Toyota Land Cruiser 1988 Repair Manual Download Page 157

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Summary of Contents for Land Cruiser 1988

Page 1: ...TOYOTA 1988 Land Cruiser Repair Manual Engine Chassis Body Electrical Specifications ...

Page 2: ...epair procedures of the 1988 Land Cruiser than those listed in this manual refer to the following manuals Manual Name Pub No Land Cruiser Hea_vy Duty hassis 36262E Body Repair Manual A440F A440L Automatic Transmission 36264E Repair Manual 1988 Model New Car Features NCF024U All information in this manual is based on the latest product information at the time of publication However specifica tions ...

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Page 4: ...lt J LUBRICATION SYSTEM llll IGNITION SYSTEM 11mJ STARTING SYSTEM l il CHARGING SYSTEM lij l AUTOMATIC TRANSMISSION FRONT AXLE AND SUSPENSION REAR AXLE AND SUSPENSION BRAKE SYSTEM 1987 TOYOTA MOTOR CORPORATION All rights reserved This book may not be reproduced or copied in whole or in part without the written permission of Toyota Motor Corporation BODY ELECTRICAL SYSTEM BODY AIR CONDITIONING SYST...

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Page 6: ...USE THIS MANUAL IN 2 IDENTIFICATION INFORMATION IN 4 GENERAL REPAIR INSTRUCTIONS IN 4 PRECAUTIONS FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER IN 7 VEHICLE LIFT AND SUPPORT LOCATIONS IN 8 ABBREVIATIONS USED IN THIS MANUAL IN 10 ...

Page 7: ...iven that pertain to all repair operations contained in that section Read these precautions before starting any repair task TROUBLESHOOTING tables are included for each system to help you diagnose the system problem and find the cause The repair for each possible cause is referenced in the remedy col umn to quickly lead you to the solution REPAIR PROCEDURES Most repair operations begin with an ove...

Page 8: ...ced technician with a FAST TRACK to the information needed The upper case task heading can be read at a glance and only when necessary the text below it provides detailed information Important specifications and warnings always stand out in bold type REFERENCES References have been kept to a minimum However when they are required you are given the page to go to SPECIFICATIONS Specifications are pr...

Page 9: ...a Before performing electrical work disconnect the negative cable from the battery terminal b If it is necessary to disconnect the battery for inspec tion or repair always disconnect the cable from the negative terminal which is grounded to the vehi cle body c To prevent damage to the battery terminal post loosen the terminal nut and raise the cable straight up without twisting it or prying it d C...

Page 10: ... gaskets to prevent leaks 8 Carefully observe all specifications for bolt tightening tor ques Always use a torque wrench 9 Use of special service tools SST and special service materials SSM may be required depending on the nature of the repair Be sure to use SST and SSM where specified and follow the proper work procedure A list of SST and SSM can be found at the back of this manual 10 When replac...

Page 11: ...on a hard floor they should be replaced and not reused e When steam cleaning an engine protect the IIA from water f Never use an impact wrench to remove or install ther mo switches or thermo sensors g When checking continuity at the wire connector insert the tester probe carefully to prevent terminals from bending h When using a vacuum gauge never force the hose onto a connector that is too large ...

Page 12: ...ning the engine at idle speed for more than 20 minutes 3 Avoid spark jump test a Spark jump test only when absolutely necessary Per form this test as rapidly as possible b While testing never race the engine 4 Avoid prolonged engine compression measurement Engine compression tests must be made as rapidly as possible 5 Do not run engine when fuel tank is nearly empty This may cause the engine to mi...

Page 13: ...ION Vehicle Lift and Support Locations VEHICLE LIFT AND SUPPORT LOCATIONS JACK POSITION Front Under the front differential Rear Under the rear differential SCREW TYPE JACK POSITION 0 SUPPORT POSITION Safety stand IN0041 IN0042 ...

Page 14: ...re Top Dead Center Bimetal Vacuum Switching Valve Dash Pot Electronic Controlled Unit Electronic Fuel Injection Exhaust Gas Recirculation Electronic Spark Advance Evaporative Emission Control Exhaust manifold valve Except Formed in Place Gasket Ignition Intake manifold valve Idle Speed Control Maximum Multipurpose Oversize Positive Crankcase Ventilation Power Steering Special Service Materials Spe...

Page 15: ... MEMO ...

Page 16: ... MA 2 MAINTENANCE OPERATIONS MA 4 GENERAL MAINTENANCE MA 14 l t t GENERAL NOTES Every service item in the periodic maintenance list must be performed Failure to do even one item can cause the engine to run poorly and increase exhaust emissions ...

Page 17: ...rake lining and drums I I I I MA 7 item 13 Brake pads and discs I I I I MA 8 item 15 Brake line pipes and hoses I I I I MA 7 item 1 3 CHASSIS Steering linkage I I I I MA 8 item 16 Ball joints and dust covers I I I I MA 8 item 16 Front wheel bearing and thrust bush grease R R MA 1 0 item 21 Steering knuckle and chassis grease 3 R R R R MA 11 item 22 Propeller shaft grease 3 l R R R R MA 11 item 22 ...

Page 18: ...7 EXHAUST Oxygen sensors Except california R 7 MA 6 item 11 BRAKES Brake lining and drums I I I I I I I I MA 7 item 13 Brake pads and discs I I I I I I I I MA 8 item 15 Brake line pipes and hoses I I I I MA 7 item 13 CHASSIS Steering linkage I I I I I I I I MA 8 item 16 Ball joints and dust covers I I I I I I I I MA 8 item 16 Automatic transmission transfer differential MA 8 item 17 steering gear ...

Page 19: ...145 25 lb 100 20 lb 145 25 lb 80 20 lb 125 25 lb If necessary adjust the drive belt tension NOTE When checking the tension be sure the gauge is on the belt protrusion ex A C drive belt New belt refers to a belt which has been used less than 5 minutes on a running engine Used belt refers to a belt which has been used on a running engine for 5 minutes or more After replacing the drive belt check tha...

Page 20: ...il filter change 7 8 liters 8 2 US qts 7 0 Imp qts REPLACE ENGINE COOLANT a Drain the coolant from radiator and engine drain cocks b Close the drain cocks c Fill system with coolant Coolant capacity wl Front heater 17 5 liters 18 5 US qts 15 4 Imp qts w I Front and rear heaters 19 5 liters 20 6 US qts 17 2 Imp qts Use a good brand of ethylene glycol base coolant mixed according to the manufacturer...

Page 21: ...nuts heat insulator oxygen sensor and gasket from the exhaust manifold c Install new gasket oxygen sensor and heat insulator with the two nuts Torque 200 kg em 14 ft lb 20 N m d Inspect the oxygen sensor operation See page Fl 80 Hot Engine Operations 12 ADJUST VALVE CLEARANCE a Warm up the engine to normal operating tempera ture b Stop the engine and remove the cylinder head cover c Set No 1 cylin...

Page 22: ... the entire circumference and length of the brake hoses using a mirror as required Turn the front wheels fully right or left before inspecting the front brake a Check all brake lines and hoses for Damage Corrosion Wear Leaks Deformation Bends Cracks Twists b Check all clamps for tightness and connections for leakage c Check that the hoses and lines are clear of sharp edges moving parts and the exh...

Page 23: ...RING LINKAGE AND DUST COVERS a Check the steering wheel freeplay Maximum steering wheel freeplay 40 mm 1 57 in With the vehicle stopped and pointed straight ahead rock the steering wheel gently back and forth with light finger pressure b Check the steering linkage for looseness or damage Check that Tie rod and relay ends so not have excessive play Dust seals and boots are not damage c Inspect the ...

Page 24: ... 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 the hole If the level is low add oil until it begins to run out the filler hole Differential oil Oil grade API GL 5 hypoid gear oil Viscosity Above 18 C O F SAE 90 Below 1s c O F SAE SOW 90 or SOW REP LACE AUTOMATIC TRANSMISSION FLUID a Remove the drain plug and drain the fl...

Page 25: ...ces for damage Pack the bearings and axle hubs with lithium base multipurpose grease Grease grade Lithium base multipurpose grease NLGI No 2 b Install the inner bearing and oil seal into the axle 1 A11so hub c Install the axle hub outer bearing and thrust washer and adjust the wheel bearing preload Using SST torque the adjusting nut SST 09607 60020 Torque 600 kg em 43 ft lb 59 N m Turn the hub rig...

Page 26: ...sher teeth outward and the other lock washer teeth inward 22 LUBE STEERING KNUCKLE CHASSIS AND PROPELLER SHAFT a Remove the screw plug from each steering knuckle and repack with lubricant Steering knuckle grease Molybdenum disulphide lithium base chassis grease NLGI No 2 b Reinstall the two screw plugs c Lubricate chassis components referring to the lubri cation chart Before pumping in grease wipe...

Page 27: ...ND NUTS ON CHASSIS AND BODY a Tighten the following parts Front seats mounting bolts Torque 380 kg em 27ft lb 37 N m Front and rear leaf spring U bolt mounting nuts Torque 1 450 kg em 105ft lb 142 N m b In addition to the scheduled maintenance items check for loose or missing bolts and nuts of the following Steering system Drive train Suspension system Fuel tank mounts Engine mounts etc ...

Page 28: ...MA 13 Seat adjusts easily and locks securely in any posi tion Front seat back locks securely in any position Folding down rear seat backs lock securely b Road test Check the engine and chassis for abnormal noises Check that the vehicle dose not wander or pull to one side Check that the brakes work properly and do not drag c Be sure to deliver a clean car and especially check Steering wheel Shift l...

Page 29: ...engine hood secondary latch secures the hood from opening when the primary latch is released INSIDE VEHICLE 7 LIGHTS a Check that the headlight stop light taillights turn signal lights and other lights are all working b Check the headlight aim 8 WARNING LIGHTS AND BUZZERS Check that all warning lights and buzzers function properly 9 HORN Check that it is working 10 WINDSHIELD GLASS Check for scrat...

Page 30: ...E lEVEl Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case If level is low add distilled water only 27 BRAKE FlUID lEVEl Check that the brake fluid level is near the upper level line on the see through reservoir 28 ENGINE DRIVE BElTS Check all drive belts for fraying cracks wear or oiliness 29 ENGINE Oil lEVEl Check the level on the dipstic...

Page 31: ... MEMO ...

Page 32: ...EM 1 ENGINE MECHANICAL Page TROUBLESHOOTING EM 2 ENGINE TUNE UP EM 6 COMPRESSION CHECK EM 10 CYLINDER HEAD EM 11 TIMING GEARS AND CAMSHAFT EM 33 CYLINDER BLOCK EM 45 1111111111 111111 ...

Page 33: ...tion problems Perform spark test Ignition coil Igniter Distributor Spark plug faulty Inspect plugs High tension cords disconnected broken Inspect cords Vacuum leaks Repair as necessary PCV line EGR line Intake manifold Air intake chamber Throttle body ISC valve Brake booster line Pulling in air between air flow meter and Repair as necessary throttle body Low compression Check compression ROUGH IDL...

Page 34: ...Page Engine hesitates Spark plug faulty Inspect plugs IG 6 poor acceleration High tension cord faulty Inspect cords IG 6 Vacuum leaks Repair as necessary PCV line EGR line Intake manifold Air intake chamber Throttle body ISC valve Brake booster line Pulling in air between air flow meter Repair as necessary and throttle body Incorrect ignition timing Reset timing IG 11 Incorrect valve clearance Adj...

Page 35: ...air as necessary Vacuum leak Check hoses and repair as PCV line necessary EGA line Intake manifold Air intake chamber Throttle body ISC valve Brake booster line Pulling in air between air flow meter Repair as necessary and throttle body Insufficient fuel flow Troubleshoot fuel system Fl 9 Incorrect ignition timing Reset timing IG 11 Incorrect valve clearance Adjust valve clearance EM 7 Carbon depo...

Page 36: ... system Fl 40 71 Spark plug faulty Inspect plugs IG 6 EG R system always on Check EG R system EC 11 Low compression Check compression EM 10 Tires improperly inflated Inflate tires to proper pressure Brakes drag Troubleshoot brakes UNPLEASANT ODOR Problem Possible cause Remedy Page Unpleasant odor Incorrect idle speed Check ISC system Fl 40 71 Incorrect ignition timing Reset timing IG 11 Vacuum lea...

Page 37: ...ION OF BATTERY See steps 1 and 2 on page CH 3 Standard specific gravity 1 25 1 27 when fully charged at 20 C 68 F INSPECTION OF HIGH TENSION CORDS See page IG 6 Maximum resistance 25 kQ per cord INSPECTION OF SPARK PLUGS See page IG 6 Recommended spark plug ND W16EXR U NGK BPR5EY Correct electrode gap 0 8 mm 0 031 in INSPECTION OF ALTERNATOR DRIVE BELT See page CH 3 Drive belt tension New belt 145...

Page 38: ...e revolution 360 and align the mark as above 4 INSPECT AND ADJUST VALVE CLEARANCE Front First a Measure only those valves indicated by arrows EM1519 Front Second 5 6 EM1519 Valve clearance Hot Intake 0 20 mm 0 008 in Exhaust 0 35 mm 0 014 in Using athickness gauge measure the valve clear ance between the valve stem and rocker arm Loosen the lock nut and turn the adjusting screw to set the proper c...

Page 39: ...R systems etc should be properly connected f EFI system wiring connectors fully plugged g Ignition timing set correctly h Transmission in N range i Tachometer and HC I CO meter at hand and cali brated 2 START ENGINE 3 CHECK OXYGEN SENSORS OPERATION a Using a service wire short terminals TE1 and E1 of the check connector b Connect the positive probe of a voltmeter to terminal VF1 VF2 of the check c...

Page 40: ...hooting Cause 1 Faulty ignition Incorrect timing Fouled shorted or improperly gapped plugs Open or crossed high tension cords Cracked distributor cap 2 Incorrect valve clearance 3 Leaky EGR valve 4 Leaky intake and exhaust valves 5 Leaky cylinder 1 Vacuum leak Fluctuating HC reading PCV hose EGR valve Intake manifold Air intake chamber Throttle body ISC valve Brake booster line 2 Lean mixture caus...

Page 41: ...surement must be done for as short time as possible d Repeat steps a through c for each cylinder Compression pressure 10 5 kglcm2 149 psi 1 030 kPa or more Minimum pressure 8 0 kglcm2 114 psi 785 kPa Difference between each cylinder 0 5 kg I cm2 7 psi 49 kPa or less e If compression of one or more cylinders is low pour a small amount of engine oil into that cylinder through the spark plug hole and...

Page 42: ...t Assembly Valve Cylinder Head __ Gasket I kg em ft lb N m I Specified torque Non reusable part CYLINDER HEAD COMPONENTS Air Intake Chamber Stay Air Pump I Isee page EM 30 Air Pump Stay t Air Intake Chamber No 2 Fuel Pipe with Engine Hanger Pulsation Damper r Delivery Pipe Manifold Stay YL Exhaust Manifold EM4485 ...

Page 43: ...se clamp d Remove the wing nut and loosen the three clips and remove the air intake hose air flow meter and air cleaner cap REMOVE PS PUMP WITHOUT DISCONNECTING HOSES a Push on the drive belt to hold the pulley in place and loosen the pulley nut b Loosen the idler pulley and adjusting bolts and re move the drive belt c Remove the drive pulley and woodruff key d Remove PS mount bolts and remove the...

Page 44: ...s securely sup ported 14 DISCONNECT EXHAUST PIPE FROM EXHAUST MANIFOLD a Loosen the bolt and disconnect the clamp from the bracket b Remove the four nuts and disconnect the exhaust pipe 15 REMOVE AIR PUMP a Disconnect the air hose b Remove the bolt nut and air pump stay c Remove the through bolt nut and air pump 16 REMOVE DELIVERY PIPE AND INJECTORS See steps 4 to 9 on pages Fl 58 59 17 REMOVE AIR...

Page 45: ...using to the cylinder head and remove the water outlet assembly and gasket 20 REMOVE SPARK PLUGS 21 REMOVE CYLINDER HEAD COVER Remove the four cap nuts seal washers cylinder head cover and gasket 22 REMOVE VALVE ROCKER SHAFT ASSEMBLY a Uniformly loosen and remove the eight bolts and four nuts in several passes in the sequence shown b Remove the rocker shaft assembly 23 REMOVE PUSH RODS Remove the ...

Page 46: ...e or cracking could re sult from removing the bolts in incorrect order b Remove the air pump bracket with engine hanger c Lift the cylinder head from the dowels on the cylin der block and place it on wooden blocks on a bench NOTE If the cylinder head is difficult to lift off pry with a screwdriver between the cylinder head and block saliences CAUTION Be careful not to damage the cylin der head and...

Page 47: ... REMOVE VALVES a Using SST press the valve springs and remove the two keepers SST 09202 43013 b Remove the spring retainer or valve rotator valve springs and valve c Using a screwdriver pry out the valve stem oil seal d Remove the valve spring seat NOTE Arrange the valves valve springs and spring re tainers or valve rotators in correct order ...

Page 48: ...on and oil from the bolt holes WARNING Protect your eyes when using high pressure air REMOVE GASKET MATERIAL Using a gasket scraper remove all the gasket material from the manifold and head surface CAUTION Be careful not to scratch the sur faces CLEAN COMBUSTION CHAMBERS Using a wire brush remove all the carbon from the com bustion chambers CAUTION Be careful not to scratch the head gasket contact...

Page 49: ...reater than maximum replace the cylinder head 7 INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrant check the combustion chamber intake and exhaust ports head surface and the top of the head for cracks If cracked replace the head 8 CLEAN VALVES a Use a gasket scraper chip any carbon from the valve head b Using a wire brush thoroughly clean the valve 9 INSPECT VALVE STEM AND GUIDE BUSHINGS a Usi...

Page 50: ...SSARY REPLACE VALVE GUIDE BUSHINGS a Using SST and a hammer drive out the valve guide bushing SST 09201 60011 b Using a caliper gauge measure the bushing bore diameter of the cylinder head Standard valve guide bore cold 14 000 14 018 mm 0 5512 0 5519 in If the bushing bore diameter of the cylinder head is more than 14 018 mm 0 5512 in machine the bore to the following dimensions and install an ove...

Page 51: ...D GRIND VALVES a Grind the valve only enough to remove pits and carbon b Check that the valve are ground to the correct valve face angle Valve face angle 44 5 c Check the valve head margin thickness Standard margin thickness Intake 1 5 2 1 mm 0 059 0 083 in Exhaust 1 7 2 3 mm 0 067 0 091 in Minimum margin thickness Intake 1 0 mm 0 039 in Exhaust 1 2 mm 0 047 in If the valve head margin thickness i...

Page 52: ...the valve face Install the valve While applying light pressure to the valve rotate the valve against the seat c Check the valve face and seat for the following If blue appears 360 around the face the valve is concentric If not replace the valve If blue appears 360 around the valve seat the guide and seat are concentric If not resurface the seat Check that the seat contact is on the middle of the v...

Page 53: ...sing calipers measure the free length of the valve spring Standard free length 51 5 mm 2 028 in Minimum free Length 50 0 mm 1 967 in If the length is less than minimum replace the valve c Using a spring tester measure the tension of the valve spring at the specified installed length Standard installed tension 32 5 kg 71 6 lb 319 N at 43 0 mm 1 693 in Minimum installed tension 27 kg 59 5 lb 265 N a...

Page 54: ...ms and rocker supports in correct order If the contacting surface of the rocker arm is worn resur face it a valve refacer and oil stone or replac e the rocker arm d Inspect the oil clearance between the rocker arm and shaft Using a caliper gauge measure the inside diame ter of the rocker arm Rocker arm inside diameter 18 494 18 515 mm 0 7281 0 7289 in Using a micrometer measure the diameter of the...

Page 55: ... diameter measurement from the inside diameter measurement of the rocker arm Standard oil clearance 0 009 0 051 mm 0 0004 0 0020 in Maximum oil clearance 0 08 mm 0 0031 in If the clearance is greater than maximum replace the rocker arm and shaft e Assemble the valve rocker shaft assembly as shown Other Oil Hole No 4 Valve Rocker Support B EM1509 ...

Page 56: ...e the push rod 16 INSPECT INTAKE AND EXHAUST MANIFOLDS Using a precision straight edge and thickness gauge measure the surfaces contacting the cylinder head and air intake chamber for warpage Maximum warpage 0 50 mm 0 0197 in If the warpage is greater than maximum replace the manifold 17 INSPECT AIR INTAKE CHAMBER Using a precision straight edge and thickness gauge measure the surfaces contacting ...

Page 57: ...ed Before installing the parts apply new engine oil to all sliding and rotating surfaces Replace all gaskets and oil seals with new ones 1 INSTALL VALVES a Place the valve spring seat on spring seat b Using SST and a hammer tap in a new oil seal SST 09201 31 01 0 c Install the valve spring and spring retainer or valve rotator NOTE Install the spring with the correct direction as shown ...

Page 58: ...sing SST compress the valve spring and place the two keepers around the valve stem SST 09202 43013 NOTE Different keepers are used for the spring retainer and valve rotator e Using a plastic faced hammer lightly tap the valve stem tip to assure proper fit 2 INSTALL AIR INJECTION MANIFOLD UNIONS ...

Page 59: ... and uniformly tighten the ten cylinder head bolts with the plate washers in several passes in the sequence shown Torque 1 250 kg em 90ft lb 123 N m 2 INSTALL PUSH RODS Install the twelve push rods 3 INSTALL VALVE ROCKER SHAFT ASSEMBLY a Place the rocker shaft assembly on the cylinder head b Align the rocker arm adjusting screws with the heads of the push rods c Install and uniformly tighten the e...

Page 60: ...m 0 008 in Exhaust 0 35 mm 0 014 in NOTE After warm up readjust the valve clearance Using athickness gauge measure the valve clear ance between the valve stem and rocker arm Loosen the lock nut and turn the adjusting screw to set the proper clearance Hold the adjusting screw in position and tighten the lock nut Recheck the valve clearance The thickness gauge should slide with a very slight drag c ...

Page 61: ...ten bolts four plate washers and nuts Torque the bolts and nuts Torque 17 mm bolt A 700 kg em 51 ft lb 69 N m 14 mm bolt B 510 kg em 37 ft lb 50 N m Nut C 570 kg em 41 ft lb 56 N m c Install the three manifold heat insulators with the six bolts Torque 120 kg em 9 ft lb 12 N m d Install the manifold stay with the two bolts Torque 300 kg em 22 ft lb 29 N m 9 INSTALL AIR INJECTION MANIFOLD Install th...

Page 62: ... COOLER PIPE a Install the heater water oil cooler pipe with the bolts b Connect the hoses to the water outlet water pump oil cooler and heater water pipe 17 CONNECT HIGH TENSION CORDS TO SPARK PLUGS AND IGNITION COIL 18 INSTALL PS PUMP AND A C COMPRESSOR BRACKETS 19 INSTALL A C COMPRESSOR a Install the A C compressor with the four bolts b Install and adjust the drive belt See page MA 4 20 INSTALL...

Page 63: ...COOLANT See page C0 3 Capacity w I Front heater 17 5 liters 18 5 US qts 15 4 Imp qts wI Front and rear heaters 19 5 liters 20 6 US qts 17 2 Imp qts 24 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 25 START ENGINE AND CHECK FOR LEAKS 26 PERFORM ENGINE ADJUSTMENT a Adjust the ignition timing See steps 10 to 14 on page IG 1 1 Ignition timing 7 BTDC idle wl Terminals TE1 and E1 short circuited b Adjus...

Page 64: ...T COMPONENTS Water Pump Pulley Fluid Coupling __ I Valve Lifter Thrust Washer Push Rod Cover Gasket Camshaft Timing L _ Gear Power Steering Pulley Gasket I Timing Gear Cover Oil Seal Crankshaft Pulley r 3 50 0 25 3 34 3 1 I kg em ft lb N m I Specified torque Non reusable part EM 33 EM4521 ...

Page 65: ...c Loosen the air intake hose clamp d Remove the wing nut and loosen the three clips and remove the air intake hose air flow meter and air cleaner cap 4 LOOSEN PS DRIVE PULLEY NUT Push on the drive belt to hold the pulley in place and loosen the pulley nut 5 REMOVE FLUID COUPLING WITH FAN AND WATER PUMP PULLEY See steps 2 to 6 on pages C0 4 5 6 REMOVE PS PUMP AND A C COMPRESSOR See steps 6 and 7 on...

Page 66: ...ginning from the No 1 valve lifters NOTE Arrange the valve lifters in correct order 13 REMOVE PS PULLEY FROM CRANKSHAFT PULLEY Remove the six bolts and PS pulley 14 REMOVE CRANKSHAFT PULLEY a Using SST and a 46 mm socket wrench remove the pulley mount bolt SST 09213 58011 and 09330 00020 b Using SST remove the pulley SST 09213 60017 15 REMOVE OIL COOLER PIPE WITH HOSE ...

Page 67: ...h 0 100 0 183 mm 0 0039 0 0072 in Maximum backlash 0 25 mm 0 0098 in If the backlash is greater than maximum replace the camshaft and crankshaft timing gears 18 REMOVE CAMSHAFT TIMING GEAR AND CAMSHAFT ASSEMBLY a Remove the two bolts mounting the thrust plate to the cylinder block b Carefully pull out the camshaft and timing gear as sembly CAUTION Be careful not to damage the camshaft bearing 19 R...

Page 68: ...le runout at the No 2 and No 3 journals Maximum circle runout 0 30 mm 0 0118 in If the circle runout is greater than maximum replace the __ _ _ _ _ _ _ _ _ ___ EM 546 camshaft EM2011 b Using a micrometer measure the cam lobe height Standard cam lobe height Intake 38 36 38 46 mm 1 51 02 1 5142 in Exhaust 38 25 38 35 mm 1 5059 1 5098 in Minimum cam lobe height Intake 38 0 mm 1 496 in Exhaust 37 9 mm...

Page 69: ...725 mm 1 7604 1 7608 in No 4 43 215 43 225 mm 1 7014 1 7018 in U 5 0 50 No 1 47 465 47 475 mm 1 8687 1 8691 in No 2 45 965 45 975 mm 1 8096 1 8888 in No 3 44 465 44 475 mm 1 7506 1 7510 in No 4 42 965 42 975 mm 1 6915 1 6919 in If the journal diameter is not within specification check the oil clearance See page EM 65 d Using a thickness gauge measure the thrust clear ance between the thrust plate ...

Page 70: ...et wrench and press press out camshaft ASSEMBLE CAMSHAFT AND CAMSHAFT TIMING GEAR a Install the timing gear set key to the camshaft b Assemble the camshaft thrust plate and timing gear as shown c Using SST and a press align the timing gear set key with the key groove of the timing gear and press in the camshaft SST 09214 6001 0 d Using snap ring pliers install the snap ring as shown 3 CHECK CAMSHA...

Page 71: ...ENT OF CRANKSHAFT FRONT OIL SEAL REPLACE CRANKSHAFT FRONT OIL SEAL NOTE There are two methods A and B to replace the oil seal as follows A If timing gear cover is removed from cylinder block a Using a screwdriver and hammer tap out the oil seal b Using SST and a hammer tap in a new oil seal SST 09223 5001 0 c Apply M P grease to the oil seal B If timing gear cover is installed to cylinder block a ...

Page 72: ... in the timing gear SST 09214 6001 0 d Using a plastic faced hammer tap in the crankshaft pulley set key 2 INSTALL CAMSHAFT TIMING GEAR AND CAMSHAFT ASSEMBLY a Set the crankshaft timing gear with the key groove facing upward by turning the crankshaft clockwise b Insert the camshaft into the cylinder block CAUTION Be careful not to damage the camshaft bearings c Align the timing marks of the cranks...

Page 73: ...ft clockwise and coun terclockwise Standard backlash 0 100 0 183 mm 0 0039 0 0072 in Maximum backlash 0 25 mm 0 0098 in 4 INSTALL OIL NOZZLE a Install and set the oil nozzle in position b Using a chisel and hammer stake the threads of the oil nozzle 5 INSTALL TIMING GEAR COVER AND CRANKSHAFT PULLEY NOTE There are three size timing gear cover bolts indi cated A 8 and C a Apply adhesive to the threa...

Page 74: ...que Bolts A 250 kg em 18ft lb 25 N m Bolts B and C 50 kg em 43 in lb 4 9 N m f Using SST and a 46 mm socket wrench install and torque the pulley mount bolt SST 09213 58011 and 09330 00020 Torque 3 500 kg em 253ft lb 343 N m INSTALL PS PULLEY TO CRANKSHAFT PULLEY Install the PS pulley with the six bolts torque the bolts Torque 185 kg em 13ft lb 18 N m 7 INSTALL VALVE LIFTERS Carefully insert the tw...

Page 75: ... intake hose air flow meter and air cleaner cap with the wing nut and three clips b Connect following hoses ISC hose Air pump hose Distributor hose PCV hose Three hoses from the intake chamber rear side Two hoses from the VCV of the charcoal canister 16 CONNECT ACCELERATOR AND THROTTLE CABLES AND ADJUST THEM 17 FILL WITH ENGINE COOLANT See page C0 3 18 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY...

Page 76: ...hing Connecting Rod Canshaft Bearing Connecting Rod Bearing Connecting Rod Cap 600 1 e Front End Plate Crankshaft Main Bearing Main Bearing Cap l il 375 css 135 1 kg em ft lb N m Specified torque Non reusable part Precoated part Oil Seal 1 175 85 115 Thrust Washer Gasket Drive Plate Transmission Case Dust Cover EM4483 ...

Page 77: ... c Disconnect the air intake hose clamp d Remove the wing nut and loosen the three clips and remove the air intake hose air flow meter and air cleaner cap e Remove the air cleaner element f Remove the three bolts and air cleaner case 7 REMOVE COOLANT RESERVOIR TANK 8 REMOVE RADIATOR See page C0 11 9 DISCONNECT FOLLOWING WIRES AND CONNECTORS a Oil pressure connector b High tension cord from ignitio...

Page 78: ...rive belt to hold the pulley in place and loosen the pulley nut b Loosen the idler pulley nut and adjusting bolt and remove the drive belt c Remove the pulley mount nut drive pulley and woodruff key d Remove PS mount bolts and remove the PS pump from the bracket 13 REMOVE A C COMPRESSOR WITHOUT DISCONNECTING HOSES a Disconnect the connector b Loosen the idler pulley nut and adjusting bolt and remo...

Page 79: ...d nuts c Remove the four nuts d Remove the propeller shaft 17 DISCONNECT SPEEDOMETER CABLE 18 DISCONNECT GROUND STRAP FROM BODY 19 DISCONNECT TWO VACUUM HOSES FROM DIAPHRAGM CYLINDER FOR TRANSFER 20 DISCONNECT TRANSFER SHIFT LEVER a Remove the clip and pin and disconnect the shift rod from the transfer b Remove the nut and then disconnect the washers and the transfer shift lever with shift rod ...

Page 80: ...en block between the jack and the transmission pan to prevent damage 24 REMOVE FRAME CROSSMEMBER Remove the eight bolts and two nuts and then remove the frame crossmember 25 REMOVE ENGINE WITH TRANSMISSION a Attach the engine hoist chain to the two engine hangers b Remove the mount nuts and washers c Lift the engine with transmission out of the vehicle slowly and carefully NOTE Make sure the engin...

Page 81: ...page EM 49 1 REMOVE FRONT END PLATE a Using a torx socket wrench remove the three screws b Remove the two bolts front end plate and gasket 2 CHECK CONNECTING ROO THRUST CLEARANCE 3 Using a dial indicator measure the thrust clearance while moving the rod back and forth Standard thrust clearance 0 160 0 300 mm 0 0063 0 0118 in Maximum thrust clearance 0 40 mm 0 0156 in If clearance is greater than m...

Page 82: ...ower bearing inserted with the con necting rod cap d Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage e Clean the crank pin and bearing f Check the crank pin and bearing for pitting and scratches If the crank pin or bearing are damaged replace the bear ings If necessary grind or replace the crankshaft g Lay a strip of Plastigage across the crank pin ...

Page 83: ... crankshaft NOTE If using a standard bearing replace with one having the same number marked on the connecting rod cap There are three sizes of standard bearings marked A B and C Reference Standard bearing thickness at center wall Mark A 1 484 1 488 mm 0 0584 0 0586 in EM43so Mark B 1 488 1 492 mm 0 0586 0 0587 in Mark C 1 492 1 496 mm 0 0587 0 0589 in k Completely remove the plastigage 4 REMOVE PI...

Page 84: ... 0 25 REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE a Uniformly loosen and remove the main bearing cap bolts in several passes in the sequence shown b Using the removed main bearing cap bolts wiggle the cap back and forth and remove the caps lower bearings and lower thrust washers No 3 cap only NOTE Keep the lower bearing and main bearing cap together Arrange the main bearing caps and lower thr...

Page 85: ... 067 mm 0 0008 0 0026 in Maximum oil clearance 0 10 mm 0 0039 in NOTE If replacing the cylinder block subassembly the bearing standard clearance will be 0 004 0 060 mm 0 002 0 0024 in If the oil clearance is greater than maximum replace the bearings If necessary grind or replace the crankshaft NOTE If replacing a standard size bearing with a stan dard oil clearance replace with one having the same...

Page 86: ...68 488 68 496 mm 2 6964 2 6967 in No 3 69 988 69 996 mm 2 7554 2 7557 in No 4 71 488 71 496 mm 2 8145 2 8148 in EM 55 Cylinder block main journal bore diameter Mark 6 No 1 72 010 72 018 mm 2 8350 2 8353 in No 2 73 510 73 518 mm 2 8941 2 8944 in No 3 75 01 0 75 018 mm 2 9531 2 9535 in No 4 76 510 76 518 mm 3 0122 3 0125 in Mark 7 No 1 72 018 72 026 mm 2 8353 2 8357 in No 2 73 518 73 526 mm 2 8944 2...

Page 87: ...remove the Plastigage 7 REMOVE CRANKSHAFT a Lift out the crankshaft b Remove the upper bearings and upper thrust wash ers NOTE Arrange the caps bearings and thrust washers in correct order INSPECTION OF CYLINDER BLOCK 1 REMOVE GASKET MATERIAL Using a gasket scraper remove all the gasket material from the cylinder block surface 2 CLEAN CYLINDER BLOCK Using a soft brush and solvent clean the block 3...

Page 88: ...BORE DIAMETER Using a cylinder gauge measure the cylinder bore di ameter at positions A B and C in the thrust and axial directions Standard diameter STD size 94 000 94 030 mm 3 7008 3 7020 in Maximum diameter STD size 94 23 mm 3 7098 in 0 S 0 50 94 73 mm 3 7295 in 0 S 1 00 95 23 mm 3 7492 in 0 S 1 50 95 73 mm 3 7689 in If the diameter is greater than maximum rebore all six cylinders If necessary r...

Page 89: ...e piston pin If any movement is felt replace the piston and pin as a set 2 REMOVE PISTON RINGS a Using a piston ring expander remove the compres sion rings b Remove the two side rails and oil ring expander by hand NOTE Arrange the rings in correct order 3 DISCONNECT CONNECTING ROD FROM PISTON a Using needle nose pliers remove the snap rings from the piston b Gradually heat the piston to approx 80 ...

Page 90: ...d pin are a matched set Arrange the pistons pins rings connecting rods and bearings in correct order INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLIES 1 CLEAN PISTONS a Using a gasket scraper remove the carbon from the piston top b Using a groove cleaning tool or broken ring clean the ring grooves c Using asoft brush and solvent thoroughly clean the piston CAUTION Do not damage the piston ...

Page 91: ...ssary replace the cylinder block 3 INSPECT CLEARANCE BETWEEN WALL OF PISTON RING GROOVE AND NEW PISTON RING Using athickness gauge measure the clearance between new piston ring and the wall of the piston ring groove Ring groove clearance No 1 0 030 0 070 mm 0012 0 0028 in No 2 0 050 0 090 mm 0020 0 0035 in If the clearance is not within specification replace the piston 4 INSPECT PISTON RING END GA...

Page 92: ...y Check for twist Maximum twist 0 15 mm 0 0059 in per 100 mm 3 94 in If twist is greater than maximum replace the connecting rod assembly b Using a caliper gauge measure the inside diameter of the connecting rod bushing Bushing inside diameter 22 012 22 027 mm 0 8666 0 8672 in c Using a micrometer measure the piston pin diame ter Piston pin diameter 22 004 22 019 mm 0 8663 0 8669 in d Subtract the...

Page 93: ... Align the oil holes of the bushing and connecting rod b Using SST and a press press in the bushing SST 09222 3001 0 3 HONE ROD BUSHING AND CHECK PISTON PIN FIT IN CONNECTING ROD a Using a pin hole grinder hone the bushing to obtain the specified clearance between the bushing and piston pin b Check the piston pin fit at normal room temperature Coat the piston pin with engine oil and push it into t...

Page 94: ...463 95 493 mm 3 7584 3 7596 in 2 CALCULATE AMOUNT TO BORE CYLINDER a Using a micrometer measure the piston diameter at a right angle to the piston pin hole center line 16 mm 0 63 in below the skirt bottom edge b Calculate the amount each cylinder is to be rebored as follows Size to be rebored P C H P Piston diameter C Piston clearance 0 027 0 047 mm 0 0012 0 0020 in H Allowance for honing 0 02 mm ...

Page 95: ...4 71 472 71 496 mm 2 8139 2 8148 in U S 0 25 No 1 66 745 66 755 mm 2 6278 2 6281 in No 2 68 245 68 255 mm 2 6868 2 6872 in No 3 69 745 69 755 mm 2 7459 2 7463 in No 4 71 245 71 255 mm 2 8049 2 8053 in U S 0 50 No 1 66 495 66 505 mm 2 6179 2 6183 in No 2 67 995 68 005 mm 2 6770 2 6774 in No 3 69 495 69 505 mm 2 7360 2 7364 in No 4 70 995 71 005 mm 2 7951 2 7955 in Crank pin diameter STD size 52 988...

Page 96: ...mm 1 7126 1 7138 in U S 0 25 No 1 47 750 47 825 mm 1 8799 1 8829 in No 2 46 250 46 325 mm 1 8209 1 8238 in No 3 44 750 44 820 mm 1 7618 1 7646 in No 4 43 250 43 320 mm 1 7028 1 7055 in U S 0 50 No 1 47 500 47 575 mm 1 8701 1 8730 in No 2 46 000 46 075 mm 1 8110 1 8140 in No 3 44 500 44 570 mm 1 7520 1 7547 in No 4 43 000 43 070 mm 1 6929 1 6957 in b Subtract the journal diameter measurement See pa...

Page 97: ...0 09215 00150 09215 0021 0 B Remove camshaft bearings Using SST remove the bearings SST 09215 00012 09215 00020 09215 00030 09215 00410 09215 00420 and 09215 001 00 09215 00130 09215 00140 09215 00150 09215 00160 09215 00240 09215 00270 C Install new camshaft bearings a Align the oil holes of the bearing and cylinder block b Using SST install the bearings SST 09215 00012 09215 00020 09215 00030 09...

Page 98: ...IF NECESSARY GRIND AND HONE CAMSHAFT JOURNALS Grind and hone the journals to the undersized finished diameter See page EM 38 INSPECTION OF VALVE LIFTER BORES INSPECT VALVE LIFTER OIL CLEARANCE a Using a caliper gauge measure the valve lifter bore diameter Bore diameter 21 417 21 443 mm 0 8432 0 8442 in b Subtract the valve lifter diameter measurement See page EM 40 fro diameter measurement Standar...

Page 99: ...l lip b Using a screwdriver pry out the oil seal CAUTION Be careful not to damage the crankshaft Tape the screwdriver tip c Check the oil seal lip contact surface of the crankshaft for cracks or damage d Apply M P grease to a new oil seal lip e Using SST and a hammer tap in the oil seal until its surface is flush with the cylinder block and main bearing cap edges SST 09223 6001 0 ...

Page 100: ...the piston to approx sooc 176 F c Coat the piston pin with engine oil d Align the notch of the piston with the protrusion of the connecting rod and push in the piston pin with your thumb e Install a new snap ring on the other side of the pin hole 2 INSTA LL PISTON RINGS a Install the oil ring expander and two side rails by hand b Using a piston ring expander install the two com pression rings with...

Page 101: ...ings with the oil hole in the connecting rod ASSEMBLY OF CYLINDER BLOCK See page EM 45 NOTE Thoroughly clean all parts to be assembled Before installing the parts apply new engine oil to all sliding and rotating surfaces Replace all gaskets 0 rings and oil seals with new parts 1 INSTALL MAIN BEARINGS NOTE The outside diameter varies with each bearing All main bearing have oil holes except No 1 and...

Page 102: ...al lip b Push in the oil seal until its surface is flush with the cylinder block edge CAUTION Be careful not to install the oil seal slantwise 5 INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS a Apply seal packing to the main bearing installation surface of the cylinder block Seal packing Part No 08820 00080 or equivalent CAUTION Be careful not to apply seal packing to the main bearing b Instal...

Page 103: ...e connecting rod bolts with a short piece of hose to protect the crankshaft from damage b Using a piston ring compressor push the correctly numbered piston and connecting rod assemblies into the cylinder with the notch of the piston facing forward INSTALL CONNECTING ROD CAPS a Match the numbered cap with the numbered con necting rod b Install the connecting rod cap with the protrusion facing forwa...

Page 104: ...INSTALL FRONT END PLATE a Install the end plate with the two bolts b Using a torx socket wrench torque the screws Torque 250 kg em 18 ft lb 25 N m c Torque the bolts Torque 310 kg em 22 ft lb 30 N m d Using a chisel and hammer stake the screws ...

Page 105: ...ean the mount bolt threads and crankshaft bolt holes of any residual sealer oil foreign particles Remove any oil with kerosene or gasoline b Apply adhesive to two or three threads of the mount bolt end Adhesive Part No 08833 00070 THREE BOND 1324 or equivalent NOTE This sealant will not harden while exposed to air It will act as a sealer or binding agent only when ap plied to threads etc and the a...

Page 106: ...ne mounting supports d Install the washers and mount nuts e Remove the hoist chain 4 RAISE VEHICLE CAUTION Be sure the vehicle is securely sup ported 5 INSTALL FRAME CROSSMEMBER Install the frame crossmember with the eight bolts and two nuts Torque Bolt 400 kg em 29ft lb 39 N m Nut 600 kg em 43 ft lb 59 N m 6 CONNECT EXHAUST PIPE TO EXHAUST MANIFOLD a Place two new gaskets on the exhaust pipe b Co...

Page 107: ...T SPEEDOMETER CABLE 11 INSTALL FRONT AND REAR PROPELLER SHAFTS a Align the matchmarks on the flanges and connect the flanges with the four nuts b Torque the nuts Torque 900 kg em 65 ft lb 88 N m a Align the matchmarks on the flanges and connect the flanges with the four bolts and nuts b Torque the bolts and nuts Torque 900 kg em 65 ft lb 88 N m 12 INSTALL TRANSFER UNDER COVER 13 INSTALL A C COMPRE...

Page 108: ...nnect the four connectors c Install the glove box CONNECT FOLLOWING HOSES a Heater hoses b Fuel hoses c Transfer hose d Brake booster hose e PS air control valve hose f AI hoses g Distributor hose h Emission control hoses CONNECT FOLLOWING WIRES AND CONNECTORS a Oil pressure connector b High tension cord from ignition coil c Neutral start switch and transfer connectors located near the starter d F...

Page 109: ...5 liters 18 5 US qts 15 4 Imp qts wl Front and rear heaters 19 5 liters 20 6 US qts 17 2 Imp qts 23 FILL WITH ENGINE OIL See page LU 4 Capacity Drain and refill wlo Oil filter change 7 0 liters 7 4 US qts 6 2 Imp qts w I Oil filter change 7 8 liters 8 2 US qts 6 9 Imp qts Dry full 8 0 liters 8 5 US qts 7 0 Imp qts 24 INSTALL BATTERY TRAY AND BATTERY 25 START ENGINE AND CHECK FOR LEAKS 26 PERFORM E...

Page 110: ...TIVE CRANKCASE VENTILATION PCV SYSTEM FUEL EVAPORATIVE EMISSION CONTROL EVAP SYSTEM DASH POT DP SYSTEM EXHAUST GAS RECIRCULATION EGR SYSTEM AIR INJECTION AI SYSTEM THREE WAY CATALYST TWC SYSTEM NOTE TROUBLESHOOTING See page EM 2 EC 1 Page EC 2 EC 3 EC 4 EC 6 1m EC 9 EC 11 EC 16 EC 21 ...

Page 111: ...on control EVAP Reduced evaporative HC Dash pot DP Reduces HC and CO Exhaust gas recirculation EGR Reduces NOx Air injection AI Reduces HC and CO Three way catalyst TWC Reduces HC CO and NOx Electronic fuel injection EFI Regulates all engine conditions for reduction of exhaust emissions For inspection and repair of the EFI system refer to the EFI section of this manual ...

Page 112: ...out and Schematic Drawing EC 3 COMPONENT LAYOUT AND SCHEMATIC DRAWING vcv Check Valve A EGR Port EGR Gas Temp Sensor Calif only EGR Valve EGR Gas Temp Sensor Calif only Air Pump vsv for Pressure Regulator EC3046 Check Valve B VSV AI EC2888 ...

Page 113: ...as HC is routed through the PCV valve to the intake manifold for combustion in the cylinders Engine not Running or Backfiring Intake Manifold Side PCV VALVE IS CLOSED Cylinder Head Side Idling or Decelerating PCV VALVE IS OPE EC1007 VACUUM PASSAGE IS SMALL EC1008 Normal Operation PCV VALVE IS OPEN VACUUM PASSAGE IS LARGE Acceleration or High Load PCV VALVE IS FULLY OPEN EC1009 EC1010 ...

Page 114: ...UTION Do not suck air through the valve Petroleum substances inside the valve are harm ___ _ _ _ _ _ _ _ _ _ e c Jo ful Air Intake Chamber Side Clean EC1012 EC3077 4 BLOW FROM AIR INTAKE CHAMBER SIDE Check that air passes through with difficulty If the PCV valve fails either of the checks replace it 5 REINSTALL PCV VALVE INSPECTION OF PCV HOSES AND CONNECTIONS VISUALLY INSPECT HOSES CONNECTIONS AN...

Page 115: ...uum in tank EC1101 Check Valve Check vcv Valve in Evaporated Fuel HC 1 2 Cap CLOSED HC from tank is absorbed into the canister CLOSED CH from canister is led OPEN into air intake chamber OPEN CLOSED CLOSED HC from tank is absorbed into the canister CLOSED OPEN OPEN Air is led into the fuel tank INSPECTION OF FUEL VAPOR LINES FUEL TANK AND TANK CAP 1 VISUALLY INSPECT LINES AND CONNECTIONS Look for ...

Page 116: ...lean the filter by blowing 3 kg cm2 43 psi 294 kPa EC1106 Air Filter Air Filter of compressed air into the tank pipe while holding the other upper canister pipe closed NOTE Do not attempt to wash the canister No activated carbon should come out 5 INSTALL CHARCOAL CANISTER INSPECTION OF BVSV CHECK BVSV BY BLOWING AIR INTO PIPE a Drain the coolant from the radiator into a suitable container b Remove...

Page 117: ...JAir INSPECTION OF VCV CHECK VCV BY BLOWING AIR INTO PIPE a Apply vacuum above 70 mmHg 2 76 in Hg to pipe s b Blow air into pipe Yand check that air comes out of pipe Z c Stop the applied vacuum d Blow air into pipe Y and check that air does not come out of pipe Z If a probtem is found replace the VCV ...

Page 118: ... throttle valve slightly more than at idle This causes the air fuel mixture to burn completely Condition Diaphragm VTV Throttle Valve Idling Pushed in by return force of throttle CLOSED Idle speed position valve Normal driving Pushed out by diaphragm spring OPEN High speed position Deceleration Pushed in by return force of throttle CLOSED Slightly opens and then slowly closes valve to idle positio...

Page 119: ...ECK DP SETTING SPEED a Maintain engine speed at 2 500 rpm b Plug the VTV hole with your finger c Release the throttle valve d Check that the DP is set DP setting speed 1 200 rpm If not as specified adjust with the DP adjusting screw 6 CHECK OPERATION OF VTV a Set the DP speed in the same procedure as above a to c b Release the plugged hole and check that the engine returns to idle in approx 1 seco...

Page 120: ...NTROL SYSTEMS Exhaust Gas Recirculation EGR System EC 11 EXHAUST GAS RECIRCULATION EGR SYSTEM 1 I EGR Valve 1 vsv EGR 9 R Port EC3047 EC2931 2 3 EGR f9 RPort EGR Vacuum Modulator EC2932 EGR Vacuum Modulator EC2933 ...

Page 121: ... recirculated I Blow EGR port I 3 500 rpm Ex 1 Pressure con OPENS passage CLOSED Not deceleration Positioned between LOW stantly alter to atmosphere recirculated HIGH ON EGR port and 2 nating between CLO ES passage I EGR R port HIGH low and high to atmosphere OPEN Recirculated Positioned above 3 CLOSES passage Recirculated OPEN EGR port HIGH to atmosphere increase Pressure increase Modulator close...

Page 122: ...he engine and check that the engine starts and runs at idle 4 CHECK VSV WITH COLD ENGINE a The coolant temperature should be below 53oC 127 F b Check that the vacuum gauge indicates zero at 2 500 rpm 5 CHECK VSV AND EGR VACUUM MODULATOR WITH HOT ENGINE a Warm up the engine b Check that the vacuum gauge indicates low vacuum at 2 500 rpm c Check that the vacuum gauge indicates zero at idle d Disconn...

Page 123: ...VACUUM MODULATOR CHECK EGR VACUUM MODULATOR OPERATION a Disconnect the vacuum hoses from ports P Q and R of the EGR vacuum modulator b Block ports P and R with your finger c Blow air into port Q Check that the air passes through to the air filter side freely d Start the engine and maintain speed at 2 500 rpm e Repeat the above test Check that there is a strong resistance to air flow f Reconnect th...

Page 124: ... REMOVE EGR VALVE Check the valve for sticking and heavy carbon deposits If a problem is found replace it 2 REINSTALL EGR VALVE WITH NEW GASKET INSPECTION OF WATER TEMPERATURE SENSOR See page Fl 77 INSPECTION OF THROTTLE POSITION SENSOR See page Fl 68 INSPECTION OF AIR FLOW METER See page Fl 66 ...

Page 125: ...EC 16 EMISSION CONTROL SYSTEMS Air Injection AI System AIR INJECTION AI SYSTEM Check Valve B From Air Cleaner Check Valve A Silencer To Air Cleaner vsv ASV EC3048 ECU Valve B EC2922 ...

Page 126: ...YSTEM 1 VISUALLY CHECK HOSES AND TUBES FOR CRACKS KINKS DAMAGE OR LOOSE CONNECTIONS 2 PREPARATION Disconnect the air by pass hose from the ASV 3 CHECK ASV WITH FOLLOWING TEMPERATURE a The coolant temperature should be below 1O C 50 F or above 4o c 104 F b Start the engine and check that air is discharged from the ASV c The coolant temperature should be between 15 c 59 F and 35 C 95 F d With engine...

Page 127: ...assembly e Reconnect the hose to the proper location INSPECTION OF ASV 1 CHECK ASV OPERATION a Disconnect the vacuum hose from the ASV b Check that air comes out from the ASV 2 CHECK OPENING PRESSURE OF RELIEF VALVE a Disconnect the air hose from the check valve b Connect SST air pump tester to the hose SST 09258 1401 0 c Disconnect the vacuum hose from the VSV and connect the vacuum hose to the g...

Page 128: ...G AIR FROM EACH SIDE a Check that air does not flow from manifold side to ASV side b Check that air flows from ASV side to manifold side If a problem is found replace the valve INSPECTION OF CHECK VALVE B CHECK VALVE BY BLOWING AIR FROM EACH SIDE a Check that air flows from the orange pipe to the black side b Check that air does not flow from the black pipe to the orange pipe INSPECTION OF SPEED S...

Page 129: ... deflects consis tently CAUTION The ohmmeter probe should be in serted from the rear side of the connector If the ohmmeter needle does not deflect check that the speed sensor terminals at the back side of the speedome ter air properly connected If the connection is OK re place the speedometer assembly RECONNECT WIRING CONNECTOR TO COMPUTER INSPECTION OF WATER TEMPERATURE SENSOR See page Fl 77 INSP...

Page 130: ...on dioxide C02 and water H20 by the catalyst Exhaust Port HC CO and NOx v EC2902 TWC Exhaust Gas Oxidation and 1 reduction INSPECTION OF EXHAUST PIPE ASSEMBLY C02 H20 N2 1 CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE 2 CHECK CLAMPS FOR WEAKNESS CRACKS OR DAMAGE INSPECTION OF CATALYST CONVERTER CHECK FOR DENTS OR DAMAGE If any part of the protector is damaged or dented to the extent that it contacts t...

Page 131: ...TALYTIC CONVERTER 1 REMOVE CONVERTER a Jack up the vehicle 2 b Check that the converter is cool c Remove the bolts at the front and rear of the con verter d Remove the converter and gaskets INSTALL CONVERTER a Place new gaskets on the converter front and rear pipes and connect the converter to the exhaust pipes b Tighten the bolts Torque Catalyst Exhaust pipe 440 kg em 32 ft lb 43 N m c Reinstall ...

Page 132: ...k and Lines Fl 64 AIR INDUCTION SYSTEM Fl 66 Air Flow Meter Fl 66 Throttle Body Fl 68 Idle Speed Control ISC Valve Fl 71 ELECTRONIC CONTROL SYSTEM Fl 73 Location of Electronic Control Parts Fl 73 EFI Main Relay Fl 74 Circuit Opening Relay Fl 75 Cold Start Injector Time Switch Fl 76 Water Temperature Sensor FJ 77 High Temperature Line Pressure Up System Fl 78 EGR Gas Temperature Sensor California V...

Page 133: ... L l I IN Tt EGR Gas 1 II I 1 T A T S emp 1r emp ensor Sensor Y if I Cc ld Start __ l L T Injector t cSXv aerli t 1 I ll lL VI 2 a Injector crr ra l 1_ _ _ _ I Cold Start Injector J l Time Switch Water Temp Switch Air EGR Valve ECU Ignition Speed Switch 1 Sensor Hi _TE n in L L_ight Battery Distributor g Check Connector Terminal TE1 Neutral Start Switch _____ D Air Conditioner bl 4WD Switch L Star...

Page 134: ...re etc the microcomputer ECU triggers the spark at precisely the right instant See IG section 3 Idle Speed Control ISC The ECU is programmed with target idling speed values to respond to different engine conditions coolant temperature air condi tioner on off etc Sensors transmit signals to the ECU which control the flow of air through the bypass of the throttle valve and adjust idle speed to the t...

Page 135: ...NGINE TUNE UP See page EM 6 2 PRECAUTIONS WHEN CONNECTING GAUGE a Use the battery as the power source for the timing light tachometer etc b Connectthe test probe of a tachometer to the termi naiiG8of the check connector 3 IN EVENT OF ENGINE MISFIRE FOLLOWING PRECAUTIONS SHOULD BE TAKEN 4 a Check proper connection of battery terminals etc b Handle high tension cords carefully c After repair work ch...

Page 136: ...hed the IC may be destroyed by static electricity AIR INDUCTION SYSTEM 1 Separation of the engine oil dipstick oil filler cap PCV hose etc may cause the engine to run out of tune 2 Disconnection looseness or cracks in the parts of the air induction system between the air flow meter and cylinder head will allow air suction and cause the engine to run out of tune ELECTRONIC CONTROL SYSTEM 1 Before r...

Page 137: ...nspecting a connector with a volt ohmmeter a Carefully take out the water proofing rubber if it is a water proof type connector b Insert the test probe into the connector from wiring side when checking the continuity amperage or voltage c Do not apply unnecessary force to the terminal d After checking install the water proofing rubber on the connector securely 9 Use SST for inspection or test of t...

Page 138: ...asket b Tighten the union bolt by hand c Tighten the union bolt to the specified torque Torque 300 kg em 22 ft lb 29 N m Flare Nut Type a Apply a light coat of engine oil the flare and tighten the flare nut by hand b Using SST tighten the flare nut to specified torque SST 09631 22020 Torque 310 kg em 22 ft lb 30 N m NOTE Use atorque wrench with afulcrum length of 30 em 11 81 in 3 Observe the follo...

Page 139: ...n switch ON b Using a service wire short terminals Band FP of the check connector c When the fuel return hose is pinched the pressure within high pressure line will rise to approx 4 kg I cm2 57 psi 392 kPa In this state check to see that there are no leaks from any part of the fuel system CAUTION Always pinch the hose Avoid bend ing as it may cause the hose to crack ...

Page 140: ...sion control system PCV system EGA system AI system g Others Ignition timing ESA system Idle speed ISC system etc 2 The most frequent cause of problems is simply a bad contact in wiring connectors Always check that connec tions are secure When inspecting the connector pay particular attention to the following points a Check to see that the terminals are not bent b Check to see that the connector i...

Page 141: ...M 1 Ignition switch BAD 2 Starter 3 Neutral start switch 4 WiringI Connection SYMPTOM DIFFICULT TO START OR NO START CRANKS OK CHECK DIAGNOSIS SYSTEM Diagnostic code s Check for output of diagnostic code Malfunction See pages Fl 24 25 See page Fl 21 code s Normal code DOES ENGINE START WITH ISC system ACCELERATOR PEDAL OK 1 ISC valve DEPRESSED 2 Wiring connection lNO CHECK FOR VACUUM LEAKS IN 1 Oi...

Page 142: ...oi 1 lnjector s shorted or leaking BAD All Plugs WET 2 Injector wiring short circuited 3 Cold start injector leakage See page Fl 52 4 Cold start injector time switch See page Fl 76 t 1 Fuel line Leakage deformation BAD 2 Fuse 3 Fuel pump See page Fl 46 4 Fuel filter 5 Fuel pressure regulator See page Fl 55 1 1 Air flow meter See page Fl 66 BAD CHECK IGNITION TIMING t aoi Ignition timing Adjust See...

Page 143: ...re regulator See page Fl 55 2 Fuel pressure at fuel hose of fuel filter can be felt See page Fl 47 iOK CHECK AIR FilTER ElEMENT Element Clean or replace OK BAD CHECK IDlE SPEED ISC system Standard 650 rpm BAD 1 Wiring connections 2 ISC valve See page Fl 71 3 ECU test by substitution OK CHECK IGNITION TIMING Ignition timing Adjust See page IG 11 1 Short terminals TE1 and E1 of the NO service connec...

Page 144: ...See page Fl 27 1 Fusible links 2 Fuses 3 EFI main relay See page Fl 74 3 Air flow meter See page Fl 66 4 Water temp sensor See page Fl 77 5 Air temp sensor See page Fl 66 6 Injection signal circuit 1 Injector wiring 2 ECU See page Fl 82 SYMPTOM ENGINE SOMETIMES STALLS CHECK DIAGNOSIS SYSTEM Diagnostic code s See pages Fl 24 25 Check for output of diagnostic code Malfunction See page Fl 21 code s N...

Page 145: ...ons 2 ISC valve See page Fl 71 3 ECU lOK CHECK IGNITION TIMING Ignition timing Adjust See page IG 11 1 Short terminal TE1 and E1 of the NO check connector 2 Check ignition timing Standard 7o BTDC idle w short circuited TE1 and E1 lOK CHECK SPARK PLUGS 1 Spark plugs and high tension cords Plug gap 0 8 mm 0 043 in BAD 2 Compression pressure NOTE Check compression pressure and Minimum 8 0 kg cm2 valv...

Page 146: ...RS Injection condition See page Fl 57 BAD lOK CHECK EFI ELECTRONIC CIRCUIT 1 Wiring connections USING VOLT OHMMETER BAD 2 Power to ECU See page Fl 27 1 Fusible links 2 Fuses 3 EFI main relay See page Fl 74 3 Air flow meter See page Fl 66 4 Water temp sensor See page Fl 77 5 Air temp sensor See page Fl 66 6 Injection signal circuit 1 Injector wiring 2 ECU See page Fl 82 7 Oxygen sensors See page F ...

Page 147: ... THROTTLE POSITION Throttle body SENSOR See page Fl 68 BAD lOK CHECK FUEL PRESSURE Fuel pressure regulator High pressure See page Fl 47 BAD JoK CHECK COLD START INJECTOR Cold start injector linkage See page Fl 52 BAD OK CHECK INJECTORS See page Fl 57 Injectors Leakage Injection quantity I OK BAD CHECK EFI ELECTRONIC CIRCUIT 1 Wiring connection USING VOLT OHMMETER BAD 2 Power to ECU See page FJ 27 ...

Page 148: ...nd E1 OK CHECK COLD START INJECTOR 1 Cold start injector See page FI 52 See page Fl 47 BAD 2 Cold start injector time switch See page Fl 76 OK CHECK FUEL PRESSURE 1 Fuel pump See page Fl 46 See page Fl 47 BAD 2 Fuel filter 3 Fuel pressure regulator See page Fl 55 OK CHECK INJECTORS Injectors Clogged See page Fl 57 BAD OK CHECK EFI ELECTRONIC CIRCUIT 1 Wiring connection USING VOLT OHMMETER BAD 2 Po...

Page 149: ... page Fl 52 BAD 2 Cold start injector time switch See page Fl 76 OK CHECK FUEL PRESSURE Fuel pressure regulator See page Fl 55 See page Fl 47 BAD OK CHECK INJECTORS See page Fl 57 I BAD L Injectors Leakage OK CHECK SPARK PLUGS 1 Spark plugs Plug gap 0 8 mm 0 031 in NO 2 Compression pressure NOTE Check compression pressure and Minimum 8 0 kg cm2 valve clearance if necessary 114 psi 785 kpa at 200 r...

Page 150: ...Check for output of diagnostic code Malfunction See page Fl 21 code s Normal code CHECK IGNITION SPARK 1 High tension cords See page IG 5 BAD 2 Distributor 3 Ignition coil 4 Igniter JOK CHECK IGNITION TIMING Ignition timing Adjust See page IG 11 1 Short terminals TE1 and E1 of the NO check connector 2 Check ignition timing Standard 7o BTDC idle wI short circuited TE1 and E1 toK CHECK FUEL PRESSURE...

Page 151: ...ugs NO 2 Compression pressure Minimum 8 0 kg cm2 114 psi 785 kpa at 200 rpm 3 Valve clearance Hot Standard IN 0 20 mm 0 008 in EX 0 35 mm 0 014 in 1 1 Wiring connections BAD 2 Power to ECU 1 Fusible links 2 Fuses 3 EFI main relay See page Fl 74 3 Air flow meter See page Fl 66 4 Water temp sensor See page FJ 77 5 Air temp sensor See page Fl 66 6 Throttle position sensor See page Fl 68 7 Injection s...

Page 152: ...ver that a malfunction has been detected The light goes out automatically when the malfunction has been cleared CHECK ENGINE WARNING LIGHT CHECK 1 The CHECK engine warning light will come on when the ignition switch is placed at ON and the engine is not running 2 When the engine is started the CHECK engine warn ing light should go out If the light remains on the diagnosis system has detected a mal...

Page 153: ...n the event of a malfunction the light will blink every 0 5 seconds The first number of blinks will equal the first digit of a 2 digit diagnostic code and after a 1 5 second pause the 2nd number of blinks will equal the 2nd If there are two or more codes there will be a 2 5 second pause between each After all the codes have been output there will be a 4 5 second pause and they will all be repeated...

Page 154: ... battery terminal a check must first be made to see if a diagnostic code has been recorded 2 After cancellation road test the vehicle to check that a normal code is now read on the CHECK engine warning light If the same diagnostic code appears it indicates that the trouble area has not been repaired thoroughly DIAGNOSIS INDICATION 1 Including normal the ECU is programmed with the following 18 ex C...

Page 155: ... sensor heater Heater Signal ECU Fl1609 Water temp sensor 22 __nn__n_n_ Water Temp Open or short circuit in water circuit Fl 37 Sensor Signal temp sensor signal Water temp sensor Fl1610 ECU Intake Air Intake air temp sensor 24 _fl fU1 flf1Jl_ Temp Sensor Open or short circuit in intake circuit Fl 36 Signal air temp sensor signal Intake air temp sensor Fl1611 ECU 1 When air fuel ratio feed Injector...

Page 156: ...nal for 8 seconds when engine speed Vehicle speed sensor 42 ___mum_nn_ Vehicle Speed in between 2 000 rpm and circuit Sensor Signal 5 000 rpm and coolant temp Vehicle speed sensor is below ao c 1 76 F except ECU Fl1615 when racing the engine ____lll1l1fLJ1J No STA signal to ECU until Ignition switch circuit 43 Starter Signal engine speed reaches 800 Ignition switch Fl 39 rpm with vehicle not movin...

Page 157: ...grounded to the body ECU terminal E1 and ECU body ground NO BAD Check bulb fuse and wiring between ECU and Repair or replace ignition switch BAD Repair or replace j Does CHECK engine warning light go off YES System Normal when the engine is started NO BAD Check wiring between ECU and CHECK Repair engine warning light OK Is there diagnostic code output when check NO Check wiring between ECU termina...

Page 158: ...first make asimple check of the fuses fusible links and the condition of the connectors The following troubleshooting procedures are based on the supposition that the trouble lies in either a short or open circuit in a component out side the computer or a short circuit within the computer If engine trouble occurs even though proper op erating voltage is detected in the computer con nector then it ...

Page 159: ... Verity that the battery voltage is 11 V or more when the ignition switch is at ON Using a voltmeter with high impedance 1 0 kQ V mini mum measure the voltage at each terminal of the wiring connectors Terminals of ECU Terminal Name Symbol Terminal Name DISTRIBUTOR STP STOP LIGHT SWITCH CHECK CONNECTOR EGR EGR VSV THROTTLE POSITION SENSOR A C A C MAGNET SWITCH DISTRIBUTOR SPD SPEED SENSOR THROTTLE ...

Page 160: ...4 3 000 rpm 0 3 1 0 4 THA E2 IgnitionS WON Intake air temperature 20 C 68 F 1 3 FI 36 5 THW E2 Ignition S W ON Coolant temperature 80 C 176 F 0 1 1 0 Fl 37 No 10 E01 6 IgnitionS WON 9 14 Fl 38 No 20 E02 7 STA E1 Cranking 6 14 Fl 39 ISC1 8 I E1 IgnitionS WON 9 14 Fl 40 ISC4 9 IGT E1 Idling 0 7 1 0 Fl 41 10 W E1 No trouble CHECK engine warning light off and 8 14 Fl 42 engine running 11 A C E1 Air co...

Page 161: ...1 1 B EFI15A MAIN 0 85R M REL Ignition Switch Fusible Link AM21 IIG2 Fuse IG S W I I 0 5G IGN 7 5A r 1 Battery of I r E1 Fl2434 CD BATT E1 CD There is no voltage between ECU terminals BATT and E1 Check that there is voltage between ECU terminal BATT and body ground NO OK Check wiring between ECU terminal E1 and body ground F10309 OK BAD Try another ECU Repair or replace I BAD J Check fuse and fusi...

Page 162: ...dy ground JoK BAD Try another ECU Replace or repair BAD Check fuse fusible link and ignition switch Repair or replace CD M REL E1 CD There is no voltage between ECU terminals M REL and E1 IG S W ON Check that there is voltage between ECU terminal M REL and body ground IG S W ON FI0315 NO tOK Check wiring between ECU terminal E1 and body ground OK BAD Try another ECU Replace or repair BAD Check EFI...

Page 163: ...ON Check that there is voltage between ECU terminal B 81 and body ground JG S W ON FI0299 NO OK Check wiring between ECU terminal E1 and body ground OK lBAD Try another ECU Replace or repair BAD Check fuse fusible link and Repair or replace wiring harness OK BAD Check EFI main relay Replace OK Refer to M REL E1 trouble section ...

Page 164: ...CD IDL E2 vc i11 VTA i OJJf l DL d E2 F12431 CD There is no voltage between ECU terminals IDL and E2 IG S W ON Throttle valve open Check that there is voltage between ECU terminal B B1 and body ground IG S W ON NO iOK Check wiring between ECU terminal E1 and body ground lOK BAD Try another ECU I I Replace or repair BAD I Refer to No 1 I t Replace or repair OK Check throttle position sensor l BAD B...

Page 165: ...Fl 30 BAD lOK Repair or replace Check wiring between ECU and throttle position sensor OK BAD Try another ECU Repair or replace wiring CD VTA E2 F11268 FI0325 mvc III VTA IDL E2 F12431 CD THere is no specified voltage at ECU terminals VTA and E2 IG S W ON Check that there is voltage between ECU terminal VC and E2 IG S W ON tNO OK Refer to VC E2 trouble section lOK BAD Check throttle position sensor...

Page 166: ...s no voltage between ECU terminals VC or VS and E22 IG S W ON Check that there is voltage between ECU terminal B B1 and body ground IG S W ON OK JNo F12444 Refer to No 1 See page Fl 30 Check wiring between ECU terminal E1 and body ground OK BAD Check air flow meter Repair or replace See page Fl 66 FI0312 BAD tOK Replace air flow Check wiring between ECU and air Air Flow Meter Ohmmeter lCl r ll Cl ...

Page 167: ...no voltage between ECU terminals THA and E22 IG S W ON CD Check that there is voltage between ECU terminal B B1 and body ground IG S W ON OK tNO Refer to No 1 See page Fl 30 Check wiring between ECU terminal E1 and body ground OK BAD Check air temp sensor See page Fl 66 Repair or replace BAD JoK Replace air Check wiring between ECU and Air Flow Mete flow meter air temp sensor OK BAD Ohmmeter Try a...

Page 168: ...D There is no voltage between ECU terminals THW and E2 IG S W ON Check that there is voltage between ECU terminal B B1 and body ground IG S W ON OK NO Refer to No 1 FI0332 See page F1 30 Check wiring between ECU terminal E1 and body ground OK lBAD Check water temp sensor See page Fl 77 Repair or replace BAD lOK Replace water Check wiring between ECU and temp sensor water temp sensor 1OK BAD Try an...

Page 169: ... terminal No 10 and I or No 20 and E01 and or E02 IG S W ON Check that there is voltage between ECU terminal No 10 or No 20 and body ground NO lOK F12442 Check wiring between ECU terminal E01 and I or E02 and body ground lOK BAD Try another ECU Repair or replace BAD Check fusible link and Repair or replace ignition switch OK Check resistance of magnetic coil in each injector STD resistance Approx ...

Page 170: ...IG S W START OK Check starter Check wiring between ECU terminal operation STA and ignition switch terminal ST1 BAD OK BAD Repair or replace Check wiring between ECU terminal E1 and body ground OK BAD Try another ECU Repair or replace Check fusible link battery wiring BAD ignition switch and neutral start Repair or replace i0311 switch OK Check that there is voltage at STA 50 terminal of starter IG...

Page 171: ...___ B _________ B1 ___ _ _ _ _ _ _ _ _ M REL r Q E1 F12437 CD There is no voltage between ECU terminals ISC1 ISC4 and E1 IG S W ON Check that there is voltage between ECU terminal B B1 and body ground IG S W ON OK NO Refer to No 1 See page Fl 30 Check wiring between ECU terminal E1 and body ground OK BAD fg Check ISC valve V See page Fl 71 Repair or replace BAD OK Replace ISC Check wiring between ...

Page 172: ...tage between ECU terminals IGT and E1 Idling Check that there is voltage between ECU terminal IGT and body ground Idling NO OK Check wiring between ECU BAD Repair or terminal E1 and body ground replace F12446 lOK Try another ECU Check fusible link and ignition BAD switch Repair or replace OK BAD Check distributor See page IG 7 l l Repair or replace F12445 OK Check wiring between ECU and BAD batter...

Page 173: ...Light E1 Combination Meter FI072S CD There is no voltage between ECU terminals W and E1 Idling Check that there is voltage between ECU terminal W and body ground NO OK Check wiring between ECU terminal E1 and body ground OK BAD Try another ECU I Repair or replace Check GAUGE fuse 7 5A and CHECK engine warning light OK BAD I Repair or replace Fuse blows again Check wiring between ECU BAD terminal W...

Page 174: ...D ECU A C Check that there is voltage between ECU terminal A C and body ground NO OK Fl1255 Check wiring between ECU terminal E1 and body ground OK JBAD Try another ECU Repair or replace OK Check compressor running Check wiring between ECU terminal A C and amplifier BAD BAD Repair or replace Check that there is voltage between BAD amplifier terminal and body ground Repair or replace OK Check wirin...

Page 175: ...al VF1 or VF2 and body ground NO OK Check wiring between ECU terminal E1 and body ground Check for suction of air into exhaust system OK Check for air leak from air intake system OK Check distributor and ignition system OK OK Check operation of oxygen sensors BAD Check wiring between oxygen sensors and ECU connectors OK Replace oxygen sensors Repair air suction BAD Repair air leak BAD Repair or re...

Page 176: ...there is voltage between ECU terminal B B1 and body ground IG S W ON OK NO Fl2946 Refer to No 1 See page Fl 30 Check wiring between ECU terminal E1 and body ground OK BAD Refer or replace BAD I I Check EG R system I I Repair or replace OK FI0312 Check EG R gas temp sensor See page Fl 79 BAD OK Replace EG R gas Check wiring between ECU and temp sensor EG R gas temp sensor OK BAD Try another ECU Rep...

Page 177: ...ET FUEL SYSTEM Fuel Pump Relief Valve heck Valve Fusible Link MAIN 0 85 t INLET M REL BATT B IG S W B1 ECU Fuse Casing IGN 7 5A Circuit Opening Battery Neutral Start Switch B Relay FP Fuel Pump Switch Air Flow Meter FI0530 F11479 F12439 ...

Page 178: ...the service wire e Turn the ignition switch OFF If there is no pressure check the following parts Fusible links Fuse EFI 15A EFI main relay Fuel pump Wiring connections 2 INSPECT FUEL PRESSURE a Check the battery voltage above 11 volts b Disconnect the cable from the negative terminal of the battery c Disconnect the cold start injector connector d Put a suitable container or shop towel under the c...

Page 179: ...ck connector j Turn the ignition switch ON k Measure the fuel pressure Fuel pressure 2 6 3 2 kg cm2 37 46 psi 255 314 kPa If pressure is high replace the fuel pressure regulator If pressure is low check the following parts Fuel hoses and connection Fuel pump Fuel filter Fuel pressure regulator I Remove the service wire m Start the engine n Disconnect the vacuum sensing hose from the fuel pressure ...

Page 180: ...s after the engine is turned off If pressure is not as specified check the fuel pump pres sure regulator and I or injector s After checking fuel pressure disconnect the battery negative cable and carefully remove the SST to prevent gasoline from splashing SST 09268 45012 t Install the cold start injector pipe with new four gaskets the union bolts and pipe clamp bolt Torque Union bolt 180 kg em 13 ...

Page 181: ...OF BATTERY 2 DRAIN FUEL FROM FUEL TANK F12374 WARNING Do not smoke or work near an open flame when working on the fuel pump 3 REMOVE FUEL TANK 4 REMOVE FUEL PUMP BRACKET FROM FUEL TANK a Remove the screw of the wire clamp b Remove the screws pull out the pump bracket 5 REMOVE FUEL PUMP FROM FUEL PUMP BRACKET a Pull off the lower side of the fuel pump from the bracket b Remove the two nuts and disc...

Page 182: ...a Connect the fuel hose to the outlet port of the fuel pump b Connect the wires to the fuel pump with the two nuts c Push the lower side of the fuel pump and install the fuel pump 3 INSTAll FUEL PUMP BRACKET TO FUEL TANK a Install a new gasket and the pump bracket with the screws Torque 35 kg em 30 in lb 3 4 N m b Connect the wire clamp with the screw Torque 20 kg em 17 in lb 2 0 N m 4 INSTAll FUE...

Page 183: ... 2 4 Q If the resistance is not as specified replace the cold start injector c Reconnect the cold start injector connector REMOVAL OF COLD START INJECTOR 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2 DISCONNECT COLD START INJECTOR CONNECTOR 3 REMOVE COLD START INJECTOR PIPE a Put a suitable container or shop towel under the injector pipe b Remove the two union bolts four gaskets pipe clam...

Page 184: ...njector e Reconnect the battery negative cable f Turn the ignition switch ON NOTE Do not start the engine g Using a service wire short terminals B and FP of the check connector h Connect the test probes of the SST wire to the battery and check that the fuel spray is as shown SST 09842 30050 CAUTION Perform this check within the short est possible time 2 INSPECT LEAKAGE a In the condition above dis...

Page 185: ...50 kg em 43 in lb 4 9 N m 2 INSTALL COLD START INJECTOR PIPE Install the cold injector pipe with new four gaskets the two union bolts and pipe clamp bolt Torque Union bolt 180 kg em 13 ft lb 18 N m Clamp bolt 120 kg em 9 ft lb 12 N m 3 CONNECT COLD START INJECTOR CONNECTOR 4 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 5 CHECK FOR FUEL LEAKAGE See page Fl 8 ...

Page 186: ... See page Fl 47 REMOVAL OF FUEL PRESSURE REGULATOR Fl2419 Fl2554 1 DISCONNECT VACUUM SENSING HOSE 2 DISCONNECT FUEL RETURN PIPE a Put a suitable container or shop towel under the pressure regulator b Remove the union bolt and two gaskets and dis connect the return pipe NOTE Slowly loosen the union bolt 3 REMOVE FUEL PRESSURE REGULATOR Remove the two bolts and pull out the pressure regula tor ...

Page 187: ...GULATOR a Apply a light coat of gasoline to a new 0 ring and install it to the pressure regulator b Install the pressure regulator with the two bolts Torque 50 kg em 43 in lb 4 9 N m 2 CONNECT FUEL RETURN PIPE Install the return pipe with new two gaskets and the union bolt Torque 180 kg em 13ft lb 18 N m 3 CONNECT VACUUM SENSING HOSE 4 CHECK FOR FUEL LEAKAGE See page Fl 8 ...

Page 188: ...ortion to engine rpm b If you have no sound scope you can check the injector transmission operation with your finger If no sound or an unusual sound is heard check the wiring connector injector or injection signal from ECU 2 INSPECT INJECTOR RESISTANCE a Disconnect the injector connector b Using an ohmmeter measure the resistance be tween the terminals Resistance Approx 13 8 0 If the resistance is...

Page 189: ... Air hose from AI check valve c Vacuum sensing hose d PCV hose e Vacuum hose for transfer f Brake booster hose 5 DISCONNECT FOLLOWING CONNECTORS AND WIRE a ISC valve connector b Throttle position sensor connector c Oxygen sensor connector d Manifold temperature sensor connector e Cold start injector connector f EGR gas sensor connector g Ground strap 6 REMOVE AIR INTAKE CHAMBER a Loosen the two un...

Page 190: ...x injector connectors b Remove the two clamps and three clamp bolts and disconnect the engine wire harness REMOVE N0 1 FUEL PIPE AND N0 2 FUEL PIPE WITH ENGINE HANGER a Disconnect the fuel and vacuum hoses b Remove the pulsation damper and two gaskets c Remove the two bolts and No 2 fuel pipe with en gine hanger d Remove the union bolt and two gaskets from the pressure regulator e Remove the two b...

Page 191: ...om the fuel filter outlet b Connect SST union and hose to the fuel filter outlet with new gaskets and the union bolt SST 09268 41 045 NOTE Use the vehicle s fuel filter c Remove the pressure regulator See page Fl 55 d Connect the fuel return hose and SST hose to the pressure regulator with SST unions new gaskets and union bolt SST 09268 41 045 e Connect SST union and hose to the injector and hold ...

Page 192: ... a In the condition above disconnect the test probes of SST wire from the battery and check the fuel leakage from the injector SST 09842 30070 Fuel drop One drop or less per minute b Disconnect the battery negative cable c Remove SST and the service wire SST 09268 41 045 INSTALLATION OF INJECTORS 1 INSTALL INJECTORS AND DELIVERY PIPE a Install a new grommet to the injector b Apply a light coat of ...

Page 193: ...uel pipe with engine hanger with the two bolts d Install the pulsation damper with the two new gas ket Torque 300 kg em 22 ft lb 29 N m e Connect the two fuel hoses and vacuum hoses CONNECT ENGINE WIRE HARNESS ON INTAKE MANIFOLD a Connect the following connectors 1 Cold start injector time switch connector 2 Water temperature sensor connector 3 Water temperature sender gauge connector 4 Water temp...

Page 194: ...G CONNECTORS AND WIRE a ISC valve connector b Throttle position sensor connector c Oxygen sensor connector d Manifold temperature sensor connector e Cold start injector connector f EGR gas sensor connector g Ground strap CONNECT FOLLOWING HOSES a Emission control hoses b Air hose from AI check valve c Vacuum sensing hose d PCV hose e Vacuum hose for transfer f Brake booster hose INSTALL AIR INTAKE...

Page 195: ... Fuel System Fuel Tank and Lines COMPONENTS Fuel Tank Cap Fuel Tube Connector Fuel Tank Inlet Pipe r J 15 1 3 in lb 1 5 Fuel Pump lL ___ Ikg em ft lb N m I Specified torque Non reusable part Gasket I Fuel Tank r 131s 27 37 1 Fuel Tank Band Fl2449 ...

Page 196: ...CT FUEL LINES AND CONNECTIONS a Check the fuel lines for cracks or leakage and all connections for deformation b Check the fuel tank vapor vent system hoses and connections 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 or fuel leakage e Hose and tube connections are as shown in the illustratio...

Page 197: ... a Disconnect the air flow meter connector b Using an ohmmeter measure the resistance be tween each terminal Between Resistance Temperature terminals E2 VS 200 soon E2 VC 200 400 n 10 20 Kn 20QC 4 F 4 7 Kn o c 32QF E2 THA 2 3 Kn 2o c 6B F 0 9 1 3 Kn 40 C 1 04 F 0 4 0 7 Kn so c 140 F E1 FC Infinity If the resistance is not as specified replace the air flow meter c Reconnect the air flow meter conne...

Page 198: ...en Resistance n Measuring plate Terminals opening Infinity Fully closed E1 FC Other than Zero closed 200 600 Fully closed E2 vs 20 1 200 Fully open NOTE Resistance between terminals E2 and VS will change in a wave pattern as the measuring plate slowly opens If the resistance is not as specified replace the meter INSTALLATION OF AIR FLOW METER 1 INSTALL AIR FLOW METER 2 CONNECT AIR CLEANER HOSE 3 C...

Page 199: ...that the throttle linkage moves smoothly b Check the vacuum at each port Start the engine Check the vacuum with your finger Port No At idling Other than idling EGR No vacuum Vacuum R No Vacuum Vacuum 2 INSPECT THROTTLE POSITION SENSOR a Disconnect the sensor connector b Insert a thickness gauge between the throttle stop screw and stop lever c Using an ohmmeter measure the resistance be tween each ...

Page 200: ...R AND THROTTLE CABLES 3 DISCONNECT AIR CLEANER HOSE 4 DISCONNECT THROTTLE POSITION SENSOR CONNECTOR 5 DISCONNECT WATER HOSES 6 DISCONNECT VACUUM HOSES 7 REMOVE THROTTLE BODY Remove the three bolts nut throttle body and gasket INSPECTION OF THROTTLE BODY 1 CLEAN THROTTLE BODY a Using a soft brush and carburetor cleaner clean the cast parts b Using compressed air clean all the passages and apertures...

Page 201: ...to the termi nals JDL and E2 of the sensor d Gradually turn the sensor clockwise until the ohm meter deflects and secure it with the two screws e Recheck the continuity between terminals IDL and E2 INSTALLATION OF THROTTLE BODY 1 INSTALL THROTTLE BODY 2 3 4 5 6 7 Install a new gasket and the throttle body with the three bolts and nut Torque 120 kg em 9 ft lb 12 N m CONNECT WATER HOSES CONNECT VACU...

Page 202: ...NSPECTION CHECK FOR OPERATING SOUND FROM ISC VALVE Check that there is a clicking sound immediately stop ping the engine REMOVAL OF ISC VALVE 1 DRAIN ENGINE COOLANT 2 DISCONNECT ISC VALVE CONNECTOR 3 DISCONNECT AIR AND TWO WATER BY PASS HOSES 4 REMOVE ISC VALVE Remove the two bolts ISC valve and gasket ...

Page 203: ...voltage to terminals 81 and 82 and while repeatedly grounding 51 52 S3 54 51 in sequence check that the valve moves toward the closed position b Apply battery voltage to terminals 81 and 82 and while repeatedly grounding 54 53 52 51 54 in sequence check that the valve moves toward the closed position If operation is not as specified replace the 15C valve INSTALLATION OF ISC VALVE 1 INSTALL ISC VAL...

Page 204: ...SYSTEM Location of Electronic Control Parts CHECK Connector Cold Start Injector Time Switch water Temr switch EFI Main Relay I Water Temp Sensor ECU EGR Gas Temp Sensor Calif only Circuit Opening Relay Oxygen Sensor vsv For High Temp Line Pressure Up System F12664 ...

Page 205: ... RELAY 1 INSPECT RELAY CONTINUITY a Using an ohmmeter check that there is continuity between 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 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals 1 and 3 b Using an ohmmeter check that there is continuity between terminals 2 and 4 If operation is not as ...

Page 206: ...at there is continuity between terminals STA and E1 b Check that there is continuity between terminals 8 and FC c Check that there is no continuity between terminals 8 and FP If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals STA and E1 b Using an ohmmeter check that there is continuity between terminals 8 and FP Battery F11909 Et...

Page 207: ...Cold Start Injector Time Switch STA Fl1374 INSPECTION OF COLD START INJECTOR TIME SWITCH INSPECT RESISTANCE OF COLD START INJECTOR TIME SWITCH Using an ohmmeter measure the resistance between each terminal STA STJ 30 50 Q below 15 c 69 F 70 90 n above 30 C 86 F STA Ground 30 90 n If the resistance is not as specified replace the switch ...

Page 208: ...ffi Q 6 a 0 4 0 20 0 20 40 60 80 100 120 4 32 68 1 04 140 176 212X248 TEMPERATURE c F FI051 5 FI0709 INSPECTION OF WATER TEMPERATURE SENSOR INSPECT RESISTANCE OF WATER TEMPERATURE SENSOR Using an ohmmeter measure the resistance between the terminals Resistance Refer to chart If the resistance is not as specified replace the sensor ...

Page 209: ...r check that there is no continu ity between the terminal and body when the oil temperature is below 98 C 208 F b Check that there is continuity between the terminal and body when the oil temperature is above 1osoc 221 OF If operation is not as specified replace the switch 2 INSPECT VSV a Check that air flows from the pipe Eto pipe F b Apply battery voltage across the terminals c Check that air fl...

Page 210: ...sor THG l E2 _ INSPECTION OF EGR GAS TEMPERATURE SENSOR ECU B 81 THG E2 E1 I F12673 FI0487 INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter measure the resistance between the terminals Resistance 69 40 88 50 k Q at 50 C 112 F 11 89 14 37 k Q at 100 C 212 F 2 79 3 59 kQ at 150 C 302 F If the resistance is not as specified replace the sensor ...

Page 211: ...in i the oxygen r sensor l Check the number of times the voltmeter needle fluctuates in 10 seconds I Less than 8 times 8 times Zero or more Warm up the oxygen sensor with the engine at Normal 2 500 rpm for approx 120 seconds And maintain engine at 2 500 rpm 8 times or more Check the number of times the voltmeter needle fluctuates in 10 seconds less than 8 times Zero Unshort terminals TE1 and E1 of...

Page 212: ...between terminals VF1 VF2 and E1 ov 5V IDisconnect the PCV hose I IMeasure voltage between terminals VF1 VF2 and E1 j ov More than 0 V Repair Over rich Disconnect the water temp sensor connector and connect resistor with a resistance of 4 8 kQ or another coded water temp sensor Short terminals TE1 and E1 of the check connector Warm up the oxygen sensor with the engine at 2 500 rpm for approx 120 s...

Page 213: ... INSPECTION OF ECU 1 NOTE The EFI circuit can be checked by measuring the and voltage at the wiring connectors of the ECU INSPECT VOLTAGE OF ECU Check the voltage between each terminal of the wiring connectors Turn the ignition switch ON Measure the voltage at each terminal NOTE Perform all voltage measurements with the connectors connected Verify that the battery voltage is 11 V or more when the ...

Page 214: ... light off and engine running A C E1 10 14 Air conditioning ON 4 6 Check connector TE1 E1 not short T E1 IgnitionS WON 0 Check connector TE1 E1 short 0 NSW E1 Ignition S W ON Shift position P or N range 10 14 Ex P or N range 10 14 4WD S W ON 4WD E1 Ignition S W ON 0 4WD S W OFF 10 14 STP E1 IgnitionS WON Stop light S W ON 0 Stop light S W OFF ECU Terminals I 1 I _j E01 No HT1 STJ T ISC ISC G6 G1 N...

Page 215: ...l of the wiring connectors Disconnect the connectors from the ECU Measure the resistance at each terminal Resistance of ECU Wiring Connectors Condition Resistance 0 Throttle valve open co Throttle valve fully closed Less than 2 300 Throttle valve open 3 500 10 300 Throttle valve fully closed 300 6 300 4 250 8 250 200 400 Measuring plate fully closed 20 600 Measuring plate fully open 20 3 000 Intak...

Page 216: ...gine to reach normal operating temperature 2 INSPECT FUEL CUT RPM a Disconnect the connector from the throttle position sensor b Short terminals IDL and E2 of the wiring connector c Gradually raise the engine rpm and check that there is fluctuation between the fuel cut and fuel return points NOTE The vehicle should be stopped Fuel cut rpm 1 300 rpm Fuel return rpm 1 000 rpm ...

Page 217: ... MEMO ...

Page 218: ...C0 1 COOLING SYSTEM Page TROUBLESHOOTING C0 2 CHECK AND REPLACEMENT OF ENGINE COOLANT C0 3 WATER PUMP C0 4 THERMOSTAT C0 9 RADIATOR C0 10 ENGINE COMPARTMENT COOLING FAN C0 13 ...

Page 219: ...Thermostat faulty Check thermostat C0 9 Ignition timing retarded Set timing IG 11 Fluid coupling faulty Replace fluid coupling Radiator hose plugged or rotted Replace hose Water pump faulty Replace water pump C0 4 Radiator plugged or cap faulty Check radiator C0 10 Cylinder head or block cracked or plugged Repair as necessary NOTE The thermostat on the 3F E engines is equipped with a by pass valve...

Page 220: ... should be free from oil If excessively dirty replace the coolant 3 REPLACE ENGINE COOLANT a Remove the radiator cap b Drain the coolant from the radiator and engine drain cocks c Close the drain cocks Torque Engine drain cock 450 kg em 33 ft lb 44 N m d Fill the system with coolant Use a good brand of ethylene glycol base coolant mixed according to the manufacturer s directions Capacity w I Front...

Page 221: ...n Drive Belt Non reusable part Oil Cooler Water Hose Gasket Gasket Pulley Seat Water Pump C00544 C00543 REMOVAL OF WATER PUMP 1 DRAIN ENGINE COOLANT See page C0 3 2 REMOVE PS DRIVE BELT Loosen the PS mount idler pulley and adjusting bolts and remove the drive belt 3 DISCONNECT COOLANT RESERVOIR HOSE 4 DISCONNECT RADIATOR INLET HOSE 5 REMOVE FAN SHROUD BOLTS ...

Page 222: ...the fan and fluid coupling with the fan shroud d Remove the fan from the fluid coupling 7 REMOVE ALTERNATOR See page CH 6 8 REMOVE A C DRIVE BELT 9 DISCONNECT HOSES FROM WATER PUMP a Water inlet hose b Water by pass hose c Heater water hose d Oil cooler water hoses 10 REMOVE WATER PUMP PS IDLER PULLEY WITH BRACKET ASSEMBLY AND ALTERNATOR STAY BRACKET a Remove the bolt two nuts and PS idler pulley ...

Page 223: ...INSPECT FLUID COUPLING Check that the fluid coupling is not damaged and that no silicon oil leaks If necessary replace the fluid coupling DISASSEMBLY OF WATER PUMP See page CO 4 1 REMOVE WATER PUMP PLATE Remove the three screws plate and gasket 2 REMOVE PULLEY SEAT a Remove the stud bolts b Using SST and a press press the shaft of the bearing and remove the pulley seat SST 09236 001 01 09237 0001 ...

Page 224: ... with the three screws INSTALLATION OF WATER PUMP See page C0 4 1 INSTALL WATER PUMP PS IDLER PULLEY WITH BRACKET ASSEMBLY AND ALTERNATOR STAY BRACKET a Temporarily install a new gasket the water pump and alternator stay bracket with the bolt and nut b Temporarily install the PS idler pulley with bracket assembly with the bolt and nuts c Torque the water pump mounting bolt and nuts Torque 380 kg e...

Page 225: ...the water pump pulley and fluid coupling with the four nuts d Place the drive belt onto each pulley e Stretch the belt tight and tighten the four nuts f Adjust the water pump drive belt tension See page MA 4 6 INSTALL FAN SHROUD BOLTS 7 CONNECT RADIATOR INLET HOSE 8 CONNECT COOLANT RESERVOIR HOSE 9 INSTALL AND ADJUST PS DRIVE BELT See page MA 4 10 FILL WITH ENGINE COOLANT See page C0 3 11 START EN...

Page 226: ... and gasket 6 REMOVE THERMOSTAT INSPECTION OF THERMOSTAT INSPECT THERMOSTAT NOTE The thermostat is numbered with the valve opening temperature a Immerse the thermostat in water and gradually heat the water b Check the valve opening temperature Valve opening temperature 86 90 C 187 194 F If the valve opening temperature is not within specifica tion replace the thermostat c Check the valve lift Valv...

Page 227: ...ot to deform the fins of the radiator core If the cleaner nozzle pressure is 30 35 kg cm2 427 498 psi 2 942 3 432 kPa keep a dis tance of at least 40 50 em 15 75 19 69 in between the radiator core and cleaner nozzle INSPECTION OF RADIATOR 1 INSPECT RADIATOR CAP Using a radiator cap tester pump the tester until the relief valve opens Check that the valve opens between 0 75 kg cm2 1 0 7 psi 74 kPa a...

Page 228: ...NSER Remove the four bolts and condenser 7 DISCONNECT COOLANT RESERVOIR HOSE 8 DISCONNECT RADIATOR HOSES 9 DISCONNECT A TOIL COOLER HOSES NOTE Be careful as some oil will leak out Catch it in a suitable container 10 REMOVE FAN SHROUD MOUNTING BOLTS 11 REMOVE RADIATOR MOUNTING BOLTS NUTS AND RADIATOR INSTALLATION OF RADIATOR 1 INSTALL RADIATOR 2 INSTALL FAN SHROUD MOUNTING BOLTS 3 CONNECT A TOIL CO...

Page 229: ...NG SYSTEM Radiator 9 FILL WITH ENGINE COOLANT See page C0 3 10 EVACUATE CHARGE AND TEST REFRIGERATION 11 START ENGINE AND CHECK FOR LEAKS 12 CHECK AUTOMATIC TRANSMISSION FLUID LEVEL Fluid type ATF DEXRON IT CAUTION Do not overfill ...

Page 230: ...ON OF ENGINE COMPARTMENT COOLING FAN COMPONENTS Cooling Fan Relay INSPECT COOLING FAN RELAY CIRCUIT a Remove the driver s cowl side trim F12430 b Disconnect the relay connector and inspect the connector on wire harness side as shown in the chart below Check for Between terminals Condition Specified value Continuity 1 Body ground Always Continuity Voltage 2 Body ground Ignition switch ON Battery vo...

Page 231: ...inals 1 and 3 b Check that there is no continuity between terminals 2 and 4 If continuity is not as specified replace the relay B Inspect relay operation a Apply battery voltage across terminals 1 and 3 b Check that there is continuity between terminals 2 and 4 If operation is not as described replace the relay Ignition relay LOCATION Under the instrument panel on the driver s side INSPECT IGNITIO...

Page 232: ...shown in the table above replace the temperature sensor Fan Motor INSPECT FAN MOTOR a Remove the shroud b Connect the battery and ammeter to the fan motor connector c Check to see that the motor rotates smoothly and current is as follows Current 2 8 3 8 A REMOVAL OF ELECTRIC COOLING FAN 1 DISCONNECT FAN MOTOR CONNECTOR 2 DISCONNECT LH HOOD LOCK BALANCER 3 REMOVE ELECTRIC COOLING FAN Remove the fou...

Page 233: ... MEMO ...

Page 234: ...LU 1 LUBRICATION SYSTEM Page TROUBLESHOOTING LU 2 OIL PRESSURE CHECK LU 3 REPLACEMENT OF ENGINE OIL AND OIL FILTER LU 4 OIL PUMP LU 5 OIL COOLER AND RELIEF VALVE LU 12 ...

Page 235: ...EM 40 68 Gasket faulty Replace gasket Low oil pressure Oil leakage Repair as necessary Relief valve faulty Repair relief valve LU 5 Oil pump faulty Repair oil pump LU 5 Engine oil poor quality Replace engine oil LU 4 Crankshaft bearing faulty Replace bearing EM 45 Connecting rod bearing faulty Replace bearing EM 45 Oil filter clogged Replace oil filter LU 4 High oil pressure Relief valve faulty Re...

Page 236: ...eplace the oil Use API grade SF or SF ICC multigrade fuel efficient and recommended viscosity oil 2 CHECK ENGINE OIL LEVEL The oil level should be between the L and F marks on the dipstick If low check for leakage and add oil up to the F mark 3 REMOVE OIL PRESSURE SENDER GAUGE 4 INSTALL OIL PRESSURE GAUGE 5 START ENGINE Start engine and warm it up to normal operating temper ature 6 CHECK OIL PRESS...

Page 237: ...esis tance e Using SST tighten the oil filter an extra 3 4 turn SST 09228 44011 3 FILL WITH ENGINE OIL a Clean and install the oil drain plug with a new gas ket Torque the drain plug Torque 400 kg em 29 ft lb 39 N m b Fill the engine with new oil API grade SF or SF CC multigrade viscosity and fuel efficient oil Capacity Drain and refill w o Oil filter change 7 0 liters 7 4 US qts 6 2 Imp qts w I 0...

Page 238: ... 33 44 Oil Outlet Pipe 1 450 33 44 I 1 100 7 1o Gasket IKg em ft lb N m I Specified torque Non reusable part OIL PUMP COMPONENTS 1 Drive Shaft Drive Gear tlliJ Driven Gear Oil Pump Strainer t Relief Valve _ Spring Plug Drain Plug 1 400 29 39 1 Gasket LU 5 LU0518 ...

Page 239: ...s securely sup ported 2 DRAIN ENGINE OIL a Remove the oil filler cap b Remove the oil drain plug and drain the oil into a container 3 REMOVE OIL PAN Remove the twenty two bolts oil pan and gasket 4 REMOVE OIL OUTLET PIPE Remove the union nut bolt two gaskets and outlet pipe 5 REMOVE OIL PUMP Remove the bolt and oil pump ...

Page 240: ...l should come out of the oil outlet hole b Close t he oil outlet hole with yo qhumb and turn the shaft as before The shaft should be difficult to turn DISASSEMBLY OF OIL PUMP See page LU 5 1 MOUNT OIL PUMP IN VISE 2 REMOVE RELIEF VALVE Remove the plug spring and relief valve 3 REMOVE OIL PUMP STRAINER Remove the four screws and oil pump strainer 4 REMOVE DRIVEN GEAR 5 REMOVE DRIVE GEAR AND OIL PUM...

Page 241: ...ter than maximum replace the Luo1ss gears or oil pump assembly B Inspect gear side clearance Using a thickness gauge and precision straight edge measure the clearance between the gear and precision straight edge Standard side clearance 0 030 0 090 mm 0 0012 0 0035 in Maximum side clearance 0 15 mm 0 0059 in If the clearance is greater than maximum replace the gears If necessary the oil pump assemb...

Page 242: ...shaft from the drive gear b Align the drive gear set key with the key groove of a new drive gear c Using a press press in the oil pump shaft until it is 0 5 mm 0 020 in from the drive gear edge 2 REPLACE DRIVEN SHAFT a Using an extension bar and press press out the driven shaft from the oil pump body b Using a press press in a new driven shaft until it is 0 5 mm 0 020 in from the oil pump body edg...

Page 243: ...Torque the screws Torque 100 kg em 7 ft lb 10 N m 5 INSTALL RELIEF VALVE Install the relief valve and spring with the relief valve plug Torque the plug Torque 375 kg em 27 ft Jb 37 N m 6 CHECK OIL PUMP OPERATION See page LU 7 INSTALLATION OF OIL PUMP See page LU 5 1 INSTALL OIL PUMP a Align the oil pump shaft slot of the oil pump with the governor shaft protrusion of the distributor b Install the ...

Page 244: ...450 kg em 33 ft lb 44 N m 3 INSTALL OIL PAN a Apply seal packing to the cylinder block the No 1 and No 4 main bearing caps as shown Seal packing Part No 08826 00080 or equivalent b Install a new gasket and the oil pan with the twenty two bolts Torque 80 kg em 69 in lb 7 8 N m 4 FILL WITH ENGINE OIL See step 3 on page LU 4 5 START ENGINE AND CHECK FOR LEAKS 6 RECHECK OIL LEVEL Recheck the engine oi...

Page 245: ...able part OIL COOLER AND OIL RELIEF VALVE COMPONENTS LU0513 REMOVAL OF OIL COOLER AND RELIEF VALVE 1 DRAIN ENGINE COOLANT See page C0 3 2 REMOVE AIR CLEANER HOSE 3 REMOVE OIL FILTER See page LU 4 4 REMOVE OIL PRESSURE SENDER GAUGE 5 DISCONNECT OIL COOLER HOSES 6 REMOVE OIL COOLER Remove the two union bolts gaskets oil cooler and 0 rings ...

Page 246: ... four bolts oil filter bracket and gasket INSPECTION OF OIL COOLER AND RELIEF VALVE 1 INSPECT OIL COOLER Check the oil cooler for damage or clogging 2 INSPECT REliEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight If operation is not as specified replace the relief valve If necessary replace the oil filter bracket ...

Page 247: ...obe to terminal IG e of the check connector 3 As some tachometers are not compatible with this ignition system we recommend that you confirm the compatibility of your unit before us ing 4 NEVER allow the tachometer terminals to touch ground as this could damage the igniter and or ignition coil 5 Do not disconnect the battery when the engine is running 6 Make sure that the igniter is properly groun...

Page 248: ... Ignition problems Ignition coil Inspect coil IG 7 Igniter Inspect igniter IG 7 Distributor Inspect distributor IG 7 High tension cords Inspect high tension cords IG 6 Engine hesitates Spark plugs faulty Inspect plugs IG 6 poor acceleration Ignition wiring faulty Inspect wiring Incorrect ignition timing Reset timing IG 11 Engine dieseling Incorrect ignition timing Reset timing IG 11 runs after ign...

Page 249: ... G ECU Ignition Coil Igniter C o J 1 To Tachometer IGT IGF IGOB31 ELECTRONIC SPARK ADVANCE ESA The ECU is programmed with data for optimum ignition timing under any and all operating conditions Using data provided by sensors which monitor various engine functions rpm intake air volume eng temperature etc the microcomputer ECU triggers the spark at precisely the right instant ...

Page 250: ...If the spark does not occur perform the test as follows Connect securely BAD CHECK RESISTANCE OF HIGH TENSION Replace the cord s CORDS See page IG 6 BAD OK CHECK POWER SUPPLY TO IGNITION Check wiring between ignition switch COIL AND IGNITER to ignition coil and igniter 1 Ignition switch turn to ON BAD 2 Check that there is battery voltage at ignition coil positive terminal OK CHECK RESISTANCE OF I...

Page 251: ...sistance is greater than maximum check the termi nals If necessary replace the high tension cord and or distributor cap INSPECTION OF SPARK PLUGS 1 REMOVE SPARK PLUGS 2 CLEAN SPARK PLUGS Using aspark plug cleaner or wire brush clean the spark plug 3 VISUALLY INSPECT SPARK PLUGS Check the spark plug for electrode wear thread damage and insulator damage If abnormal replace the plugs Recommended spar...

Page 252: ...nal and high tension terminal Secondary coil resistance Cold 11 5 15 5 k l If the resistance is not as specified replace the ignition coil 4 RECONNECT HIGH TENSION CORD INSPECTION OF DISTRIBUTOR 1 INSPECT AIR GAP Using a thickness gauge measure the gap between the signal rotor and pickup coil projection Air gap 0 2 mm 0 008 in or more If the gap is not as specified replace the distributor 2 INSPEC...

Page 253: ...ap Non reusable part IGOB39 REMOVAL OF DISTRIBUTOR 1 REMOVE AIR CLEANER HOSE 2 DISCONNECT DISTRIBUTOR CONNECTOR 3 DISCONNECT VENTILATION HOSES 4 DISCONNECT HIGH TENSION CORDS FROM SPARK PLUGS AND IGNITION COIL 5 REMOVE DISTRIBUTOR Remove the mount bolt and pull out the distributor 6 REMOVE 0 RING FROM DISTRIBUTOR HOUSING ...

Page 254: ...AUTION Be careful not to damage the gover nor shaft b Mount the driven gear in a vice c Using a pin punch and hammer tap out the straight pin d Remove the driven gear 2 INSTALL NEW DRIVEN GEAR a Slide a new driven gear onto the governor shaft b Position the drill mark on the driven gear and rotor as shown c Install a new straight pin d Secure the ends of the straight pin ...

Page 255: ...C compression If not repeat the process Install the No spark 1 plug 2 SET OIL PUMP SHAFT SLOT Position the oil pump shaft slot in the direction shown in the figure 3 INSTALL NEW 0 RING a Install a new 0 ring to the housing b Apply a light coat of engine oil on the 0 ring 4 INSTALL DISTRIBUTOR a Insert the distributor aligning the center of the flange with that of the bolt hole on the cylinder head...

Page 256: ...uld result in damage to the ig niter and or ignition coil As some tachometers are not compatible with this ignition system we recommend that you confirm the compatibility of your until before using 12 ADJUST IGNITION TIMING a Using a service wire short terminals TE1 and E1 of the check connector b Check the idle speed Idle speed 650 rpm c Using atiming light slowly turn the distributor until the t...

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Page 258: ...ST 1 STARTING SYSTEM Page TROUBLESHOOTING ST 2 STARTER ST 3 ...

Page 259: ...y Repair starter ST 3 Ignition switch faulty Replace ignition switch Engine cranks slowly Battery charge low Check battery specific gravity CH 3 Charge or replace battery Battery cables loose corroded or worn Repair or replace cables Starter faulty Repair starter ST 3 Starter keeps running Starter faulty Repair starter ST 3 Ignition switch faulty Replace ignition switch Short in wiring Repair wiri...

Page 260: ...ing I Clutch Assembly Steel Ball Return Spring Magnetic Switch Assembly ST0484 REMOVAL OF STARTER 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2 DISCONNECT CABLE AND CONNECTOR ST0483 Remove the nut and disconnect the battery cable from the magnetic switch on the starter motor Disconnect the connector from terminal 50 3 REMOVE STARTER MOTOR a Remove the bolt and disconnect the ground strap ...

Page 261: ... the field frame with the armature from the magnetic switch assembly REMOVE STARTER HOUSING CLUTCH ASSEMBLY AND IDLE GEAR a Remove the two screws b Remove the following parts from the switch assembly 1 Starter housing 2 Idle gear and bearing 3 Clutch assembly 4 Return spring magnetic 3 REMOVE STEEL BALL Using a magnetic finger remove the steel ball from the Magretic Finger clutch shaft hole 4 REMO...

Page 262: ...e is no continuity between any segment replace the armature 2 INSPECT COMMUTATOR FOR GROUND Using an ohmmeter check that there is no continuity between the commutator and armature coil core If there is continuity replace the armature Commutator 1 INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES If the surface is dirty or burnt correct it with sandpaper No 400 or a lathe 2 INSPECT COMMUTATOR CIRCLE ...

Page 263: ...depth is less than mi nimum correct it with a hacksaw blade Field Frame Field Coil 1 INSPECT FIELD COIL FOR OPEN CIRCUIT Using an ohmmeter check that there is continuity be tween the lead wire and field coil brush lead If there is no continuity replace the field frame 2 INSPECT FIELD COIL FOR GROUND Using an ohmmeter check that there is no continuity between the field coil end and field frame If t...

Page 264: ...h hold ers If there is continuity repair or replace the brush holder Clutch and Gears 1 INSPECT GEAR TEETH Check the gear teeth on the pinion gear idler gear and clutch assembly for wear or damage If damaged replace the gear or clutch assembly If damaged also check the drive plate ring gear for wear or damage 2 INSPECT CLUTCH Rotate the clutch pinion gear clockwise and check that it turns freely T...

Page 265: ... Using a press press in a new rear bearing Magnetic Switch 1 PERFORM PULL IN COIL OPEN CIRCUIT TEST Using an ohmmeter check that there is continuity be tween terminals 50 and C 2 If there is no continuity replace the magnetic switch assembly PERFORM HOLD IN COIL OPEN CIRCUIT TEST Using an ohmmeter check that there is continuity be tween terminal 50 and the switch body If there is no continuity rep...

Page 266: ... a screwdriver hold the brush spring back and connect the brush into the brush holder Con nect the four brushes NOTE Check that the positive lead wires are not grounded c Install the end cover to the field frame with the two screws 3 INSERT STEEL BALL INTO CLUTCH SHAFT HOLE a Apply grease to the steel ball b Insert the steel ball into the clutch shaft hole 4 INSTALL CLUTCH ASSEMBLY IDLE GEAR AND S...

Page 267: ...aring d Assemble the starter housing and magnetic switch assembly and install the two screws 5 INSTALL FIELD FRAME WITH ARMATURE TO MAGNETIC SWITCH ASSEMBLY a Align the protrusion of the field frame with the cutout of the magnetic switch assembly b Install the two through bolts c Connect the lead wire to the magnetic switch termi nal C and install the nut ...

Page 268: ... clutch pinion gear returns inward replace the mag netic switch assembly 3 INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative lead from the switch body Check that the clutch pinion gear returns inward If the clutch pinion gear does not return replace the magnetic switch assembly 4 PERFORM NO LOAD PERFORMANCE TEST a Connect the battery and ammeter to the starter as shown b Check that the sta...

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Page 270: ...CH 1 CHARGING SYSTEM Page PRECAUTIONS CH 2 TROUBLESHOOTING CH 2 ON VEHICLE INSPECTION CH 3 ALTERNATOR CH 6 CHARGE LIGHT RELAY CH 15 ...

Page 271: ...rm tests with a high voltage insula tion resistance tester 4 Never disconnect the battery while the engine is running TROUBLESHOOTING Possible cause Remedy Page Fuse blown Check CHARGE and GAUGE fuses Light burned out Replace Jgiht Wiring connections loose Tighten loose connections IC regulator faulty Replace IC regulator CH 6 Drive belt loose or worn Adjust or replace drive belt CH 3 Battery cabl...

Page 272: ...es for continuity 3 INSPECT DRIVE BELT a Visually check the drive belt for cracks oiliness or wear Check that the belt does not touch the bottom of the pulley groove If necessary replace the drive belt b Using a belt tension gauge check the drive belt tension Belt tension gauge Nippondenso BTG 20 95506 00020 or Borroughs NO BT 33 73F Drive belt tension New belt 145 25 lb Used belt 100 20 lb If the...

Page 273: ...WITHOUT LOAD NOTE If a batteryI alternator tester is available con nect the tester to the charging circuit according to the manufacturer s instructions a If a tester is not available connect a voltmeter and ammeter to the charging circuit as follows Disconnect the wire from terminal B of the alter nator and connect the wire to the negative terminal of the ammeter Connect the test lead from the pos...

Page 274: ...ge replace the IC regulator If the voltage reading is less than standard voltage check the alternator 7 INSPECT CHARGING CIRCUIT WITH LOAD a With the engine running at 2 000 rpm turn on the high beam headlights and place the heater blower switch at HI b Check the reading on the ammeter Standard amperage 30 A or more If the ammeter reading is less than 30 A repair the alter nator See page CH 6 NOTE...

Page 275: ...nal Insulator Rectifier End Frame Insulator Washer JC Regulator Rectifier Holder CH0594 REMOVAL OF ALTERNATOR 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CH0586 2 DISCONNECT CONNECTOR AND WIRE FROM ALTERNATOR 3 REMOVE DRIVE BELTS 4 REMOVE ALTERNATOR a Remove the bolt nut and air pump stay b Remove the adjusting lock bolt two bolts and ad justing bar c Remove the pivot bolt nut and alterna...

Page 276: ... CAUTION Do not pry on the coil wires 2 REMOVE PULLEY FAN AND DRIVE END FRAME FROM ROTOR a Mount the rotor in a soft jaw vise b Remove the pulley nut spring washer pulley and fan c Remove the spacer collar and drive end frame d Remove the spacer ring and snap ring 3 REMOVE RECTIFIER END FRAME a Remove the four nuts condenser and two terminal insulators b Remove the rectifier end frame c Remove the...

Page 277: ...INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter check that there is continuity be tween the slip rings Standard resistance 2 8 3 0 0 If there is no continuity replace the rotor 2 INSPECT ROTOR FOR GROUND Using an ohmmeter check that there is no continuity between the slip ring and the rotor If there is continuity replace the rotor 3 INSPECT SLIP RINGS a Check the slip rings are not rough or score...

Page 278: ...lace the stator Brushes 1 INSPECT EXPOSED BRUSH LENGTH Using a scale measure the exposed brush length Standard exposed length 20 0 mm 0 787 in Minimum exposed length 5 5 mm 0 217 in If the length is less than minimum replace the brushes 2 IF NECESSARY REPLACE BRUSHES a Unsolder and remove the brush and spring b Insert the brush wire through the spring c Install the brush in the brush holder d Sold...

Page 279: ... tester 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 holder 2 INSPECT NEGATIV E SIDE RECTIFIER a Using an ohmmeter connect one tester probe to the negative terminal and the other to each rectifier terminal b Reverse the polarity of the tester probes and repeat step a c Check that one shows continuity a...

Page 280: ...ove the three screws and bearing retainer and re place the bearing 3 INSPECT REAR BEARING Check that the bearing is not rough or worn 4 IF NECESSARY REPLACE REAR BEARING a Using SST remove the bearing from the rotor shaft SST 09286 4601 1 b Using a press press in a new rear bearing onto the rotor shaft ...

Page 281: ...pliers while soldering the terminals CAUTION Protect the rectifiers from heat 3 INSTALL RECTIFIER END FRAME TO RECTIFIER HOLDER a Place the insulator washer on the positive stud of the rectifier holder b Place the two cushions on the brush holder and alternator terminal c Place the rectifier end frame on the rectifier holder d Check that the wires are not touching the rectifier end frame e Place t...

Page 282: ...o the rotor shaft e Install and torque the nut Torque 900 kg em 65 ft lb 88 N m 5 ASSEMBLE DRIVE END FRAME AND RECTIFIER END FRAME a Bend the rectifier lead wires back to clear the rotor b Using a curved tool push the brushes in as far as they will go and hold them in place by inserting a stiff wire through the access hole in the rectifier end frame c Assemble the drive end frame and the rectifier...

Page 283: ... and nut b Install the adjusting bar with the two bolts and ad justing lock bolt Do not tighten the adjusting lock bolt c Install the air pump stay with the bolt and nut 2 INSTALL DRIVE BELTS a Install the drive belt b Using a belt tension gauge adjust the belt tension See page CH 3 Drive belt tension New belt 145 25 lb Used belt 100 20 lb c Tighten the pivot and adjusting lock bolts 3 CONNECT CON...

Page 284: ... there is no continu ity between terminals 1 and 2 b Connect the one test probe to terminal 3 and the other to terminal 4 c Reverse the polarity of test probes and repeat step b d Check that one shows continuity and other shows no continuity If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Connect a positive lead from the battery to terminal 3 b Connect a negative le...

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Page 286: ...hooting LAND CRUISER 36262E Heavy Duty On Vehicle Repair A440F A440L Disassembly and Automatic 36264E Assembly of Transmission Transmission NOTE The following page contains only the points which differ from the above listed manuals Page TESTS AT 2 Stall Test AT 2 Hydraulic Test AT 2 AUTOMATIC SHIFT DIAGRAM AT 2 r t tflllll lll ...

Page 287: ...of the Repair Manual for Chassis and Body of the Land Cruiser Heavy Duty Pub No 36262E Output shaft rpm Vehicle speed Reference Governor pressure kg cm2 psi kPa 1 000 32 km I h 20 mph 0 8 1 2 11 17 78 118 1 800 57 km h 35 mph 1 9 2 3 27 33 186 226 3 500 111 km h 69 mph 5 7 6 3 81 90 559 618 AUTOMATIC SHIFT DIAGRAM km h mph 0 range throttle valve fully open fully closed 2 range L range Tire Size Lo...

Page 288: ...NUAL FOR CHASSIS AND BODY Pub No 36262E FA 1 NOTE The following pages contain only the points which differ from the above listed manual Page TROUBLESHOOTING FA 2 FRONT WHEEL ALIGNMENT FA 2 FRONT AXLE HUB FA 5 STEERING KNUCKLE AND AXLE SHAFT FA 10 FRONT SUSPENSION FA 11 ...

Page 289: ...toe in FA 2 C27TS FRONT WHEEL ALIGNMENT 1 MAKE FOLLOWING CHECKS AND CORRECT ANY PROBLEMS a Check the tires for wear and proper inflation Cold tire inflation pressure kg cm2 psi kPa Tire sie Front Rear P225 75R15 1 8 26 177 2 4 34 235 EXTRA LOAD b Check the wheel runout Lateral runout Less than 1 2 mm 0 047 in c Check the front wheel bearings for looseness d Check the front suspension for looseness...

Page 290: ...ake the center of each rear tread at spindle height and measure the distance between the marks of right and left tires c Advance the vehicle until the marks on the rear side of the tires come to the front NOTE The toe in should be measured at the same point on the tire and at the same level d Measure the distance between the marks on the front side of the tires Toe in mm in Inspection STD Adjustme...

Page 291: ... make sure that the wheel is not touching the body or brake flexible hose If maximum steering angles differ from the standard value adjust the wheel angle with the knuckle stopper bolts Torque 450 kg em 33 ft lb 44 N m If the wheel angle still cannot be adjusted within limits inspect and replace damaged or worn steering parts 7 INSPECT SIDE SLIP WITH SIDE SLIP TESTER Side slip limit less than 3 0 ...

Page 292: ...n changed as follows Torque 1 600 kg em 116 ft lb 157 N m COMPONENTS Outer Bearing Inner Bearing f Oil Seal 315 23 31 Free Wheel Hub Ikg em ft lb N m I Specified torque Non reusable part Axle Hub with Disc 100 7 10 l Adjusting Nut Thrust Washer Lock Nut 900 65 88 I Lock Washer Cap 315 23 31 I Snap Ring Flange and Gasket FA0503 FA0086 ...

Page 293: ...air manual chassis and body LAND CRUISER Heavy Duty Pub No 36262E a Remove the cap from the flange b Using snap ring pliers remove the snap ring c Remove the mounting nuts d Using a brass bar and hammer tap the bolt heads and remove the cone washers e Install and tighten the two bolts and remove the flange 3 REMOVE AXLE HUB WITH DISC a Using a screwdriver release the lock washer b Using SST remove...

Page 294: ... BEARING OUTER RACE a Using a brass bar and hammer drive out the bearing outer race b Using SST carefully drive in the new bearing outer race SST 09608 35014 Inner Bearing 09608 06020 09608 0621 0 Outer Bearing 09608 06020 09608 06200 ASSEMBLY OF FRONT AXLE HUB See page FA 5 1 PACK BEARINGS WITH MP GREASE a Place M P grease in the palm of your hand b Pack grease into the bearing continuing until t...

Page 295: ...m d Loosen the nut until it can be turned by hand e Using a spring tension gauge measure the frictional force of the oil seal at the hub bolt f Retighten the adjusting nut Torque 40 70 kg em 35 60 in lb 4 0 6 8 N m g Using a spring tension gauge measure the preload Preload starting Frictional force plus 2 8 5 7 kg 6 2 12 5 lb 27 5 55 8 N 6 INSTALL LOCK WASHER AND LOCK NUT a Install the lock washer...

Page 296: ...e nuts _ _ _ _ _ _ _ _ _ ___ _ _FA oos J Torque 315 kg em 23 ft lb 31 N m FAQ084 d Install a bolt in the axle shaft and pull it out e Using snap ring pliers install the snap ring f Remove the bolt g Install the cap to the flange 8 INSTALL BRAKE CALIPER a Install the brake caliper to the steering knuckle Torq ue the mounting bolts Torque 900 kg em 65 ft lb 88 N m b Using SST connect the brake tube ...

Page 297: ...m bly of the steering knuckle and axle shaft refer to the repair manual chassis and body LAND CRUISER Heavy Outy Pub No 36262E COMPONENTS Shims Bearing Oil Seal Set Dust Cover I Dust Seal 475 34 47 Ikg cm ft lb N m I Specified torque Non reusable part Lock Nut I900 65 88 I i 315 23 31 I G eeo Front Axle Hub with Disc Free Wheel Hub r 315 23 31 I I I100 7 Ti 0 j L 02953 ...

Page 298: ... and stabilizer bar refer to the repair manual chassis and body LAND CRUISER Heavy Duty Pub No 36262E COMPONENTS I l I I r _ Shock Absorber I I I I I I r 1 Bolt yYith Washer j 650 47 64 I 11 1 cushaon _ Washer U bolt Stabilizer Bar YJr Spring Lower Seat I 30 9 3 Leaf Spring Component Ikg em ft lb N m I Tightening torque Non reusable part Leaf No 1 Leaf No 2 SA0165 ...

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Page 300: ...TO LAND CRUISER Heavy Duty REPAIR MANUAL FOR CHASSIS AND BODY Pub No 36262E NOTE The following pages contain only the points which differ from the above listed manual Page REAR AXLE SHAFT Semi floating Type RA 2 REAR SUSPENSION RA 3 ...

Page 301: ...t REAR AXLE SHAFT Semi floating Type For removal installation of the rear axle shaft refer to the repair manual chassis and body LAND CRUISER Heavy Duty Pub No 36262E COMPONENTS b f 1 I Ikg cm ft lb N m Specified torque Non reusable part Deflector Gasket 11 600 116 1571 ...

Page 302: ...AR SU Suspension Rear SUSPENSION COMPONENTS Washer Bumper Bracket Spring Bumper i k Absorber Shoe W th Washer Bolt 1 I I 375 27 37 C hi1l Bracket 130 9 13 Washer r l3 Stabilizer Bar ponent Leaf Spring Com I I I I I I I I I RA 3 ...

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Page 304: ...vy Duty REPAIR MANUAL FOR CHASSIS AND BODY Pub No 36262E BR 1 NOTE The following pages contain only the points which differ from the above listed manual Page CHECKS AND ADJUSTMENTS BR 2 FRONT BRAKE BR 2 LOAD SENSING PROPORTIONING VALVE BR 2 ...

Page 305: ...y hand until the beginning of the second resistance is felt measure the distance as shown Pedal freeplay 3 6 mm 0 12 0 24 in NOTE The freeplay to the first resistance is due to the play between the clevis and pin And it is 1 3 mm 0 04 0 12 in on the pedal FRONT BRAKE PAD LINING THICKNESS Minimum thickness Previous 1 0 mm 0 039 in New 4 0 mm 0 157 in LOAD SENSING PROPORTIONING VALVE SET REAR AXLE L...

Page 306: ...AND CRUISER Heavy Duty REPAIR MANUAL FOR CHASSIS AND BODY Pub No 36262E NOTE The following pages contain only the points which differ from the above listed manual Page REAR WIPER AND WASHER BE 2 COMBINATION METER BE 5 REAR HEATER BE 8 1 11 ...

Page 307: ...perate Wiper relay faulty Check relay in INT position Wiper control relay faulty Check relay Wiper motor faulty Check motor Wiring or ground faulty Repair as necessary Washer does not operate Washer hose or nozzle Repair as necessary clogged Washer motor faulty Check motor Wiper switch faulty Check switch Wiring or ground faulty Repair as necessary Wiring Diagram Rear Wiper Control Relay Rear Wipe...

Page 308: ...T OPERATION a Connect the positive lead from the battery to terminal1 and the negative leads to both termi nal 2 and motor body b Check that the motor operates intermittently for 10 15 seconds If operation is not as specified check that the rear wiper control relay INSPECTION MOTOR OPERATES STOPPING AT STOP POSITION a Start motor operation by connecting the positive lead from the battery to termin...

Page 309: ...ery positive ter minal c Check that there is a relay operation noise when changing terminal 2 to the battery negative ter minal and another operation noise 3 to 5 seconds later If operation is not as specified replace the relay Rear Washer Motor Connect the positive lead from the battery to termi nal 2 and the negative lead to terminal 1 check that the motor operation CAUTION These tests must be p...

Page 310: ...15 Combination Meter Connector C 6 13 5 4 3 2 1 12 11 10 9 8 7 Connector A BE2068 BE2072 BE2069 G 13 2 COMBINATION METER CIRCUIT Connector Terminal Wiring Connector Side 1 Hi Beam indicator 2 Oil Pressure Sender Gauge 3 GAUGE Fuse 4 5 6 Water Temperature Sender Gauge A 7 Parking Brake Switch and Brake Fluid Level Warning Switch 8 CHARGE Fuse 9 Ground 10 TAIL Fuse 11 Ground 12 Ground 13 Fuel Sender...

Page 311: ...20 20 23 40 40 43 5 60 60 64 80 80 84 5 100 100 105 If error is excessive replace the speedometer b Check the speedometer for pointer vibration and abnormal noise NOTE Pointer vibration can be caused by a loose speedometer cable Tachometer System INSPECT TACHOMETER ON VEHICLE a Connect a tune up test tachometer and start the engine CAUTION Reversing the connection of the tachometer will damage the...

Page 312: ...ceiver gauge resistance and voltage regulator MEASURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals A and B Resistance Approx 55 Q If resistance value is not as specified replace the receiver gauge 3 INSPECT SENDER GAUGE OPERATION a Connect a series of three 1 5 V dry cell batterys b Connect the positive lead from the dry cell bat tery to terminal 1 through a 3 4 W test bulbs ...

Page 313: ...ce hose Heater radiator leaking or Replace radiator clogged Wiring Diagram Rear Heater Relay Rear Heater Switch Rear Heater Rear Heater Blower Switch INSPECT SWITCH CONTINUITY Page BE 8 BE 8 BE 9 BE2059 Inspect the switch continuity between terminals BE2060 GA 4 2 AC0503 Terminal 1 2 3 4 Switch position HI 0 1 o OFF LO 0 1 D If continuity is not as specified replace the switch Rear Heater Relay 1 ...

Page 314: ...er Blower Resistor INSPECT RESISTOR CONTINUITY a Check that there is continuity between terminals 1 and 4 b Check that there is continuity between terminals 2 and 3 c Check that there is continuity between terminals 3 and 5 If continuity is not as specified replace the resistor Rear Heater Blower Motor INSPECT MOTOR OPERATION a Connect the positive lead from the battery to terminal 4 and the negat...

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Page 316: ... BODY REFER TO LAND CRUISER Heavy Duty REPAIR MANUAL FOR CHASSIS AND BODY Pub No 36262E NOTE The following pages contain only the points which differ from the above listed manual Page INSTRUMENT PANEL B0 2 ...

Page 317: ...ent Panel INSTRUMENT PANEL COMPONENTS GJ Side Defroster Nozzle c g 8 _ Radio and Tape Player r No 2 Air Duct No 3 Air Duct Assist Grip ia l 4l lSI e Li h b Throttle Cable l Fuel Lid Opener Hood Lock Release Leve Heater Control Panel and Spacer Cigarette Lighter Steering Column Cover Pad Steering Wheel 602506 ...

Page 318: ...4 801109 REMOVAL OF INSTRUMENT PANEL 1 DISCONNECT BATTERY CABLE FROM NEGATIVE TERMINAL 2 REMOVE STEERING WHEEL 3 REMOVE STEERING COLUMN COVER 4 REMOVE NO 2 AIR SIDE DUCT AND NO 3 AIR DUCT a Remove four screws bracket and No 2 air side duct b Remove the clip and No 3 air duct 5 REMOVE THROTTLE CABLE a Disconnect the throttle cable from accelerator pedal and retainer b Remove the throttle cable set ...

Page 319: ...ven screws b Remove the instrument cluster finish panel c Disconnect the speedometer cable d Disconnect the connectors 9 REMOVE RADIO AND TAPE PLAYER a Remove four screws and radio with tape player b Disconnect the connectors and antenna code 10 REMOVE GLOVE COMPARTMENT a Remove three screws and glove compartment door b Remove the courtesy switch and illumination light c Remove four screws door lo...

Page 320: ...se 14 REMOVE SAFETY PAD a Remove four screws and four nuts b Loose two clips and remove the safety pad to rear ward 2 Cfip 802512 15 REMOVE HEATER CONTROL PANEL AND NO 2 AIR DUCT a Remove four screws heater control panel and spacer b Disconnect the connectors c Remove two screws and No 2 air duct d Push in the remaing heater control to forward 16 REMOVE MIRROR CONTROL SWITCH RHEOSTAT AND 4WD CONTR...

Page 321: ...fifteen bolts and instrument panel to rear ward I I 802514 20 REMOVE FOLLOWING PARTS AS NECESSARY Side defroster nozzle Switches Rheostat Assist grip Wire harness etc INSTALLATION OF INSTRUMENT PANEL INSTALL PARTS OF INSTRUMENT PANEL IN REVERSE SEQUENCE OF REMOVAL ...

Page 322: ...CHASSIS BODY LAND CRUISER Pub No 36262E AC 1 NOTE The following pages contain only the points which differ from above listed manual SPECIAL TOOLS AND EQUIPMENT AC 2 AIR CONDITIONING SYSTEM CIRCUIT AC 2 COMPRESSOR AC 3 AIR CONDITIONER AMPLIFIER AC 13 ...

Page 323: ...rs 07114 84020 To remove and install snap ring Key remover 07112 45021 To remove key Shaft plate remove 07112 15010 To remove shaft plate Shaft plate installing tool 07114 15010 To install shaft plate Hexagon wrench set 07110 61050 To remove and install service valves and front housing Shaft Seal tool 07112 25010 To remove and install shaft seal Key press tool 07114 4501 0 To install key AIR CONDI...

Page 324: ...ied torque AC0943 Rotor Bearing Snap Ring Compressor Non reusable part AC0694 DISASSEMBLY OF MAGNETIC CLUTCH 1 REMOVE PRESSURE PLATE a Using SST and socket remove the shaft nut SST 07112 76040 b Using SST and socket remove the pressure plate SST 07112 71 010 c Remove the shims from the shaft ...

Page 325: ...stator lead wires from the compres sor housing b Using SST remove the snap ring Remove the sta tor SST 07114 84020 4 REMOVE ROTOR BEARINGS NOTE Press out the bearings only if they are to be replaced a Remove the bearing snap ring from the rotor b Using SST press out the two bearings SST 0711 0 77011 5 INSPECT PRESSURE PLATE AND ROTOR a Inspect the pressure plate and rotor surfaces for wear and sco...

Page 326: ...orque Non reusable part AC1240 AC1241 AC0015 i 1 2ao 19 25 1 Do not disassemble DISASSEMBLY OF COMPRESSOR 1 REMOVE FELT 2 REMOVE SNAP LING Using SST remove the snap ring SST 071 14 84020 3 REMOVE KEY Using SST remove the key from the shaft SST 071 12 45021 AC 5 AC1248 ...

Page 327: ...ainst the shaft Then push the holder ring downward SST 07112 15010 b Pull up the remover bar and remove the shaft plate REMOVE SHAFT SEAL Insert SST against the shaft and turn it to the right while pressing on the remover Then remove the shaft seal SST 07112 2501 0 7 REMOVE SERVICE VALVE a Using SST remove the bolts holding the service valve SST 0711 0 61 050 b Remove the 0 ring from the service v...

Page 328: ...move the five through bolts NOTE Do not reuse the five washers SST 07110 61050 b Using a screwdriver remove the front housing CAUTION Be careful not to scratch the sealing surface of the front housing 10 REMOVE FRONT VALVE PLATE Remove the two pins from the front housing Discard the pins 11 REMOVE REAR HOUSING Using a screwdriver remove the rear housing CAUTION Be careful not to scratch the sealin...

Page 329: ...dis charge valve over the pins on the rear cylinder NOTE The rear valve plate is marked with an R e Lubricate the new gasket with compressor oil In stall the gasket on the valve plate 2 INSTALL REAR HOUSING ON REAR CYLINDER 3 INSTALL FRONT VALVE PLATE ON FRONT CYLINDER a Install the two pins in the front cylinder b Lubricate a new 0 ring with compressor oil Install the 0 ring in the rear housing c...

Page 330: ... tighten the five through bolts in two or three passes SST 0711 0 61 050 Torque 260 kg em 19 ft lb 25 N m 5 INSTALL SHAFT SEAL a Fit the shaft seal onto SST SST 07112 25010 b Apply oil to the ore Insert SST and turn it counterclockwise while lightly pressing in Then pull up the SST SST 07112 2501 0 6 INSTALL SHAFT PLATE a Put in the shaft plate b Press in SST SST 07114 15010 ...

Page 331: ...STALL SERVICE VALVE a Lubricate new 0 ring with compressor oil Install the 0 rings in the service valve b Install the service valve on the compressor Using SST and torque wrench tighten the bolts SST 0711 0 61 050 Torque 260 kg em 19 ft lb 25 N m 10 CHECK SHAFT STARTING TORQUE Torque 30 kg em 26 in lb 2 9 N m or less ASSEMBLY OF MAGNETIC CLUTCH 1 INSTALL TWO BEARINGS IN ROTOR a Using SST press a s...

Page 332: ... clearance is not within tolerance add or reduce the number of shims to obtain the standard clearance b Using SST and torque wrench install the shaft nut SST 07112 76040 Torque 165 kg em 12 ft lb 16 N m 5 CHECK CLEARANCE OF MAGNETIC CLUTCH ____ _ _ _ _ _ _ _ _ _ _ _ A co ss j7 a Set the dial gauge to the pressure plate of the mag Dial Gauge AC0801 netic clutch b Connect the magnetic clutch lead wi...

Page 333: ...L Ac o J7o7 b Charge the compressor with refrigerant through the charge valve until the pressure is 3 kg I cm2 43 psi 294 kPa c Using gas leak detector check the compressor for leaks If leaks are found check and replace the compressor 2 EVACUATE COMPRESSOR AND CHARGE WITH REFRIGERANT Make sure the caps are tight and the compressor is free from the moisture and contamination NOTE When storing a com...

Page 334: ...he amplifier and inspect the connector on the wire harness side as shown in the chart below Test conditions 1 Ignition switch ON 2 Temperature control lever MAX COOL 3 Blower switch HI Condition Specified valve Continuity Turn A C switch on Battery voltage Turn A C switch off No voltage Turn A C switch on Battery voltage Turn A C switch off No voltage Turn on IG switch to ST position Battery volta...

Page 335: ... MEMO ...

Page 336: ... ENGINE MECHANICAL A 3 EFI SYSTEM A 7 COOLING SYSTEM A 1 0 LUBRICATION SYSTEM A 10 IGNITION SYSTEM A 11 STARTING SYSTEM A 11 CHARGING SYSTEM A 11 AUTOMATIC TRANSMISSION A 12 FRONT AXLE AND SUSPENSION A 12 REAR AXLE AND SUSPENSION A 13 LUBRICANT A 14 ...

Page 337: ...lter change w I o Oil filter change w I Front heater w I Front and rear heaters NO NGK STD Intake Exhaust Limit Limit Limit Limit Limit Wheel bearing friction preload starting Steering wheel freeplay Torque specifications Seat mounting bolts Leaf spring U bolt 145 25 lb 100 20 lb 145 25 lb 100 201b 125 25 lb 80 20 lb 7 8 liters 8 2 US qts 7 0 liters 7 4 US qts 17 5 liters 18 5 US qts 19 5 liters 2...

Page 338: ... Rocker arm inside diameter STD Shaft diameter STD Rocker arm oil clearance STD Limit Circle runout Limit 650 rpm 420 mmHg 16 54 in Hg 56 0 kPa or more 10 5 kg I cm2 149 psi 1 030 kPa or more 8 0 kg I cm2 114 psi 785 kPa 0 5 kg I cm2 7 psi 49 kPa or less 0 15 mm 0 10 mm 25 45 70 45 65 45 1 1 1 7 mm 1 4 2 0 mm 8 01 0 8 030 mm 14 028 14 041 mm 14 078 14 091 mm 124 8 mm 128 0 mm 124 3 mm 127 5 mm 44 ...

Page 339: ...475 mm 1 7506 1 7510 in No 4 42 965 42 975 mm 1 6915 1 6919 in Bearing inside diameter STD No 1 48 000 48 030 mm 1 8898 1 8909 in No 2 46 500 46 530 mm 1 8307 1 8319 in No 3 45 000 45 030 mm 1 7717 1 7728 in No 4 43 500 43 530 mm 1 7126 1 7138 in UIS 0 25 No 1 47 750 47 825 mm 1 8799 1 8829 in No 2 46 250 46 325 mm 1 8209 1 8238 in No 3 44 750 44 820 mm 1 7618 1 7646 in No 4 43 250 43 320 mm 1 702...

Page 340: ...mm 0 0520 in Oil 1 42 mm 0 0559 in Connecting rod Thrust clearance STD 0 160 0 300 mm 0 0063 0 0118 in and piston pin Limit 0 40 mm 0 0156 in Connecting rod bearing center wall thickness STD Mark A 1 484 1 488 mm 0 0584 0 0586 in Mark B 1 488 1 492 mm 0 0586 0 0587 in Mark C 1 492 1 496 mm 0 0587 0 0589 in Connecting rod oil clearance STD STD 0 020 0 050 mm 0 0008 0 0020 in UIS 0 25 and 0 50 0 019...

Page 341: ... 0989 in Crank pin diameter STD 52 988 53 000 mm 2 0861 2 0866 in U S 0 25 52 701 52 711 mm 2 0748 2 0752 in U S 0 50 52 451 52 461 mm 2 0650 2 0654 in Circle runout Limit 0 12 mm 0 0048 in Taper and out of round Main journal and crank pin Limit 0 02 mm 0 0008 in Torque Specifications Part tightened kg em ft lb N m Cylinder head x Cylinder block 1 250 90 123 Valve rocker support x Cylinder head 12...

Page 342: ...90 64 87 2 6 3 2 kgI cm2 37 46 psi 255 314 kPa 2 40 One drop or less per minute Approx 13 8 0 47 59 cc 2 9 3 6 cu in per 15 sec 5 cc 0 31 cu in or less One drop or less per minute Throttle posi Clearance between stop Between terminals Resistance tion sensor screw and lever Omm 0 in VTA E2 0 3 6 3 kn 0 77 mm 0 0303 in IDL E2 Less than 2 3 kn 1 09 mm 0 0429 in IDL E2 Infinity Throttle valve fully op...

Page 343: ...connected Verity that the battery voltage is 11 V or above with the ignition switch is ON Voltage Terminals Condition STD voltage V BATT E1 10 14 IG S W E1 IgnitionS WON 10 14 M REL E1 Ignition S W ON 10 14 8 81 E1 Ignition S W ON 10 14 IDL E2 Throttle valve open 4 6 VC E2 4 6 Ignition S W ON Throttle valve fully closed VTA E2 0 1 1 0 Throttle valve fully open 4 5 VC E22 4 6 IgnitionS WON Measurin...

Page 344: ...ing plate fully open 20 1 200 THA E2 Intake air temperature 20 C 68 F 2 000 3 000 THW E2 Coolant temperature 80 C 176 F 200 400 GI G6 140 180 NE G6 140 180 ISC1 ISC2 _ 8 10 30 ISC3 ISC4 Fuel cut rpm Fuel cut rpm 1 300 rpm Fuel return rpm 1 000 rpm Torque Specifications Part tightened kg em ft lb N m Cold start injector pipe x Cold start injector 180 13 18 Cold start injector pipe x Delivery pipe 1...

Page 345: ...valve plug x Oil pump strainer Oil pump x Cylinder block Oil outlet pipe Oil pan x Cylinder block Oil filter bracket x Cylinder block Relief valve x Oil filter bracket Oil cooler STD Limit at Idle at 4 000 rpm STD Limit STD Limit STD Limit See page A 2 86 so c 187 194 F 10 mm 0 39 in or more 0 75 1 05 kglcm2 1 0 7 14 9 psi 74 103 kPa 0 6 kglcm2 8 5 psi 59 kPa kg em ft lb N m 450 33 44 380 27 37 18...

Page 346: ... and output power 12 V 1 0 kW No load characteristic Ampere 90 A or less at 11 5 V rpm 3 000 rpm or more Commutator Outer diameter STD 30 mm 1 18 in Limit 29mm 1 14in Under cut depth STD 0 6 mm 0 024 in Limit 0 2mm 0 008 in Circle runout Limit 0 05 mm 0 0020 in Brush Length STD 13 5 mm 0 531 in Limit 8 5 mm 0 335 in Spring installed load 1 79 2 41 kg 3 9 5 3 lb 18 24 N CHARGING SYSTEM Drive belt t...

Page 347: ...5 kg cm2 psi kpa FJ62LV EXTRA LOAD Front wheel Camber alignment King pin inclination Caster FJ62LG FJ62LV Toe in FJ62LG FJ62LV 0 D 3 3 2 2 1 102 116 64 78 29 43 63 72 40 48 18 28 Front 1 8 26 180 1 45 9 3o 45 o so 1 Inspection STD 1 2 mm 11 17 psi 78 118 kPa 27 33 psi 186 226 kPa 81 90 psi 559 618 kPa fully closed 2 range L range Lock up Lock up 3 2 2 1 ON OFF 79 92 75 88 81 95 36 50 49 57 47 55 5...

Page 348: ...t stabilizer bar bracket x Axle housing Front stabilizer x Frame Wheel nut REAR AXLE AND SUSPENSION Torque Specifications Rear axle shaft Part tightened Semi floating type Differential rear cover x Axle housing Rear suspension Spring U bolt x Axle housing Front spring bracket x Hanger pin Frame x Hanger pin Rear spring shackle x Leaf spring Rear shock absorber x Axle housing Rear shock absorber x ...

Page 349: ...ricant LUBRICANT Capacity Item Classification Liters US qts Imp qts Engine oil API grade SF or SFICC Dry fill 8 0 8 5 7 0 multigrade viscosity oil Drain and refill w I Oil filter change 7 8 8 2 6 9 w I o Oil filter change 7 0 7 4 6 2 ...

Page 350: ...8 1 STANDARD BOLT TORQUE SPECIFICATIONS Page STANDARD BOLT TORQUE SPECIFICATIONS B 2 ...

Page 351: ...ass Hexagon Bolt 4 4T Stud bolt head bolt head No 5 5T No mark 6 6T 7 7T 4T 0 No mark 4T Hexagon 0 flange bolt Grooved w washer No mark 4T hexagon bolt 6T Hexagon 0 head bolt Two protruding 5T lines Hexagon 0 Welded bolt flange bolt Two w washer protruding 6T hexagon bolt lines 4T Hexagon head bolt 0 Three protruding 7T lines ...

Page 352: ... 35 47 540 39 53 I I 14 1 5 760 55 75 850 61 83 16 1 5 1 150 83 113 6 1 65 56 in lb 6 4 8 1 25 160 12 16 10 1 25 330 24 32 5T 12 1 25 600 43 59 14 1 5 930 67 91 16 1 5 i 1 400 101 137 6 1 80 69 in lb 7 8 90 78 in lb 8 8 8 1 25 195 14 19 215 16 21 6T 10 1 25 400 29 39 440 32 43 i I 12 I 1 25 730 53 72 810 59 79 I 14 I 1 5 1 250 90 123 j 6 1 110 8 11 I 120 9 12 8 1 25 260 19 25 290 21 28 I 10 1 25 5...

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Page 354: ...C 1 SST AND SSM Page SST SPECIAL SERVICE TOOLS C 2 SSM SPECIAL SERVICE MATERIALS C 6 ...

Page 355: ...olving disassembly of components C SST required for rather special less frequent work not of classifiable as either A or B EM EC Fl co LU ST CH FA RA Valve Stem Oil Seal Replacer 8 Valve Guide Bushing Remover Replacer A Valve Spring Compressor A Crankshaft Pulley Holding Tool A Crankshaft Pulley Gear Pulley Set A 09214_ 60010 Crankshaft Pulley B L Gear Replacer g g Camshaft Bearing Qg 09215 00012 ...

Page 356: ...over Replacer q Camshaft Bearing 09215 00100 Remover Replacer c Set AN 09215 00130 Bolt i3 09215 00140 Nut 09215 00150 Shaft A 09215 00160 Pin e 09215 00240 Remover Replacer e 09215 00270 Remover Replacer Connecting Rod 09222 30010 Bushing Remover B Replacer r 09223 50010 Crankshaft Front Oil Seal Replacer B 09223 60010 Crankshaft Rear Oil Seal Replacer B 09228 44011 Oil Filter Wrench A ...

Page 357: ... J 09308 1001 0 09330 00021 Water Pump Overhaul Tool Set Water Pump Bearing Remover Replacer Shaft B Water Pump Bearing Remover Replacer Air Pump Tester Injection Measuring Tool Set EFI Fuel Pressure Gauge Injection Pump Camshaft Bearing Cone Replacer Injection Pump Spline Shaft Puller Oil Seal Puller Oil Seal Puller Companion Flange Holding Tool B B A B A c c A A A EM EC Fl co 1 Remarks 1 Cranksh...

Page 358: ...g B Tool Set I 09608 06020 Handle Rear Hub Outer 09608 06150 Bearing Cup Replacer 09608 06200 Rear Axle Bearing Replacer 09608 0621 0 Rear Axle Bearing Replacer Power Steering 1 09631 22020 Hose Nut 14 x 17 A Wrench 09751 36011 Brake Tube Union Nut 10 x 12 Wrench A 09842 30050 Wiring Au EFI Inspection 8 09842 30070 Wiring F B EFI Inspection i Remarks 1 Fuel line flare nut NOTE For reference to SST...

Page 359: ...S Part Name Part No Sec Use etc Seal packing or equivalent 08826 00080 EM Main bearing caps No 1 and No 4 Adhesive 1324 08833 00070 EM Drive plate mount bolt Three bond 1324 or equivalent Adhesive 1344 Three bond 1344 08833 00080 EM Timing gear cover Loctite 242 or equivalent ...

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Page 362: ...CK Wire Color Block No I I R G 2 Block Inside WIRE COLOR Wire colors are indicated by an alphabetical code Wire Color I R B Black LG Light Green W White BR Brown 0 Orange Y Yellow G Green P Pink GR Gray R Red The 1st letter indicates the basic wire color and the 2nd indicates the stripe color Example R G indicates a Red wire with a Green stripe ABBREVIATION The following abbreviations are used in ...

Page 363: ...8 Rear Window Defogger 4 1 Charging 411 1 6 Rear Wiper and Washer 2 7 Cigarette Lighter 4 3 Remote Control Mirrors 4 5 Clock 4 3 Starting 6 1 2 I Combination Meter 2 4 Stop Lights t 3 1 I I Cooling Fan Engine 4 7 Taillights and Illumination 3 4 I Door Locks 3 6 Unlock and Seat Belt Warning 4 1 EFI I IF o i 1 3 Turn Signal and Hazard 3 2 I i I I c Front Wiper and Washer 2 6 4WD 1 8 Headlight Cleane...

Page 364: ...ING DIAGRAM 1988 Model Page 1 to Page 4 6 Power Source AI I I I Fl J I Fj I INJECTOR GrounciPOifltl l g PDR EFI I a located on englne blocfc I 4WOI AC F om AJC mplif NSW From tgmt1on SJW b t oated on ftoft fr011t pill C L ocetmon ...

Page 365: ......

Page 366: ...h t A ri Y IJu U li IQS Ol 19 A e l tii JIII I JOa Ol 1 A VII _ _ J81ndwo w o Vil lWOJ 1 1 441 cc Yt ut0J1 lii I UJIM Jt J WOJ 1 r 1 ...

Page 367: ......

Page 368: ... i To Check En lneUght 11 4 TOC te WATER TEMP a 0 Warnin Llgt lt WATER TEMP SENDER 11 6 G l To IGMsln R ttvfl Sf i3 2 To _ BeltW ni 9 Llghtt3 11 To4WOSvnem 1 1 _fi I 113 v 21 _JI W 8 V 8 BRA KE I I PARKING BRAKE S W I I tr o l t o 3 H 51 Ground polnn hz L oeat 01 left frol t Pillar C L caced on rifht front pillar d Dl tC Mtft efbkt 1 ...

Page 369: ......

Page 370: ...9 l ll b i 01 r II I I r III It r R 2o I 1 I r s I 1 I M I I ffi ffi Iw i i I ll O M I I M g fo O 3i lu r 0 1 r rrrl ffi i Hofo M I M I 1n 3 il 1 __ i lli I Kft r 1 I A C Jiii 1 __I JH DI1 ONINUVM tM U Oln1 C liY MI LCUn1 J IY r 1 l oo ill 1 A M O A MIS J YVlS lH I1 tfO l d JIONI MIS NOllISOd 1VUJ fUN 1VU l0l IN 1Vt U 03N UidSNVUl l oo r 1 A _ ____ J HOI l M J H I l WO lV OIONI OMto WO lY IQNI OMf...

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Page 372: ... Unlock and Seat Belt Warning t Turn Signal and Hazard 2 Horn Taillights anc1 Illumination 3 G _ jf 9 g e Gnnmd polnu e ll i 0 I_ ffi _ o b l Deltld tttefl fntnt paw c t oc Ndontlfht from 4 t o at on certW of baclt 7fi al 4 ...

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Page 374: ... Headlights 1 Power Windows Door Locks 5 6 7 8 B I l i I I z 11 JFI i y r lii c I OORCB J l r r I i POWER WINDOW R ELAY m POWER WINDOW MOTOR b 3 ...

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Page 376: ...i J 2 a 1 a a LLI 1 1 5 a 0 z N I tl A l 1 u IUIIM li B lW S WOJ f 8 i j g a e i j 5 ...

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Page 378: ... _ ______ d r twof 1 j 1 3NION3 ll l01 1 A B N 1 1 L J 1J lt lri Sn l Voj QQQ WDJ f l f0 N3S dW3 l 010 tiiiiVW t a ro l N _ 1 D N II M M 1 HO LOW IIIV ONI100 ...

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Toyota Land Cruiser 1988, Repair Manual

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