connector between terminal B of ECM connector...

Page 551: ...coil of the circuit opening relay the relay switches on power is supplied to the fuel pump and the fuel pump operates While the NE signal is generated engine running the ECM keeps Tr1 ON circuit open...

Page 552: ...e Block R G R W 5 Fuel Pump Relay 1 2 3 1 2 Fuel Pump Resister R B R B ID2 BO1 13 3 3 6 Fuel Pump W B 5 BO1 W B W R R W IH1 17 E7 E7 E4 3 13 14 MRLY R FC FPR B E01 E01 ECM BF EA2 7 Fusible Link FEI EB...

Page 553: ...e DLC3 c Turn ignition switch ON and TOYOTA hand held tester main switch ON d Use ACTIVE TEST mode to operate the fuel pump CHECK Check for fuel pressure in the fuel return hose when it is pinched off...

Page 554: ...between terminal FC of ECM and circuit open ing relay and fuse block See page IN 28 4 Connect the TOYOTA hand held tester and check operation of fuel pump relay PREPARATION a Connect the TOYOTA hand...

Page 555: ...Apply battery voltage between terminals 1 and 5 b Measure voltage between terminals 1 and 2 OK Terminals 1 and 2 Battery voltage NG Replace fuel pump relay OK 6 Check voltage between terminal FPR of...

Page 556: ...K Check operation of fuel pump when it is operated by the TOYO TA hand held tester and terminal FPR of ECM is grounded and is not grounded OK There is pressure in the inlet hose HINT At this time you...

Page 557: ...scan tool excluding TOYOTA hand held tester 1 Check fuel pump operation PREPARATION a Remove instrument panel speaker No 1 panel See page SF 65 b Turn ignition switch ON CHECK a Connect between termin...

Page 558: ...open ing relay and fuse block See page IN 28 4 Check operation of fuel pump relay See step 5 of TOYOTA hand held tester NG Replace fuel pump relay OK 5 Check voltage between terminal FPR of ECM conne...

Page 559: ...pressure in the inlet hose HINT At this time you will hear a fuel flowing noise FPR is grounded Low speed FPR is not grounded High speed NG NG Go to step 8 NG OK Go to step 9 OK NG Repair or replace h...

Page 560: ...ump resistor See page SF 58 NG Replace fuel pump resistor OK Check for open and short in harness and connector between fuel pump relay and fuel pump resis tor and fuel pump See page IN 28 Brought to y...

Page 561: ...UIT DESCRIPTION The ECM turns on a VSV Vacuum Switching Valve to draw the air into the diaphragm chamber of the pressure regulator if it de tects that the temperature of the engine coolant is too high...

Page 562: ...urn ignition switch ON and TOYOTA hand held tester main switch ON d Select the ACTIVE TEST mode on the TOYOTA hand held tester CHECK Check operation of VSV when VSV is operated by the TOYOTA hand held...

Page 563: ...fuel pressure control See page SF 59 NG Replace VSV for fuel pressure control OK 2 Check voltage between terminal FPU of ECM connector and body ground PREPARATION a Remove instrument panel speaker No...

Page 564: ...LAND CRUISER RM451U 3 Check fuel pressure regulator See page SF 19 NG Repair or replace fuel pressure regulator OK Check and replace ECM See page IN 28 Brought to you by BirfMark Brought to you by Bi...

Page 565: ...mptom occurs DTC Check DI 131 OK Code 11 Preliminary Check DTC Chart Mechanical System Tests Manual Shifting Test OK OK Chapter 1 Electronic Chapter 2 On Vehicle OK Chapter 3 Off Vehicle OK Matrix Cha...

Page 566: ...hift 1st 2nd 2nd 3rd 3rd O D No down shift O D 3rd 3rd 2nd 2nd 1st Lock up malfunction Shift point too high or too low Harsh engagement N D Lock up Any drive position Slip or shudder No kick down Othe...

Page 567: ...to the MIL lighting up when a malfunction is detected the applicable DTCs pre scribed by SAE J2012 are recorded in the ECM memory See page DI 13 If the malfunction does not occurs in 3 trips the MIL g...

Page 568: ...OSIS a Check the MIL 1 The MIL lights up when the ignition switch is turned ON and the engine is not running HINT If the MIL does not light up troubleshoot the combination meter See page BE 2 2 When t...

Page 569: ...TOYOTA hand held tester only Compared to the normal mode the check mode has high sens ing ability to detect malfunctions Furthermore the same diag nostic items which are detected in the normal mode ca...

Page 570: ...he codes See the OBD II scan tool s instruction book for operating instructions NOTICE If the TOYOTA hand held tester switches the ECM from the normal mode to the check mode or vice versa or if the ig...

Page 571: ...page IN 18 4 Check the cnnector connection and terminal See page IN 28 5 Visual check and contact pressure See page IN 28 6 Handle the connector See page IN 28 5 ROAD TEST NOTICE Perform the test at...

Page 572: ...a big jump in engine RPM there is no lock up b 2 position test Shift into the 2 position and while driving with the accelerator pedal held constantly at the full throttle valve opening position push i...

Page 573: ...ATF is replaced or the engine does not run 1 Park the vehicle on a level surface and set the park ing brake 2 With the engine idling and the brake pedal de pressed shift the shift lever into all posi...

Page 574: ...e leaks it is necessary to repair or replace O rings Seal packings oil seals plugs or other parts e Inspect and adjust the throttle cable 1 Check that the throttle valve is fully closed 2 Check that t...

Page 575: ...Hold in position and tighten the bolt Torque 13 N m 130 kgf cm 9 ft lbf For continuity inspect of the park neutral position switch see page DI 169 h Check the idle speed Idle speed 650 50 rpm In N po...

Page 576: ...e engine is idling there will be a certain time lapse or lag before the shock can be felt This is used for checking the condition of the O D direct clutch forward clutch direct clutch and 1st and reve...

Page 577: ...NOTICE Release the accelerator pedal and stop test if the rear wheels begin to rotate before the engine speed reaches the specified stall speed 8 In the same manner do the test in R position Specifie...

Page 578: ...med that there is a mechanical problem a Turn the ignition switch OFF b Disconnect the solenoid wire connector c Warm up the engine d Drive the vehicle e Check the transmission operation when the shif...

Page 579: ...rcuit S Shift solenoid valve No 1 S ECM F f P0755 DI 156 Shift Solenoid B Malfunction Shift Solenoid Valve No 2 S Shift solenoid valve No 2 is stuck open or closed S Valve body is blocked up or stuck...

Page 580: ...Neutral Position Switch No 2 Vehicle Speed Sensor Shift Solenoid Valve No 2 Shift Solenoid Valve No 1 Engine Coolant Temperature Sensor Throttle Position Sensor ATF Temperature Sensor DLC3 Transfer N...

Page 581: ...tion 9 14 SP2 E6 2 SP E6 8 V V G IG OFF Disconnect ECM connector 560 680 Engine is running Pulse signal is output Below 1 5 4 6 OD1 E7 18 E1 E4 24 G O BR B IG ON 9 14 OD2 E7 19 E1 E4 24 P L BR B O D m...

Page 582: ...ttern select switch PWR 7 5 14 TFN E7 21 E1 E4 24 Y L BR B IG ON Transfer N position Below 3 IG ON Transfer other than N position 9 14 L4SW E7 9 E1 E4 24 B L BR B IG ON Transfer L4 position 7 5 14 IG...

Page 583: ...rt 7 Off vehicle repair matrix chart Vehicle does not move in a particular position or positions 1 On vehicle repair matrix chart 2 Off vehicle repair matrix chart No up shift 1st 2nd 1 Shift solenoid...

Page 584: ...it 6 Park neutral position switch circuit 7 Engine coolant temp sensor circuit 8 On vehicle repair matrix chart 9 Off vehicle repair matrix chart 10 ECM DI 163 DI 35 DI 87 DI 166 DI 185 DI 169 DI 30 D...

Page 585: ...chart 2 Off vehicle repair matrix chart Slip or shudder A particular position 1 On vehicle repair matrix chart 2 Off vehicle repair matrix chart No engine braking 1 On vehicle repair matrix chart 2 O...

Page 586: ...epair matrix chart L Lock up does not engage or lock up does not disengage 1 Lock up relay valve 2 Off vehicle repair matrix chart L Harsh engagement N D 1 Accumulator control valve 2 Off vehicle repa...

Page 587: ...and L positions 1 Forward clutch C1 L Vehicle does not move in D and 2 positions 1 No 2 one way clutch F2 L Vehicle does not move in 2 position 1 1st and reverse brake B3 L Vehicle does not move in L...

Page 588: ...engine braking 1st 1 1st and reverse brake B3 L No engine braking 2nd 1 2nd coast brake B1 L Poor acceleration All positions 1 Torque converter clutch AT 26 Poor acceleration O D 1 O D brake B0 2 O D...

Page 589: ...IC TRANSMISSION DI 153 1996 LAND CRUISER RM451U CIRCUIT INSPECTION DTC P0500 Vehicle Speed Sensor Malfunction No 1 Vehicle Speed Sensor See page DI 87 Brought to you by BirfMark Brought to you by Birf...

Page 590: ...fluid temperature into resistance value which is input into the ECM DTC No DTC Detecting Condition Trouble Area P0710 Either a or b is detected for 0 5 sec or more a Temp sensor resistance is less th...

Page 591: ...tance between terminals of the ATF tempera ture sensor at 20 C 68 F and 110 C 230 F OK Resistance 20 C 68 F Approx 12 2 k 110 C 230 F Approx 770 NG Replace ATF temperature sensor OK 2 Check harness an...

Page 592: ...Shift solenoid valve No 1 No 2 is stuck open or closed S Valve body is blocked up or stuck HINT Check the shift solenoid valve No 1 when DTC P0750 is output and check shift solenoid valve No 2 when DT...

Page 593: ...er shift solenoid ON and OFF to shift to the gear positions shown in the table below The ECM also turns the shift solenoid valve SL OFF at the same time If both solenoids are malfunction hydraulic con...

Page 594: ...RANSMISSION 1996 LAND CRUISER RM451U WIRING DIAGRAM INSPECTION PROCEDURE 1 Measure resistance between terminal S1 or S2 of ECM and body ground PREPARATION Disconnect the connector from the ECM CHECK M...

Page 595: ...connector PREPARATION Disconnect the solenoid connector from the automatic trans mission CHECK Check the harness and connector between terminals S1 or S2 of the ECM and S1 or S2 terminals of the sole...

Page 596: ...lenoid valve No 1 or No 2 CHECK a Measure the resistance between solenoid connector and body ground b Connect positive lead to terminal of the solenoid con nector negative lead to the solenoid body OK...

Page 597: ...erter clutch DTC No DTC Detecting Condition Trouble Area P0770 Lock up does not occur when driving in the lock up range normal driving at 80 km h 50 mph or lock up remains ON in the lock up OFF range...

Page 598: ...ANSMISSION 1996 LAND CRUISER RM451U 2 Check valve body See page DI 147 NG Repair or replace valve body OK Replace torque converter clutch See page AT 26 Brought to you by BirfMark Brought to you by Bi...

Page 599: ...e hydraulic pressure acting on the lock up relay valve which then controls operation of the lock up clutch Fail Safe Function If the ECM detects a malfunction it turns the shift solenoid valve SL OFF...

Page 600: ...nd body ground OK Resistance 11 15 OK Check and replace ECM NG 2 Check harness and connector between ECM and automatic transmission sole noid connector PREPARATION Disconnect the solenoid connector fr...

Page 601: ...lenoid valve SL CHECK a Measure the resistance between the shift solenoid valve SL connector terminal and its body ground b Connect positive lead to terminal of the solenoid con nector negative lead t...

Page 602: ...s from this vehicle speed sensor and the throttle position sensor signal If the No 2 vehicle speed sensor malfunctions the ECM uses input signals from the No 1 vehicle speed sensor as a back up signal...

Page 603: ...cover b Connect an OBD II scan tool or TOYOTA hand held tes ter to the DLC3 c Start the engine and turn the OBD II scan tool or TOYOTA hand held tester main switch ON CHECK Drive the vehicle and read...

Page 604: ...e voltage between terminals 1 and 2 of the ve hicle speed sensor when a magnet is put close to the front end of the vehicle speed sensor then taken away quickly OK a Resistance 560 680 b Voltage is ge...

Page 605: ...s signals to the ECM The ECM receives signals NSW R 2 and L from the park neutral position switch When the signal is not sent to the ECM from the park neutral position switch the ECM judges that the s...

Page 606: ...Connect a TOYOTA hand held tester to the DLC3 c Turn the ignition switch ON and TOYOTA hand held tes ter main switch ON CHECK Shift lever into the P R N 2 and L positions and read the PNP REVERSE 2 an...

Page 607: ...rminal shown below when the shift lever is moved to each position OK Shift Position Terminal No to continuity Terminal No to continuity P 4 7 5 6 R 4 8 N 4 10 5 6 D 4 9 2 2 4 L 3 4 NG Replace park neu...

Page 608: ...ol ECU sends O D cut signals to the ECM as necessary and the ECM cancels overdrive shifting until these signals are discontinued For details see the Cruise Control section page DI 292 WIRING DIAGRAM I...

Page 609: ...connector b Turn ignition switch ON CHECK Measure the voltage between terminal OD of the cruise control ECU harness side connector and body ground OK Voltage 9 14 V OK Check and replace cruise contro...

Page 610: ...switch pushed in Contact go on with switch once again DI 174 DIAGNOSTICS AUTOMATIC TRANSMISSION 1996 LAND CRUISER RM451U O D Main Switch O D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O D mai...

Page 611: ...main switch CHECK a Turn the ignition switch ON b Check the O D OFF indicator light when the O D main switch is pushed in to ON OK O D OFF indicator light goes off CHECK Check the O D OFF indicator li...

Page 612: ...n Switch OVRDRIVE CUT SW2 Signal O D ON pushed in OFF O D OFF pushed out ON When not using TOYOTA hand held tester PREPARATION Turn the ignition switch ON CHECK Check the voltage between terminal OD2...

Page 613: ...e ON open OFF 0 continuity NG Replace O D main switch OK Check and replace the combination meter See page BE 32 O D OFF indicator light remains ON 1 Check O D main switch CHECK a Disconnect the O D ma...

Page 614: ...ck harness and connector between O D OFF indicator light and O D main switch and O D OFF indicator light and ECM See page IN 28 NG Repair or replace harness or connector OK Check and replace ECM Broug...

Page 615: ...t Switch Circuit PWR Mode Switch CIRCUIT DESCRIPTION The ECM memory contains the shift programs for the NORMAL and POWER patterns 2 position L position and the lock up patterns Following the programs...

Page 616: ...witch PATTERN SEL SW Signal PWR ON NORM OFF When not using TOYOTA hand held tester PREPARATION Turn the ignition switch ON CHECK Measure the voltage between terminal PWR of the ECM con nector and body...

Page 617: ...h connector when the PWR mode switch is set to PWR and NORM positions OK PWR Mode Switch Resistance PWR 0 continuity NORM open NG Replace pattern select switch OK 4 Check harness and connector between...

Page 618: ...ush the 2nd start swtch once again The 2nd start is automatically cancelled out when the ignition switch is turned OFF DI 182 DIAGNOSTICS AUTOMATIC TRANSMISSION 1996 LAND CRUISER RM451U Pattern Select...

Page 619: ...CHECK Check the 2nd STRT indicator light when the 2nd start switch is pushed again or PWR mode switch is pushed into OFF OK 2nd STRT indicator light goes off When PWR mode switch is pushed in to ON 2...

Page 620: ...and body ground PREPARATION a Turn ignition switch ON b Disconnect the connector from the ECM CHECK Check the voltage between terminal HOLD of the ECM and body ground when the select switch is set to...

Page 621: ...t CIRCUIT DESCRIPTION When 2nd start mode is selected with the pattern select switch the ECM controls the solenoid valves and the transmission starts from 2nd gear In D position the transmission autom...

Page 622: ...ts up CHECK Check 2nd STRT indicator light when 2nd start switch is pushed again or PWR mode switch is pushed into OFF OK 2nd STRT indicator light goes off When PWR mode switch is pushed in to ON 2nd...

Page 623: ...n terminals HOLD and HI of ECM and body ground PREPARATION a Turn ignition switch ON b Disconnect the connector of ECM CHECK Check voltage between terminal HOLD of ECM and body ground when the select...

Page 624: ...DI 201 DI 235 DTC Chart P DI 196 Malfunction code Problem Symptoms Table P DI 200 Check for Fluid Leakage P DI 237 Identification of Problem Normal code Repair Confirmation Test End 1 2 3 4 5 6 7 8 9...

Page 625: ...nt times a day ABS does not operate ABS does not operate efficiently ABS Warning Light Abnormal Remains ON Does not Light Up DTC Check 1st Time 2nd Time Normal Code Malfunction Code Code Normal Code M...

Page 626: ...DI 230 S When the transfer is in L position center differential lock the ABS does not operate and the ABS warning light stays ON b Check the DTC 1 Confirm that the center differential is free 2 Disco...

Page 627: ...e same time the low est numbered DTC will be displayed 1st c Clear the DTC 1 Confirm that the center differential is free 2 Using SST connect terminals Tc and E1 of the DLC1 and remove the short pin f...

Page 628: ...ECELERATION SEN SOR CHECK a Check the speed sensor signal 1 Conform that the center differential is free 2 Turn the ignition switch OFF 3 Using SST connect terminals Ts and E1 of the DLC1 SST 09843 18...

Page 629: ...Turn the ignition switch OFF 3 Using SST connect terminals Ts and E1 of the DLC1 SST 09843 18020 4 Start the engine 5 Check that the ABS warning light blinks HINT If the ABS warning light does not bli...

Page 630: ...head at about 20 km h 12 4 mph or more lightly depress the brake pedal 2 Check that there is no change in the warning light pattern 3 Drive the vehicle straight ahead at about 20 km h 12 4 mph or more...

Page 631: ...tput voltage of left rear speed sensor S Left rear speed sensor S Sensor installation S Sensor rotor S Sensor wire harness 75 Abnormal change in output voltage of right front speed sen sor S Right fro...

Page 632: ...ort circuit in 3 position solenoid circuit for left front wheel S ABS actuator S Open or short in SFLcircuit 23 DI 207 Open or short circuit in 3 position solenoid circuit for rear wheel S ABS actuato...

Page 633: ...24 Pump motor is locked Open in pump motor ground S ABS pump motor Always ON DI 225 Malfunction in ECU IG power source circuit S Battery S IC regulator S Open or short in power source circuit S ECU Br...

Page 634: ...Stop Light Switch ABS Warning Light Deceleration Sensor DLC1 ABS ECU ABS Actuator ABS Relay Front Speed Sensor Rotor DI 198 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM 1996 LAND CRUISER RM451U PARTS LOCATION B...

Page 635: ...rcuit for leakage See page DI 237 DI 190 DI 215 DI 210 BR 53 ABS does not operate effi ciently Only when 1 4 are all normal and the problem is still occurring replace the ABS ECU 1 Check the DTC recon...

Page 636: ...n DTC No DTC Detecting Condition Trouble Area 11 Conditions 1 and 2 continue for 0 2 sec or more 1 ABS control solenoid relay terminal SR voltage Battery positive voltage 2 2 ABS control solenoid rela...

Page 637: ...A7 2 and A7 6 of the ABS control relay harness side connector OK Voltage 10 14 V NG Check and repair harness or connector OK 2 Check continuity between terminals A7 5 and A4 4 A4 4 and A5 2 and A5 2...

Page 638: ...battery positive voltage between terminals A7 1 and A6 3 b Check the continuity between each terminal of the ABS control solenoid relay OK Terminals A7 5 and A7 6 Open Terminals A7 2 and A7 5 Continu...

Page 639: ...3 continue for 0 05 sec or more 1 ABS control solenoid relay terminal SR voltage Battery positive voltage 2 Voltage of ABS ECU terminal AST Battery positive volt age 3 When power transistor of ECU is...

Page 640: ...No 2 B W B W R B No 2 F00026 1 3 LOCK 7 4 A5 A4 4 DI 208 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM 1996 LAND CRUISER RM451U WIRING DIAGRAM INSPECTION PROCEDURE 1 Check ABS actuator solenoid PREPARATION Disco...

Page 641: ...nector between ABS ECU and ac tuator See page IN 28 NG Repair or replace harness or connector OK If same code is still output after DTC is deleted check contact condition of each connection If connect...

Page 642: ...t 7 times in the time between switching the igni tion switch ON and switching it OFF 3 Abnormal fluctuation of speed sensor signals with the vehicle speed 20 km h 12 mph or more Right front left front...

Page 643: ...2 A13 A12 FR FR FL FL RR RR RL RL 16 1 2 Bf1 Bd2 Bd1 Bd2 Bg1 Bh1 Bh1 Bh1 Bh1 BQ2 BQ2 BQ2 BQ2 ID3 ID3 ID3 ID3 L W W W W B FSS RSS B 1 1 2 1 2 2 4 1 16 4 4 L L L BR BR B W B 3 3 3 3 Y P V Y G A13 A13 A1...

Page 644: ...asure resistance between terminals 1 and 2 of speed sensor connector and body ground OK Resistance 1 M or higher Rear PREPARATION Disconnect speed sensor connector CHECK Measure resistance between ter...

Page 645: ...ss or connector OK 3 Check speed sensor and rotor serrations Reference INSPECTION USING OSCILLOSCOPE PREPARATION a Remove the ABS ECU with connector still connected b Connect the oscilloscope to the t...

Page 646: ...se Rear PREPARATION Remove the rear brake caliper and disc CHECK Check the sensor rotor serrations OK No scratches or missing teeth CHECK Check the sensor tip OK No scratches or foreign objects on the...

Page 647: ...ower source for the ECU hence the CPU and actuators DTC No DTC Detecting Condition Trouble Area 41 Vehicle speed is 3 km h 1 9 mph or more and voltage of ECU terminal IG1 remains at more than 17 V or...

Page 648: ...emove the ABS ECU with connectors still connected CHECK a Turn the ignition switch ON b Measure the voltage between terminals IG1 and GND of the ABS ECU connector OK Voltage 10 14 V OK Check and repla...

Page 649: ...from the Fuse block CHECK Check the continuity of the ECU IG fuse OK Continuity NG Check for short in all harness and components connected to ECU IG fuse See attached wiring diagram OK Check for open...

Page 650: ...tinuously 2 When the brake pedal is not depressed at vehicle speed of 5 km h or more forward and backward G more than 0 4 G is detected for 30 seconds or more S Deceleration sensor S Wire harness for...

Page 651: ...e The sensor signal is used in ABS control If the sensor func tions abnormally the ABS warning light comes on but the ABS still operates DTC No DTC Detecting Condition Trouble Area 44 Either of the fo...

Page 652: ...r connector OK 2 Check voltage between terminals GS1 GS2 GST of ABS ECU and body ground PREPARATION a Remove the ABS ECU with connectors still connected b Disconnect the deceleration sensor connector...

Page 653: ...ISER RM451U DTC 48 Center Differential Lock Circuit CIRCUIT DESCRIPTION DTC No DTC Detecting Condition Trouble Area 48 Open or short circuit in center differential lock circuit Center differential is...

Page 654: ...tep 6 YES 4 Check that bulb for CENTER DIFF LOCK indicator light is not burnt out YES Replace indicator light NO 5 Check for open in harness and connector between battery and CENTER DIFF LOCK indicato...

Page 655: ...51U 6 Check for short in harness and connector between CENTER DIFF LOCK indica tor light and ABS ECU See page IN 28 NG Repair or replace harness or connector OK Check and replace ABS ECU Brought to yo...

Page 656: ...V B W AM1 W B W B R B No 2 B W DI 224 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM 1996 LAND CRUISER RM451U DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION DTC No DTC Detecting Condition Trouble Area 51 Pump mot...

Page 657: ...rcuit CIRCUIT DESCRIPTION This is the power source for the ECU hence the CPU and the actuator DTC No DTC Detecting Condition Trouble Area Alway ON Voltage of ECU terminal B remains at more than 17 V o...

Page 658: ...in harness and connector between ABS solenoid relay and DLC1 See page IN 28 NO 3 Is ABS warning light go off YES Check for open or short in harness and connec tor between ECU IG fuse and ECU See page...

Page 659: ...nect the connector from the ABS ECU c Turn the ignition switch ON CHECK Check the ABS warning light goes off OK Check and replace ABS ECU NG Check for short in harness and connector between combinatio...

Page 660: ...DESCRIPTION This stop light switch senses whether the brake pedal is depressed or released and sends the signal to the ECU WIRING DIAGRAM INSPECTION PROCEDURE 1 Check operation of stop light CHECK Ch...

Page 661: ...age between terminal STP of the ABS ECU and body ground when the brake pedal is depressed OK Voltage 8 14 V OK Proceed to next circuit inspection shown on problem symptoms table See page DI 200 NG 3 C...

Page 662: ...ABS warning light while at the same time prohibiting ABS control At this time the ECU records a DTC in memory After removing the short pin of the DLC1 connect terminals Tc and E1 of the DLC1 to make...

Page 663: ...HECK a Apply battery positive voltage between terminals A7 1 and A6 3 b Check the continuity between each terminal of the ABS control relay OK Terminals A7 5 and A7 6 Open Terminals A7 2 and A7 5 Cont...

Page 664: ...ght go off if short pin is removed NO Check for short in harness and connector be tween warning light and DLC1 and ECU See page IN 28 YES 5 Check ABS control relay See step 2 NG Replace ABS control re...

Page 665: ...ECU to display the DTC by flashing the ABS warning light WIRING DIAGRAM INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC1 CHECK a Turn the ignition switch ON b Measure the volta...

Page 666: ...2 Check for open and short in harness and connector between ABS ECU and DLC1 and DLC1 and body ground See page IN 28 NG Repair or replace harness or connector OK Check and replace ABS ECU Brought to...

Page 667: ...with the DTC check Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check WIRING DIAGRAM INSPECTION PROCEDURE 1 Check voltage between terminals Ts and E1 of DLC1 CHECK a...

Page 668: ...2 Check for open and short in harness and connector between ABS ECU and DLC1 and DLC1 and body ground See page IN 28 NG Repair or replace harness or connector OK Check and replace ABS ECU Brought to...

Page 669: ...TI LOCK BRAKE SYSTEM DI 237 1996 LAND CRUISER RM451U Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines DI5MP 02 Brought to you by BirfMark Brought to you by BirfMark Ver...

Page 670: ...g the use of the TOYOTA hand held tester 3 4 5 10 11 12 DI 239 DI 240 DI 271 DI 240 DI 240 DI 240 Malfunction Code Clearance 4 DI 240 9 DTC Check 11 DI 240 12 Does Not Light Up Normal Code Normal Code...

Page 671: ...g Light Inspection DTC Inspection 1st Time 2nd Time 1st Time 2nd Time Inspector s Name Fine Cloudy Rainy Snowy Other Approx Starting Idling Driving Constant speed Acceleration Deceleration Other Remai...

Page 672: ...ort in the SRS warning light circuit can be considered likely Proceed to SRS warning light system malfunction on page DI 274 DI 276 2 DTC CHECK Using diagnosis check wire a Output the DTC 1 Turn the i...

Page 673: ...of a number of trouble codes indication will start from the smallest numbered code tot he larger S If it does not output a DTC or outputs a DTC without termi nal connection proceed to the Tc terminal...

Page 674: ...ground is absolute Finally keep applying body ground to terminal Tc HINT When alternately grounding terminals Tc and AB release ground from one terminal and immediately apply it to the other terminal...

Page 675: ...bag sensor assembly S Wire harness ON 14 DI 260 S Open in D squib circuit S Steering wheel pad D squib S Spiral cable S Airbag sensor assembly S Wire harness ON 31 DI 265 S Airbag sensor assembly malf...

Page 676: ...sembly Steering Wheel Pad With Airbag Spiral Cable Airbag Sensor Assembly DI 244 DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM 1996 LAND CRUISER RM451U PARTS LOCATION Brought to you by BirfMark Brought to...

Page 677: ...me A Electrical Connection Check Mechanism B Electrical Connection Check Mechanism 1 P Squib Passenger 2 P Squib Passenger 3 D Squib Driver 4 D Squib Driver 5 E1 Ground 6 E2 Ground 7 Tc Diagnosis 8 LA...

Page 678: ...switch is in the LOCK position S SRS warning light system malfunction Always lit up when ignition switch is in LOCK position DI 274 S With the ignition switch at ACC or ON the SRS warning lights does...

Page 679: ...loy when the SRS deployment conditions are satisfied For details of the function of each component see FUNCTION OF COMPONENTS on page RS 2 DTC 11 is recorded when ground short is detected in the squib...

Page 680: ...PECTION PROCEDURE 1 Preparation See step 1 on page DI 271 2 Check D squib circuit CHECK For the connector on the spiral cable side between the spiral cable and steering wheel pad measure the resistanc...

Page 681: ...onnector on the airbag sensor assembly side be tween the airbag sensor assembly and front passenger airbag assembly measure the resistance between P P and body ground OK Resistance 1 M or Higher NG Re...

Page 682: ...tween airbag sensor as sembly and front passenger airbag assembly d Connect negative terminal cable to battery and wait at least 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least 2...

Page 683: ...ble to battery and wait at least 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least 20 se conds b Clear malfunction code stored in memory See page DI 240 c Turn ignition switch to L...

Page 684: ...ACC or ON and wait at least 20 se conds b Clear malfunction code stored in memory See page DI 240 c Turn ignition switch to LOCK and wait at least 20 se conds d Turn ignition switch to ACC or ON and w...

Page 685: ...ween airbag sensor assembly and spiral cable CHECK Measure resistance between D on spiral cable side of connec tor between spiral cable and steering wheel pad and body ground OK Resistance 1 M or High...

Page 686: ...is detected in the squib circuit DTC No DTC Detection Condition Trouble Area 12 S Short circuit in squib wire harness to B S Squib malfunction S Spiral cable malfunction S Airbag sensor assembly malf...

Page 687: ...CHECK For the connector on the airbag sensor assembly side be tween airbag sensor assembly and front passenger airbag as sembly measure the voltage between P P and body ground OK Voltage 0 V NG Repair...

Page 688: ...etween airbag sensor as sembly and front passenger airbag assembly d Connect negative terminal cable to battery and wait at least 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least...

Page 689: ...ble to battery and wait at least 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least 20 se conds b Clear malfunction code stored in memory See page DI 240 c Turn ignition switch to L...

Page 690: ...ACC or ON and wait at least 20 se conds b Clear malfunction code stored in memory See page DI 240 c Turn ignition switch to LOCK and wait at least 20 se conds d Turn ignition switch to ACC or ON and w...

Page 691: ...onnect connector between airbag sensor assembly and spiral cable c Turn ignition switch ON CHECK Measure voltage at D on spiral cable side of connector be tween spiral cable and steering wheel pad and...

Page 692: ...of the function of each component see FUNCTION OF COMPONENTS on page RS 2 DTC 14 is recorded when an open is detected in the squib circuit DTC No DTC Detection Condition Trouble Area 14 S Open circuit...

Page 693: ...2 Check D squib circuit PREPARATION Using service wire connect D and D on airbag sensor assem bly connector CHECK For the connector on the spiral cable side between the spiral cable and steering wheel...

Page 694: ...tive terminal cable to battery and wait at least 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least 20 se conds b Clear malfunction code stored in memory See page DI 240 c Turn igni...

Page 695: ...to ACC or ON and wait at least 20 se conds b Clear malfunction code stored in memory See page DI 240 c Turn ignition switch to LOCK and wait at least 20 se conds d Turn ignition switch to ACC or ON an...

Page 696: ...low 1 NG Repair or replace spiral cable OK 6 Check harness between airbag sensor assembly and spiral cable PREPARATION Using service wire connect D and D on airbag sensor assem bly connector CHECK For...

Page 697: ...sensor assembly is detected DTC No DTC Detection Condition Trouble Area 31 S Airbag sensor assembly malfunction S Airbag sensor assembly INSPECTION PROCEDURE HINT When a malfunction code other than co...

Page 698: ...h to LOCK and wait at least 20 se conds b Turn ignition switch to ACC or ON and wait at least 20 se conds c Repeat operation in step a and b at least 5 times d Using SST connect terminals Tc and E1 of...

Page 699: ...ment conditions are satisfied For details of the function of each component see FUNCTION OF COMPONENTS on page RS 2 DTC 54 is recorded when an open is detected in the P squib circuit DTC No DTC Detect...

Page 700: ...N Using service wire connect P and P on airbag sensor assem bly connector CHECK For the connector on the airbag sensor assembly side be tween the airbag sensor assembly and front passenger airbag asse...

Page 701: ...y c Connect negative terminal cable to battery and wait at least 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least 20 se conds b Clear malfunction code stored in memory See page DI...

Page 702: ...ACC or ON and wait at least 20 se conds b Clear malfunction code stored in memory See page DI 240 c Turn ignition switch to LOCK and wait at least 20 se conds d Turn ignition switch to ACC or ON and w...

Page 703: ...drops When the battery voltage drops the voltage increase circuit DC DC converter functions to increase the voltage of the SRS to normal voltage The diagnosis system malfunction display for this circu...

Page 704: ...t passenger airbag assem bly See page RS 22 d Disconnect connector of airbag sensor assembly See page RS 33 CAUTION Store the steering wheel pad with the front surface facing upward 2 Check source vol...

Page 705: ...n ignition switch ON CHECK Operate electric system defogger wiper headlight heater blower etc and check that SRS warning light goes off NO Check DTC if a DTC is output perform trouble shooting accordi...

Page 706: ...is in LOCK position CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter When the SRS is normal the SRS warning light lights up for approx 6 seconds after the ignition switch...

Page 707: ...t passenger airbag assem bly See page RS 22 CAUTION Store the steering wheel pad with the front surface facing upward 2 Does SRS warning light turn off PREPARATION a Turn ignition switch to LOCK b Dis...

Page 708: ...here is a malfunction in the SRS the SRS warning light lights up to inform the driver of the abnormality When terminals Tc and E1 of the DLC1 are connected the DTC is displayed by the blinking of the...

Page 709: ...repair SRS warn ing light circuit OK 4 Does SRS warning light come on PREPARATION a Disconnect negative terminal cable from the battery b Connect airbag sensor assembly connector c Connect negative te...

Page 710: ...RUISER RM451U 5 Is new ECU B fuse burnt out again NO Using simulation method reproduce malfunc tion symptoms See page IN 18 YES Check harness between ECU B fuse and SRS warning light Brought to you by...

Page 711: ...EM DI 279 1996 LAND CRUISER RM451U Tc Terminal Circuit CIRCUIT DESCRIPTION By connecting terminals Tc and E1 of the DLC1 the airbag sensor assembly is set in the DTC output mode The DTCs are displayed...

Page 712: ...light up for approx 6 seconds PREPARATION Check operation of SRS warning light after ignition switch is turned from LOCK position to ACC or ON position NO Check SRS warning light system See page DI 24...

Page 713: ...UISER RM451U 3 Check voltage between terminals Tc of DLC1 and body ground CHECK Measure voltage between terminals Tc of DLC1 and body ground OK Voltage 10 14 V OK Check harness between terminal E1 of...

Page 714: ...from back side as shown e Connect airbag sensor assembly connector with service wire f Connect negative terminal cable to battery g Turn ignition switch to ACC or ON and wait at least 20 se conds h C...

Page 715: ...assembly and body ground PREPARATION a Turn ignition switch to LOCK b Disconnect negative terminal cable from the battery and wait at least 90 seconds c Disconnect airbag sensor assembly connector CHE...

Page 716: ...his manual with the page number indicated in the bottom portion See the indicated pages for detailed explanations 1 2 3 4 5 6 7 8 9 10 Step 2 5 8 10 Diagnostic steps permitting the use of the TOYOTA h...

Page 717: ...ncel does not occur j With brake ON j Except D position shift j At 40 km h 25 mph or less j When control SW turns to CANCEL position j Cruise control malfunction j Slip to acceleration side j Slip to...

Page 718: ...ncel does not occur j With brake ON j Except D position shift j At 40 km h 25 mph or less j When control SW turns to CANCEL position j Cruise control malfunction j Slip to acceleration side j Slip to...

Page 719: ...ed to trouble shooting See page BE 34 for the combination meter section b Check the DTC HINT If a malfunction occurs in the No 1 vehicle speed sensors or ac tuator etc during cruise control driving th...

Page 720: ...SUREMENT BY USING TOYOTA BREAK OUT BOX AND TOYOTA HAND HELD TESTER a Hook up the TOYOTA break out box and TOYOTA hand held tester to the vehicle b Read the ECU input output values by following the pro...

Page 721: ...that the ve hicle cruises at the set speed when the switch is re leased 4 Momentarily press the control switch upward in the RES ACC and then immediately release it Check that the vehicle speed incre...

Page 722: ...ruise control switch to CANCEL e Inspect the RESUME switch 1 Push the main switch ON 2 Drive at a desired speed 40 km h 25 mph or high er 3 When operating one of the followings check that the cruise c...

Page 723: ...ON OFF 1sec 0 25 sec 0 25 sec DIAGNOSTICS CRUISE CONTROL SYSTEM DI 290 1996 LAND CRUISER RM451U 5 INPUT SIGNAL CHECK HINT 1 For check No 1 No 3 Turn ignition switch ON 2 For check No 4 Jack up the veh...

Page 724: ...osition Sensor Circuit S Actuator position sensor S Harness or connector between cruise control ECU and actuator position sensor S Cruise control ECU 14 DI 304 S Actuator Mechanical Malfunction S Actu...

Page 725: ...Control Switch Main Switch Control Switch Stop Light Switch No 1 Vehicle Speed Sensor Park Neutral Position Switch Instrument Panel Fuse Block GAUGE Fuse ECU IG Fuse ECU B Fuse DI 292 DIAGNOSTICS CRUI...

Page 726: ...tch ON 10 16 V During cruise control driving OD switch OFF 3rd driving Below 1 V L GND C18 10 C18 13 R BR During cruise control driving 9 15 V Except during cruise control driving Below 1 V MC GND C18...

Page 727: ...g driving 3 7 V IDL GND C18 21 C18 13 G W BR Ignition switch ON Throttle valve fully closed Below 1 V Ignition switch ON Throttle valve fully opened 10 16 V ECT GND C18 22 C18 13 ECT GND C18 22 C18 13...

Page 728: ...r Motor Circuit 4 Cruise Control ECU DI 336 DI 314 DI 296 IN 28 Cruise control not cancelled even when transmission is shifted to N postion 1 Cruise Control Cable 2 Park Neutral Position Switch Circui...

Page 729: ...n and deceleration signals are trans mitted by changes in the Duty Ratio See note below Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle For example if A is the period o...

Page 730: ...een terminals 6 and 7 HINT If control plate position is fully opened or fully closed resistance can not measure OK Resistance more than 4 2 NG Replace cruise control actuator OK 2 Check for open and s...

Page 731: ...is depressed the stop light switch turns on supplying electrical power to the stop light Power supply to the magnetic clutch is mechanically cut and the magnetic clutch is turned OFF When driving dow...

Page 732: ...t panel fuse block CHECK Check fuse continuity OK There is continuity NG Replace STOP fuse OK 2 Check stop light switch PREPARATION Disconnect the stop light switch connector CHECK Check continuity be...

Page 733: ...resistance between terminals 4 and 5 OK Resistance 34 65 42 35 NG Replace cruise control actuator OK 4 Check for open and short in harness and connectors between cruise control ECU and actuator magnet...

Page 734: ...SCRIPTION The circuit detects the rotation position of the actuator control plate and sends a signal to the ECU DTC No Detection Item Trouble Area S 13 S Position sensor detects abnormal voltage S Act...

Page 735: ...decel eration side to the acceleration side OK Voltage Fully closed Approx 1 3 V Fully opened Approx 4 1 V In addition as the control plate is turned the voltage should increase gradually without inte...

Page 736: ...slowly by hand from the decel eration side to the acceleration side OK Voltage 1 3 4 0 V HINT As the control plate is turned the voltage should increase grad ually without interruption NG Replace crui...

Page 737: ...control ECU and actuator motor S Cruise control ECU WIRING DIAGRAM See page DI 296 INSPECTION PROCEDURE 1 Check cruise control actuator arm locking operation PREPARATION a Turn ignition switch OFF b D...

Page 738: ...the negative lead to terminals 4 and 7 of actuator OK Control arm moves to full open side CHECK Connect the positive lead from the battery to terminals 4 and 7of actuator connect the negative lead to...

Page 739: ...sor sends a 4 pulse signal through the combination me ter to the cruise control ECU See the following This signal is converted inside the combination meter and sent as a 4 pulse signal to the cruise c...

Page 740: ...2 1 1 Ea1 EC1 3 6 Y Y GAUGE AM1 Y Y BR BR EC1 Ea1 IH1 2 2 Instrument Panel Fuse Block Fusible Link Battery W B B I12 I12 Ignition Switch 2 4 1 3 F11 F11 Y B B J4 JUNCTION CONNECTOR EA1 6 2 2 3 4 B L F...

Page 741: ...below 40 km h 25 mph OK Vehicle speed above 40 km h 25 mph Indicator light blinks Vehicle speed below 40 km h 25 mph Indicator light stays on OK Check and replace cruise control ECU See page IN 28 NG...

Page 742: ...309 1996 LAND CRUISER RM451U 4 Check vehicle speed sensor See page BE 34 NG Replace vehicle speed sensor OK Check and replace cruise control ECU See page IN 28 Brought to you by BirfMark Brought to yo...

Page 743: ...is abnormal When speed signal is not input to the ECU below 0 2 sec code will be dis played S Vehicle speed sensor S Cruise control ECU WIRING DIAGRAM See page DI 306 INSPECTION PROCEDURE 1 Check vehi...

Page 744: ...Control Switch CIRCUIT DESCRIPTION This circuit carries the SET COAST RESUME ACCEL and CANCEL signals each voltage to the ECU DTC No Detection Item Trouble Area 32 S Short in control switch circuit S...

Page 745: ...witch is ON The signal should disappear when the switch is turned OFF CANCEL switch The indicator light goes off when the cancel switch is turned ON OK Wait and see NG 2 Check voltage between terminal...

Page 746: ...erated Switch position Resistance Neutral No continuity RES ACC 50 80 SET COAST 180 220 CANCEL 400 440 NG Replace control switch OK 4 Check harness and connector between cruise control ECU and cruise...

Page 747: ...harness connected to terminal STP has an open circuit terminal STP will have battery positive volt age and the cruise control will be turned off Also when the brake is on the magnetic clutch circuit...

Page 748: ...se control ECU connector and body ground when the brake pedal is de pressed and released OK Depressed 10 14 V Released Below 1 V OK Proceed to next circuit inspection shown on problem symptoms table S...

Page 749: ...turned ON a signal is sent to the ECU The ECU uses this signal to correct the dis crepancy between the throttle valve position and the actuator position sensor value to enable accurate cruise control...

Page 750: ...l IDL of ECU connector and body ground when the throttle valve is fully closed and fully opened OK Throttle valve position Voltage Fully opened 10 14 V Fully closed Below 2 V OK Proceed to next circui...

Page 751: ...alve is fully closed and fully opened OK Throttle valve position Resistance Fully opened 1 M or higher Fully closed Below 2 3 k NG Replace throttle position sensor OK 5 Check for open and short in har...

Page 752: ...a signal to prevent upshift until the end of the up hill slope is sent from the cruise control ECU to the electronically controlled transmission Terminal ECT of the cruise control ECU detects the shi...

Page 753: ...r electronically controlled transmission See page DI 129 OK 2 Check voltage between terminal OD of harness side connector of cruise control ECU and body ground PREPARATION a Remove the ECU with connec...

Page 754: ...0 5 V OK Proceed to next circuit inspection shown on problem symptoms table See page DI 295 NG 4 Check harness and connector between terminal ECT of cruise control ECU and electronically controlled t...

Page 755: ...Fusible Link F6 2 D Fusible Link Y DI 322 DIAGNOSTICS CRUISE CONTROL SYSTEM 1996 LAND CRUISER RM451U Park Neutral Position Switch Circuit CIRCUIT DESCRIPTION When the shift position is put in except D...

Page 756: ...s normally and that the engine starts NG Proceed to engine troubleshooting See page DI 1 OK 2 Input signal check PREPARATION See input signal check on page DI 286 CHECK Check the indicator light when...

Page 757: ...en shifting into D position and other positions OK Shift Position Voltage D position 10 14 V Other positions Below 1 V OK Proceed to next circuit inspection shown on problem symptoms table See page DI...

Page 758: ...1 F11 B B Y B 6 EA2 B GND 13 14 AM1 FL AM1 1 ID DIAGNOSTICS CRUISE CONTROL SYSTEM DI 325 1996 LAND CRUISER RM451U ECU Power Source Circuit CIRCUIT DESCRIPTION The ECU power source supplies power to th...

Page 759: ...y NG Check for short in all the harness and compo nents connected to ECU B fuse OK 2 Check voltage between terminals B and GND of cruise control ECU connector PREPARATION a Remove the ECU with connect...

Page 760: ...and body ground See page IN 28 CHECK Measure resistance between terminal GND of ECU connector and body ground OK Resistance Below 1 NG Repair or replace harness or connector OK Check and repair harnes...

Page 761: ...CIRCUIT DESCRIPTION The ECU back up power source provides power even when the ignition is off and is used for DTC memory etc WIRING DIAGRAM INSPECTION PROCEDURE 1 Check ECU IG fuse PREPARATION Remove...

Page 762: ...the ECU with connector still connected CHECK Measure voltage between terminal BATT of ECU connector and body ground OK Voltage 10 14 V OK Proceed to next circuit inspection shown on problem symptoms...

Page 763: ...k voltage between terminal CMS of cruise control ECU connector and body ground PREPARATION a Remove the ECU with connector still connected b Turn ignition switch ON CHECK Measure voltage between termi...

Page 764: ...5 of control switch connector when main switch is held on and off OK Switch position Tester connection Specified condition OFF 3 5 No continuity Hold ON 3 5 Continuity NG Replace control switch OK 3 C...

Page 765: ...12 4 Instrument Panel Fuse Block 1 AM1 AM1 J1 JUNCTION CONNECTOR PI 7 DI 332 DIAGNOSTICS CRUISE CONTROL SYSTEM 1996 LAND CRUISER RM451U CRUISE MAIN Indicator Light Circuit CIRCUIT DESCRIPTION When the...

Page 766: ...asure voltage between terminals PI and GND of ECU con nector when main switch on and off OK Switch position Voltage OFF 10 16 V ON Below 1 2 V OK Proceed to next circuit inspection shown on problem sy...

Page 767: ...o the ECU that DTC output is required WIRING DIAGRAM INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC1 PREPARATION Turn ignition switch ON CHECK Measure voltage between terminal...

Page 768: ...ck harness and connector between cruise control ECU and DLC1 DLC1 and body ground See page IN 28 NG Repair or replace harness or connector OK Check and replace cruise control ECU See page IN 28 Brough...

Page 769: ...t the cable and link are connected correctly b Check that the actuator and bell crank are operating smoothly c Check that the cable is not loose or too tight OK Freeplay less than 10 mm HINT S If the...

Page 770: ...e function of each system is shown in the following table System Abbreviation Function 1 Positive Crankcase Ventilation 2 Evaporative Emission Control 3 Exhaust Gas Recirculation 4 Three Way Catalytic...

Page 771: ...EMISSION CONTROL PARTS LAYOUT AND SCHEMATIC DRAWING 615 Author Date 1996 LAND CRUISER RM451U PARTS LAYOUT AND SCHEMATIC DRAWING LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1...

Page 772: ...EC07J 05 EMISSION CONTROL PARTS LAYOUT AND SCHEMATIC DRAWING EC 3 1996 LAND CRUISER RM451U DRAWING Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 773: ...r into the cylinder head side and check that air passes through easily CAUTION Do not suck air through the valve Petroleum substances inside the valve are harmful b Blow air into the air intake chambe...

Page 774: ...TROL EVAPORATIVE EMISSION EVAP CONTROL SYSTEM EC 5 618 Author Date 1996 LAND CRUISER RM451U EVAPORATIVE EMISSION EVAP CONTROL SYSTEM COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Ve...

Page 775: ...nect the EVAP hose from the union pipe c Start the engine d Gradually increase the engine speed from idle to 3 000 rpm and check that air suction is not felt at the union pipe 5 INSPECT OPERATION OF V...

Page 776: ...and check that air flow with out resistance from tank pipe If a problem is found replace the charcoal canister 11 CLEAN FILTER IN CANISTER Clean the filter by blowing 294 kPa 3 kgf cm2 43 psi of com...

Page 777: ...r c Heat the TVV to above 64 C 147 F with hot water d Check that air flows from pipe J to pipe K If operation is not as specified replace the TVV 18 REINSTALL TVV a Apply adhesive to 2 or 3 threads of...

Page 778: ...VCV 23 REINSTALL VCV 24 INSTALL INTAKE MANIFOLD STAY Torque 36 N m 360 kgf cm 26 ft lbf 25 REMOVE INTAKE MANIFOLD STAY 26 REMOVE CHECK VALVE 27 INSPECT CHECK VALVE a Check that air flows from the oran...

Page 779: ...SSION CONTROL EXHAUST GAS RECIRCULATION EGR SYSTEM 623 Author Date 1996 LAND CRUISER RM451U EXHAUST GAS RECIRCULATION EGR SYSTEM COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Versio...

Page 780: ...nd check that the engine starts and runs at idle 4 CONNECT TOYOTA HAND HELD TESTER OR OBD II SCAN TOOL See page EM 10 5 INSPECT VSV OPERATION WITH COLD ENGINE a The engine coolant temperature should b...

Page 781: ...t the vacuum hoses to the proper locations If no problem is found with this inspection system is normal otherwise inspect each part 10 CANCEL DIAGNOSTIC TROUBLE CODE 11 REMOVE AIR INTAKE CHAMBER See p...

Page 782: ...R port b Disconnect the vacuum hose from Q port c Disconnect the vacuum hose from P port 19 INSPECT EGR VACUUM MODULATOR OPERATION a Block ports P and R with your finger b Blow air into port Q and che...

Page 783: ...icking and heavy carbon deposits If a problem is found replace the valve 24 REINSTALL EGR VALVE a Using 2 nuts temporarily install a new gasket and EGR valve with the 2 stud bolts Torque 9 N m 90 kgf...

Page 784: ...eck clamps for weakness cracks or damage 2 TWC INSPECTION Check for dents or damage If any part of the protector is damaged or dented to the extent that it touches the TWC repair or replace it 3 HEAT...

Page 785: ...EGR systems etc should be properly connected f SFI system wiring connectors fully plugged g Ignition timing set correctly h Transmission in neutral position i Tachometer and CO HC meter calibrated by...

Page 786: ...S Cracked distributor cap 4 Incorrect valve clearance 5 Leaky EGR valve 6 Leaky intake and exhaust valves 7 Leaky cylinders Low High Rough idle Fluctuating HC reading 1 Vacuum leaks S PCV hose S EGR v...

Page 787: ...a through c for each cylinder NOTICE This measurement must be done in as short a time as pos sible Compression pressure 1 176 kPa 12 0 kgf cm2 171 psi or more Minimum pressure 883 kPa 9 0 kgf cm2 128...

Page 788: ...disconnect the heater valve 4 DISCONNECT HIGH TENSION CORDS FROM SPARK PLUGS See page IG 1 5 REMOVE CYLINDER HEAD COVER Remove the 13 bolts cylinder head cover and gasket 6 SET NO 1 CYLINDER TO TDC C...

Page 789: ...mm 0 006 0 010 in Exhaust 0 25 0 35 mm 0 010 0 041 in b Turn the crankshaft pulley 1 revolution 360 and align the its groove with timing mark 0 of the timing chain cov er c Check only the valves indi...

Page 790: ...shim size by follow ing the Formula or Charts S Using a micrometer measure the thickness of the removed shim S Calculate the thickness of a new shim so that the valve clearance comes within specified...

Page 791: ...ess as close as pos sible to the calculated value HINT Shims are available in 17 sized in increments of 0 05 mm 0 0020 in from 2 50 mm 0 0984 in to 3 30 mm 0 1299 in e Place a new adjusting shim on th...

Page 792: ...he 2 800 mm 0 1102 in shim is installed and the measured clearance is 0 440 mm 0 0173 in Replace the 2 800 mm 0 1102 in shim with a No 12 shim HINT New shims have the thickness in millimeter imprinted...

Page 793: ...5 mm 0 010 0 014 in EXAMPLE The 2 800 mm 0 1102 in shim is installed and the measured clearance is 0 440 mm 0 0173 in Replace the 2 800 mm 0 1102 in shim with a No 10 shim HINT New shims have the thic...

Page 794: ...eed Idle speed 650 50 rpm 5 INSPECT AND ADJUST IGNITION TIMING a Using SST connect terminals TE1 and E1 of the DLC1 SST 09843 18020 b Using a timing light check the ignition timing Ignition timing 3 B...

Page 795: ...should be properly connected f SFI system wiring connectors fully plugged g Ignition timing set correctly h Transmission in neutral position i Air conditioning switched OFF 2 CONNECT TOYOTA HAND HELD...

Page 796: ...EM1E8 01 EM 12 ENGINE MECHANICAL TIMING CHAIN 515 Author Date 1996 LAND CRUISER RM451U TIMING CHAIN COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 797: ...drive belt b Remove the 4 mounting bolts and disconnect the com pressor from the bracket HINT Put aside the compressor and suspend it c Remove the 5 bolts and A C compressor bracket 6 REMOVE RADIATOR...

Page 798: ...1 OIL PAN TO TRANS MISSION HOUSING Remove the 6 bolts 12 REMOVE NO 2 OIL PAN See page LU 5 13 REMOVE NO 1 OIL PAN See page LU 5 14 REMOVE CRANKSHAFT PULLEY a Using SST remove the pulley bolt SST 0921...

Page 799: ...or timing chain cover 16 REMOVE DRIVE BELT IDLER PULLEY Remove the bolt and idler pulley 17 REMOVE TIMING CHAIN COVER a Remove the 9 mounting bolts 2 mounting nuts and drive belt adjusting bar b Remov...

Page 800: ...IPPER AND VIBRA TION DAMPER a Using a 10 mm hexagon wrench remove the bolt and slip per b Remove the 2 bolts and damper 21 REMOVE OIL JET Remove the bolt and oil jet 22 REMOVE CRANKSHAFT ROTOR 23 REMO...

Page 801: ...pers measure the timing gear diameter with the chain NOTICE Vernier calipers must contact the chain rollers for measur ing Minimum gear diameter w Chain Camshaft 126 0 mm 4 961 in Crankshaft 65 4 mm 2...

Page 802: ...01 EM 18 ENGINE MECHANICAL TIMING CHAIN 1996 LAND CRUISER RM451U REPLACEMENT REPLACE CRANKSHAFT FRONT OIL SEAL See page EM 99 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21...

Page 803: ...on the shaft portion of the gear b Install the gear 4 INSTALL CRANKSHAFT ROTOR 5 INSTALL OIL JET Install the oil jet with the bolt Torque 20 N m 200 kgf cm 14 ft lbf 6 INSTALL CHAIN TENSIONER SLIPPER...

Page 804: ...SST SST 09636 20010 8 INSTALL TIMING CHAIN AND CAMSHAFT TIMING GEAR a Install the timing chain on the camshaft timing gear with the bright link aligned with the timing mark on the cam shaft timing gea...

Page 805: ...ly clean all components to remove all the loose material S Using a non residue solvent clean both sealing surfaces b Apply seal packing to the timing chain cover as shown in the illustration Seal pack...

Page 806: ...rd from the chain 10 INSTALL DRIVE BELT IDLER PULLEY Install the pulley with the bolt Torque 43 N m 440 kgf cm 32 ft lbf 11 INSTALL CRANKSHAFT PULLEY a Align the pulley set key with the key groove of...

Page 807: ...Install a new gasket and water pump with the 4 bolts and 2 nuts Torque 21 N m 210 kgf cm 15 ft lbf 19 INSTALL RADIATOR PIPE a Connect the No 2 radiator hose to the water inlet b Install the 2 nuts hol...

Page 808: ...EM1E2 01 EM 24 ENGINE MECHANICAL CYLINDER HEAD 527 Author Date 1996 LAND CRUISER RM451U CYLINDER HEAD COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 809: ...ENGINE MECHANICAL CYLINDER HEAD EM 25 528 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 810: ...EM 26 ENGINE MECHANICAL CYLINDER HEAD 529 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 811: ...ENGINE MECHANICAL CYLINDER HEAD EM 27 530 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 812: ...NNECT ENGINE GROUND STRAPS a Disconnect the ground strap from the No 1 engine hang er b Disconnect the ground strap from the air intake chamber 8 DISCONNECT CONNECTOR ON INTAKE MANIFOLD FROM LH FENDER...

Page 813: ...O ring from the dipstick guide 22 REMOVE INTAKE MANIFOLD STAY Remove the 2 bolts and intake manifold stay 23 DISCONNECT FUEL INLET HOSE Remove the union bolt and 2 gaskets and disconnect the fuel inle...

Page 814: ...e bolt holding the engine wire to the intake manifold h Disconnect the connectors 1 Disconnect the connector for the emission control valve set assembly 2 Disconnect the 3 injector connectors i Discon...

Page 815: ...nd No 1 support bracket f Remove the 4 nuts front exhaust pipe and 2 gaskets 27 REMOVE NO 1 AND NO 2 EXHAUST MANIFOLDS a Remove the 6 bolts No 1 heat insulator and No 2 heat insulator b Remove the 13...

Page 816: ...d 2 dots of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration If not turn the crankshaft 1 revolution 360 and align the marks as above...

Page 817: ...gear upward by turning the hexagon wrench head por tion of the exhaust camshaft with a wrench 2 Secure the exhaust camshaft sub gear to the main gear with a service bolt Recommended service bolt Threa...

Page 818: ...o 4 and No 6 bearing cap bolts Then re verse the order of above steps from g to e and repeat steps from c to h once again NOTICE Do not pry on or attempt to force the camshaft with a tool or other obj...

Page 819: ...ted out straight and level re tighten the 4 No 2 and No 5 bearing cap bolts Then re verse the order of above steps from e to c and repeat steps from a to f once again NOTICE Do not pry on or attempt t...

Page 820: ...ral passes in the sequence shown NOTICE Cylinder head warpage or cracking could result from re moving bolts in incorrect order c Lift the cylinder head from the dowels on the cylinder block and place...

Page 821: ...ove the 2 bolts and disconnect the pipe and hose 5 REMOVE AIR INTAKE CHAMBER AND INTAKE MAN IFOLD ASSEMBLY a Disconnect the 2 vacuum hoses from the TVV b Remove the 10 bolts 2 nuts intake manifold and...

Page 822: ...CABLE BRACKET Remove the 2 bolts and 2 cable brackets 11 REMOVE VALVE LIFTERS AND SHIMS HINT Arrange the valve lifters and shims in correct order 12 REMOVE VALVES a Using SST compress the valve sprin...

Page 823: ...finger remove the spring seat by blowing air HINT Arrange the valves valve springs spring seats and spring re tainers in correct order 13 REMOVE ECT SENDER GAUGE 14 REMOVE ECT CUT SWITCH 15 REMOVE EC...

Page 824: ...ir blow carbon and oil from the bolt holes CAUTION Protect your eyes when using high compressed air 2 CLEAN CYLINDER HEAD a Using a gasket scraper remove all the gasket material from the cylinder bloc...

Page 825: ...mum warpage Cylinder block side 0 15 mm 0 0059 in Manifold side 0 10 mm 0 0039 in If warpage is greater than maximum replace the cylinder head b Inspect for cracks Using a dye penetrant check the comb...

Page 826: ...de diameter measurement Standard oil clearance Intake 0 025 0 060 mm 0 0010 0 0024 in Exhaust 0 030 0 065 mm 0 0012 0 0026 in Maximum oil clearance Intake 0 08 mm 0 0031 in Exhaust 0 10 mm 0 0039 in I...

Page 827: ...VE SEATS a Using a 45 carbide cutter resurface the valve seats Remove only enough metal to clean the seats b Check the valve seating position Apply a light coat of prussian blue or white lead to the v...

Page 828: ...d valve seat with an abrasive com pound e After hand lapping clean the valve and valve seat 8 INSPECT VALVE SPRINGS a Using a steel square measure the deviation of the valve spring Maximum deviation 2...

Page 829: ...circle runout is greater than maximum replace the cam shaft b Inspect the cam lobes Using a micrometer measure the cam lobe height Standard cam lobe height 50 61 50 71 mm 1 9925 1 9965 in Minimum cam...

Page 830: ...re the Plastigage at its widest point Standard oil clearance 0 025 0 062 mm 0 0010 0 0024 in Maximum oil clearance 0 10 mm 0 0039 in If the oil clearance is greater than maximum replace the cam shaft...

Page 831: ...mm 1 3386 1 3394 in b Using a micrometer measure the lifter diameter Lifter diameter 33 966 33 976 mm 1 3372 1 3376 in c Subtract the lifter diameter measurement from the lifter bore diameter measure...

Page 832: ...0 30 mm 0 0118 in If warpage is greater than maximum replace the manifold 13 INSPECT EXHAUST MANIFOLDS Using a precision straight edge and thickness gauge measure the surface contacting the cylinder h...

Page 833: ...If the bushing bore diameter of the cylinder head is greater than 11 513 mm 0 4533 in machine the bushing bore to the follow ing dimension 11 542 11 563 mm 0 4544 0 4552 in If the bushing bore diamete...

Page 834: ...ng a screwdriver pry out the tube gasket b Using SST and a hammer tap in a new tube gasket as shown in the illustration SST 09950 60010 09951 00480 09950 70010 09951 07150 c Apply a light coat of MP g...

Page 835: ...rd protrusion 45 5 mm 1 791 in b Apply adhesive to the spark plug tube hole of the cylinder head Sealant Part No 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent c Using a press press in a new...

Page 836: ...SST push in a new oil seal SST 09236 00101 09236 15010 HINT Different oil seals are used for the intake and exhaust b Install the valve 1 spring seat 2 valve spring 3 and spring retainer 4 c Using SST...

Page 837: ...INTAKE MAN IFOLD ASSEMBLY a Place a new gasket so that the rear mark is toward the rear side b Install the intake manifold with the 10 bolts and 2 nuts Torque 21 N m 210 kgf cm 15 ft lbf c Connect th...

Page 838: ...tened in 3 progressive steps steps b d and e S If any cylinder head bolt is broken or deformed replace it 1 Apply a light coat of engine oil on the threads and under the heads of the cylinder head bol...

Page 839: ...lt A into the service hole of the cam shaft sub gear e Using a screwdriver align the holes of the camshaft main gear and sub gear by turning camshaft sub gear clock wise and install a service bolt B N...

Page 840: ...r head 6 Place the No 3 No 4 No 6 and No 7 bearing caps in their proper location 7 Temporarily tighten these bearing cap bolts alter nately tightening the left and right bolts uniformly 8 Place the No...

Page 841: ...the No 2 No 3 No 5 and No 7 bearing caps in their proper location 9 Temporarily tighten these bearing cap bolts alter nately tightening the left and right bolts uniformly 10 Place the No 1 bearing ca...

Page 842: ...linder head surface as shown in the illustration 5 INSTALL CAMSHAFT TIMING GEAR HINT Check that the matchmarks on the camshaft timing gear and timing chain are aligned a Place the gear over the straig...

Page 843: ...ng mark 0 of the timing chain cover NOTICE Always turn the crankshaft clockwise b Check that the timing marks 1 and 2 dots of the camshaft drive and driven gears are in straight line on the cylinder h...

Page 844: ...the timing marks with 1 and 2 dots are in straight line on the cylinder head surface as shown in the illustration If not turn the crankshaft 1 revolution 360 and align the mark as above 12 INSTALL CYL...

Page 845: ...kgf cm 17 ft lbf c Connect the clamp and tighten the clamp bolt Torque 19 5 N m 195 kgf cm 14 ft lbf d Connect the front exhaust pipe to the rear TWC with a new gasket 2 bolts and 2 nuts Torque 46 N...

Page 846: ...nnect the knock sensor connector 5 Connect the crankshaft position sensor connector 19 CONNECT FUEL INLET HOSE Connect the fuel inlet hose to the fuel filter with 2 new gaskets and the union bolt Torq...

Page 847: ...the heater valve with the 2 bolts b Connect the engine wire and ground strap with the 2 bolts 30 CONNECT HEATER HOSES 31 CONNECT FUEL RETURN HOSE 32 CONNECT EVAP HOSE 33 CONNECT BRAKE BOOSTER VACUUM H...

Page 848: ...olt c Install the battery and hold down clamp with the nuts d Connect the battery cables 41 FILL RADIATOR WITH ENGINE COOLANT 42 START ENGINE AND CHECK FOR LEAKS 43 ADJUST IGNITION TIMING See page EM...

Page 849: ...EM1EC 01 ENGINE MECHANICAL ENGINE UNIT EM 65 568 Author Date 1996 LAND CRUISER RM451U ENGINE UNIT COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 850: ...EM 66 ENGINE MECHANICAL ENGINE UNIT 569 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 851: ...ENGINE MECHANICAL ENGINE UNIT EM 67 570 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 852: ...EM 68 ENGINE MECHANICAL ENGINE UNIT 571 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 853: ...ground strap d Remove the 5 bolts and battery tray 5 REMOVE RADIATOR GRILLE Remove the 5 screws clip and radiator grille 6 REMOVE RADIATOR See page CO 14 7 DISCONNECT OIL COOLER HOSE FROM OIL COOL ER...

Page 854: ...Disconnect the connector on the intake manifold from the fender apron f Disconnect the high tension cord from the ignition coil g Disconnect the ground strap from the No 1 engine hang er h Disconnect...

Page 855: ...d glove compartment door b Remove the screw and speaker panel c Remove the screw and disconnect the A C amplifier d Disconnect the connectors 1 Disconnect the 3 connectors from the ECM 2 Disconnect th...

Page 856: ...e 4 nuts d Remove the propeller shaft 25 REMOVE TRANSFER SHIFT LEVER a Remove the nut and transmission control rod b Remove the transfer shift lever knob c Remove 4 screws d Lift up the console slight...

Page 857: ...r b Remove the 2 nuts and 2 bolts holding the front exhaust pipe to the rear TWC c Disconnect the front exhaust pipe and remove the gas ket d Loosen the clamp bolt and disconnect the clamp from the No...

Page 858: ...smission out of the vehicle slowly and carefully NOTICE Make sure that the engine is clear of all wiring and hoses d Place the engine and transmission assembly onto the stand 31 REMOVE OIL DIPSTICK GU...

Page 859: ...3 clamp mounting bolts b Loosen the 2 union nuts and remove the oil cooler pipes 35 DISCONNECT THROTTLE CABLE FROM THROTTLE BODY 36 REMOVE HOLE PLUG 37 REMOVE 6 TORQUE CONVERTER CLUTCH MOUNT ING BOLT...

Page 860: ...by turning the crankshaft Torque 55 N m 550 kgf cm 41 ft lbf HINT First install the green colored bolt and then the remaining 5 bolts 4 INSTALL HOLE PLUG 5 CONNECT THROTTLE CABLE TO THROTTLE BODY 6 IN...

Page 861: ...e hoist chain 11 INSTALL FRAME CROSSMEMBER a Temporarily install the crossmember to the engine rear mounting insulator with the 2 nuts b Install the 8 bolts holding the crossmember to the frame Torque...

Page 862: ...f cm 48 in lbf d Connect the 3 connectors to the transmission shift lever assembly e Install the console box with the 3 bolts f Connect the pattern select switch connector g Install the console with t...

Page 863: ...rks on the flanges and connect the flanges with the 4 nuts b Torque the nuts Torque 74 N m 750 kgf cm 54 ft lbf for front shaft 88 N m 900 kgf cm 65 ft lbf for rear shaft 18 INSTALL STABILIZER BAR a T...

Page 864: ...MPRESSOR AND BRACKET a Install the A C compressor bracket with the 5 bolts Torque 37 N m 375 kgf cm 27 ft lbf b Install the A C compressor with the 4 bolts Torque 25 N m 250 kgf cm 18 ft lbf c Install...

Page 865: ...OR See page CO 16 36 INSTALL RADIATOR GRILLE Install the radiator grille with the 5 screws and clip 37 INSTALL BATTERY TRAY AND BATTERY a Install the battery tray with the 5 bolts b Connect the ground...

Page 866: ...EM1EF 01 EM 82 ENGINE MECHANICAL CYLINDER BLOCK 585 Author Date 1996 LAND CRUISER RM451U CYLINDER BLOCK COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 867: ...TO ENGINE STAND FOR DIS ASSEMBLY 3 REMOVE CYLINDER HEAD See page EM 28 4 REMOVE TIMING CHAIN AND GEARS See page EM 13 5 REMOVE OIL FILTER See page LU 2 6 REMOVE OIL FILTER UNION 7 REMOVE KNOCK SENSOR...

Page 868: ...cover with the oil cooler and gasket 12 REMOVE REAR OIL SEAL RETAINER Remove the 4 bolts and retainer 13 CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator measure the thrust clearance whil...

Page 869: ...d lift off the connecting rod cap HINT Keep the lower bearing inserted with the connecting rod cap d Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage e C...

Page 870: ...ace the bear ings If necessary grind or replace the crankshaft HINT If using a standard bearing replace with one having the same number If the number of the bearing cannot be determined se lect the co...

Page 871: ...ng rod and cap together S Arrange the piston and connecting rod assemblies in cor rect order 16 CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator measure the thrust clearance while prying the c...

Page 872: ...t HINT Keep the upper bearing and upper thrust washers together with the cylinder block d Clean each main journal and bearing e Check each main journal and bearing for pitting and scratches If the jou...

Page 873: ...the same number as the total There are 5 sizes of standard bearings marked 2 3 4 5 and 6 accorking ly Reference Cylinder block main journal bore diameter Mark 1 74 026 74 032 mm 2 9144 2 9146 in Mark...

Page 874: ...ETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin If any movement is felt replace the piston and pin as a set 22 REMOVE PISTON RINGS a Using a piston ring expander r...

Page 875: ...rings b Gradually heat the piston to 80 90 C 176 194 F c Using plastic faced hammer and brass bar lightly tap out the piston pin and remove the connecting rod HINT S The piston and pin are a matched s...

Page 876: ...ea sure the surfaces contacting the cylinder head gasket for warpage Maximum warpage 0 05 mm 0 0020 in If warpage is greater than maximum replace the cylinder block b Visually check the cylinder for v...

Page 877: ...ter is greater than maximum rebore all the 6 cylin ders If necessary replace the cylinder block d Remove the cylinder ridge If the wear is less than 0 2 mm 0 008 in using a ridge reamer grind the top...

Page 878: ...the carbon from the pis ton top b Using a groove cleaning tool or broken ring clean the pis ton ring grooves c Using solvent and a brush thoroughly clean the piston NOTICE Do not use a wire brush 5 IN...

Page 879: ...re diameter measurement Standard oil clearance 0 040 0 060 mm 0 0016 0 0024 in Maximum oil clearance 0 080 mm 0 0031 in If the oil clearance is greater than maximum replace all the 6 pistons and rebor...

Page 880: ...mm 0 0441 in No 2 1 17 mm 0 0461 in Oil Side rail 1 12 mm 0 0441 in If the end gap is greater than maximum replace the piston ring If the end gap is greater than maximum even with a new piston ring r...

Page 881: ...r measurement from the bushing inside diameter measurement Standard oil clearance 0 004 0 012 mm 0 0002 0 0005 in Maximum oil clearance 0 05 mm 0 0020 in If the oil clearance is greater than maximum r...

Page 882: ...f each main journal and crank pin Main journal diameter STD 68 982 69 000 mm 2 7158 2 7165 in U S 0 25 68 745 68 755 mm 2 7065 2 7069 in Crank pin diameter STD 56 982 57 000 mm 2 2434 2 2441 in U S 0...

Page 883: ...the connecting rod c Using SST and a press press in the bushing SST 09950 60010 09951 00280 09950 70010 09951 07100 d Using a pin hole grinder hone the bushing to obtain the standard specified cliaran...

Page 884: ...ored P C H P Piston diameter C Piston oil clearance 0 040 0 060 mm 0 0016 0 0024 in H Allowance for honing 0 02 mm 0 0008 in or less d Bore and hone the cylinders to calculated dimensions Maximum honi...

Page 885: ...09316 00051 4 REPLACE CRANKSHAFT REAR OIL SEAL HINT There are 2 methods a and b to replace the oil seal a If the rear oil seal retainer is removed from the cylinder block 1 Using a screwdriver and a...

Page 886: ...a new oil seal until its surface is flush with the rear oil seal retainer edge SST 09223 15030 09950 70010 09951 07150 NOTICE Do not let foreign matter get onto the lip of the oil seal 4 Check that th...

Page 887: ...side of the piston pin hole b Gradually heat the piston to 80 90 C 176 194 F c Coat the piston pin with engine oil d Align the front marks of the piston and connecting rod and push in the piston pin w...

Page 888: ...od or connecting rod cap b Install the bearings in the connecting rod and connecting rod cap 4 INSTALL CYLINDER BLOCK ORIFICE 5 INSTALL OIL NOZZLES AND CHECK VALVES a Align the pin of the oil nozzle w...

Page 889: ...each main bearing cap to indicate the installation position 7 INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No 4 journal position of the cylinder block with the oil grooves facin...

Page 890: ...earing caps in several passes in the sequence shown Torque 74 N m 750 kgf cm 54 ft lbf If any one of the main bearing cap bolts does not meet the torque specification replace the main bearing cap bolt...

Page 891: ...S The connecting rod cap nuts are tightened in 2 progres sive steps steps b and d S If any connecting rod bolt is broken or deformed replace it 1 Apply a light coat of engine oil on the threads and un...

Page 892: ...all the loose material S Using a non residue solvent clean both sealing surfaces b Apply seal packing to the retainer as shown in the illustra tion Seal packing Part No 08826 00080 or equivalent S Ins...

Page 893: ...nstall the pump with the 2 nuts Torque 36 N m 370 kgf cm 27 ft lbf 17 INSTALL KNOCK SENSORS Using SST install the 2 knock sensors SST 09816 30010 Torque 44 N m 450 kgf cm 33 ft lbf 18 INSTALL OIL FILT...

Page 894: ...EM0EE 10 EM 110 ENGINE MECHANICAL EXHAUST SYSTEM 613 Author Date 1996 LAND CRUISER RM451U EXHAUST SYSTEM COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 895: ...75 240 325 CHECK IGT SIGNAL FROM ECM See page DI 93 Check wiring between ignition switch to ignition coil and igniter Replace the ignition coil Replace the distributor housing assembly BAD OK CHECK PO...

Page 896: ...RK PLUGS a Remove the 2 mounting bolts of the No 1 and No 2 cord clamps b Disconnect the high tension cords at the rubber boot Do not pull on the cords NOTICE Pulling on or bending the cords may damag...

Page 897: ...ng an ohmmeter measure the resistance Maximum resistance 25 k per cord If the resistance is greater than maximum check the terminals If necessary replace the high tension cord 9 RECONNECT HIGH TENSION...

Page 898: ...and distributor cap as shown in the illustration c Check that the lock claw of the holder is engaged by lightly pulling the holder 10 RECONNECT HIGH TENSION CORDS TO SPARK PLUGS a Secure the high tens...

Page 899: ...with the 2 clamp bolts 14 INSTALL NO 2 PCV HOSE 15 DISCONNECT HIGH TENSION CORDS FROM SPARK PLUGS 16 REMOVE SPARK PLUGS Using a 16 mm plug wrench remove the spark plug 17 CLEAN SPARK PLUGS Using a spa...

Page 900: ...2 F to 100 C 212 F 22 DISCONNECT IGNITION COIL CONNECTOR 23 DISCONNECT HIGH TENSION CORD 24 INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter measure the resistance between the posi tive and negative...

Page 901: ...If the gap is not as specified replace the distributor housing 32 INSPECT SIGNAL GENERATOR PICKUP COIL RE SISTANCE Using an ohmmeter check that the resistance of the pickup coil Pickup coil resistanc...

Page 902: ...T POSITION SENSOR RESIS TANCE Using an ohmmeter measure the resistance between the ter minals Resistance NE NE Cold 1 630 2 740 Hot 2 065 3 225 If the resistance is not as specified replace the cranks...

Page 903: ...IG0IC 01 IGNITION DISTRIBUTOR IG 9 743 Author Date 1996 LAND CRUISER RM451U DISTRIBUTOR COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 904: ...n the crankshaft pulley until the timing mark is aligned with 0 mark on the timing chain cover b Check that the distributor rotor direction is as shown If not turn the crankshaft pulley one complete r...

Page 905: ...nkshaft 1 revolution 360 and align the mark as above 2 INSTALL DISTRIBUTOR a Install a new O ring to the distributor HINT Always use a new O ring when installing the distributor b Align the groove of...

Page 906: ...W 01 IG 12 IGNITION CRANKSHAFT POSITION SENSOR 746 Author Date 1996 LAND CRUISER RM451U CRANKSHAFT POSITION SENSOR COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2...

Page 907: ...nd crankshaft position sensor protector Torque 20 N m 200 kgf cm 14 ft lbf 3 DISCONNECT CRANKSHAFT POSITION SENSOR BRACKET AND CONNECTOR 4 REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt 2 nuts and...

Page 908: ...IGNITION CRANKSHAFT POSITION SENSOR 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page IG 13 Brought to you by BirfMark Brought to you by BirfMark Version 1...

Page 909: ...l should be between the L and F marks on the dip stick If low check for leakage and add oil up to F mark 3 REMOVE OIL PRESSURE SWITCH AND INSTALL OIL PRESSURE GAUGE 4 WARM UP ENGINE Allow the engine t...

Page 910: ...designated dis posal sites 1 DRAIN ENGINE OIL a Remove the oil filler cap b Remove the oil drain plug and drain the oil into a contain er 2 REPLACE OIL FILTER a Using SST remove the oil filter SST 092...

Page 911: ...LU0KF 04 LUBRICATION OIL PUMP LU 3 714 Author Date 1996 LAND CRUISER RM451U OIL PUMP COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 912: ...LU 4 LUBRICATION OIL PUMP 715 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 913: ...remove the drive belt b Remove the 4 mounting bolts and disconnect the com pressor from the bracket HINT Put aside the compressor and suspend it c Remove the 5 bolts and A C compressor bracket 6 REMO...

Page 914: ...2 OIL PAN a Remove the 17 mounting bolts and 2 nuts b Insert the blade of SST between the No 1 and No 2 oil pans cut off applied sealer and remove the No 2 oil pan SST 09032 00100 NOTICE Be careful no...

Page 915: ...k and No 1 oil pan 14 REMOVE OIL PAN BAFFLE PLATE Remove the bolt 7 nuts and baffle plate 15 REMOVE OIL STRAINER Remove the bolt 2 nuts oil strainer and gasket 16 REMOVE CRANKSHAFT PULLEY See page EM...

Page 916: ...tor driven rotor and gasket HINT At the time of installation place a new gasket on the pump body 2 REMOVE RELIEF VALVE Remove the plug gasket spring and relief valve Torque 49 N m 500 kgf cm 36 ft lbf...

Page 917: ...cessary replace the oil pump assembly 3 INSPECT ROTOR SIDE CLEARANCE Using a thickness gauge and precision straight edge measure the clearance between the rotors and precision straight edge Standard s...

Page 918: ...LU08T 03 LU 10 LUBRICATION OIL PUMP 1996 LAND CRUISER RM451U REPLACEMENT REPLACE CRANKSHAFT FRONT OIL SEAL See page EM 99 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 919: ...1 LUBRICATION OIL PUMP LU 11 1996 LAND CRUISER RM451U REASSEMBLY Reassembly is in the reverse order of disassembly See page LU 8 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 2...

Page 920: ...a Remove any old packing FIPG material and be careful not to drop any oil on the contact surfaces of the oil pan oil pump and cylinder block S Using a razor blade and gasket scraper remove all the old...

Page 921: ...Using a non residue solvent clean both sealing surfaces b Apply seal packing to the No 2 oil pan as shown in the il lustration NOTICE Do not use a solvent which will affect the painted surfaces Seal...

Page 922: ...f cm 15 ft lbf 15 INSTALL RADIATOR PIPE a Connect the No 2 radiator hose to the water inlet b Install the 2 nuts holding the radiator pipe to the No 1 oil pan Torque 21 N m 210 kgf cm 15 ft lbf 16 INS...

Page 923: ...LU08W 03 LUBRICATION OIL COOLER LU 15 726 Author Date 1996 LAND CRUISER RM451U OIL COOLER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 924: ...pipe to the rear TWC c Disconnect the front exhaust pipe and remove the gas ket d Loosen the clamp bolt and disconnect the clamp from the No 1 support bracket e Remove the 2 bolts and No 1 support br...

Page 925: ...move the 10 bolts 2 nuts oil cooler and oil cooler cover as sembly and gasket 7 SEPARATE OIL COOLER AND OIL COOLER COVER Remove the 4 nuts oil cooler and 2 gaskets from the oil cooler cover 8 REMOVE R...

Page 926: ...nd check that it falls smoothly into the valve hole by its own weight If it doesn t replace the relief valve If necessary replace the oil cooler cover 2 INSPECT OIL COOLER Check the oil cooler for dam...

Page 927: ...ITE 242 or equivalent b Install the oil pressure switch 5 INSTALL NO 1 EXHAUST MANIFOLD a Install a new gasket and the exhaust manifold with the 6 nuts Torque 39 N m 400 kgf cm 29 ft lbf b Install the...

Page 928: ...LU0KL 01 LU 20 LUBRICATION OIL NOZZLE 731 Author Date 1996 LAND CRUISER RM451U OIL NOZZLE COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 929: ...GEARS See page EM 13 3 REMOVE CRANKSHAFT See page EM 83 4 REMOVE OIL NOZZLES Remove the 6 check valves and oil nozzles Torque 25 N m 250 kgf cm 18 ft lbf HINT At the time of installation align the pi...

Page 930: ...HECK VALVES Push the valve with a wooden stick to check if it is stuck If stuck replace the check valve 2 INSPECT OIL NOZZLES Check the oil nozzles for damage or clogging If necessary replace the oil...

Page 931: ...LUBRICATION OIL NOZZLE LU 23 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page LU 21 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12...

Page 932: ...interval months S Maintenance service after the last period should be performed at the same interval as before unless otherwise noted S Failure to do even one item can cause the engine to run poorly a...

Page 933: ...ights turn signal lights and other lights are all working b Check the headlights aim 3 WARNING LIGHTS AND BUZZERS Check that all warning lights and buzzers function properly 4 HORN Check that it is wo...

Page 934: ...ce check that the brakes do not pull to one side when applied 16 PARKING BRAKE See page BR 8 a Check that the lever has the proper travel b On a safe incline check that the vehicle is held securely wi...

Page 935: ...ls is between the upper and lower level lines on the case If level is low add distilled water only 6 BRAKE FLUID LEVELS Check that the brake fluid level is near the upper level line on the see through...

Page 936: ...n blow off the outside of the element 3 REPLACE AIR FILTER Replace the air cleaner element with a new one 4 REPLACE SPARK PLUGS See page IG 1 5 REPLACE ENGINE OIL AND OIL FILTER See page LU 2 6 REPLAC...

Page 937: ...S Check for deformation S Check for cracks S Check for corrosion S Check for leaks S Check for bends S Check for twists b Check all clamps for tightness and connections for leak age c Check that the h...

Page 938: ...131 5 INSPECT OIL LEVEL IN TRANSFER AND DIFFEREN TIAL a Transfer Remove the filler plug and feel inside the hole with your finger Check that the oil comes to within 5 mm 0 20 in of the bottom edge of...

Page 939: ...2 5 lmp qts Front differential oil w Differential lock 2 65 liters 2 8 US qts 2 3 lmp qts Rear differential oil 3 25 liters 3 4 US qts 2 9 lmp qts 8 REPACK FRONT WHEEL BEARINGS See pages SA 7 and SA 9...

Page 940: ...perates properly Hood locks securely when closed S Front and rear doors Door locks operate properly Doors close properly S Back door Door lock operates properly S Seats Seat adjusts easily and locks s...

Page 941: ...01 PREPARATION MAINTENANCE PP 1 50 Author Date 1996 LAND CRUISER RM451U MAINTENANCE EQUIPMENT Mirror Brake hose Torque wrench Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21...

Page 942: ...pressor 09202 00010 Attachment 09213 58012 Crankshaft Pulley Holding Tool 09223 15030 Oil Seal Bearing Replacer Crankshaft rear oil seal 09236 00101 Water Pump Overhaul Tool Set 09236 15010 Bearing St...

Page 943: ...9636 20010 Upper Ball Joint Dust Cover Replacer Crankshaft timing gear 09816 30010 Oil Pressure Switch Socket Knock sensor 09843 18020 Diagnosis Check Wire 09950 40011 Puller B Set Crankshaft timing g...

Page 944: ...5020 Center Bolt 150 09954 05020 Claw No 2 09950 60010 Replacer Set 09951 00280 Replacer 28 Connecting rod bushing 09951 00350 Replacer 35 Crankshaft timing gear 09951 00480 Replacer 48 Spark plug tub...

Page 945: ...LAND CRUISER RM451U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09200 00010 Engine Adjust Kit 09258 00030 Hose Plug Set Plug for the vacuum hose fuel hose etc Brought to you by BirfMark Br...

Page 946: ...penetrant Engine tune up tester Heater Magnetic finger Micrometer OBD II scan tool Engine speed Piston ring compressor Piston ring expander Plastigage Precision straight edge Soft brush Spring tester...

Page 947: ...IPG Over space between cylinder block and timing chain case Timing cgain cover Semi circular plug Oil pan Rear oil seal retainer 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent Plug tube 08833...

Page 948: ...EPARATION EMISSION CONTROL 57 Author Date 1996 LAND CRUISER RM451U EMISSION CONTROL RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester Brought to you by BirfMark Brought to you by BirfMark Version...

Page 949: ...EMISSION CONTROL PP 9 1996 LAND CRUISER RM451U EQUIPMENT Heater TVV OBD II scan tool Engine speed Thermometer TVV Torque wrench Vacuum gauge Brought to you by BirfMark Brought to you by BirfMark Vers...

Page 950: ...PARATION EMISSION CONTROL 1996 LAND CRUISER RM451U SSM Special Service Materials 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent TVV Brought to you by BirfMark Brought to you by BirfMark Versi...

Page 951: ...ool Set 09268 41091 NO 7 Union 90405 09015 No 1 Union 09268 45012 EFI Fuel Pressure Gauge 09631 22020 Power Steering Hose Nut 14 x 17 mm Wrench Set Fuel line flare nut 09816 30010 Oil Pressure Switch...

Page 952: ...CRUISER RM451U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09200 00010 Engine Adjust Kit 09258 00030 Hose Plug Set Plug for vacuum hose fuel hose etc Brought to you by BirfMark Brought to...

Page 953: ...R RM451U EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector OBD II scan tool Engine speed Soft brush Throttle body Sound scope Injector Torque wrench Brought to you by BirfMark Bro...

Page 954: ...ION COOLING 63 Author Date 1996 LAND CRUISER RM451U COOLING EQUIPMENT Heater Thermostat Radiator cap tester Thermometer Thermostat Torque wrench Brought to you by BirfMark Brought to you by BirfMark V...

Page 955: ...T Item Capacity Classification Engine coolant w Front heater w Front heater and rear heaters 12 5 liters 13 2 US qts 11 1 lmp qts 13 4 liters 14 2 US qts 11 8 lmp qts Ethylene glycol base Brought to y...

Page 956: ...UBRICATION 65 Author Date 1996 LAND CRUISER RM451U LUBRICATION SST Special Service Tools 09032 00100 Oil Pan Seal Cutter 09228 44011 Oil Filter Wrench Brought to you by BirfMark Brought to you by Birf...

Page 957: ...PP30E 01 PREPARATION LUBRICATION PP 17 1996 LAND CRUISER RM451U RECOMMENDED TOOLS 09200 00010 Engine Adjust Kit Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 958: ...PP 18 PREPARATION LUBRICATION 1996 LAND CRUISER RM451U EQUIPMENT Oil pressure gauge Precision straight edge Oil pump Torque wrench Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12...

Page 959: ...o Oil filter change 8 0 liters 8 5 US qts 7 0 Imp qts 7 4 liters 7 8 US qts 6 5 Imp qts 6 9 liters 7 3 US qts 6 1 Imp qts API grade SH Energy Conserving II multigrade engine oil or ILSAC multigrade e...

Page 960: ...al Service Materials 08826 00080 Seal Packing Black or equivalent FIPG Oil pump Oil pan Timing chain cover 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Oil pressure switch Broug...

Page 961: ...ITION PP 21 70 Author Date 1996 LAND CRUISER RM451U IGNITION RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09200 00010 Engine Adjust Kit Brought to you by BirfMark Brought to you by BirfMark...

Page 962: ...PP30J 01 PP 22 PREPARATION IGNITION 1996 LAND CRUISER RM451U EQUIPMENT Spark plug cleaner Torque wrench Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 963: ...pecial Service Tools 09286 46011 Injection Pump Spline Shaft Puller Armature bearing 09810 38140 Starter Magnet Switch Nut Wrench 14 Terminal nut 09820 00030 Alternator Rear Bearing Replacer Armature...

Page 964: ...PP30L 01 PP 24 PREPARATION STARTING 1996 LAND CRUISER RM451U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 965: ...l indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V block Commutator Vernier calipers Commutator Brush Bro...

Page 966: ...n Pump Spline Shaft Puller Rectifier end frame 09820 00021 Alternator Rear Bearing Puller 09820 00030 Alternator Rear Bearing Replacer 09820 63010 Alternator Pulley Set Nut Wrench Set 09950 60010 Repl...

Page 967: ...PP30O 01 PREPARATION CHARGING PP 27 1996 LAND CRUISER RM451U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 968: ...P 28 PREPARATION CHARGING 1996 LAND CRUISER RM451U EQUIPMENT Belt tension gauge Torque wrench Vernier calipers Rotor Slip ring Brush Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 969: ...eplacer Set Speedometer driven gear oil seal 09201 01080 Valve Guide Bushing Remover Replacer 8 09350 30020 TOYOTA Automatic Transmission Tool Set 09351 32010 One way Clutch Test Tool 09351 32020 Stat...

Page 970: ...PREPARATION AUTOMATIC TRANSMISSION 1996 LAND CRUISER RM451U RECOMMENDED TOOLS 09031 00030 Pin Punch 09082 00040 TOYOTA Electrical Tester Brought to you by BirfMark Brought to you by BirfMark Version 1...

Page 971: ...R RM451U EQUIPMENT Dial indicator with magnetic base Check drive plate runout OBD II scan tool Straight edge Torque converter clutch Torque wrench Vernier Calipers Torque converter clutch Brought to y...

Page 972: ...ER RM451U LUBRICANT Item Capacity Classification Automatic transmission fluid Dry fill Drain and refill 11 0 liters 11 6 US qts 9 7 lmp qts 1 9 liters 2 0 US qts 1 7 lmp qts ATF DEXRON II Brought to y...

Page 973: ...51U SSM Special Service Materials 08826 00090 Seal Packing 1281 THREE BOND 1281 or equivalent FIPG Oil pan 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Extension housing Brought...

Page 974: ...11 Replacer Pipe Front extension housing Rear extension housing Idler gear Component parts removal and instal lation Center differential 09316 00021 Replacer A Rear extension housing 09316 00031 Repla...

Page 975: ...dler gear Center differential Front extension housing 09950 00030 Bearing Remover Attachment Center differential 09950 40011 Puller B Set Component parts removal and instal lation Front extension hous...

Page 976: ...DED TOOLS 09031 00030 Pin Punch 09040 00010 Hexagon Wrench Set 09042 00010 Torx Socket T30 09042 00020 Torx Socket T40 09082 00040 TOYOTA Electrical Tester 09905 00012 Snap Ring No 1 Expander Brought...

Page 977: ...N TRANSFER PP 37 1996 LAND CRUISER RM451U EQUIPMENT Dial indicator Feeler gauge Magnetic finger Straight edge Torque wrench Vernier calipers Brought to you by BirfMark Brought to you by BirfMark Versi...

Page 978: ...TRANSFER 1996 LAND CRUISER RM451U LUBRICANT Item Capacity Classification Transfer oil 1 7 liters 1 8 US qts 1 5 lmp qts API GL 4 or GL 5 SAE 75W 90 Brought to you by BirfMark Brought to you by BirfMa...

Page 979: ...lent FIPG Front case x Rear case Rear case x Case cover Case x Extension housing 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent Dynamic damper set bolt 08833 00080 Adhesive 1344 THREE BOND 13...

Page 980: ...R SHAFT 89 Author Date 1996 LAND CRUISER RM451U PROPELLER SHAFT SST Special Service Tools 09332 25010 Universal Joint Bearing Remover Replacer Spider bearing Brought to you by BirfMark Brought to you...

Page 981: ...PP2Y7 01 PREPARATION PROPELLER SHAFT PP 41 1996 LAND CRUISER RM451U EQUIPMENT Dial indicator Torque wrench Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 982: ...ler Front axle Front differential Rear axle Rear differential 09308 10010 Oil Seal Puller Front differential Rear differential 09315 00022 Clutch Release Bearing Remover Replacer Rear differential 093...

Page 983: ...Axle Shaft Oil Seal Replacer Rear axle 09550 10013 Replacer Set B Rear differential Rear suspension 09553 10010 Differential Side Bearing Replacer 09557 10011 Differential Drive Pinion Front Bearing R...

Page 984: ...Front axle 09710 22021 Front Suspension Bushing Tool Set Rear suspension 09710 01071 Lower Arm Bushing Remover 09710 22042 Rear Suspension Bushing Tool Set Front suspension 09710 02051 Base 09710 020...

Page 985: ...ler A Set Front differential Rear differential 09951 03010 Upper Plate 09953 03010 Center Bolt 09954 03010 Arm 09955 03030 Lower Plate 130 09956 03020 Adapter 18 09950 40011 Puller B Set Front differe...

Page 986: ...placer Set Front differential Rear differential Rear suspension 09951 00480 Replacer 48 09951 00490 Replacer 49 09951 00540 Replacer 54 09950 60020 Replacer Set No 2 Front axle Rear axle Rear differen...

Page 987: ...ND CRUISER RM451U 09951 00910 Replacer 91 09950 70010 Handle Set Front axle Front suspension Rear axle Rear differential Rear suspension 09951 07100 Handle 100 09951 07150 Handle 150 Brought to you by...

Page 988: ...al 09040 00011 Hexagon Wrench Set Front differential 09043 20060 Socket Hexagon Wrench 6 09044 00020 Torx Socket E10 Rear differential 09082 00050 TOYOTA Electrical Tester Set Differential locking sys...

Page 989: ...AXLE PP 49 1996 LAND CRUISER RM451U EQUIPMENT Dial indicator or dial indicator with magnetic base Feeler gauge Micrometer Spring tension gauge Torque wrench Brought to you by BirfMark Brought to you...

Page 990: ...al oil Front w o Dfferential lock w Dfferential lock Rear 2 80 liters 2 9 US qts 2 5 lmp qts 2 65 liters 2 8 US qts 2 3 lmp qts 3 25 liters 3 4 US qts 2 9 lmp qts Hypoid gear oil API GL 5 Above 18 C 0...

Page 991: ...cking 1281 THREE BOND 1281 or equivalent FIPG Front differential Rear differential Differential locking system 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Front differential Re...

Page 992: ...ng Remover 09718 20010 Brake Shoe Return Spring Replacer 09737 00010 Brake Booster Push Rod Gauge 09751 36011 Brake Line Union Nut 10 x 12 mm Wrench 09843 18020 Diagnosis Check Wire 09990 00150 ABS Ac...

Page 993: ...REPARATION BRAKE PP 53 1996 LAND CRUISER RM451U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09905 00013 Snap Ring Pliers Brought to you by BirfMark Brought to you by BirfMark Version 1 00 1...

Page 994: ...PARATION BRAKE 1996 LAND CRUISER RM451U EQUIPMENT Dial indicator Brake disc Micrometer Brake disc Torque wrench Vernier calipers Brake disc Brought to you by BirfMark Brought to you by BirfMark Versio...

Page 995: ...PREPARATION BRAKE PP 55 1996 LAND CRUISER RM451U LUBRICANT Item Capacity Classification Brake fluid SAE J1703 or FMVSS No 116 DOT 3 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 1...

Page 996: ...g Worm Bearing Adjusting Socket PS gear 09628 62011 Ball Joint Puller Steering linkage 09630 00014 Power Steering Gear Housing Overhaul Tool Set 09631 00051 No 3 Wrench PS gear 09631 00121 Teflon Ring...

Page 997: ...011 Puller Clamp Tilt steering column 09912 00010 Puller Slide Hammer Tilt steering column 09950 40011 Puller B Set 09957 04010 Attachment Tilt steering column 09958 04011 Holder Tilt steering column...

Page 998: ...Claw No 2 Tilt steering column 09950 60010 Replacer Set 09951 00360 Replacer 36 PS gear 09951 00410 Replacer 41 PS gear 09952 06010 Adapter PS gear 09950 70010 Handle Set 09951 07200 Handle 200 PS gea...

Page 999: ...010 Torque Wrench 30 kgf cm PS vane pump PS gear 09042 00010 Torx Socket T30 Tilt steering column 09904 00010 Expander Set 09904 00050 No 4 Claw 09905 00012 Snap Ring No 1 Expander 09905 00013 Snap Ri...

Page 1000: ...AND CRUISER RM451U EQUIPMENT Caliper gauge PS vane pump Calipers PS vane pump Dial indicator PS gear Feeler gauge PS vane pump Micrometer PS vane pump Torque wrench Brought to you by BirfMark Brought...

Page 1001: ...PP 61 1996 LAND CRUISER RM451U LUBRICANT Item Capacity Classification Power steering fluid Total 0 8 liters 0 9 US qts 0 7 lmp qts ATF DEXRON II or III Brought to you by BirfMark Brought to you by Bir...

Page 1002: ...STEM 111 Author Date 1996 LAND CRUISER RM451U SUPPLEMENTAL RESTRAINT SYSTEM SST Special Service Tools 09082 00700 SRS Airbag Deployment Tool 09843 18020 Diagnosis Check Wire Brought to you by BirfMark...

Page 1003: ...RESTRAINT SYSTEM PP 63 1996 LAND CRUISER RM451U RECOMMENDED TOOLS 09042 00020 Torx Socket T40 Airbag sensor assembly 09082 00040 TOYOTA Electrical Tester Brought to you by BirfMark Brought to you by...

Page 1004: ...Airbag disposal Rope no projections difficult to break Airbag disposal Tire Width 185 mm 7 28 in Inner diam 360 mm 14 17 in Airbag disposal Tire with disc wheel Width 185 mm 7 28 in Inner diam 360 mm...

Page 1005: ...TION BODY ELECTRICAL PP 65 114 Author Date 1996 LAND CRUISER RM451U BODY ELECTRICAL RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester Brought to you by BirfMark Brought to you by BirfMark Version...

Page 1006: ...p remover For removing cowl louver Dry cell battery Fuel sender gauge Masking tape Rear window defogger wire Oil bath Engine oil level warning switch Test lead Thermometer Engine coolant temperature s...

Page 1007: ...wer seat housing set nut Power seat slide and vertical motor set screw 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Low oil pressure warning switch Engine coolant temperature se...

Page 1008: ...Y 117 Author Date 1996 LAND CRUISER RM451U BODY SST Special Service Tools 09806 30010 Windshield Moulding Remover 09812 00010 Door Hinge Set Bolt Wrench Brought to you by BirfMark Brought to you by Bi...

Page 1009: ...PP2YW 01 PREPARATION BODY PP 69 1996 LAND CRUISER RM451U LUBRICANT Item Capacity Classification MP grease Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1010: ...pecial Service Materials 08833 00030 Three cement black or equivalent Back door glass 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent Front door Rear door Power seat regulator Brought to you b...

Page 1011: ...er Discharge Diam 16 mm 07117 58090 Quick Disconnect Adapter Suction Diam 13 mm 07117 78050 Refrigerant Charging Gauge 07117 88060 Refrigerant Charging Hose Discharge Color Red 07117 88070 Refrigerant...

Page 1012: ...RATION AIR CONDITIONING 121 Author Date 1996 LAND CRUISER RM451U 07114 84020 Snap Ring Pliers 07116 38360 Gas Leak Detector Assembly Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 1013: ...P2YZ 01 PREPARATION AIR CONDITIONING PP 73 1996 LAND CRUISER RM451U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1014: ...assification Compressor oil When replacing receiver When replacing condenser When replacing evaporator When replacing compressor 10 cc 0 35 fl oz 40 cc 1 4 fl oz 40 cc 1 4 fl oz 120 cc 4 1 fl oz ND OI...

Page 1015: ...rs indicate the priority of the likely cause of the problem Check each part in order If necessary replace these parts Symptom Suspect Area See page Noise 3 Seeve yoke spline worn 4 Spider bearing worn...

Page 1016: ...ring z Snap Ring Grease Fitting Sleeve Yoke Specified torque Flange Yoke Flange Yoke Front Propeller Shaft 74 750 54 88 900 65 74 750 54 74 750 54 74 750 54 74 750 54 88 900 65 88 900 65 88 900 65 Rea...

Page 1017: ...n the propeller shaft flange and dif ferential d Remove the 4 nuts bolts and washers Torque 74 N m 750 kgf cm 54 ft lbf e Remove the front propeller shaft 2 REMOVE REAR PROPELLER SHAFT a Place matchma...

Page 1018: ...the sleeve yoke from the shaft 2 Remove the dust cover from the shaft 3 INSPECT SPIDER BEARING S Check the spider bearings for wear or damage S Check the spider bearing axial play by turning the yoke...

Page 1019: ...INSTALLATION Installation is in the reverse order of removal See page PR 3 HINT After installation pump MP grease into each fitting with a grease gun until the grease begins to flow around the oil sea...

Page 1020: ...m the grooves 4 REMOVE SPIDER BEARINGS a Using SST push out the bearing from the flange SST 09332 25010 HINT Sufficiently raise the part indicated by A so that it does not come into contact with the b...

Page 1021: ...rk HINT At time of the reassemble there are 2 types of rear propeller shafts type A and type B Referring to the illustration measure the distance between the welding points X and Y to identify which o...

Page 1022: ...2 450 0 0945 0 0965 8 2 450 2 500 0 0965 0 0984 Rear Propeller Shaft Type A Color Thickness mm in 2 00 0 0787 Brown 2 03 0 0799 Blue 2 06 0 0811 2 09 0 0823 b Using a hammer tap the yoke until there i...

Page 1023: ...No 2 No 1 SPIDER GREASE FITTING ASSEMBLY DIRECTION Rear Propeller Shaft Sleeve Yoke Sleeve Yoke No 1 No 2 No 1 Sleeve Yoke The Figure at left shows the locations of the grease fittings as seen from th...

Page 1024: ...g sensor assembly have been dropped or if there are cracks dents or other defects in the case bracket or connector replace them with new ones S Use a volt ohmmeter with high impedance 10 k V minimum f...

Page 1025: ...er contains a squib igniter charge gas generant etc and inflates the bag when instructed by the airbag sensor assembly 4 SRS WARNING LIGHT The SRS warning light is located on the combination meter It...

Page 1026: ...bag Activation Prevention Mechanism Connectors 2 3 4 3 Electrical Connection Check Mechanism Connectors 1 4 Connector Twin Lock Mechanism Connectors 2 3 4 a All connectors in the SRS are colored yello...

Page 1027: ...ece construction con sisting of a housing and a spacer This design se cures the locking of the terminal by two locking de vices the retainer and the lance to prevent terminals from coming out 2 Airbag...

Page 1028: ...nection Check Mechanism This mechanism electrically checks if connectors are connected correctly and completely The electri cal connection check mechanism is designed so that the disconnection detecti...

Page 1029: ...k is larger than the pre determined level the SRS is activated automatically A safing sensor is designed to go on at a smaller decelera tion rate than the airbag sensor As illustrated in Fig 2 ignitio...

Page 1030: ...ESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE RS 7 1106 Author Date 1996 LAND CRUISER RM451U STEERING WHEEL PAD AND SPIRAL CABLE COMPONENTS Brought to you by BirfMark Brought to you by BirfMark...

Page 1031: ...NTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE 1996 LAND CRUISER RM451U REMOVAL REMOVE STEERING WHEEL AND SPIRAL CABLE See page SR 11 Brought to you by BirfMark Brought to you by BirfMark V...

Page 1032: ...llowing items S Check for cuts and cracks in or marked discolor ation of the steering wheel pad top surface and its grooved portion S Check for cuts and cracks in wire harnesses and for chipping in co...

Page 1033: ...e vehicle S Check for deformation of the horn button contact plate of the steering wheel S Check for damage to the spiral cable connector and wire harness HINT There should be no interference between...

Page 1034: ...oduces a sizeable exploding sound when it deploys so perform the operation out of doors and where it will not create a nuisance to nearby residents S When deploying the airbag always use the specified...

Page 1035: ...ative terminal HINT Do not connect the yellow connector which will be connected with the supplemental restraint system 2 Check functioning of the SST Press the SST activation switch and check that th...

Page 1036: ...tch and deploy the air bag HINT The airbag deploys simultaneously as the LED of the SST ac tivation switch lights up d Dispose of steering wheel pad with airbag CAUTION S The steering wheel pad is ver...

Page 1037: ...heel pad keep the upper sur face of the pad facing upward b Remove the connector on the rear surface of the steering wheel pad from the bracket c Using a service purpose wire harness tie down the stee...

Page 1038: ...erous 3 Face the upper surface of the steering wheel pad upward Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub nut holes Position the steering whee...

Page 1039: ...ground 1 Connect the connector of 2 SST to the steering wheel pad connector SST 09082 00700 09082 00760 NOTICE To avoid damaging the SST connector and wire harness do not lock the secondary lock of th...

Page 1040: ...cardboard box will be broken by the shock from the air bag deployment S Covering method using tires Place at least 3 tires without disc wheel on top of the disc wheel with tire to which the steering w...

Page 1041: ...Use gloves and safety glasses when handling a steer ing wheel pad with deployed airbag S Always wash your hands with water after completing the operation S Do not apply water etc to a steering wheel p...

Page 1042: ...to be faulty in troubleshooting Spiral cable If the steering wheel pad has been found to be faulty during checking items See page RS 9 Steering wheel pad If the steering wheel has been found to be fa...

Page 1043: ...AL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE 1996 LAND CRUISER RM451U INSTALLATION INSTALL STEERING WHEEL AND SPIRAL CABLE See page RS 7 Brought to you by BirfMark Brought to you by BirfMar...

Page 1044: ...L RESTRAINT SYSTEM FRONT PASSENGER AIRBAG ASSEMBLY RS 21 1120 Author Date 1996 LAND CRUISER RM451U FRONT PASSENGER AIRBAG ASSEMBLY COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Vers...

Page 1045: ...ing the airbag connector take care not to dam age the airbag wire harness c Disconnect the airbag connector 2 REMOVE INSTRUMENT PANEL See pages BO 76 3 REMOVE FRONT PASSENGER AIRBAG ASSEMBLY a Remove...

Page 1046: ...Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle S Check cuts minute cracks or marked discoloration on the front passenger airbag...

Page 1047: ...owing items with the front passenger airbag assembly removed from the vehicle S Check the deformation or cracks on the instrument panel and instrument panel reinforcement S Check the damage on the con...

Page 1048: ...eable exploding sound when it deploys so perform the operation out of doors and where it will not create a nuisance to nearby residents S When deploying the airbag always use the specified SST SRS Air...

Page 1049: ...nnector to the front passenger airbag assembly connector SST 09082 00700 NOTICE To avoid damaging the SST connector and wire harness do not lock the secondary lock of the twin lock 2 Move the SST to a...

Page 1050: ...MENT WHEN DISPOSING OF FRONT PAS SENGER AIRBAG ASSEMBLY ONLY NOTICE S When disposing of the front passenger airbag assem bly only never use the customer s vehicle to deploy the airbag S Be sure to fol...

Page 1051: ...owing dimensions Width 185 mm 7 28 in Inner diameter 360 mm 14 17 in CAUTION S Make sure that the wire harness is tight It is very dan gerous if looseness in the wire harness results in the front pass...

Page 1052: ...p to the battery negative terminal 2 Confirm that no one is within 10 m 33 ft area around the tire which the front passenger airbag as sembly is tied to 3 Press the SST activation switch and deploy th...

Page 1053: ...e front passenger airbag assembly has been found to be faulty during checking items See page RS 23 Front passenger airbag assembly If the instrument panel has been found to be faulty during checking i...

Page 1054: ...E If the front passenger airbag assembly has been dropped or there are cracks dents or other defects in the case or connector replace the front passenger airbag assembly with a new one 2 INSTALL INSTR...

Page 1055: ...32 SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG SENSOR ASSEMBLY 1131 Author Date 1996 LAND CRUISER RM451U AIRBAG SENSOR ASSEMBLY COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 1056: ...may be destroyed by static electricity 1 REMOVE THESE PARTS a Transfer shirt knob b Front console box 2 REMOVE AIRBAG SENSOR ASSEMBLY a Disconnect the connector NOTICE Remove the connector with the s...

Page 1057: ...ION Do a diagnostic system check See page DI 240 2 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check See page DI 240 3 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS D...

Page 1058: ...y S If the SRS has been deployed in a collision S If the airbag sensor assembly has been found to be faulty in troubleshooting S If the airbag sensor assembly has been dropped CAUTION For removal and...

Page 1059: ...tool Torque 21 N m 210 kgf cm 15 ft lbf b Connect the connector NOTICE S Installation of the connector is done with the sensor assembly installed S Make sure the sensor assembly is installed to the sp...

Page 1060: ...ng Wheel Pad Airbag Sensor Assembly SUPPLEMENTAL RESTRAINT SYSTEM WIRE HARNESS AND CONNECTOR RS 37 1136 Author Date 1996 LAND CRUISER RM451U WIRE HARNESS AND CONNECTOR LOCATION Brought to you by BirfM...

Page 1061: ...orrugated tube and all the connectors in the system are a standard yellow color 1 VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check See page DI 240 2 VEHICLES INVOLVED IN COLLISION a Do...

Page 1062: ...rt of the SRS wire harness or any connector has been found to be faulty in troubleshoot ing S If any part of the SRS wire harness or any connector has been found to be faulty during the check in items...

Page 1063: ...orn or improperly inflated 2 Wheels out of balance 3 Shock absorber worn out 4 Wheel alignmemt incorrect 5 Hub bearings loosen or worn 6 Steering linkage loosen or worn 7 Steering gear out of adjustme...

Page 1064: ...witch RR or FR RR position 1 DIFF fuse blown 2 Diff lock control switch faulty 3 Diff lock ECU faulty 4 Wiring or ground faulty BE 9 SA 101 SA 101 Differential lock does not operate 1 Diff lock positi...

Page 1065: ...tire 3 INSPECT WHEEL BALANCE a Check and adjust the Off the car balance b If necessary check and adjust the On the car balance Unbalance after adjustment 13 0 g 0 029 lb or less 4 CHECK WHEEL BEARING...

Page 1066: ...AXIS INCLINATION Camber Left righterror 1 00 45 45 or less Caster Left right error 3 00 1 45 or less Steering axis inclination 13 00 45 Camber caster and steering axis inclination are not adjustable...

Page 1067: ...es b Turn the steering wheel fully and measure the turning angle Inside wheel 32 00 35 00 Outside wheel 31 00 Reference HINT When the steering wheel is fully turned make sure that the wheel is not tou...

Page 1068: ...SA1UA 01 SA 6 SUSPENSION AND AXLE FRONT AXLE HUB 863 Author Date 1996 LAND CRUISER RM451U FRONT AXLE HUB COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1069: ...s and remove the 6 cone washers plate washers and nuts e Remove the flange f Remove the gasket 4 REMOVE AXLE HUB WITH DISC a Using a screwdriver release the lock washer b Using SST remove the lock nut...

Page 1070: ...s and remove the 6 cone washers plate washers and nuts e Remove the flange f Remove the gasket 4 REMOVE AXLE HUB WITH DISC a Using a screwdriver release the lock washer b Using SST remove the lock nut...

Page 1071: ...rque 59 N m 600 kgf cm 43 ft lbf b Turn the hub right and left 2 or 3 times c Using SST torque the adjusting nut SST 09607 60020 Torque 59 N m 600 kgf cm 43 ft lbf d Loosen the nut until it can be tur...

Page 1072: ...6 cone washers plate washers and nuts e Torque the 6 nuts Torque 35 N m 360 kgf cm 26 ft lbf f Install the bolt in the axle shaft and pull it out g Using a snap ring expander install a new snap ring h...

Page 1073: ...b Remove the 6 bolts and disc from the axle hub c Install the nut to the hub bolt d Using an extension bar and a press remove the hub bolt e Using an extension bar and press install a new hub bolt f...

Page 1074: ...SUSPENSION AND AXLE STEERING KNUCKLE AND AXLE SHAFT 869 Author Date 1996 LAND CRUISER RM451U STEERING KNUCKLE AND AXLE SHAFT COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1...

Page 1075: ...AXLE SHAFT Position one flat part of the outer shaft upward and remove the axle shaft 6 DISCONNECT TIE ROD FROM KNUCKLE ARM a Remove the cotter pin and nut b Using SST disconnect the tie rod from the...

Page 1076: ...g SST remove the knuckle arm and shim from the steering knuckle SST 09606 60020 HINT S Use the SST without a collar S In some cases to satisfy the standard value of preload more than one shims are use...

Page 1077: ...ACE BEARING OUTER RACE a Using a brass bar and hammer remove the bearing outer race b Using SST and a hammer carefully install a new bearing outer race SST 09605 60010 5 INSPECT BIRFIELD JOINT INNER P...

Page 1078: ...penings in the cage against the pro truding parts of the outer shaft k Make sure to position the wide side of the cage and the inner race protruding end outward l Fit in the inner race and cage and in...

Page 1079: ...m the outer side c Do the same around the bearing circumference 4 INSTALL STEERING KNUCKLE AND BEARINGS a Place the bearings in positions on the knuckle and axle housing b Install the knuckle on the a...

Page 1080: ...8 CONNECT TIE ROD TO KNUCKLE ARM Torque the nut and secure it with a new cotter pin Torque 91 N m 925 kgf cm 67 ft lbf 9 INSTALL OIL SEAL END RETAINER TO KNUCKLE ARM Install the oil seal end retainer...

Page 1081: ...lbf 13 CONNECT ABS SPEED SENSOR Connect the speed sensor and 2 bolts to the steering knuckle Torque 18 N m 185 kgf cm 13 ft lbf 14 INSTALL AXLE HUB See page SA 9 15 CHECK FRONT WHEEL ALIGNMENT See pa...

Page 1082: ...SUSPENSION AND AXLE FRONT DIFFERENTIAL REAR OIL SEAL 877 Author Date 1996 LAND CRUISER RM451U FRONT DIFFERENTIAL REAR OIL SEAL COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version...

Page 1083: ...part of the nut b Using SST to hold the flange remove the nut and plate washer SST 09330 00021 c Using SST remove the companion flange SST 09950 30010 09951 03010 09953 03010 09954 03010 09955 03030...

Page 1084: ...T install a new oil storage ring SST 09316 60011 09316 00011 09316 00021 11 INSTALL REAR BEARING a Using SST install the bearing outer race SST 09316 60011 09316 00011 09316 00021 b Install the rear b...

Page 1085: ...bf 14 ADJUST DRIVE PINION PRELOAD See page SA 36 15 STAKE DRIVE PINION NUT 16 INSTALL FRONT PROPELLER SHAFT See page PR 5 17 FILL DIFFERENTIAL WITH GEAR OIL Torque 49 N m 500 kgf cm 39 ft lbf Oil type...

Page 1086: ...SA 24 SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER 881 Author Date 1996 LAND CRUISER RM451U FRONT DIFFERENTIAL CARRIER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 1...

Page 1087: ...il Slinger Differential Case Drive Pinion Ring Gear Side Baring Straight Pin Adjusting Nut z Bearing Spacer z z Oil Storage Ring Outer Race Outer Race z Non reusable part z Lock Plate x 10 x 5 Pinion...

Page 1088: ...O Ring Pinion Washer Rear Bearing z z Dust Deflector Front Bearing Outer Race Adjusting Nut Sleeve Spider Side Gear LH Differential Case RH Differential Case x 8 L Precoated part z Gasket Indicator Sw...

Page 1089: ...e in the differential lock condition e Disconnect the cable from the negative terminal of the battery 2 DRAIN DIFFERENTIAL OIL 3 REMOVE FRONT AXLE SHAFTS See page SA 13 4 REMOVE TIE ROD FROM KNUCKLE A...

Page 1090: ...D CRUISER RM451U 7 REMOVE DIFFERENTIAL CARRIER ASSEMBLY a Remove the 10 nuts washers and differential carrier as sembly NOTICE Be careful not to damage the installation surface Torque 27 N m 280 kgf c...

Page 1091: ...et 3 CHECK RING GEAR BACKLASH Using a dial indicator measure the ring gear backlash Backlash 0 13 0 18 mm 0 0051 0 0071 in If the backlash is not within the specification adjust the side bearing prelo...

Page 1092: ...LOCK REMOVE ACTUATOR a Remove the bolt and actuator from the differential carrier b Remove the O ring 9 w DIFFERENTIAL LOCK REMOVE INDICATOR SWITCH Remove the indicator switch and gasket 10 w DIFFERE...

Page 1093: ...SEAL AND OIL SLINGER a Using SST remove the oil seal from the differential carrier SST 09308 10010 b Remove the oil slinger 13 REMOVE REAR BEARING Using SST remove the rear bearing from the drive pini...

Page 1094: ...the drive pinion with the front bearing b Remove the bearing spacer 16 REMOVE DRIVE PINION FRONT BEARING a Using SST and a press remove the bearing from the drive pinion SST 09950 00020 HINT If the d...

Page 1095: ...DE BEARING FROM DIFFERENTIAL CASE Using SST pull the side bearing from the differential case SST 09950 40010 09951 04010 09952 04020 09953 04020 09954 04010 09955 04010 09957 04010 09958 04010 09950 6...

Page 1096: ...34 SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER 1996 LAND CRUISER RM451U S 4 Pinion gears S 4 Pinion gear thrust washers Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 201...

Page 1097: ...REPLACEMENT 1 REMOVE DUST DEFLECTOR TO COMPANION FLANGE Using SST and a press remove the dust deflector SST 09950 00020 2 INSTALL DUST DEFLECTOR TO COMPANION FLANGE Using SST and a press install a new...

Page 1098: ...pinion gears pinion gear thrust washers and pinion shaft HINT Align the hole for the pinion shaft with the case hole d Using a dial indicator measure the side gear backlash with holding one pinion gea...

Page 1099: ...f Using a dial indicator holding the side gear and spider and measure the side gear backlash Backlash 0 05 0 20 mm 0 0020 0 0079 in HINT S Measure at all 4 locations S Measure the backlash at the RH c...

Page 1100: ...the ring gear from the water d After the moisture on the ring gear has completely evapo rated quickly install the ring gear to the differential case e Align the matchmarks on the ring gear and differ...

Page 1101: ...Front side Using SST and a press install the 2 outer races SST 09316 60011 09316 00011 09316 00051 S Rear side Using SST and a press install the 2 outer races SST 09316 60011 09316 00011 09316 00021 1...

Page 1102: ...TIAL LOCK INSTALL DIFFERENTIAL CASE IN CARRIER a Place the bearing outer races on their respective bear ings Make sure the left and right outer races are not inter changed b Install the case in the ca...

Page 1103: ...d torque and loosen them to the point where the adjusting nuts can be turned by SST SST 09504 00011 Torque 78 N m 800 kgf cm 58 ft lbf b Fully tighten the 4 bearing cap bolts by hand c Using the SST t...

Page 1104: ...right adjusting nuts equal amounts For example loosen the nut on the left side one notch and torque the nut on the right side one notch i Torque the 4 bearing cap bolts Torque 78 N m 800 kgf cm 58 ft...

Page 1105: ...7 18 REMOVE COMPANION FLANGE See page SA 29 19 REMOVE OIL SLINGER AND REAR BEARING 20 REMOVE REAR BEARING OUTER RACE AND OIL STORAGE RING See page SA 29 21 INSTALL BEARING SPACER AND REAR BEARING a In...

Page 1106: ...eplace the bear ing spacer If the preload is less than the specification retighten the nut a little at a time with a torque of 13 N m 130 kgf cm 9 ft lbf until the specified preload is reached Maximum...

Page 1107: ...ft retainer d Apply FIPG to the carrier as shown FIPG Part No 08826 00090 THREE BOND 1281 or equivalent HINT Install the shaft retainer within 10 minutes after applying FIPG e Clean the threads of the...

Page 1108: ...gf cm 16 ft lbf 31 w DIFFERENTIAL LOCK MEASURE DISTANCE BETWEEN SLEEVE AND DIF FERENTIAL CASE END SIDE Measure distance between the sleeve and tip of the differential case when differential is free an...

Page 1109: ...ectrify moreover c Install a new O ring to the actuator d Apply a light coat of gear oil on the O ring e Apply MP grease to the gear part f Insert the actuator so that the long hole on the actuator si...

Page 1110: ...tor of the vehicle side S w differential lock Before installation check that the sleeves on work with switching over the differential lock control switch After checking lock the front differential S A...

Page 1111: ...AND AXLE COIL SPRING AND FRONT SHOCK ABSORBER SA 49 906 Author Date 1996 LAND CRUISER RM451U COIL SPRING AND FRONT SHOCK ABSORBER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Vers...

Page 1112: ...bsorber and remove the lower mounting nut shock absorber cushions and retainers Torque 69 N m 700 kgf cm 51 ft lbf 3 DISCONNECT STABILIZER BAR FROM AXLE HOUS ING See page SA 60 4 REMOVE COIL SPRING a...

Page 1113: ...ER Compress and extend the shock absorber rod and check that there is abnormal resistance or unusual operation sounds If there is any abnormality replace the shock absorber with a new one NOTICE When...

Page 1114: ...SHOCK ABSORBER Before discarding the shock absorber drill a hole 2 3 mm 0 079 0 118 in in diameter at the location shown in the il lustration to release the gas inside NOTICE When drilling chips may...

Page 1115: ...XLE COIL SPRING AND FRONT SHOCK ABSORBER SA 53 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SA 50 Brought to you by BirfMark Brought to you by BirfMar...

Page 1116: ...SCONNECT LATERAL CONTROL ROD FROM AXLE HOUSING Remove the bolt and disconnect the lateral control rod from the axle housing Torque 171 N m 1 750 kgf cm 127 ft lbf HINT After stabilizing the suspension...

Page 1117: ...e the bushing from the lateral control rod SST 09710 22042 09710 02051 09710 02071 09950 70010 09951 07150 2 INSTALL BUSHING Using SST install a new bushing into the lateral control rod SST 09710 2204...

Page 1118: ...NSION AND AXLE FRONT LATERAL CONTROL ROD 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SA 54 Brought to you by BirfMark Brought to you by BirfMark Vers...

Page 1119: ...VE LEADING ARM a Remove the bolt plate washer and nut from the leading arm to the frame side Torque 177 N m 1 800 kgf cm 130 ft lbf HINT After stabilizing the suspension torque the bolt b Remove the 2...

Page 1120: ...CEMENT REPLACE BUSHINGS Using SST and a press replace the bushing from the leading arm SST Front side 09710 30050 SST Rear side 09710 22042 09710 02061 HINT When assembling a new bushing as shown in t...

Page 1121: ...ION AND AXLE FRONT LEADING ARM SA 59 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SA 57 Brought to you by BirfMark Brought to you by BirfMark Version...

Page 1122: ...k from the bracket Torque 103 N m 1 050 kgf cm 76 ft lbf HINT After stabilizing the suspension torque the nut b Remove the bolt and nut and remove the stabilizer bar from the axle housing Torque 25 N...

Page 1123: ...ON AND AXLE FRONT STABILIZER BAR SA 61 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SA 60 Brought to you by BirfMark Brought to you by BirfMark Versio...

Page 1124: ...SA1V4 01 SA 62 SUSPENSION AND AXLE REAR AXLE SHAFT 919 Author Date 1996 LAND CRUISER RM451U REAR AXLE SHAFT COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1125: ...f b Using a brass bar and hammer strike the center part of the axle shaft to remove the 6 cone washers c Install and gradually tighten 2 bolts evenly and pull the axle shaft d Remove the 2 bolts from...

Page 1126: ...he runout of axle shaft Maximum runout 0 8 mm 0 031 in If the runout is greater than the maximum replace the axle shaft 2 REPLACE OIL SEAL a Using SST remove the oil seal SST 09308 00010 b Using SST a...

Page 1127: ...SION AND AXLE REAR AXLE SHAFT SA 65 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SA 63 Brought to you by BirfMark Brought to you by BirfMark Version 1...

Page 1128: ...SA1V8 01 SA 66 SUSPENSION AND AXLE REAR AXLE HUB 923 Author Date 1996 LAND CRUISER RM451U REAR AXLE HUB COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1129: ...SCONNECT ABS SPEED SENSOR Remove the bolt and disconnect the ABS speed sensor 5 REMOVE REAR AXLE BEARING LOCK NUT a Remove the 2 screws from the lock nut b Using SST remove the lock nut SST 09509 2501...

Page 1130: ...er races SST 09950 60020 09951 00710 09950 70010 09951 07150 S Inside race Using SST and a press install new bearing outer races SST 09950 60020 09951 00810 09950 70010 09951 07150 4 PACK BEARINGS WIT...

Page 1131: ...e rear axle hub and temporarily install the 2 hub nuts 4 ADJUST PRELOAD a Using SST torque the bearing lock nut SST 09509 25011 Torque 59 N m 600 kgf cm 43 ft lbf b Make the bearing smooth by turning...

Page 1132: ...no axial play 5 INSTALL BEARING LOCK NUT SCREW Tighten the 2 lock nut screws Torque 5 4 N m 55 kgf cm 48 in lbf 6 CONNECT ABS SPEED SENSOR Connect the ABS speed sensor install the bolt Torque 18 N m...

Page 1133: ...REMOVE HUB BOLT Using SST and a press remove hub bolt from the axle hub SST 09950 70010 09951 07150 NOTICE Be careful not to damage the ABS speed sensor rotor 3 INSTALL HUB BOLT Using SST and a press...

Page 1134: ...SUSPENSION AND AXLE REAR DIFFERENTIAL FRONT OIL SEAL 929 Author Date 1996 LAND CRUISER RM451U REAR DIFFERENTIAL FRONT OIL SEAL COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version...

Page 1135: ...art of the nut b Using SST to hold the flange remove the nut and plate washer SST 09330 00021 c Using SST remove the companion flange SST 09950 30010 09951 03010 09953 03010 09954 03010 09955 03030 09...

Page 1136: ...nger b Using SST install a new oil seal as shown SST 09214 76011 Oil seal drive in depth 1 0 mm 0 039 in c Apply MP grease to the oil seal lip 12 INSTALL COMPANION FLANGE a Using SST install the compa...

Page 1137: ...51U 16 FILL DIFFERENTIAL WITH GEAR OIL Torque 49 N m 500 kgf cm 39 ft lbf Oil type Hypoid gear oil API GL 5 Recommended oil viscosity Above 18 C 0 F SAE 90 Below 18 C 0 F SAE 80W 90 or 80W Capacity 3...

Page 1138: ...SA 76 SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER 933 Author Date 1996 LAND CRUISER RM451U REAR DIFFERENTIAL CARRIER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12...

Page 1139: ...SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER SA 77 934 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1140: ...SA 78 SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER 935 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1141: ...ial HINT Rotating the tires check they are in the differential lock condi tion d Disconnect the cable from the negative terminal of the battery 2 DRAIN DIFFERENTIAL OIL 3 REMOVE REAR AXLE SHAFTS See p...

Page 1142: ...20 mm 0 0059 0 0079 in HINT Perform the measurements at 3 or more positions around the circumference of the ring gear If the backlash is not within the specification adjust the side bearing preload or...

Page 1143: ...R SWITCH Remove the indicator switch and gasket 8 w DIFFERENTIAL LOCK REMOVE COVER a Remove the 3 bolts b Using a brass bar and hammer tap on the cover to re move it 9 w DIFFERENTIAL LOCK REMOVE SLEEV...

Page 1144: ...VE FRONT BEARING Using SST remove the front bearing from the drive pinion SST 09556 22010 If the front bearing is damaged or worn replace the bearing 14 w o DIFFERENTIAL LOCK REMOVE DIFFERENTIAL CASE...

Page 1145: ...om the differential carrier HINT Tag the bearing outer races to show the location for reassembly 16 REMOVE DRIVE PINION AND BEARING SPACER FROM DIFFERENTIAL CARRIER a Remove the drive pinion with the...

Page 1146: ...o DIFFERENTIAL LOCK REMOVE SIDE BEARINGS FROM DIFFERENTIAL CASE Using SST remove the 2 side bearings from the differential case SST 09950 40010 09951 04010 09952 04010 09953 04020 09955 04060 09957 0...

Page 1147: ...Side gear thrust washers 24 w DIFFERENTIAL LOCK DISASSEMBLE DIFFERENTIAL CASE a Place matchmarks on the case and cover b Using a torx socket wrench remove the 5 set bolts and 3 pinion shaft pins c Usi...

Page 1148: ...AND CRUISER RM451U REPLACEMENT 1 REMOVE DUST DEFLECTOR Using SST and a press remove the dust deflector SST 09950 00020 2 INSTALL DUST DEFLECTOR Using SST and a press install a new dust deflector SST 0...

Page 1149: ...hrust washer thickness Thickness mm in Thickness mm in 1 60 0 063 1 90 0 075 1 75 0 069 2 05 0 081 c Install the side gears with the side gear thrust washers pinion gears pinion gear thrust washers an...

Page 1150: ...pin ion shaft pins Torque 58 N m 590 kgf cm 43 ft lbf k Using a dial indicator with holding the side gear and mea sure the backlash Backlash 0 02 0 20 mm 0 0008 0 0079 in HINT Measure at all 4 locati...

Page 1151: ...a Clean the contact surfaces of the differential case and ring gear b Heat the ring gear to about 100 C 212 F in boiling wa ter c Carefully remove the ring gear from the boiling water d After the moi...

Page 1152: ...0 70010 09951 07150 b Rear side Using SST and a press install the 2 outer races SST 09950 60020 09951 00890 09950 70010 09951 07150 8 INSTALL DRIVE PINION REAR BEARING a Install the washer on the driv...

Page 1153: ...FFERENTIAL CASE IN CARRIER a Place the 2 bearing outer races on their respective bear ings Make sure that the left and right outer races are not interchanged b Install the case in the carrier HINT Mak...

Page 1154: ...differential carrier e Install the plate washer into the lower part of the carrier f Place the plate washer onto the differential case together with the outer race and install the differential case w...

Page 1155: ...e Torque 113 N m 1 150 kgf cm 83 ft lbf g Using a dial indicator adjust the ring gear backlash until it is within the specification Backlash 0 15 0 20 mm 0 0059 0 0079 in If it is not within the speci...

Page 1156: ...e the 4 bearing cap bolts to the specified torque then loosen them to the point where the adjusting nuts can be turned by SST SST 09504 00011 Torque 78 N m 800 kgf cm 58 ft lbf b Fully tighten the 4 b...

Page 1157: ...i Torque the 4 bearing cap bolts Torque 78 N m 800 kgf cm 58 ft lbf j Recheck the ring gear backlash Backlash 0 15 0 20 mm 0 0059 0 0079 in 17 MEASURE TOTAL PRELOAD Using a torque wrench measure the...

Page 1158: ...ot contacting properly use the following chart to select a proper washer for correction Thickness mm in Thickness mm in 1 05 0 0413 1 35 0 0531 1 10 0 0433 1 40 0 0551 1 15 0 0453 1 45 0 0571 1 20 0 0...

Page 1159: ...00 kgf cm 181 ft lbf 24 ADJUST DRIVE PINION PRELOAD Using a torque wrench measure the preload of the backlash between the drive pinion and ring gear Preload at starting New bearing 1 3 2 0 N m 13 20 k...

Page 1160: ...s Torque 13 N m 130 kgf cm 9 ft lbf 29 w DIFFERENTIAL LOCK INSTALL ACTUATOR SHIFT FORK AND SLEEVE a Clean contacting surfaces of any FIPG material using gasoline or alcohol b Apply FIPG to the actuato...

Page 1161: ...COVER a Clean contacting surfaces of any FIPG material using gasoline or alcohol b Apply FIPG to the cover FIPG Part No 08826 00090 THREE BOND 1281 or equivalent HINT Install the cover within 10 minu...

Page 1162: ...IER 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SA 79 HINT After installation fill the differential with gear oil See page SA 27 Brought to you by Bi...

Page 1163: ...witch is set to the RR position the indicator light rear side is turned on Differential lock is applied to the rear wheel at this time HINT If the gears of the differential lock system are not meshed...

Page 1164: ...me 8 Return the Diff lock control switch to OFF 9 Stop the engine and lower the vehicle 2 INSPECT DIFF LOCK SYSTEM CIRCUIT a Inspect the system circuit with connector disconnected Disconnect the conne...

Page 1165: ...itch ON Diff lock control switch FR RR Battery positive voltage Ignition switch ON Diff lock control switch OFF or RR About 0 V HINT When a signal enters the ECU to LOCK the front differential and set...

Page 1166: ...14 5 Approx 1 sec 0 5 or less 5 M4 7 M3 FR RR RR or OFF 0 5 or less 10 14 5 Approx 1 sec 0 5 or less If the circuit is not as specified replace the ECU d Install the ECU in place 3 INSPECT DIFF LOCK...

Page 1167: ...ace the switch 5 INSPECT DIFF LOCK POSITION SWITCH a Front and Rear Inspect the diff lock position switch 1 Check that there is continuity between terminals when the switch is pushed differential conn...

Page 1168: ...1VM 01 SA 106 SUSPENSION AND AXLE DIFFERENTIAL LOCKING SYSTEM 1996 LAND CRUISER RM451U DIFFERENTIAL LOCKING SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 201...

Page 1169: ...s bolt and actuator d Remove the O ring from the actuator 2 REMOVE REAR ACTUATOR a Shifting the gear differential lock b Remove the actuator protector Remove the 2 nuts bolt and protector c Disconnect...

Page 1170: ...LE DIFFERENTIAL LOCKING SYSTEM 1996 LAND CRUISER RM451U f Remove the shift fork set bolt g Remove the 4 bolts h Using a screwdriver pry out the actuator Brought to you by BirfMark Brought to you by Bi...

Page 1171: ...or is not in the specified place the actuator is difficult to be installed S Do not supply the battery positive voltage between terminals S If the matchmark comes to the extension limit of the rotatio...

Page 1172: ...26 00090 THREE BOND 1281 or equivalent HINT Install the actuator within 10 minutes after applying FIPG c Install the actuator to the differential and match the shaft with the shaft fork hole d Clean t...

Page 1173: ...nsertion of the bleeder tube into the hose is approx 15 mm 0 59 in S Take care that the water or the equivalent will not adhere to the connectors and hose k Install the actuator protector Install the...

Page 1174: ...PENSION AND AXLE COIL SPRING AND REAR SHOCK ABSORBER 969 Author Date 1996 LAND CRUISER RM451U COIL SPRING AND REAR SHOCK ABSORBER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Versi...

Page 1175: ...kgf cm 37 ft lbf d Remove these parts from the shock absorber S Nut S 3 Retainers S 2 Cushions S Bracket Torque 69 N m 700 kgf cm 51 ft lbf 3 DISCONNECT STABILIZER BAR BRACKETS FROM REAR AXLE HOUSING...

Page 1176: ...COIL SPRING AND REAR SHOCK ABSORBER 1996 LAND CRUISER RM451U c Remove the bolt and follow spring from the frame Torque 28 N m 290 kgf cm 21 ft lbf Brought to you by BirfMark Brought to you by BirfMar...

Page 1177: ...Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sounds If there is any abnormality replace the shock absorber with a new one NOTICE When...

Page 1178: ...fore discarding the shock absorber drill a hole 2 3 mm 0 079 0 118 in in diameter at the location shown in the il lustration to release the gas inside NOTICE When drilling chips may fly out work caref...

Page 1179: ...LE COIL SPRING AND REAR SHOCK ABSORBER SA 117 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SA 113 Brought to you by BirfMark Brought to you by BirfMar...

Page 1180: ...6 ft lbf 2 REMOVE LATERAL CONTROL ROD a Remove the bolt nut and plate washer and disconnect the lateral control rod Torque 177 N m 1 800 kgf cm 130 ft lbf HINT After stabilizing the suspension torque...

Page 1181: ...EPLACEMENT REPLACE LATERAL CONTROL ROD BUSHING a Using SST and a press remove the bushing SST 09550 10012 09553 10010 09710 22021 09710 01071 b Using SST and a press install a new bushing SST 09550 10...

Page 1182: ...ENSION AND AXLE REAR LATERAL CONTROL ROD 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SA 118 Brought to you by BirfMark Brought to you by BirfMark Ver...

Page 1183: ...2 REMOVE UPPER CONTROL ARM Remove the 2 bolts plate washers nuts and upper control arm from the frame Torque 177 N m 1 800 kgf cm 130 ft lbf HINT After stabilizing the suspension torque the bolt 3 REM...

Page 1184: ...09226 10010 09950 60010 09951 00490 09950 70010 09951 07100 b Using SST and a press install a new bushing SST 09226 10010 09506 35010 2 REPLACE LOWER CONTROL ARM BUSHING a Using SST and a press remove...

Page 1185: ...AXLE REAR UPPER AND LOWER CONTROL ARM SA 123 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SA 121 Brought to you by BirfMark Brought to you by BirfMark...

Page 1186: ...e 15 N m 153 kgf cm 11 ft lbf HINT After stabilizing the suspension torque the nut c Remove the 2 bolts nuts and links from the stabilizer bar d Remove the 4 bolts and stabilizer bar from the axle hou...

Page 1187: ...N AND AXLE REAR STABILIZER BAR SA 125 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SA 124 Brought to you by BirfMark Brought to you by BirfMark Versio...

Page 1188: ...eaning the engine compartment be espe cially careful to protect the electrical system from water b Precautions when handling the oxygen sensor 1 Do not allow the oxygen sensor to drop or hit against a...

Page 1189: ...try of water Also when washing the engine compartment prevent water from getting on the SFI parts and wiring connectors g Parts should be replaced as an assembly h Care is required when pulling out an...

Page 1190: ...When connecting the union bolt on the high pressure pipe union observe the following procedures 1 Always use a new gasket 2 Tighten the union bolt by hand 3 Tighten the union bolt to the specified to...

Page 1191: ...ect the TOYOTA hand held tester to the DLC3 3 Turn the ignition switch ON and TOYOTA hand held tester main switch ON NOTICE Do not start the engine 4 Select the active test mode on the TOYOTA hand hel...

Page 1192: ...SFI SFI SYSTEM SF 5 633 Author Date 1996 LAND CRUISER RM451U g Install the fuse cover on the instrument panel Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1193: ...SF1EF 01 SFI FUEL PUMP SF 9 1996 LAND CRUISER RM451U COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1194: ...SF 10 SFI FUEL PUMP 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1195: ...Disconnect the fuel pump and sender gauge connector HINT At the time of installation plaese refer to the following items Check for fuel leakage b Remove the union bolt and gaskets and disconnect the...

Page 1196: ...UMP 1996 LAND CRUISER RM451U HINT At the time of installation plaese refer to the following items install a new gasket to the pump bracket Brought to you by BirfMark Brought to you by BirfMark Version...

Page 1197: ...ubber cushion from the fuel pump 2 REMOVE FUEL PUMP FILTER FROM FUEL PUMP a Using a small screwdriver remove the clip HINT At the time of installation plaese refer to the following items install the p...

Page 1198: ...8 F If the resistance is not as specified replace the fuel pump 9 INSPECT FUEL PUMP OPERATION Connect the positive lead from the battery to terminal 6 of the connector and the negative lead to termina...

Page 1199: ...nstall the service hole cover with the 3 screws 12 REINSTALL FLOOR MATS 13 REINSTALL STEP PLATE 14 REINSTALL SIDE GARNISH 15 REINSTALL SCUFF PLATE 16 REINSTALL SECOND SEATS Torque 39 N m 400 kgf cm 29...

Page 1200: ...J 01 SF 16 SFI FUEL PUMP 1996 LAND CRUISER RM451U REASSEMBLY Reassembly is in the reverse order of disassembly See page SF 13 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2...

Page 1201: ...K 01 SFI FUEL PUMP SF 17 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SF 11 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2...

Page 1202: ...SF1EL 01 SF 18 SFI FUEL FILTER 646 Author Date 1996 LAND CRUISER RM451U FUEL FILTER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1203: ...SURE REGULATOR SF 19 647 Author Date 1996 LAND CRUISER RM451U FUEL PRESSURE REGULATOR ON VEHICLE INSPECTION INSPECT FUEL PRESSURE See page SF 1 Brought to you by BirfMark Brought to you by BirfMark Ve...

Page 1204: ...SF0XZ 04 SF 20 SFI FUEL PRESSURE REGULATOR 1996 LAND CRUISER RM451U COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1205: ...ATOR 2 DISCONNECT FUEL RETURN HOSE FROM FUEL PRESSURE REGULATOR CAUTION Put a shop towel under the pressure regulator 3 REMOVE FUEL PRESSURE REGULATOR a Loosen the lock nut and remove the pressure reg...

Page 1206: ...sure regulator into the delivery pipe by hand completely d Turn the pressure regulator counterclockwise until the fuel outlet port faces in the direction indicated in the il lustration e Tighten the l...

Page 1207: ...sure regulator into the delivery pipe by hand completely d Turn the pressure regulator counterclockwise until the fuel outlet port faces in the direction indicated in the il lustration e Tighten the l...

Page 1208: ...STANCE a Disconnect the 6 injector connectors b Using an ohmmeter measure the resistance between the terminals Resistance 13 4 14 2 at 20 C 68 F If the resistance is not as specified replace the injec...

Page 1209: ...SF0OS 05 SF 24 SFI INJECTOR 1996 LAND CRUISER RM451U COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1210: ...SFI INJECTOR SF 25 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1211: ...EMOVE BOLT HOLDING HEATER INLET PIPE AND AIR INTAKE CHAMBER 9 DISCONNECT NO 1 PCV HOSE 10 DISCONNECT VACUUM SENSING HOSE 11 DISCONNECT NO 2 WATER BYPASS HOSE 12 DISCONNECT EVAP HOSE 13 DISCONNECT BRAK...

Page 1212: ...the 2 bolts and intake manifold stay 22 DISCONNECT VACUUM HOSES FROM TVV 23 DISCONNECT NO 1 WATER BYPASS HOSE FROM CYLINDER HEAD 24 REMOVE AIR INTAKE CHAMBER Remove the 6 bolts 2 nuts air intake cham...

Page 1213: ...ctors b Remove the 3 bolts and delivery pipe together with the 6 injectors NOTICE Be careful not to drop the injectors when removing the de livery pipe c Remove the 6 insulators and 3 spacers from the...

Page 1214: ...405 09015 Torque 29 N m 300 kgf cm 22 ft lbf b Remove the fuel pressure regulator See page SF 21 c Install the O ring to the fuel inlet of pressure regulator d Connect SST hose to the fuel inlet of th...

Page 1215: ...manual for further details n If you have no TOYOTA hand held tester connect the positive and negative leads from the battery to the fuel pump connector See page SF 14 o Connect SST wire to the injecto...

Page 1216: ...41045 e Reinstall the fuel pressure regulator to the delivery pipe See page SF 22 f Disconnect the TOYOTA hand held tester from the DLC3 g Reinstall the fuse cover on the instrument panel Brought to...

Page 1217: ...3 spacers in position on the intake manifold f Place the 6 injectors together with the delivery pipe in position on the intake manifold g Temporarily install the 3 bolts holding the delivery pipe to...

Page 1218: ...f 3 INSTALL FUEL RETURN PIPE a Install the fuel return pipe with the 2 bolts Torque 20 N m 200 kgf cm 14 ft lbf b Connect the fuel hose to the fuel pressure regulator 4 INSTALL AIR INTAKE CHAMBER Inst...

Page 1219: ...BLY 13 CONNECT IDLE AIR CONTROL VALVE CONNECTOR 14 CONNECT THROTTLE POSITION SENSOR CONNEC TOR 15 CONNECT BRAKE BOOSTER HOSE 16 CONNECT EVAP HOSE 17 CONNECT NO 2 WATER BYPASS HOSE 18 CONNECT VACUUM SE...

Page 1220: ...SFI INJECTOR SF 35 1996 LAND CRUISER RM451U 27 FILL WITH ENGINE COOLANT Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1221: ...LAND CRUISER RM451U FUEL TANK AND LINE COMPONENTS CAUTION S Always use new gaskets when replacing the fuel tank or component parts S Apply the proper torque to all parts tightened Brought to you by B...

Page 1222: ...el tank vapor vent system hoses and connec tions for looseness sharp bends or damage c Check the fuel tank for deformation cracks fuel leakage or tank band looseness d Check the filler neck for damage...

Page 1223: ...SF0P1 06 SF 38 SFI MASS AIR FLOW MAF METER 666 Author Date 1996 LAND CRUISER RM451U MASS AIR FLOW MAF METER COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1224: ...nnector and wire clamp b Disconnect the cruise control actuator cable c Loosen the air cleaner hose clamp d Disconnect the 3 clips and remove the wing nut air cleaner cap and MAF meter 2 REMOVE MAF ME...

Page 1225: ...F THA E2 0 4 0 7 k 60 C 140 F THA E2 0 2 0 4 k 80 C 176 F If the resistance is not as specified replace the MAF meter 2 INSPECT MAF METER OPERATION a Connect the MAF meter connector b Using a voltmete...

Page 1226: ...I MASS AIR FLOW MAF METER SF 41 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SF 39 Brought to you by BirfMark Brought to you by BirfMark Version 1 00...

Page 1227: ...e between each terminal Throttle valve condition Between terminals Resistance Fully closed VTA E2 0 2 5 7 k Fully closed IDL E2 2 3 k or less Open IDL E2 Infinity Fully open VTA E2 2 0 10 2 k VC E2 2...

Page 1228: ...alve and check that the engine re turns to idle in a few seconds 4 CHECK THROTTLE OPENER a Disconnect the vacuum hose from the throttle opener and plug the hose end b Check the throttle opener setting...

Page 1229: ...SF1EV 01 SF 44 SFI THROTTLE BODY 1996 LAND CRUISER RM451U COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1230: ...3 vacuum hoses c Disconnect the No 2 water bypass hose d Remove the 4 bolts and disconnect the throttle body from the air intake chamber Torque 21 N m 210 kgf cm 15 ft lbf e Remove the throttle body...

Page 1231: ...throttle valve is fully closed 3 INSPECT THROTTLE POSITION SENSOR a Apply vacuum to the throttle opener b Insert a 0 50 mm 0 020 in or 0 75 mm 0 030 in feeler gauge between the throttle stop screw an...

Page 1232: ...an ohmmeter to the terminals IDL and E2 of the sensor e Gradually turn the sensor clockwise until the ohmmeter deflects and secure it with the 2 set screws f Recheck the continuity between terminals I...

Page 1233: ...01 SF 48 SFI THROTTLE BODY 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SF 45 Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21...

Page 1234: ...tion is not as specified check the IAC valve wiring and ECM 2 INSPECT IAC VALVE RESISTANCE a Disconnect the IAC valve connector b Using an ohmmeter measure the resistance between the terminals B1 S1 a...

Page 1235: ...SF1F0 01 SF 50 SFI IDLE AIR CONTROL IAC VALVE 1996 LAND CRUISER RM451U COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1236: ...RM451U REMOVAL 1 REMOVE THROTTLE BODY See page SF 45 2 REMOVE IAC VALVE Remove the 2 screws IAC valve and O ring HINT At the time of installation install the IAC valve with a new O ring Brought to you...

Page 1237: ...grounding S1 S2 S3 S4 S1 in sequence and check that the valve moves toward the closed posi tion b Apply battery voltage to terminals B1 and B2 and while repeatedly grounding S4 S3 S2 S1 S4 in sequenc...

Page 1238: ...IDLE AIR CONTROL IAC VALVE SF 53 1996 LAND CRUISER RM451U INSTALLATION Installation is in the reverse order of removal See page SF 51 Brought to you by BirfMark Brought to you by BirfMark Version 1 0...

Page 1239: ...Using an ohmmeter check that there is continuity be tween terminals 1 and 3 b Check that there is no continuity between terminals 2 and 4 If continuity is not as specified replace the relay 3 INSPECT...

Page 1240: ...t Opening Relay Foot Rest Scuff Plate SFI CIRCUIT OPENING RELAY SF 55 683 Author Date 1996 LAND CRUISER RM451U CIRCUIT OPENING RELAY COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Ve...

Page 1241: ...ontinuity be tween terminals 1 and 3 b Check that there is no continuity between terminals 2 and 4 If continuity is not as specified replace the relay 3 INSPECT CIRCUIT OPENING RELAY OPERATION a Apply...

Page 1242: ...er check that there is continuity be tween terminals B1 and FPR b Check that there is continuity between terminals B2 and FP c Check that there is no continuity between terminals B2 and PR If continui...

Page 1243: ...r connector b Remove the bolt and fuel pump resistor 2 INSPECT FUEL PUMP RESISTOR Using an ohmmeter measure the resistance between the ter minals Resistance 0 70 0 76 at 20 C 68 F If there is no conti...

Page 1244: ...inuity replace the VSV 4 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each terminal and the body If there is continuity replace the VSV 5 INSPECT VSV OPERATION a...

Page 1245: ...SV FOR EXHAUST GAS RECIRCULATION EGR 688 Author Date 1996 LAND CRUISER RM451U VSV FOR EXHAUST GAS RECIRCULATION EGR INSPECTION See page EC 11 Brought to you by BirfMark Brought to you by BirfMark Vers...

Page 1246: ...eep socket wrench remove the ECT sensor and gasket 3 INSPECT ECT SENSOR Using an ohmmeter measure the resistance between the ter minals Resistance Refer to the chart graph If the resistance is not as...

Page 1247: ...ck sensor SST 09816 30010 2 INSPECT KNOCK SENSOR Using an ohmmeter check that there is no continuity between the terminal and body If there is continuity replace the sensor 3 REINSTALL KNOCK SENSOR a...

Page 1248: ...AS TEMPERATURE SENSOR 2 INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter measure the resistance between the ter minals Temperature Resistance 50 C 122 F 64 97 k 100 C 212 F 11 16 k 150 C 302 F 2 4...

Page 1249: ...EN SENSORS a Disconnect the heated oxygen sensor connector b Using an ohmmeter measure the resistance between ter minals B and HT Resistance 11 16 at 20 C 68 F If resistance is not as specified replac...

Page 1250: ...SF0Q0 07 SFI ENGINE CONTROL MODULE ECM SF 65 693 Author Date 1996 LAND CRUISER RM451U ENGINE CONTROL MODULE ECM COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1251: ...SF 66 SFI ENGINE CONTROL MODULE ECM 1996 LAND CRUISER RM451U INSPECTION 1 REMOVE ECM 2 INSPECT ECM See page DI 17 3 REINSTALL ECM Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12...

Page 1252: ...LC3 c Please refer to the TOYOTA hand held tester or OBD II scan tool operator s manual for further details 3 INSPECT FUEL CUTOFF PRM a Increase the engine speed to at least 3 500 rpm b Use a sound sc...

Page 1253: ...d with SRS Supplemental Restraint System such as the driver airbag and front passenger airbag Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy...

Page 1254: ...orn 15 Suspension arm ball joints Worn 16 Steering column Binding 17 Power steering vane pump 18 Power steering gear SA 3 SR 4 SA 4 SR 21 SR 33 Poor return 1 Tires Improperly inflated 2 Front wheel al...

Page 1255: ...Run the engine at idle for a few minutes 6 TURN STEERING WHEEL a With the engine idling turn the wheel to left or right full lock and keep it there for 2 3 seconds then turn the wheel to the opposite...

Page 1256: ...rt the engine and run it at idle d Turn the steering wheel from lock to lock several times to boost fluid temperature Fluid temperature 80 C 176 F e Check for foaming or emulsification If there is foa...

Page 1257: ...is in the open position c Bleed the power steering system See page SR 3 d Start the engine and run it at idle e Turn the steering wheel from lock to lock several times to boost fluid temperature Fluid...

Page 1258: ...490 kPa 5 kgf cm2 71 psi or less NOTICE Do not turn the steering wheel i With the engine idling and valve fully opened turn the steering wheel to full lock Minimum fluid pressure 9 316 kPa 95 kgf cm2...

Page 1259: ...SR169 01 STEERING TILT STEERING COLUMN SR 9 1060 Author Date 1996 LAND CRUISER RM451U TILT STEERING COLUMN COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1260: ...SR 10 STEERING TILT STEERING COLUMN 1061 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1261: ...the 2 screws until the groove along the screw circumfer ence catches on the screw case d Pull out the wheel pad from the steering wheel and dis connect the airbag connector CAUTION When storing the w...

Page 1262: ...airbag connector c Remove the 4 screws NOTICE Do not disassemble the cable or apply oil to it 7 REMOVE 4 COLUMN HOLE COVER SET BOLTS 8 REMOVE LINK JOINT PROTECTOR Remove the 2 bolts 9 DISCONNECT SLID...

Page 1263: ...the center of the 2 tapered head bolts b Using a 3 4 mm 0 12 0 16 in drill drill into the 2 bolts c Using a screw extractor remove the 2 bolts 5 REMOVE COMPRESSION SPRING a Remove the bolt b Remove t...

Page 1264: ...c Remove the upper tube with the shaft assembly from the column lower tube 11 REMOVE TURN SIGNAL BRACKET Remove the 2 bolts 12 REMOVE MAIN SHAFT ASSEMBLY a Using SST compress the compression spring S...

Page 1265: ...e BE 11 5 IF NECESSARY REPLACE IGNITION SWITCH WITH KEY UNLOCK WARNING SWITCH a Remove the 2 screws b Install a new switches with the 2 screws 6 INSPECT KEY INTERLOCK SOLENOID See page SR 9 7 IF NECES...

Page 1266: ...a new snap ring 3 INSTALL TURN SIGNAL BRACKET Torque the 2 bolts Torque 4 9 N m 50 kgf cm 43 in lbf 4 SELECT TILT NO 2 BOLTS Select the bolt with plain thread end when the column upper tube mark is 2...

Page 1267: ...side pawl to the ratchet c Torque the nut Torque 5 9 N m 60 kgf cm 52 in lbf 9 SELECT AND INSTALL 2 TILT PAWL STOPPERS a With the tilt pawl and ratchet engaged install the stopper b Check that the ali...

Page 1268: ...le cover c Torque 2 bolts Torque 5 9 N m 60 kgf cm 52 in lbf 16 CONNECT UNIVERSAL JOINT a Align the matchmarks on the intermediate No 2 shaft and universal joint then torque the bolt Torque 34 N m 350...

Page 1269: ...4 COLUMN HOLE COVER SET BOLTS Torque 13 N m 130 kgf cm 9 ft lbf 6 INSTALL COMBINATION SWITCH WITH SPIRAL CABLE a Tighten the 4 screws b Connect the airbag connector c Connect the 2 connectors 7 INSTA...

Page 1270: ...fects in the case or connector re place the wheel pad with a new one When installing the wheel pad take care that the wirings do not interfere with other parts and are not pinched between other parts...

Page 1271: ...16F 01 STEERING POWER STEERING VANE PUMP SR 21 1072 Author Date 1996 LAND CRUISER RM451U POWER STEERING VANE PUMP COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 20...

Page 1272: ...SR 22 STEERING POWER STEERING VANE PUMP 1073 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1273: ...U REMOVAL 1 DISCONNECT RETURN HOSE 2 DISCONNECT PRESSURE FEED TUBE Remove the union bolt and 2 gaskets 3 REMOVE PS VANE PUMP ASSEMBLY a Remove the 2 nuts b Remove the O ring from the vane pump assembl...

Page 1274: ...ng from the union 3 REMOVE VANE PUMP DRIVE GEAR a Using soft jaws on a vise clamp the gear in the vise NOTICE Be careful not to damage the gear b Remove the gear set nut c Using SST press out the gear...

Page 1275: ...g from the housing 6 REMOVE SIDE REAR PLATE a Gently tap the PS pump assembly on a wood block and remove the plate b Remove the O ring from the plate 7 REMOVE CAM RING VANE PUMP ROTOR AND 10 VANE PLAT...

Page 1276: ...E a Using SST tap out the plate from the front housing SST 09631 10030 NOTICE Be careful not to damage the front housing b Remove the 2 O rings from the plate 11 REMOVE LONGER STRAIGHT PIN Using plier...

Page 1277: ...aximum replace the front housing and vane pump shaft 2 INSPECT VANE PUMP ROTOR AND 10 VANE PLATES a Using a micrometer measure the height thickness and length of the plate Minimum height 8 6 mm 0 339...

Page 1278: ...T FLOW CONTROL VALVE a Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight b Check the valve for leakage Close one of the holes and apply 39...

Page 1279: ...power steering fluid d Using a press press in the bearing NOTICE Be careful not to damage the shaft e Install a new snap ring to the shaft 6 IF NECESSARY REPLACE OIL SEAL a Using a screwdriver and ham...

Page 1280: ...k nut c Turn the cross shaft adjusting screw clockwise to de crease steering wheel freeplay and counterclockwise to increase it HINT Turn the adjusting screw in small increments and check the freeplay...

Page 1281: ...e to consider the tire type pressure and contact surface before making your diagnosis e Torque the steering wheel set nut Torque 34 N m 350 kgf cm 25 ft lbf f Install the steering wheel pad See page S...

Page 1282: ...damage the pin 4 INSTALL SIDE FRONT PLATE a Coat 2 new O rings with power steering fluid and install them to the plate b Align the hole of the plate and longer straight pin NOTICE Make sure you instal...

Page 1283: ...valve facing the correct direction See page SR 21 b Coat a new O ring with power steering fluid and install it to the union c Torque the union Torque 69 N m 700 kgf cm 51 ft lbf 12 INSTALL VANE PUMP D...

Page 1284: ...assembly b Torque the 2 nuts Torque 36 N m 370 kgf cm 27 ft lbf 2 CONNECT PRESSURE FEED TUBE Torque the union bolt with 2 new gaskets Torque 56 N m 575 kgf cm 42 ft lbf HINT Make sure the stopper of...

Page 1285: ...SR16L 01 STEERING POWER STEERING GEAR SR 33 1084 Author Date 1996 LAND CRUISER RM451U POWER STEERING GEAR COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1286: ...SR 34 STEERING POWER STEERING GEAR 1085 Author Date 1996 LAND CRUISER RM451U Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1287: ...CONNECT PITMAN ARM WITH RELAY ROD a Remove the pitman arm set nut and spring washer b Using SST disconnect the pitman arm from the gear as sembly SST 09628 62011 7 DISCONNECT PRESSURE FEED AND RETURN...

Page 1288: ...c Remove the O ring from the cover 4 REMOVE CROSS SHAFT Using a plastic hammer tap on the cross shaft end and pull out the shaft 5 REMOVE POWER PISTON PLUNGER GUIDE NUT COMPRESSION SPRING POWER PISTO...

Page 1289: ...AND CRUISER RM451U c Pull out the valve body assembly NOTICE Ensure that the worm gear does not come off the worm shaft d Remove the 2 O rings from the gear housing Brought to you by BirfMark Brought...

Page 1290: ...3 IF NECESSARY ADJUST CROSS SHAFT ADJUSTING SCREW THRUST CLEARANCE a Using a chisel and hammer unstake the No 1 lock nut b Using SST remove the No 1 lock nut SST 09630 00014 09631 00051 c Using a scre...

Page 1291: ...l seal to the gear housing SST 09950 60010 09951 00340 09951 00450 09950 70010 09951 07200 NOTICE Make sure you install the oil seal facing the correct direc tion 5 IF NECESSARY REPLACE TEFLON RING AN...

Page 1292: ...extractor remove the 2 union seats from the worm gear valve body assembly b Using a hammer and extension bar tap in 2 new union seats NOTICE Before installing the union seat remove dust sticking to t...

Page 1293: ...que 61 N m 620 kgf cm 45 ft lbf NOTICE Be careful not to damage the teflon ring e Using SST and a torque wrench check the valve body as sembly rotating torque SST 09616 00010 Rotating torque 0 3 0 5 N...

Page 1294: ...he gear housing so that the center teeth mesh together d Torque the 4 bolts in a diagonal pattern Torque 61 N m 620 kgf cm 45 ft lbf 6 ADJUST TOTAL PRELOAD a Install SST with a torque wrench on the wo...

Page 1295: ...ROD a Align the alignment marks on the cross shaft and pitman arm and connect the pitman arm b Install the spring washer and pitman arm set nut Torque 177 N m 1 800 kgf cm 130 ft lbf 5 POSITION FRONT...

Page 1296: ...SR16R 01 SR 44 STEERING STEERING LINKAGE 1095 Author Date 1996 LAND CRUISER RM451U STEERING LINKAGE COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1297: ...g washer d Using SST disconnect the pitman arm from the PS gear assembly SST 09628 62011 3 REMOVE STEERING DAMPER WITH STEERING DAMPER BRACKET a Remove the nut and 2 damper bracket set bolts b Using S...

Page 1298: ...VE TIE ROD ASSEMBLY a Remove the 2 cotter pins and nuts b Using SST disconnect the tie rod assembly from the RH and LH knuckle arms SST 09611 22012 7 REMOVE TIE ROD ENDS AND RELAY ROD ENDS Loosen the...

Page 1299: ...Torque 91 N m 925 kgf cm 67 ft lbf c Install 2 new cotter pins d After adjusting toe in torque the clamp bolts and nuts Torque 37 N m 375 kgf cm 27 ft lbf 3 INSTALL RELAY ROD ASSEMBLY a Connect the re...

Page 1300: ...tall the spring washer and set nut Torque 177 N m 1 800 kgf cm 130 ft lbf b Connect the pitman arm to the relay rod assembly c Torque the nut Torque 91 N m 925 kgf cm 67 ft lbf d Install a new cotter...

Page 1301: ...2 Protruding lines 3 Protruding lines 4 Protruding lines Hexagon flange bolt w washer hexagon bolt Hexagon flange bolt w washer hexagon bolt Hexagon flange bolt w washer hexagon bolt Stud bolt Welded...

Page 1302: ...Hexagon flange bolt N m kgf cm ft lbf N m kgf cm ft lbf in lbf in lbf in lbf in lbf in lbf in lbf SS 2 SERVICE SPECIFICATIONS STANDARD BOLT 1996 LAND CRUISER RM451U SPECIFIED TORQUE FOR STANDARD BOLTS...

Page 1303: ...INTENANCE SS 3 126 Author Date 1996 LAND CRUISER RM451U MAINTENANCE TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Front seat mounting bolt 39 400 29 Brought to you by BirfMark Brought to you b...

Page 1304: ...usion height 7 010 7 030 mm 0 2760 0 2768 in 11 492 11 513 mm 0 4524 0 4533 in 11 542 11 563 mm 0 4544 0 4522 in 8 2 8 6 mm 0 323 0 339 in Valve Valve overall length STD Intake Exhaust Minimum Intake...

Page 1305: ...and vibra tion damper Wear Maximum 1 0 mm 0 039 in Cylinder block Cylinder head surface warpage Maximum Cylinder bore diameter STD Mark 1 2 3 Maximum STD O S 0 50 O S 1 00 Main bearing bolt outside d...

Page 1306: ...mm 0 0020 in 8 40 8 60 mm 0 3307 0 3386 in 8 00 mm 0 3150 in Crankshaft Thrust clearance STD Maximum Thrust washer thickness STD O S 0 125 O S 0 250 Main journal oil clearance STD STD U S 0 25 Maximu...

Page 1307: ...manifold x Cylinder head 39 400 29 Heat insulator x Exhaust manifold 19 195 14 Front exhaust pipe x Exhaust manifold 63 630 46 No 1 support bracket x Transmission 24 240 17 No 1 support bracket clamp...

Page 1308: ...lutch x Drive plate 55 550 41 A T oil cooler pipe x Union Transmission 34 350 25 Starter x Transmission 39 400 29 Frame crossmember x Frame 61 620 45 Frame crossmember x Engine rear mounting insulator...

Page 1309: ...ICATIONS EMISSION CONTROL SS 9 132 Author Date 1996 LAND CRUISER RM451U EMISSION CONTROL SERVICE DATA VSV for EVAP Resistance at 20 C 68 F 30 34 Brought to you by BirfMark Brought to you by BirfMark V...

Page 1310: ...al canister bracket x Body 18 185 13 TVV x Cylinder head 29 300 22 Intake manifold stay x Air intake chamber 36 360 26 Intake manifold stay x Cylinder block 36 360 26 EGR valve x Air intake chamber fo...

Page 1311: ...200 300 rpm 700 1 000 rpm Throttle position sensor Clearance between stop screw and lever 0 mm 0 in VTA E2 0 50 mm 0 020 in IDL E2 0 75 mm 0 030 in IDL E2 Throttle valve fully open VTA E2 VC E2 0 2 5...

Page 1312: ...fold 20 200 14 Air intake chamber x Intake manifold 21 210 15 Intake manifold stay x Air intake chamber 36 360 26 Intake manifold stay x Cylinder block 36 360 26 PS reservoir tank x Air intake chamber...

Page 1313: ...A Thermostat Valve opening temperature Valve lift at 95 C 203 F 80 84 C 176 183 F 10 mm 0 39 in or more Radiator cap Relief valve opening pressure STD Minimum 74 103 kPa 0 75 1 05 kgf cm2 10 7 14 9 ps...

Page 1314: ...A Thermostat Valve opening temperature Valve lift at 95 C 203 F 80 84 C 176 183 F 10 mm 0 39 in or more Radiator cap Relief valve opening pressure STD Minimum 74 103 kPa 0 75 1 05 kgf cm2 10 7 14 9 ps...

Page 1315: ...2 4 3 psi or more 245 490 kPa 2 5 5 0 kgf cm2 36 71 psi Oil pump Body clearance STD Maximum Side clearance STD Maximum Tip clearance STD Maximum 0 100 0 170 mm 0 0039 0 0067 in 0 30 mm 0 0118 in 0 030...

Page 1316: ...il pan 5 4 55 48 in lbf Water pump x Cylinder block 21 210 15 Radiator pipe x No 1 oil pan 21 210 15 A C compressor bracket x No 1 oil pan 37 375 27 A C compressor bracket x Cylinder block 37 375 27 A...

Page 1317: ...031 in Ignition coil Primary coil resistance at cold at hot Secondary coil resistance at cold at hot 0 36 0 55 0 45 0 65 9 0 15 4 k 11 4 18 1 k Distributor Air gap Pickup coil resistance at cold G1 G...

Page 1318: ...ightened N m kgf cm ft lbf Spark plug x Cylinder head 20 200 14 Distributor x Cylinder head 18 180 13 Crankshaft position sensor protector x No 1 oil pan 20 200 14 Crankshaft position sensor x No 1 oi...

Page 1319: ...1 20 kgf 2 7 lbf 30 0 mm 1 18 in 29 0 mm 1 14 in 0 6 mm 0 024 in 0 2 mm 0 008 in 0 05 mm 0 0020 in 0 9 mm 0 035 in Starter 2 0 kW Rated voltage and output power No load characteristics Current rpm Br...

Page 1320: ...minal 30 17 173 12 5 End cover x Magnetic housing 1 4 kW 2 0 kW 2 5 3 6 25 37 22 in lbf 32 in lbf End cover x Field frame 1 4 kW 2 0 kW 1 5 3 8 15 40 13 in lbf 35 in lbf Starter hosing x Magnetic swit...

Page 1321: ...f 200 390 N 20 4 40 0 kgf 45 0 88 2 lbf Generator Rated output Rotor coil resistance at 20 C 68 F Slip ring diameter STD Minimum Brush exposed length STD Minimum 12 V 80 A 2 8 3 0 14 2 14 4 mm 0 559 0...

Page 1322: ...y x Rotor 110 1 125 81 Rectifier x Rectifier holder 2 9 30 25 in lbf Rear end cover x Rectifier holder 4 4 45 39 in lbf Rectifier plate x Rectifier holder 3 8 39 34 in lbf Terminal insulator x Rectifi...

Page 1323: ...tle cable adjustment throttle valve fully closed Between boot and face and inner cable stopper 0 1 mm 0 0 04 in Torque converter clutch installation distance Drive plate runout Max Torque converter cl...

Page 1324: ...ront exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x TWC 39 400 29 Oil cooler pipe 34 350 25 Transmission x Engine 71 730 53 Exhaust pipe clamp 19 195 14 Park neutral position switch Nu...

Page 1325: ...mm 0 0216 in Input gear snap ring thickness Mark A B C D E F G H J 2 00 mm 0 0787 in 2 10 mm 0 0827 in 2 20 mm 0 0866 in 2 30 mm 0 0906 in 2 40 mm 0 0945 in 2 50 mm 0 0984 in 2 60 mm 0 1024 in 2 70 m...

Page 1326: ...1 8 mm 0 0709 in Front output shaft hub snap ring thickness Mark A B C D E 1 8 mm 0 0709 in 1 9 mm 0 0748 in 2 0 mm 0 0787 in 2 1 mm 0 0827 in 2 2 mm 0 0866 in Oil pump driven rotor body clearance ST...

Page 1327: ...sion housing x Rear case 37 380 27 Front extension housing x Front case 37 380 27 Center differential lock Indicator switch 37 380 14 L4 position switch 37 380 27 Neutral position switch 37 380 27 Scr...

Page 1328: ...pe B Mark Color 1 2 3 Brown Blue 6 7 8 Rear propeller shaft Type A Color Brown Blue 2 100 2 150 mm 0 0827 0 0846 in 2 150 2 200 mm 0 0846 0 0866 in 2 200 2 250 mm 0 0866 0 0886 in 2 250 2 300 mm 0 088...

Page 1329: ...Part tightened N m kgf cm ft lbf Front propeller shaft x Front differential 74 750 54 Front propeller shaft x Transfer 74 750 54 Rear propeller shaft x Rear differential 88 900 65 Rear propeller shaft...

Page 1330: ...b or less 28 56 N 2 9 5 7 kgf 6 4 12 6 lbf 26 57 N 2 6 5 8 kgf 5 7 12 8 lbf Front axle Steering knuckle bearing preload Rotating load at knuckle end before installing dust seal 25 44 N 2 5 4 5 kgf 5 5...

Page 1331: ...cm 6 1 8 7 in lbf Total preload at starting w o Differntial lock w Differntial lock Drive pinion preload plus 0 4 0 6 N m 4 6 kgf cm 3 5 5 2 in lbf 0 3 0 7 N m 3 7 kgf cm 2 6 6 1 in lbf Drive pinion t...

Page 1332: ...2 88 mm 0 1134 in 2 91 mm 0 1146 in 2 94 mm 0 1157 in 2 97 mm 0 1169 in 3 00 mm 0 1181 in 3 03 mm 0 1193 in 3 06 mm 0 1205 in 3 09 mm 0 1217 in 3 12 mm 0 1228 in 3 15 mm 0 1240 in 3 18 mm 0 1252 in 3...

Page 1333: ...ion x Companion flange 196 343 2 000 3 500 145 253 Differential LH case x RH case 47 480 35 Differential lock shift retainer 24 240 17 Differential lock screw plug 22 220 16 Differential lock indicato...

Page 1334: ...l cover 58 590 43 Differential lock shift fork set bolt 20 200 14 Differential lock actuator 24 240 17 Differential lock cover 18 185 13 Differential lock indicator switch 40 410 30 Actuator protector...

Page 1335: ...unout Maximum 0 15 mm 0 0059 in Rear brake pad thickness STD Minimum 10 0 mm 0 394 in 1 0 mm 0 039 in Rear brake disc thickness STD Minimum 18 0 mm 0 709 in 16 0 mm 0 630 in Rear brake disc runout Max...

Page 1336: ...13 130 9 Rear disc brake cliper x Spindle pin 88 900 65 Rear disc brake caliper x Flexible hose 30 310 22 Rear disc brake torque plate x Knuckle 103 1 050 76 LSP BV bracket x Frame 25 260 19 LSP BV x...

Page 1337: ...ness Minimum 1 397 mm 0 05500 in Vane plate length Minimum 14 991 mm 0 59016 in Vane plate and pump rotor groove clearance Maximum 0 033 mm 0 00130 in Vane plate length Pump rotor mark None 1 2 Cam ri...

Page 1338: ...MP Pressure feed tube set union bolt 56 575 42 PS vane pump assembly set nut 36 370 27 Suction port union set bolt 13 130 9 Vane pump drive gear set nut 74 750 54 Pressure port union 69 700 51 PS GEAR...

Page 1339: ...STRAINT SYSTEM TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Steering wheel set nut 34 350 25 Steering wheel pad 9 0 90 80 in lbf Front passenger airbag assembly x Instrument panel reinforceme...

Page 1340: ...0 4 150 5 000 4 850 5 150 FUEL RECEIVER GAUGE A B 85 5 105 5 A C 126 150 B C 90 110 FUEL SENDER GAUGE Float position F Approx 15 mm 0 59 in Approx 3 Float position E Approx 200 7 87 in Approx 110 ENGI...

Page 1341: ...lbf Window regulator x Door panel 5 50 43 in lbf WIPER AND WASHER Front wiper arm x Wiper link 20 210 15 Wiper link x Body 5 4 55 48 in lbf Wiper motor x Body 5 4 55 48 in lbf Rear wiper arm x Wiper...

Page 1342: ...k x Seat truck inner reinforcement 20 210 15 Front seat horizontal seat screw x Front seat motor slide housing 19 200 14 Slide motor x Front seat horizontal jack screw Bolt Nut 10 2 100 20 7 17 in lbf...

Page 1343: ...AIR CONDITIONING SERVICE DATA Refrigerant charge volume 850 50 g 59 98 1 76 oz Drive belt tension New belt Used belt 100 150 lbf 60 100 lbf Idle up speed 800 rpm Magnetic clutch clearance 0 5 0 15 mm...

Page 1344: ...r bracket 25 250 18 Compressor bracket x Engine 37 375 27 Receiver x Liquid tube 5 4 55 48 in lbf Condenser x Discharge hose 10 100 7 Cooling unit x Liqied tube 10 100 7 Cooling unit x Suction tube 10...

Page 1345: ...IPG material from the gasket sur faces S Thoroughly clean all components to remove all the loose material S Clean both sealing surfaces with a non residue solvent S Apply FIPG in an approx 1 mm 0 04 i...

Page 1346: ...aft Shift Fork No 2 Center Diff Lock Indicator Switch Lever Lock Pin Washer z Oil Seal Shift Inner Lever Oil Receiver Breather Hose Front Case Snap Ring Shift Fork No 1 Shaft z Non reusable part L Pre...

Page 1347: ...rential lock condition S Apply FIPG to the front case FIPG Part No 08826 00090 THREE BOND 1281 or equivalent Torque 18 N m 185 kgf cm 13 ft lbf 4 REMOVE OUTPUT GEAR FROM FRONT CASE HINT At the timie o...

Page 1348: ...REE BOND 1281 or equivalent Torque 37 N m 380 kgf cm 27 ft lbf 8 REMOVE CLUTCH SLEEVE SHIFT FORK NO 2 SHAFT AND SHIFT FORK NO 2 HINT At the time of reassebly make sure to install the clutch sleeve in...

Page 1349: ...ss Dimension A Dimension B 0 022 0 049 mm 0 0009 0 0019 in e From the following table select a shim so that its thick ness is within the range of the calculation Mark Thickness mm in Mark Thickness mm...

Page 1350: ...y apply liquid sealer to the bolt threads Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent Torque 37 N m 380 kgf cm 27 ft lbf b Using a brass bar and hammer tap the case cover and...

Page 1351: ...SEPARATE SHIFT FORK NO 1 AND SHIFT FORK NO 1 SHAFT a Using a pin punch and hammer drive out the slotted spring pin b Separate the shift fork No 1 and shift fork No 1 shaft 20 REMOVE SHIFT OUTER LEVER...

Page 1352: ...316 00011 09316 00041 b Using a brass bar and hammer remove the bearing race for output shaft HINT At the time of reassembly please refer to the following item Using SST and a press install the bearin...

Page 1353: ...the oil seal b Using SST and a hammer drive in a new oil seal SST 0608 00081 09950 70010 09951 07150 2 REPLACE INPUT SHAFT OIL SEAL a Using SST and a hammer drive out the oil seal SST 09316 60011 093...

Page 1354: ...D CRUISER RM451U REASSEMBLY Reassembly is in the reverse order of disassembly See page TR 4 HINT Coat all of the sliding and rotating surfaces with gear oil before assembly Brought to you by BirfMark...

Page 1355: ...TR0B5 01 TR 12 TRANSFER INPUT SHAFT 822 Author Date 1996 LAND CRUISER RM451U INPUT SHAFT COMPONENTS Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 2010...

Page 1356: ...der remove the snap ring b Using a socket wrench and press remove the rear ball bearing 2 REMOVE INPUT GEAR a Using a snap ring expander remove the snap ring b Using a press remove the input gear 3 RE...

Page 1357: ...in Mark Thickness mm in A 2 00 0 0787 F 2 50 0 0984 B 2 10 0 0827 G 2 60 0 1024 C 2 20 0 0866 H 2 70 0 1063 D 2 30 0 0906 J 2 80 0 1102 E 2 40 0 0945 c Using a snap ring expander install a new snap r...

Page 1358: ...igh and Low Clutch Sleeve Needle Roller Bearing Idler Low Gear Rear Taper Roller Bearing TRANSFER IDLER GEAR TR 15 825 Author Date 1996 LAND CRUISER RM451U IDLER GEAR COMPONENTS Brought to you by Birf...

Page 1359: ...measure the idler low gear radial clearance Standard clearance 0 015 0 068 mm 0 0006 0 0027 in Maximum clearance 0 068 mm 0 0027 in 2 REMOVE FRONT TAPER ROLLER BEARING Using SST remove the front taper...

Page 1360: ...LUTCH SLEEVE HINT Make sure to install the high and low clutch sleeve in the correct direction 3 INSTALL NEEDLE ROLLER BEARING AND IDLER LOW GEAR TO IDLER GEAR a Apply gear oil to the needle roller be...

Page 1361: ...Straight Pin x 12 Differential Rear Case Thrust Washer Pinion Gear Pinion Shaft Front Side Gear Thrust Washer Differential Front Case z Non reusable part Low Gear Straight Pin z Snap Ring Front Taper...

Page 1362: ...ng expander remove the snap ring b Using SST and a press remove the front drive gear piece SST 09950 00020 09950 60010 09951 00320 NOTICE Be careful not to drop the center differential assembly 3 REMO...

Page 1363: ...RUST WASHER a Remove the straight pin from the pinion shaft b Remove the pinion shaft 2 pinion gears and thrust wash ers c Remove the front side gear and thrust washer 12 REMOVE LOW GEAR Using a plast...

Page 1364: ...g water c Carefully remove the low gear from the water d After the moisture on the low gear has completely evapo rated quickly install the low gear to the differential case 3 INSTALL PINION SHAFT PINI...

Page 1365: ...E SET BOLT a Torque the rear case 12 set bolts Torque 88 N m 900 kgf cm 65 ft lbf b Turn the pinion gear c Loosen the rear case 12 set bolts d Torque the rear case 12 set bolts Torque 98 N m 1 000 kgf...

Page 1366: ...ARING a Apply gear oil to the needle roller bearing b Install the high speed output gear and needle roller bear ing 13 INSTALL FRONT TAPER ROLLER BEARING Using SST and a press install the front taper...

Page 1367: ...1996 LAND CRUISER RM451U b Using a snap ring expander install a new snap ring 16 INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE See page TR 19 Brought to you by BirfMark Brought to you by...

Page 1368: ...using Ball Bearing z Snap Ring Drive Clutch Hub z Snap Ring z Snap Ring TRANSFER FRONT EXTENSION HOUSING TR 25 835 Author Date 1996 LAND CRUISER RM451U FRONT EXTENSION HOUSING COMPONENTS Brought to yo...

Page 1369: ...put shaft 3 REMOVE DUST DEFLECTOR a Using SST and a press remove the dust deflector SST 09950 00020 b Using a screwdriver and hammer tap the dust deflector and remove it from the extension housing 4 R...

Page 1370: ...w dust deflector to the front output shaft SST 09316 20011 09316 60011 09316 00011 2 INSTALL BALL BEARING a Using SST and a press install the ball bearing to the front extension housing SST 09316 6001...

Page 1371: ...ont output shaft and drive clutch hub SST 09316 20011 09316 60011 09316 00011 09316 00041 09316 00071 b Select a snap ring that will allow minimum axial play Mark Thickness mm in A 1 8 0 0709 B 1 9 0...

Page 1372: ...r Extension housing Oil Pump Drive Shaft Ball Spring L Screw Plug Valve Seat z Dust Deflector z Oil Seal Seal Ring Rear Output Shaft z Non reusable Part L Precoated part Separator Driven Rotor TRANSFE...

Page 1373: ...ING BALL AND VALVE SEAT a Using a hexagon wrench remove the screw plug b Using a magnetic finger remove the spring ball and valve seat from the rear extension housing 6 REMOVE CENTER DIFFERENTIAL CONT...

Page 1374: ...R a Using a screwdriver and hammer remove the rear exten sion housing dust deflector b Using a screwdriver and hammer remove the rear output shaft dust deflector 11 REMOVE OIL SEAL Using a screwdriver...

Page 1375: ...ECT DRIVEN ROTOR TIP CLEARANCE Using a feeler gauge measure the tip clearance between the driver rotor and driven rotor Standard tip clearance 0 05 0 15 mm 0 0020 0 0059 in Maximum tip clearance 0 15...

Page 1376: ...l allow minimum axial play Mark Thickness mm in A 1 7 0 0669 B 1 8 0 0709 c Using a screwdriver install a new snap ring 2 INSTALL DUST DEFLECTOR a Using SST and a hammer install a new rear extension h...

Page 1377: ...ing a snap ring expander install the snap ring 6 INSTALL OIL PUMP PLATE AND SEPARATOR a Install the oil pump plate b Install the separator c Install and torque the 3 bolts Torque 4 9 N m 50 kgf cm 43...

Page 1378: ...r b Install the drive rotor HINT Align the alignment marks 11 INSTALL OIL PUMP COVER a Install the oil pump cover b Using a torx socket wrench T30 install and torque the 3 screws Torque 4 9 N m 50 kgf...

Page 1379: ...BL 01 TR 36 TRANSFER MOTOR SHIFT CONTROL SYSTEM 846 Author Date 1996 LAND CRUISER RM451U MOTOR SHIFT CONTROL SYSTEM LOCATION Brought to you by BirfMark Brought to you by BirfMark Version 1 00 12 21 20...

Page 1380: ...t goes off when the lever is shifted to the N or H position 2 INSPECT CENTER DIFF LOCK CONTROL RELAY a Check that there is continuity between the terminals as shown in the chart HINT There is a diode...

Page 1381: ...e between the terminals 2 and 3 Standard resistance 0 3 100 b Measure the resistance between the terminals 2 or 3 and body ground Standard resistance More than 0 5 M If the resistance value is not as...

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